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TECHNICAL SERVICES GROUP

SPECIFICATION FOR MOTOR OPERATED VALVE (MOV)

CAIRN-TSG-E-SP-0022

CAIRN ENGINEERING STANDARD

B1 28/08/12 Issued for Implementation C.Nallakuttalam C.Nallakuttalam AA

A1 24/08/2012 Issued for Review C.Nallakuttalam C.Nallakuttalam AA

Revision Date Description Originator Checker Approver

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TECHNICAL SERVICES GROUP
SPECFICATION FOR MOTOR OPERATED VALVE (MOV)
CAIRN-TSG-E-SP-00022 A1
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REVISION RECORD

Revision Philosophy
All revisions for review will be issued at A1, with subsequent A2, A3, etc as required.
All revisions approved for issue or implementation will be issued at B1, with subsequent B2, B3, etc as
required.
All revisions approved for issue or design and construction will be issued at C1, with subsequent C2, C3,
etc as required.
Narrative sections revised from previous pprove issues are to be noted in the table below and/or
highlighted using the appropriate revision status thus: | A2
Previous revision highlighting to be removed at subsequent issues.
Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the affected areas
and by the use of a triangle containing the revision status.

Revision History

Revision Date of Reason for change


No. issue

A1 24/08/2012 Issued for review

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TECHNICAL SERVICES GROUP
SPECFICATION FOR MOTOR OPERATED VALVE (MOV)
CAIRN-TSG-E-SP-00022 A1
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CONTENTS
1.0 SCOPE ERROR! BOOKMARK NOT DEFINED.
2.0 CODES AND STANDARDS 4
3.0 SITE CONDITIONS 5
4.0 SYSTEM DESIGN REQUIREMENT 5
5.0 NAMEPLATES AND FINISH 8
6.0 INSPECTION AND TESTING 8
7.0 VENDOR DOCUMENTATION 9
8.0 MANDATORY SPARE PARTS 9

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TECHNICAL SERVICES GROUP
SPECFICATION FOR MOTOR OPERATED VALVE (MOV)
CAIRN-TSG-E-SP-00022 A1
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1.0 SCOPE
This specification covers the requirement for design, engineering, manufacture, assembly, factory
testing, transportation, and supply of Motor Operated Valves (MOVs) and components, suitable for
inching, on/off or regulating duty as specified valve schedule / datasheet.
2.0 CODES AND STANDARDS
2.1 The equipment shall comply with the requirements of latest revision of following standards issued
by BIS (Bureau of Indian standards) unless otherwise specified.
CODE Description
IS5 Shades of paints
IS 325 Three phase induction motors
IS 900 Code of practice for installation and maintenance of induction motors
IS 996 Single phase small ac and universal electric motors
IS 2148 Flameproof enclosures for electrical apparatus
Designation for type of construction and mounting arrangement of rotating
IS 2253
electrical machines.
IS 3682 Flameproof ac motor for use in mines
IS 4691 Degrees of protection provided by enclosure for rotating electrical machinery
IS 4722 Rotating electrical machines
IS 4728 Terminal marking and direction of rotation for rotating electrical machines
IS 4889 Method of determination of efficiency of rotating electrical machines
IS 5571 Guide for selection of electrical equipment for hazardous areas
IS 6362 Designation of methods of cooling of rotating electrical machines
IS 6381 Construction and testin9 of electrical apparatus with type of protection 'e'
Classification of maximum surface temperatures of electrical equipment for use in
IS 8239
explosive atmospheres
IS:9334 Specification for Electric Motor Operated Actuators.
IS 12065 Permissible limits of noise level for rotating electrical machines
Mechanical vibration of rotating electrical machines with shaft heights 56mm and
IS 12075
higher - measurement, evaluation and limits of vibration severity
IS 12824 Type of duty and classes of rating assigned to rotating electrical machines
IS 12802 Temperature rise measurement of rotating electrical machines
Code of practice for the selection, installation & maintenance of electrical
IS 13408 apparatus for use in potentially explosive atmospheres (other than mining
application or explosive processing & manufacture)
Oil Industry Safety Directorate Recommended Practice for Design aspects for
OISD RP 149
safety in electrical system

2.2 Regulations
2.2.1 The MOVs shall be in conformance to the statutory regulations.
2.2.2 All equipment to be used in hazardous area shall be of a type already tested by Central Mining
Research Institute (CMRI), Dhanbad and approved by Chief Controller of Explosives
(CCE)/Directorate General of Mines Safety (DGMS)/ Directorate General Factory Advice Service &
Labour Institute (DGFASLI), as required, for use in specified gas group locations. BIS marking is
mandatory

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TECHNICAL SERVICES GROUP
SPECFICATION FOR MOTOR OPERATED VALVE (MOV)
CAIRN-TSG-E-SP-00022 A1
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2.2.3 In case electrical equipments to be used in hazardous area are type tested by other reputed
agencies outside India, the vendor shall approach applicable statutory bodies specified above and
get the equipment approved by them for use in the specified area of utilization prior to bidding.
2.2.4 The equipment shall also conform to the provisions of Indian Electricity rules and other statutory
regulations currently in force in the country in case Indian standards are not available for any
equipment, standards issued by IEC/BS /VDE / NEMA or equivalent agency shall be applicable.
In case of any contradiction between various referred standards I specifications I data sheet and
statutory regulations the following order of priority shall govern:
x Statutory regulations
x Data sheets
x Job specification
x This specification
x Codes and standards
In addition, work shall conform to the following statutory requirements as applicable.
x Indian Electricity act and rules
x Fire insurance regulations
x Regulations laid down by Chief Controller of Explosives/DGMS as applicable.
x Regulations laid down by Electrical Inspectorate/CEA
x Indian Petroleum Rules
x OISD guidelines/standards
x Regulations laid down by local authorities from time to time.
3.0 SITE CONDITIONS
3.1 The equipment shall be suitable for installation and satisfactory operation in tropical, humid and
corrosive atmosphere as prevalent in Refineries/Petrochemical Plants. Unless otherwise specified,
ambient temperature of 50°C and altitude not exceeding 1000 m above MSL shall be considered.
4.0 SYSTEM DESIGN REQUIREMENT
4.1 General Requirement
4.1.1 Generally, MOVs shall be designed to deliver rated performance at extreme site conditions as
specified in Project General Information Sheets
4.1.2 MOVs shall be suitable for ambient temperature for -20°C to + 80°C for ON-OFF duty and -20°C to
+ 60°C for regulating duty. For motors installed outdoor and exposed to direct sunrays, the effect of
solar heat shall be considered in the determination of design ambient temperature.
4.1.3 MOVs shall have fungus protection involving special treatment of insulation and metal against
fungus, insects and corrosion.
4.1.4 Motor voltages, phases, frequencies:
a. 0.25kW -160kW -------- 415V t 6%, 3-cp, 50Hz, t 3%
b. Less than 250W -------- 240V t 6%, 1-cp, 2W, 50Hz.:t 3%
4.2 Type and Rating
4.2.1 For ON-OFF duty, MOVs shall be of S2-15 min duty and shall be suitable for a maximum of 60
starts / hr.
4.2.2 For INCHING duty, MOVs shall be of S2-15 min duty and shall be suitable for a maximum of 150
starts / hr.

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TECHNICAL SERVICES GROUP
SPECFICATION FOR MOTOR OPERATED VALVE (MOV)
CAIRN-TSG-E-SP-00022 A1
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4.2.3 Generally, three phase motors shall be general purpose, constant speed, severe duty, high
efficiency squirrel cage three phase induction type. Single phase motor shall be general purpose,
constant speed, severe duty, high efficiency, capacitor start and run type in accordance with BIS
996
4.2.4 All MOVs shall be rated to deliver output over the entire range of voltage and frequency variation
specified in clause 4.1.4 above.
4.2.5 MOVs shall also be suitable for long period of inactivity.
4.3 Specific Requirements
4.3.1 The stall torque of motor shall be at least 25% greater than maximum torque required for operation
of level.
4.3.2 Motorized Actuators for inching duty shall have facility for remote position indication through 4 to 20
mm Potential-metric transducer. The indication accuracy should be within 0.5% service duty.
4.3.3 Hand wheel shall be provided for all MOVs. It shall have mechanically independent manual drive
arrangement with hand wheel & motor declutching mechanism. The manual drive shall be provided
with clutch & gearing as required to limit hand wheel effort to 23 KGF maximum, along with suitable
latch and locking arrangement to keep the hand wheel in engaged position during manual
operation. The hand wheel shall disengage automatically during motor operation.
4.3.4 Dial type continuous mechanical position indicator shall be provided for local indication
4.3.5 All devices required for safe operation and control of MOVs shall be provided.
4.4 Starting Requirements
4.4.1 The motor shall be suitable for direct on line (DOL) starting. Single phase induction motor shall be
capacitor start and run type. Starting current will not exceed 6.0 times the full load current subject
to IS tolerance.
4.4.2 Motor shall start with rated load and accelerate to full speed with 80% rated voltage at motor
terminals
4.5 General Construction
4.5.1 Motors shall be of totally enclosed not ventilated (TENV) or totally enclosed surfaced cooled
(TESC) enclosure construction with degree of ingress protection IP 67.
4.5.2 Horizontal, cast iron, ribbed frame and end shield, internal ribs for stator end windings, integrally
cast feet over the length of the frame, suitable for classified hazardous area specified in datasheet,
complete with drain holes and provisions for vertical jack screws.
4.5.3 For MOVs weighing less than 25KG one lifting eye-bolts shall be provided. It shall be screwed into
the frame that swivel 360deg, tilt 180deg and align in direction of pull. For MOVs weighing 25KG
and above two lifting eye-bolts welded to the frame shall be provided.
4.5.4 MOVs shall be equipped with stainless steel drains and plugs located at the lowest point in the
enclosure.
4.6 Stator Construction
4.6.1 Motor stator core shall be made of high grade steel laminations, stacked compressed and keyed in
yoke.
4.6.2 Motor stator insulation shall be Class F with Class B temperature rise.
4.6.3 Motor shall have thermistors embedded, one in each winding of the motor for protection against
burn-out. Thermistor for protection of MOVs shall be filled with high quality grease (Molybdenum
Disulfide based) to facilitate mounting at any angle I position.
4.7 Rotor Construction
4.7.1 Motor rotor shall be made of pressure die cast aluminium.
4.7.2 Motor rotor insulation shall be Class H with Class F temperature rise.

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TECHNICAL SERVICES GROUP
SPECFICATION FOR MOTOR OPERATED VALVE (MOV)
CAIRN-TSG-E-SP-00022 A1
Page 7 of 9

4.7.3 Motor rotor assembly shall be dynamically balanced with securely fastened weights to IEC60034-
14. The use of solder or similar deposits is not acceptable.
4.8 Torque Limit Switches
4.8.1 MOV torque limit switches shall be provided to protect the motor from over loading by cutting-off
the supply to motor in both opening I closing directions.
4.8.2 The switch shall be provided with heavy-duty type silver inlaid 2 NO + 2 NC potential free contacts
rated for 5 A at 230 V AC.
4.8.3 It shall be possible to set the value of torque from 5% to 100% of rated torque of actuators. A
metallic disc spring shall be provided to ensure perfect response in case of overloading.
4.8.4 Torque limiter plate shall also be provided to avoid unauthorized setting of limit switch beyond limit.
4.9 Travel Limit Switches
4.9.1 MOV position limit switch shall be provided to cut-off the supply to the motor at the end of preset
limit of VALVE travel and shall be provided with 2 NO + 2 NC potential free contacts rated for 5A at
230 V AC.
4.10 Terminal Box
4.10.1 Motor connections, space heater connection and all auxiliary contacts of all devices I switches
shall be brought out to a terminal blocks in a common terminal compartment for COMPANY's cable
connection.
4.10.2 The terminal box shall be made of cast iron and it shall be split type with removable cover with
access to connections and shall have the same degree of protection IP 67.
4.10.3 Terminals shall be suitable for accommodating incoming wires up to cross section of 4 sq. mm
copper conductor for power and 2.5 sq. mm copper conductor for control. Screw type terminals for
power and control.
4.10.4 The terminal box shall accommodate power and control cables, ground bar and fitted with an
approved drain plug. It shall be complete with cable lugs, nickel plated brass double compression
glands and earthing terminals.
4.10.5 The terminal box shall to withstand 65kA fault level for a minimum duration of 0.2 Sec.
4.10.6 Generally, the terminal box shall be located at the right hand side when viewed from driving end.
It shall be possible to turn it in steps of 90" of thru 360" unless otherwise approved in written by
COMPANY
4.10.7 The terminal box shall have separate grounding pad
4.11 Internal Wiring
4.11.1 Internal wiring shall be suitable for the conditions listed in the specification and sized for a
minimum of 10 A rating on control circuit and appropriately for 3-phase motors.
4.11.2 Each wire shall be carefully tagged and identified at each end.
4.11.3 The wiring and terminal blocks used for the wiring of the transducer shall be of different colour to
discriminated the Power /Control / Signal wiring.
4.12 Accessories
4.12.1 Space heaters rated for 240V AC, single phase, 50Hz shall be provided inside the enclosure for
MOVs. Space heater shall have control thermostat.
4.12.2 Thermistor one per phase shall be provided (3 for 3phase motors and one for single phase
motor) for stator protection shall be provided.
4.12.3 Following nickel plated brass double compression cable glands with lugs shall be provided along
with MOV terminal box:
a. 1 x 1" NPT for control cable for Limit & Torque switches to PMCC.
b. 1 x 1" NPT for Power cable from PMCC to actuator.

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TECHNICAL SERVICES GROUP
SPECFICATION FOR MOTOR OPERATED VALVE (MOV)
CAIRN-TSG-E-SP-00022 A1
Page 8 of 9

c. 1 x 314"NPT for Power cable for space heater to PMCC.


4.13 Bearings and Lubrication
4.13.1 Bearings shall be provided at both drive and non-drive ends.
4.13.2 Bearings will be provided with radial/axial seals as required to prevent entrance of foreign
matters like dirt, water etc. into the bearing area or leakage of lubricant.
4.13.3 Anti-friction bearing life expectancy of L'0 design as defined by ISO R 281, i.e., 100,000hrs for
direct coupled drives
4.13.4 Generally, motors shall be provided with greased for life bearing.
4.14 Grounding
4.14.1 Provide two ground connector lugs on the motor frame at opposite sides.
5.0 NAMEPLATES AND FINISH
5.1 Nameplates
5.1.1 An engraved stainless steel nameplate marked with at least the following details, shall be
permanently attached for convenient reading:
a. MOVTAG No.
b. Duty Type.
c. Area classification, Temperature code, CMRI Type Test No.1 DGMS Approval No.
d. Degree of protection
e. KW, voltage, phases and full load current.
f. Rated Torque.
g. Type 1 Catalogue Number.
h. Bearing identification no.
i. Recommended lubricants
5.2 Finish
5.2.1 Metal surfaces cleaned, degreased, coated twice with rust inhibiting epoxy primer then painted with
corrosion proof paints shade 631 as per IS 5.
6.0 INSPECTION AND TESTING
6.1 Testing
6.1.1 Upon completion, each motor shall be subject to standard routine tests as per IS 9334 -1986. In
addition, any special test called for in the driven equipment specification shall be performed.
6.1.2 Type test certificate on any motor, if so desired by the COMPANY shall be furnished. Otherwise,
the motor shall be type tested, free of charge, to prove the design
6.1.3 The following operational test as per IS shall be performed on a sample of motor of each type and
rating, even if type test certificates of any the tests are submitted for COMPANY's approval.
a. Response time test as per BIS 9334 - 1986
b. Variation of supply voltage (Rated Voltage +/-10%).
c. Variation of frequency (Rated Frequency +/- 5%).
d. Tests for motor as per BIS: 325-1978.
e. Tests for limit switches as per BIS 9334 -1986
f. Tests on output shaft as per BIS 9334 -1986
g. Tests for terminal boxes a per BIS: 2147.

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TECHNICAL SERVICES GROUP
SPECFICATION FOR MOTOR OPERATED VALVE (MOV)
CAIRN-TSG-E-SP-00022 A1
Page 9 of 9

h. Damp heat cycling test as per BIS: 21 06 (part - II).


i. Factory setting of Open & Close limit switches shall be done at 100% & 0% of valve open
condition respectively
6.2 Inspection requirements
6.2.1 The COMPANY's authorized representative shall be afforded the opportunity to witness the testing
of the equipment at the VENDOR's work. The VENDOR shall give 14 days' advance notice of the
date when the type I routines tests are to be carried out to enable the. COMPANY representative to
witness these tests.
7.0 VENDOR DOCUMENTATION
7.1.1 The VENDOR shall have to take approval of relevant drawings and data from the COMPANY in
writing before starting manufacture of any equipment. The VENDOR shall at his own cost rectify
defects in any manufacture done prior to the approval of drawings I data in accordance with the
approved drawings/data and the equipment shall be delivered within stipulated time.
7.1.2 Drawings, data, information and manuals shall be submitted as indicated below:
a. Before award of contract
- Individual MOV data sheet as per format
- Scheme & write up on forced lubrication system, if any
- Type Test Report
b. After award of contract
- Dimensional general arrangement drawing
- Foundation plan & loading
- Cable end box details
- Motor thermal withstand curves hot & cold
- Starting and speed torque characteristics at 80% & 100% voltage
- Complete MOV data
- Erection & Maintenance manual
- Test reports in VENDOR's format
8.0 MANDATORY SPARE PARTS
8.1.1 The VENDOR shall supply construction, start-up, commissioning, insurance and capital spares as
required

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