NIOEC-SP-70-04(3)

DOCUMENT CODE NO. OF PAGES: 10

PLAN/PRJ/SUB UNIT PHASE DISCIPLINE DOCUMENT TYPE SERIAL NO. REV. NO. DATE
NIOEC 000 EG IN SP 7004 A3 SEPTEMBER, 2014

NATIONAL IRANIAN OIL REFINING & DISTRIBUTION COMPANY

NATIONAL IRANIAN OIL ENGINEERING
& CONSTRUCTION COMPANY

NIOEC SPECIFICATION
FOR

ELECTRIC MOTOR OPERATED VALVES

FIRST EDITION

JULY, 2005

THIS SPECIFICATION IS THE PROPERTY OF NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY. IT IS CONFIDENTIAL AND ALL
RIGHTS RESERVED TO THE OWNER. NEITHER WHOLE NOR ANY PART OF THIS DOCUMENT MAY BE DISCLOSED TO ANY THIRD PARTY,
REPRODUCTED, STORED IN ANY RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN
CONSENT OF THE NATIONAL IRANIAN OIL ENGINEERING & CONSTRUCTION COMPANY.
 September, 2014 NIOEC-SP-70-04(3)

IN THE NAME OF GOD

FOREWORD

By their very nature, technical Specifications are continuously subject to modifications and
revisions. To strengthen their merit and usefulness, continuous improvements, addendum, deletion
of disparate information and consequently provision of updated revisions are to be made in order to
ascertain that such Specifications meet the current requirements, inclusive of Iranian Petroleum
Standards (IPS) and the recognized and acceptable national and international Standards, as well as
the optimal codes and practices based on the accumulated in-house know-how and plant knowledge
and experiences.

However, in reality, due to several reasons, not to mention the complexity of the matter, the ultimate
goal of continuous direct embedment of the required changes on the relevant Specifications may be
far reaching. Therefore, in the interim periods between the officially issued revisions, the required
changes will appear in other documents related to the engineering and design work of the ongoing
projects.

In response to the initiative of the Design and Engineering Directorate, and considering that the task
of the execution of several important and mega projects for the realization of the new oil refineries,
pipelines and oil terminals as well as improvements of the existing facilities, has been assigned to
NIOEC, it was decided to update the NIOEC Specifications and to issue new official revisions.

The Design and Engineering Directorate was itself entrusted to carry out this important task, and as
such by forming several special technical committees, working in close co-operation and cohesion
and sharing their expertise and knowledge, the updated and revised NIOEC Specifications were
successfully prepared and complied.

These Specifications are intended to be used for Oil Refineries, Distribution Depots, Oil Terminals,
Pipelines and Pump Stations within NIOEC's projects, and have been proven to be of high value for
such purposes. It must however be appreciated that these Specifications represent the minimum
requirements and should in no way be interpreted as a restriction on the use of better procedures,
engineering and design practices or materials.

We encourage and highly appreciate the users and other clear sighted and experts to send their
comments on the Specifications to the Design and Engineering Director of NIOEC for evaluation
and approval.
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REVISION INDEX
REV. REV. REV. REV.
PAGE 1 2 3 4 5 PAGE
1 2 3 4 5 PAGE 1 2 3 4 5 PAGE 1 2 3 4 5
1 X 26 51 76
2 X 27 52 77
3 X 28 53 78
4 X X X 29 54 79
5 X X 30 55 80
6 X 31 56 81
7 X 32 57 82
8 X X 33 58 83
9 X X 34 59 84
10 X 35 60 85
11 36 61 86
12 37 62 87
13 38 63 88
14 39 64 89
15 40 65 90
16 41 66 91
17 42 67 92
18 43 68 93
19 44 69 94
20 45 70 95
21 46 71 96
22 47 72 97
23 48 73 98
24 49 74 99
25 50 75 100

NOTES:
1) THIS SHEET IS A RECORD OF ALL REVISIONS TO THIS SPECIFICATION.
2) WHEN APPROVED EACH REVISION SHALL BE CONSIDERED AS A PART OF THE ORIGINAL
DOCUMENT.
3) NUMBER OF PAGES EXCLUDES THIS SHEET AND THE COVER SHEET.

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A.ARMAN
3 SEPTEMBER, 2014 H.KHODAM H.SHIRINPOUR M.ORDOOBADI
MOGHADAM

2 JUNE, 2009 Instrument DISC. KHATIB

1 FEBRUARY, 2007 JOUHARY ORDOOBADI M.R.FARZAM SAJEDI

0 JULY, 2005 ALAM ORDOOBADI M.R.FARZAM SAJEDI

REV. DATE PREPARED CHECKED APPROVED AUTHORIZED

 September, 2014 NIOEC-SP-70-04(3)

CONTENTS: PAGE NO.

1. SCOPE ............................................................................................................................................. 2

2. REFERENCES................................................................................................................................ 2

3. UNITS .............................................................................................................................................. 3

4. DEFINITIONS ................................................................................................................................ 3

5. ABBREVIATIONS ......................................................................................................................... 3

6. GENERAL....................................................................................................................................... 3

7. MOTOR OPERATOR AND CONTROLLER ............................................................................. 3

8. INSPECTION AND TESTS ........................................................................................................... 8

9. SPARE PARTS, MAINTENANCE TOOLS AND START-UP KITS......................................... 9

10. PREPARATION FOR SHIPMENT ............................................................................................ 9

11. GUARANTEES ............................................................................................................................. 9

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1. SCOPE
This specification defines NIOEC’s minimum requirements for motor operated valve actuators.
Included are the specification for the motor, gear train, geared limit switches, torque switches and
hand wheel for manual operation. Also covered is the mounting of actuator on valve body,
inspection, and testing of completed assembly. Reference shall be made to NIOEC valve and piping
specifications for valve body codes, design, connections and welding requirements.
Deviations from this specification will only be permitted on obtaining written approval from
NIOEC.
Resolution on cases not explicitly stipulated in this Specification, or on cases where conflicts may
arise among the requirements of the referenced IPS and the international standards, shall be made
through written consent and approval of NIOEC.

2. REFERENCES
The following standards, codes, and specifications, to the extent specified hereinafter, shall
constitute a part of this NIOEC Specification. Latest edition of the undated referenced documents
and the cited edition of the dated references shall apply. The applicability of changes made to the
dated references ,after the cited date shall be mutually agreed upon between NIOEC and the
Vendor/ Contractor.
ANSI (AMERICAN NATIONAL STANDARDS INSTITUTE)
ANSI B2.1 “Pipe Threads”

IEC (INTERNATIONAL ELECTRO TECHNICAL COMMISSION)

IEC-60079-1 “Electrical Apparatus for Explosive Gas Atmospheres - Flameproof
Enclosures "d"”

ISA (INSTRUMENTATION, SYSTEMS, AND AUTOMATION SOCIETY OF AMERICA)

96.02.01 “Guidelines for the Specification of Electric Valve Actuators”

NEC (NATIONAL ELECTRIC CODE)

NIOEC SP (NIOEC SPECIFICATIONS)

NIOEC-SP-50-04 “Specification for Piping Material”
NIOEC-SP-50-18 “Specification for Piping Material Purchase Valves”
NIOEC-SP-90-02 “Welding of Plant Piping Systems”
NIOEC-SP-60-02 “Specification for Low Voltage Induction Motors”
NIOEC-SP-00-10 “Standard Specification for Units”

NIOEC SIP (NIOEC SHOP INSPECTION PROCEDURE)

NIOEC-SIP-70-01 “Shop Inspection Procedure for Instruments”

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3. UNITS
International System of Units (SI) shall be used in accordance with NIOEC-SP-00-10, unless
otherwise specified.

4. DEFINITIONS
In cases where this specification is part of a direct order, Purchaser shall mean the National Iranian
Oil Engineering and Construction Company. Where this specification forms part of contract
documents, Purchaser shall mean the Contractor. In references to inspection by Purchaser, when
this specification forms part of contract documents, this shall be construed to mean that NIOEC
shall also have the right of inspection.

5. ABBREVIATIONS
ESD: Emergency Shut Down
FAT: Factory Acceptance Test
PC: Personal Computer
PCS: Process Control System
UPS: Un-interruptible Power Supply

6. GENERAL
6.1. All motor operators in hazardous areas shall be explosion-proof type Hazardous area
classification shall be according to IEC 60079.

6.2. All electrical equipment and motors shall be totally enclosed and shall be weatherproof
according to IEC 60529 – at least IP 65. For special underground applications electrical
equipments shall be watertight to IEC 60529-IP 67 and for submersible IP 68.

6.3. Valve body codes, design, connections and welding requirements shall be as specified in
NIOEC specifications NIOEC-SP-50-04, NIOEC-SP-50-18, and NIOEC-SP-90-2.

6.4. Vendor shall supply the valve actuator compatible with the valve. All information required for
sizing the actuator shall be obtained from the purchaser and/or Valve Supplier.

6.5. Torque requirements of valve and torque characteristics of the actuator shall be supplied to the
purchaser for approval.

7. MOTOR OPERATOR AND CONTROLLER

7.1. Actuating Unit
7.1.1. The actuating unit shall include a 3-phase electric motor, reduction limit switches, and
torque switches, space heaters, terminals, together with a hand wheel for manual operation
with declutching lever and valve position indicator. The actuating unit and motor shall be
sized for the torque requirements according to the valve size, maximum cold working
pressure of the valve temperature, and speed operation.
7.1.2. All gearing shall be totally enclosed and continuously lubricated. All shafts shall be
mounted on ball or roller bearings. Limit switch drive shall be stainless steel.

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7.1.3. “Lost Motion" hammer blow gearing shall be provided for unseating of the valve.
7.1.4. The valve and actuator mounting bracket must be capable of withstanding the stall torque of
the actuator, with torque and limit switches disconnected.
7.1.5. The actuator shall provide both torque and position limitation in both directions. An
automatic override shall be provided to prevent the torque switches from tripping the motor
on initial valve unseating.
7.1.6. The actuator shall be capable of operating at any mounting angle.
7.1.7. The actuator shall be designed so that there will be no release of high stem thrust of torque
reaction spring forces when covers are removed from actuator gear box, even when the
valve is under full line pressure conditions.
7.1.8. Failure of the motor, power, or motor gearing shall not prevent manual operation of the
valve through the use of the hand wheel. When the motor drive is declutched, the hand
wheel drive shall be engaged safely, with the motor running or stopped.
A means of locking the actuator in either the manual or motor condition shall be provided.
If not locked in either position, starting of the motor shall automatically restore the power
drive.
7.1.9. The actuator shall be capable of functioning within the ambient temperature range as
specified in the job specification, but in any case not less than -30C to +80C.
7.1.10. Clockwise rotation of the actuator hand wheel shall close the valve. The hand wheel drive
must be mechanically independent of the motor drive, and gearing should be such as to
permit emergency manual operation in a reasonable time. The Vendor shall state the number
of hand wheel turns required to operate valve from fully open to fully close and also the
approximate hand wheel torque.
7.1.11. Provision shall be made for the addition of extra sets of limit switches in each actuator. Each
set shall be adjustable to any point of valve position. Each unit shall be provided with
auxiliary contacts, 24 VDC, volt free contacts for remote position indication. They are to be
continuously adjustable.
7.1.12. No valve shall require more than two (2) minutes for full operation, i.e., from closed to fully
open or open to fully closed.

7.2. Actuator Sizing

The actuator shall be sized to guarantee valve closure at the specified differential pressure. The
safety margin of motor power available for seating and unseating the valve shall be sufficient
to ensure torque switch trip at maximum valve torque with the supply voltage 10% below
nominal.

7.3. Terminals
7.3.1. Power terminals shall be of stud type, segregated by an insulating cover. Adequate numbers
of cable entry shall be provided. For explosion proof type equipment the entries shall be
suitable for flameproof cable glands. Each entry shall be provided with M25 threads to ANSI
B2.1 and according to IEC 60079-1.
7.3.2. The actuator terminal box shall be double sealed in such a way that when the terminal box
cover is removed for the connection of incoming cables, the remaining electrical components
are still protected by the watertight or weatherproof enclosure according to the application
requirement. The terminal compartment shall be provided with a minimum of 3 threaded
cable entries.

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7.4. Internal Wiring
Internal wiring shall be tropical grade PVC insulated stranded cable of appropriate size for the
control and 3- phase power. Each wire shall be clearly identified at each end.
The terminals shall be embedded in a terminal block of high tracking resistance compound.
All wiring supplied as part of the actuator to be contained within the main enclosure for
physical and environmental protection. External conduit connections between components are
not acceptable.
A durable terminal identification card showing plan of terminals shall be provided attached to
the inside of the terminal box cover indicating the following information:
 Serial number
 External voltage values
 Wiring diagram number
 Terminal layout

7.5. Space Heater

Temperature controlled space heater shall be provided to prevent the build up of moisture due
to condensation.

7.6. Motor
7.6.1. The motor shall be pre-lubricated and all bearings shall be of anti-friction type.
7.6.2. The motor shall be of sufficient size to open and close the valve against maximum
differential pressure when the voltage to motor terminals is within ±10% of rated voltage
before starting. Motor shall be able to accelerate to full speed at 20% reduced voltage during
starting. Motor nameplate rating shall be 400 Volt, 3 phase, 50 Hz. Frequency variation
would be + 2% - 5%. Position limit switches shall be provided at each end of travel for
remote indication and sequencing, torque and limits switches shall be easily adjustable.
7.6.3. The motor shall have class "F" insulation, and shall be short time rated with burn-out
protection provided. An interlocked motor starter shall be provided in the actuator housing.
Power and control wiring shall be segregated and insulated from each other.

7.7. Integral Controls

7.7.1. The actuator shall have an integral motor starter, local controls, lamp indication, and phase
discriminator relay.
7.7.2. The starter shall include a mechanically and electrically interlocked reversing contactor, with
control transformer having a grounded screen between primary and secondary windings. The
common point of contactor coils and secondary winding shall also be grounded, so that any
ground fault will cause contactors to drop-out. Terminals for remote controls shall be
provided.
7.7.3. Starter components shall be readily accessible for inspection without disconnecting external
cables. Internal wiring shall be number-identified at both ends.
7.7.4. Local push buttons shall be provided for "open-stop-close" control of valve, with a three
position lockable selector switch providing local/off/remote positions.
7.7.5. Provision shall also be made to incorporate when required in offsite or tank farm DC
interposing relays for open, stop and close control from remote 24 volt DC supply, to
eliminate possible interference due to cable capacitance.

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7.7.6. Local indication of "close" and "open" positions shall be provided by means of dial which is
illuminated red for close and green for open.

7.8. Remote Control System

7.8.1. The actuator of the valve shall be able to be controlled by the control system and the valve
will be open/close manually from field and automatically from the control room by selector
switch.

7.8.2. The remote control system shall consist of Field units, Master Stations and Communication
Control Units.
Master Station and Communication Control Units will be located in control room. Each
Master Station shall be connected to a group of Field Units. The system shall be able to
maintain control functions in event of a cable fault (open circuit or short circuit). In event of
field unit failure it shall be possible to operate the actuator with local manual control.
One spare cable shall be installed with sufficient distance from the above mentioned cable.
The spare cable shall not be connected to field units and Master Stations.

7.8.3. The control system shall consist of the following:

7.8.3.1. Field Units
Each actuator shall normally have one Field Unit, which shall be microprocessor type and
shall be powered from a supply within the associated actuator.
The enclosure for the Field Units shall be similar to that of the associated actuator.
Facility shall be provided in each Field Unit to select a unique address and a baud rate for
transmission of data to suit the overall system so that only the appropriate field unit can
respond to a command or request of status from the master station.

7.8.3.2. Master Stations

Master Stations shall be rack mounted suitable for indoor installation.
The Master Stations shall be suitable for interfacing with a PCS via communication
protocol link through the Communication Control Units.
Master Station shall be capable of receiving inputs/outputs for a group of actuators
connected in one loop through the associated field unit.
The Master Stations and Field Units shall be provided with surge protection.
The Master Stations shall be suitable for connection to 230 VAC, 50 Hz single phase supply
from uninterruptible power supply system (UPS). Each Master Station shall have 20%
spare capacity.

7.8.3.3. Communication Control Units

Communication Control Units shall be rack mounted suitable for indoor installation.
The Communication Control Units shall be suitable for communication between various
Master Stations and PCS via (communication protocol link) link.
The Communication Control Units shall be suitable for connection to 230 VAC, 50 Hz
single phase supply from UPS.

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7.8.3.4. Alternative/complementary controls/displays
Complementary supervisory control and data acquisition software package complete with
industrial type PC, with a keyboard and a monitor shall be provided through which it is
possible to control and monitor the motor operated valve.
Equipment for testing of field units and control system shall be provided.

7.8.3.5. Protocol Conversion Unit (Interface)

Protocol Conversion Unit shall be provided for interface the Communication Control Units
to PCS.
Protocol Conversion Unit shall have sufficient speed matched for communication between
Communication Control Unit and PCS.
Protocol Conversion Unit shall be supplied by PCS Vendor.

7.8.3.6. If digital communication is applicable for controlling the MOV’s, the following shall be
considered:
Actuators shall be provided with an integrally-mounted device providing connectivity with
host control system for actuator control, status indication, and monitoring. The control
device shall meet the appropriate recognized protocol or BUS system standards. The units
should be certified by the appropriate organization. Typical protocols/buses include:
a) Modbus
b) Profibus
c) Devicenet
d) Foundation Fieldbus
e) Proprietary BUS. Proprietary systems specified by the manufacturer/supplier or
purchaser may also be used.

7.8.3.7. Control Functions

The facility for following remote control shall be provided:
MOV full open
MOV full close
MOV stop in between

7.8.3.8. Status Indication

The facility for following remote status indications shall be provided in control room.
Valve running
Valve opened, valve closed
Valve stopped

7.8.3.9. Self diagnostics

The system shall be self diagnostic and the following common alarms shall be indicated in
control room on the consol of PCS and system monitor.
Loop fault
Actuator fault

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Field Unit fault
Master Station fault
Communication Control Unit fault
Protocol Conversion Unit fault
The individual alarms shall be identified by the complementary control/display and printer.

7.8.4. ESD Facility

7.8.4.1. Facility for emergency shutdown (ESD) shall be provided for one or other of the following
functions by making appropriate internal connections between the Field Unit and the
actuator terminal block.
ESD close
ESD open
Stay put.

7.8.5. Redundancy
The following requirement shall be followed with respect to redundancy of the system.
7.8.5.1. 100% back up redundant hot standby shall be provided for each Master station and
Communication Control Unit with manual change switches.
7.8.5.2. Protocol conversion unit shall be redundant if technically feasible based on Vendor proven
Technology.

7.8.6. Cable Size

The cable size and standard specified distance for cabling in one loop or between master
stations and communication control unit shall be in accordance with manufacturer's
recommendation.

8. INSPECTION AND TESTS

8.1. Inspection
All motor operated valves are subject to inspection by purchaser.
All tests and inspections shall be performed in accordance with the relevant NIOEC inspection
and test procedures including Shop Inspection Procedure (NIOEC-SIP-70-01).
Inspection and FAT will include stroking the valve from the fully closed to the fully open, stop
between position, vice-versa, using the motor operator.
Each actuator shall be permanently installed on its respective valve, inspected and tested before
shipment to jobsite.

8.2. Tests
8.2.1. Each actuator must be performance tested and individual test certificates shall be supplied
free of charge. The test equipment should simulate a typical valve load, and the following
parameters should be recorded:
 Current at maximum torque setting
 Torque at max. torque setting
 Flash test voltage

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 Actuator output speed or operating time.
In addition, the test certificate should record details of specification such as gear ratios for
both manual and automatic and second stage gearing if provided, drive closing direction,
wiring diagram number.
8.2.2. All motor operated valves are subject to inspection and FAT by purchaser.

8.2.3. When delivered with the valve, each actuator shall be permanently installed on its respective
valve, inspected and tested before shipment to jobsite.

9. SPARE PARTS, MAINTENANCE TOOLS AND START-UP KITS

9.1. Pre-commissioning and Commissioning Spare Parts
VENDOR shall recommend the spare parts for pre-commissioning, commissioning which will
be purchased together with the equipment, and include the cost of spare parts in the quotation.

9.2. Spare Parts for Two Years of Operation

VENDOR shall recommend the spare parts required for 2 years of operation and provide a
price list. PURCHASER may purchase the spare parts listed in Vendor’s recommended spare
part list after review. Validity of spare parts proposal shall be 12 months.

9.3. Maintenance Tools

If the supplied equipment requires special maintenance tools, the VENDOR shall include in his
proposal a price list for one complete set of such special tools. At least one set of special tools
shall be provided by VENDOR. PURCHASER may purchase the tools in a similar manner to
spare parts as indicated in Section 8.2.

9.4. Start-up kits

Each actuator shall be supplied with a start-up kit comprising installation instruction manual,
electrical wiring diagram and cover seals to make good any site losses during the
commissioning period. In addition, sufficient actuator commissioning tools shall be supplied to
enable actuator set up and adjustment during valve/actuator testing and site installation
commissioning.

10. PREPARATION FOR SHIPMENT

Preparation for Shipment shall be in accordance with Manufacture’s standards unless otherwise
noted on the Request for Quotation and/or Purchase Order. The Manufacturer shall be solely
responsible for the adequacy of the Preparation for Shipment provisions employed in respect of
materials and application, to provide materials to their destination in ox-works condition when
handled by commercial carrier systems.

11. GUARANTEES
VENDOR shall guarantee that he is able to support and supply spare parts for the supplied
hardware, software and firmware for at least 10 years from the date of shipment.

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If the VENDOR believes that parts of the system will be withdrawn from sale after 10 years, he
shall provide a statement detailing the equipment to be withdrawn, the timing and how updated
parts can replace the withdrawn parts.
The VENDOR shall also guarantee that the equipment supplied is free from fault in design,
workmanship and material, and is of adequate design and proper material to fulfil satisfactorily the
specified operating conditions.
Should any failure or defect in design, material, workmanship or operating characteristics develop
under the start-up and commissioning periods or during the first 12 months of operation, but not
later than 24 months from the date of shipment, the Vendor shall make all required repairs,
alterations or replacements of the defective equipment, free of charge, and shall pay transportation
fees involved to and from NIOEC’s site.

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