OUTLINE SPECIFICATION

Valve Remote Control System

OUTLINE SPECIFICATION
VALVE REMOTE CONTROL SYSTEM
by
Ragnar O. Øhrn, Technical Manager
Scana Skarpenord as, Rjukan

This outline specification points out some of the requirements to be complied with in the design
of the valve remote control system in order to satisfy existing rules and requirements.
It also gives recommendations and guidelines in selecting types of system and equipment.

* * * * *

INDEX

1. SYSTEM ARCHITECTURE ......................................................................................................................2

1.1 CONTROL FUNCTION ...................................................................................................................................3
1.2 POSITION INDICATION .................................................................................................................................4
2. SYSTEM DESCRIPTION ...........................................................................................................................4
2.1 CONTROL PANEL .........................................................................................................................................4
2.2 ELECTRO-HYDRAULIC SOLENOID VALVE CABINET (SVC) ...........................................................................5
2.3 HYDRAULIC POWER UNIT (HPU) ................................................................................................................5
2.4 HYDRAULIC ACTUATORS ............................................................................................................................5
2.5 VALVES ......................................................................................................................................................5
2.6 INDICATION SYSTEM ...................................................................................................................................5
2.7 MANUAL OPERATION / EMERGENCY OPERATION .........................................................................................6
3. RECOMMENDATIONS AND SELECTION GUIDELINES ..................................................................7
3.1 SYSTEM ......................................................................................................................................................7
3.2 CONTROL TYPE ...........................................................................................................................................7
3.3 INDICATION ................................................................................................................................................7
3.4 HYDRAULIC POWER UNIT (HPU) ................................................................................................................7
3.5 ACTUATORS................................................................................................................................................8
3.5.1 Actuator type ....................................................................................................................................8
3.5.2 Valve position indication..................................................................................................................8
3.5.3 Manual operation / emergency operation ........................................................................................8
4. GENERAL INFORMATION......................................................................................................................9
4.1 REQUIREMENTS FROM CLASSIFICATION SOCIETIES AND OTHER AUTHORITIES .............................................9
4.2 OTHER IMPORTANT INFORMATION FOR YARD, SHIPOWNER AND SYSTEM OPERATORS .................................9

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Valve Remote Control System

1. System architecture
Today, there are basically three main types of a valve remote control system’s architecture:
1: Decentralised system with electro-hydraulic actuators (“self-contained units”)
Advantages: Disadvantages:
• No hydraulic tubing to actuators • Limited applications - actuators cannot
• No hydraulic power unit be submerged in tanks nor installed in
• No solenoid valve cabinets hazardous area
• Complicated maintenance and
troubleshooting - all mechanical and
sensitive components on the actuator
• Electric cables to all actuators
• Indirect indication not available

Systems based on electro-hydraulic actuators, “self –contained units”, have been used on a
limited number of newbuildings, typically on ballast systems for dry cargo vessels, since the
introduction 4-5 years ago. Cost savings for the shipyards are obvious, but due to the limited
operation time, there are limited experience available with regards to the reliability, life cycle
cost, maintenance requirement etc.

2: Centralised power unit with solenoid valves located in deck-stations

Advantages: Disadvantages:
• Short hydraulic tubing from solenoid • Expensive equipment (Ex proof solenoid
valve to actuator valves on deck on tankers)
• Easy flushing and venting of hydraulic • Electrical cabling on deck
tubes • High risk of malfunction due to sensitive
components installed in corrosive
environment

System architecture of type 2 is typically used on larger vessels, VLCCs, FPSOs etc. to obtain
an acceptable distance between the solenoid valve and actuator. On ships with an “acceptable”
distance from each actuator to engine room/pump room, a conventional system with
centralised power unit and solenoid valve cabinet(s) have set the standard.

3: Centralised power unit and solenoid-valve cabinet

Advantages: Disadvantages:
• Less expensive system • Long control lines to actuators
• Easy maintenance and troubleshooting
- all mechanical and critical/sensitive
parts installed in dry, safe area
• Indirect position indication available
This document will describe a
conventional system with a centralised
power unit and solenoid valve cabinet(s).

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Valve Remote Control System

ELECTRO - HYDRAULIC VALVE CONTROL SYSTEM

CONTROL CONSOLE

WALL- MOUNTED CONTROL PANEL

SHIP
AUTOMATION VENDOR SYSTEM
PC

ELECTRO INTERFACE
HPU
IN SAFE AREA
DECK BOX SOLENOID VALVE CABINET
IN SAFE AREA

ELECTRO AND HYDRAULIC INTERFACE

SINGLEACTING SINGLEACTING ACTUATOR DOUBLEACTI NG ACTUATOR ACTUATOR ACTUATOR WI TH

ACTUATOR WITH DIRECT INDI CATION ACTUATOR WITH EM' CY BLOCK WI TH EM' CY BLOCK DI RECT I NDICATI ON
ON ACTUATOR ON DECK

The above diagram shows an overview of a valve remote control system consisting of
different types of conventional hydraulically operated actuators, a centralised hydraulic power
unit (HPU), a centralised solenoid valve cabinet combined with a de-centralised solenoid
valve deck box.

1.1 Control function

Control function can be done from a conventional control console, from the CRT of a
computer/PLC based system or from an integrated ship automation system. This is often
combined with smaller wall mounted control panels located locally e.g. in the engine room or
on deck.
Valves can be controlled with OPEN/CLOSE position or with possibilities for throttling,
depending of valve service. In case of OPEN/CLOSE control, the remote operated valve will
be in either fully open or fully closed position. In case of throttling control, the remote
operated valve can be set in any position from fully open to fully closed.

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Valve Remote Control System

1.2 Position indication

Monitoring of valve position can be by signal from the actuator, independent of hydraulic
system - "direct indication", or by signals from the hydraulic system - "indirect indication".

SOLENID VALVE C ABI NET

24V DC 24V DC
P

T
A B A B

Doubleacting actuator Doubleacting actuator

with indirectindication with directindication

2. System description
A centralised electro-hydraulic valve remote control system consists of control panel(s) (or a
computer system), electro-hydraulic solenoid valve cabinet(s), hydraulic power unit(s) and
hydraulic actuators mounted on the valves.

2.1 Control panel

A control panel is normally installed in the control console located in the cargo control room
or in the engine control room. For selected remote operated valves decentralised control can
be done from locally installed control panels.
The control console is normally designed as a “piano type” console with control switches and
position indicators in a mimic diagram in the horizontal part and other equipment for system
handling, tank monitoring, alarm system etc. located in the vertical part.
In case the remote operation is performed from a computer system, the mimic diagram with
switches and indicators will be replaced by one or more CRTs. However, a conventional
mimic diagram with control switches may be used as a secondary control panel and a
simplified mimic diagram with position indicators may be used as a secondary indicator panel
for valve position.

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2.2 Electro-hydraulic solenoid valve cabinet (SVC)

An electro-hydraulic cabinet receives control signals from the control switches in the control
console (or from the computer system) which activates the solenoid valves.
The cabinet consists of solenoid valves, throttle valves for adjusting actuator operation time,
high-pressure filter and quick connectors for portable hand pump. In case the valve position
indication is of indirect type, flow switches and/or volumetric hydraulic indicators are also
installed in this cabinet.
The solenoid valve cabinet is installed in safe, non-hazardous area.

2.3 Hydraulic power unit (HPU)

A hydraulic power unit supplies the hydraulic fluid to the solenoid valves in the electro-
hydraulic solenoid valve cabinet and shall include a hydraulic accumulator unit.
The unit includes a locally mounted starter cabinet and alarm cabinet. A remote operation
panel to be installed in the control console is available as option.

2.4 Hydraulic actuators

The hydraulic actuators are mounted on the valves and remotely operated from the solenoid
valves. Depending on the valve function, the actuators are single acting, fail safe type (e.g.
shut down functions) or double acting (on-off or throttle). Double acting actuators with a fail
safe, spring return function is also available.
Hydraulic actuators can include a manual override by means of a de-clutchable gear.

2.5 Valves
Normally valves are purchased directly from the valve supplier and delivered to the actuator
maker for actuator/valve assembly and testing of complete units connected to the control
system. Alternatively, the remote control system supplier can include the valves in the
delivery, however a modest handling charge will then be applied.

2.6 Indication system

Direct indication of the valve position (also called ”true indication”) means that the indicator
transmitter is mounted directly on the actuator.
For actuators with OPEN/CLOSE control, direct position indication is done by means of
limit-switches or inductive contacts located in a protected box mounted on the actuator and
for actuators with throttle control, by means of a potentiometer or position transmitter with 4-
20mA output. In both cases electric wiring from actuator to control console is required and
will require Ex proof equipment or intrinsically circuits if actuator is located in hazardous
area.
Direct indication is not recommended if the actuator is submerged.

Indirect indication means that the valve position is determined by transmitters installed in the
solenoid valve cabinet, which monitors the hydraulic branch lines to/from each actuator.
Valve position for actuators with OPEN/CLOSE control is done by means of flow switches in
the hydraulic branch lines, and for actuators with throttle control by means of a volumetric
indicator. No cabling to the actuators is required and is therefor recommended where actuators
are submerged or located in hazardous area.

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Valve Remote Control System

NOTE: Volumetric indicators should not be used for the smallest actuators due to these
actuator’s small stroke volume.

2.7 Manual operation / emergency operation

Manual or emergency operation of the actuators is typically done by means of a portable
handpump or a stationary handpump fixed to the actuator.

The portable hand pump is connected to an “emergency connection block” mounted on the
actuator or in the actuator’s branch lines. Submerged actuators shall have a connection block
for portable handpump in dry space close to the actuator.
There are two alternative emergency connection blocks available:
A: Emergency operation block with shut-off valves
Requires manual operation of the shut-off valves to allow operation of the handpump.
B: 3-way valve with quick connector (one on each connection port)
Requires manual operation of a 3-way valves to enable operation of the handpump.
Can be used on single-acting actuators.
There are also connection blocks in the solenoid valve cabinet and on the hydraulic power unit
for a centralised manual operation of the complete system by the portable hand pump.

The stationary handpump may be fixed to the actuator or installed in the vicinity of the
actuator in order to ensure easy access for manual operation.

Alternatively, a de-clutchable manual gear mounted on the actuator, or mounted in between

the actuator and the valve, is available for manual emergency operation of the actuator.

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3. Recommendations and selection guidelines

3.1 System
Centralised electro-hydraulic system with conventional control should be used if a separate
hydraulic room is available and control / monitoring from more than one location is required.
Electro-hydraulic system with computer control should be selected if the valve control system
is to be integrated with other systems. (Pump control, tank monitoring, high-level alarm, anti-
heeling systems etc.) This system type is also suitable for programming of automatic
sequences for loading and unloading.

3.2 Control type

OPEN / CLOSE control to be used for valves with only fully open or fully closed position.
Throttling control to be used for valves requiring continuos control of valve position, e.g.
process valves, pump discharge valves and main suction valves in tanks etc.

3.3 Indication
Direct indication is recommended for all non-submerged valves. Especially for shipside and
bilge valves. For shipside valves the Classification Societies previously required "true
indication", which means that the signal shall be given directly from the valve/actuator. Even
though some classification societies has waived this requirement, this solution is still
recommended to ensure the most reliable position indication.
Indirect indication is recommended for all submerged valves. Indirect indication will reduce
cabling etc. and may therefor also be used on non-submerged valves in order to save cost.

3.4 Hydraulic power unit (HPU)

To be built and delivered as one skid-mounted unit and should contain the following main
components:
- Oil reservoir with a capacity to be calculated depending on number of actuators.
Reservoir volume to be minimum 20 times the capacity of one pump.
- 2 off selectable gear pumps with electric motor. Each pump shall have enough capacity
to operate the complete system. The pumps have the capacity to operate min.10% of the
actuators in one minute. Electric motors to be controlled from separate starters.
- Accumulator(s) with the capacity to operate 10% of the actuators without pump in
operation. Capacity to be calculated to operate all shipside valves simultaneously, and to
compensate the leakage through the directional valves for a period of five minutes when
no valves are operated.
- Pressure control for start/stop of pumps at preset values
- Safety valve
Pressure gauge
- Tank level monitoring
- Oil temperature monitoring
- Control unit:
A local starter cabinet, or a remote operation panel in control console, with manual
switch for selecting pump in operation.
- Alarm unit:

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Valve Remote Control System

A local alarm unit with visual alarms and with possibility of interfacing individual
alarms or a common alarm to the vessel’s computer system.
Recommended working pressure of the power unit (nominal system pressure) is 100 - 140 bar.

3.5 Actuators
To be of piston / scotch yoke type (for maximum torque in both end positions).
Actuators with mechanical locking in both end positions to be used for butterfly valves.
Actuators with adjustable stroke to be used for ball valves.
Size of actuators to be calculated to give min. 120% of required valve torque at minimum
hydraulic pressure.

ACTUATOR WITH MECHANICAL LOCK Pl unger bear i ng Bl eed Pl ug

ACTUATOR, ADJUSTABLE STROKE
Pl unger

Loc al i ndi cat or Seal i ng

Cr osspi n
Adj us t ment sc r ew

For k
Loc ki ng s c r ew/ nut

3.5.1 Actuator type

Double acting actuator to be used for valves that shall remain in actual position in case of
power failure. ("Fail to set" function.)
Single acting actuator to be used for valves requiring a "Fail to safe" function. Single-acting
actuators on valves with "throttle" function should be avoided.

3.5.2 Valve position indication

All actuators shall have a local visual position indicator.
Remote indication can be of “direct” or “indirect” type.
Direct position indication shall be by means of signal transmitters mounted on the actuator,
e.g. limit-switches for OPEN/CLOSE indication and potentiometer for continuous indication.
For actuators located in hazardous area, the signal transmitters must be suitable for
intrinsically safe circuits, Ex(i) type.
Indirect position indication shall be by means of hydraulic open/close indicators installed in
the hydraulic lines for OPEN/CLOSE indication and volumetric indicators for continuos
position indication. Volumetric indicators should be of piston type for maximum accuracy.

3.5.3 Manual operation / emergency operation

All actuators shall be equipped with facilities for manual emergency operation by means of
connectors for portable handpump or a stationary handpump.
Doubleacting actuators shall have an emergency operation block with shut-off valves.
Singleacting actuators may have a 3-way valve with quick connector on each connection port.

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Submerged actuators shall have a connection block for portable handpump in dry space close
to the actuator.
The stationary handpump shall be possible to install in the vicinity of the actuator in order to
ensure easy access for manual operation.

4. General information
Recommended hydraulic operation pressure is 100 - 140 bar (max 220 bar).
Inner diameter of pipe to actuators to be 4 - 10 mm (to be desided for each system)
Inner diameter of pipe from HPU to solenoid valve cabinet to be 12 - 16 mm (depending on
distance and qty/size of remote operated valves).

4.1 Requirements from classification societies and other authorities

Pressure vessels (e.g. actuators) shall be certified by Classification Society.
Valve position indication system and devices for emergency operation to be in accordance
with classification rules.
Complete installation to be approved by Classification Society.

4.2 Other important information for yard, shipowner and system operators
Additional requirements regarding loading and discharge safety may be applicable for ships
operating in special areas.

------ * ------

For further information, please contact:

Scana Skarpenord as, Rjukan
Visiting adress: Såheimsveien 2,
Mail adress: P.O.Box 3,
N-3361 Rjukan
NORWAY

Tel.: +47 35093200

Fax: +47 35091801
e-mail: ssr@scana.no
web site: www.skarpenord.no

contacts:
Ragnar O. Øhrn, Technical Manager
Harry B. Bystrøm, Sales Manager

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