Oil & Gas · EPC / Turnkey · 2025

PS1 & PS2 — Valve Automation and Control System

Engineering, design, procurement, installation, testing and commissioning of a complete valve automation and control system for the PS1 & PS2 facilities.

48” valve before automation

New electric actuator

The challenge

The project involved automating 48-inch ASME Class 600 valves with electric actuators. The original valve data sheets and torque data were unavailable, so PVE performed a full technical assessment, valve torque calculations and actuator sizing. Because of the long distance between field equipment and the control room, a fibre optic communication network was designed and implemented.

PVE scope of work

Site survey and field engineering
Complete electrical and control system design
Engineering calculation and actuator sizing for 48” Class 600 valves
Selection and procurement of electric actuators
Design, supply and assembly of Ex-proof (ATEX/IECEx) control panels
Supply, programming and commissioning of Siemens PLC
Fibre optic communication system design and installation
PLC–SCADA integration
Power, control and fibre optic cable installation
Factory and site acceptance testing (FAT/SAT)
Testing, commissioning and operational handover

Key challenges & engineering achievements

Actuator selection without OEM valve data
Engineered actuator selection without the OEM valve performance data.
In-house torque calculations
Performed in-house torque calculations for large 48-inch Class 600 valves.
Long-distance communication
Designed and implemented a long-distance fibre optic communication system.
Hazardous area
Engineered explosion-proof field control panels.
SCADA integration
Successfully integrated a Siemens PLC with the existing SCADA system.
Remote operation
Delivered reliable remote operation and real-time monitoring of all automated valves.