Zubair 1 Depot — Actuator Replacement for Large-Size Valves
EPC project to replace Rotork actuators with AUMA actuators in Zubair 1 Depot, including engineering, installation and commissioning for large-size 42” and 36” valves.
The challenge
A strategic oil-sector facility with limited as-built information, large valves, restricted working space and the need to keep the depot operating.
PVE scope of work
- FEED site survey
- Engineering: sizing and retrofit calculation
- Replacement from Rotork to AUMA
- Installation
- Commissioning
- Strategic oil-sector reference
Key challenges & engineering achievements
Limited existing site data / as-built information
Before engineering, the team verified actual site conditions, valve orientation, mounting dimensions, mounting flanges, available space, electrical connections and existing actuator configuration through a pre-engineering site survey.
Retrofit compatibility from Rotork to AUMA
Replacing one actuator brand with another required careful verification of mechanical interfaces — mounting flange, drive bush, stem dimensions, torque requirements, handwheel position and space limitations.
Large-size valve operation: 42” and 36” valves
Accurate torque sizing and retrofit calculations ensured the new actuators could safely and reliably operate the valves under site conditions.
Restricted site access and working space
Limited space around the valves made dismantling, lifting, alignment and installation of heavy actuators and accessories more difficult.
Safe removal and installation works
Lifting, handling and installation of heavy equipment were managed with proper HSE controls, PPE compliance and safe work practices.
Integration with existing electrical / control system
New actuators were connected and commissioned with the existing power supply, control wiring, local/remote operation, limit and torque settings and end-user requirements.
Minimising interruption to depot operation
Work was planned and executed carefully to avoid operational delays or extended shutdown periods.
Field commissioning and functional testing
Each actuator was set, calibrated, open/close verified, torque/limit switches adjusted and finally commissioned.
Equipment
AUMA electric actuators, controls and gearboxes
Outcome
All actuators replaced, commissioned and handed over — a strategic oil-sector reference for PVE.
Project photo gallery
Real photographs from site. Click any photo to enlarge.
