Valve Remote Control Systems (VRCS) | MOWE Products/Marine
HYDRAULIC AUTOMATION SOLUTIONS
Cargo Ballast Valve Remote
Control System – FPSO, FSO
(Hydraulics)
Reliable. Safe. Engineered for Marine & Offshore.
Hydraulic Valve Remote Control System (VRCS) for Cargo and Ballast Valve operation on FPSO, FSO, FPU and offshore vessels, providing centralized hydraulic valve control, actuation, monitoring and position feedback for demanding marine and offshore applications.
MOWE Hydraulic
Valve Remote Control System
Cargo Ballast Valve Remote Control System
Floating Production, Storage, and Offloading (FPSO) units represent some of the most complex assets in the offshore oil and gas industry. Managing fluid movement across these vessels requires hundreds of critical valves operating under harsh marine conditions, high pressures and demanding safety constraints.
A Hydraulic Valve Remote Control System (VRCS) serves as the primary infrastructure to actuate, monitor and regulate these valves safely from a centralized control room.
Unlike pneumatic systems, which can face freezing risk and lower force density, or purely electric actuators, which can be bulky and require suitable explosion protection for hazardous environments, hydraulic systems provide high torque-to-weight ratios and reliable actuation for demanding offshore applications.
Hydraulic systems can also incorporate reliable failsafe capabilities through stored mechanical energy using accumulators or springs, depending on the required system design and application.
MOWE is a focused Offshore FPSO, FSO, FPU and offshore vessel Valve Remote Control System integrator and manufacturer. With over 20 years of experience working on hydraulic valve remote control systems across multiple projects in the Asia Pacific and international offshore markets, MOWE has developed experience in designing systems to meet different vessel layouts, operating environments and project requirements.
Over the past 20 years, MOWE has delivered systems for more than 20 FPSO projects, gaining experience in the design and integration of valve control systems for different climates, vessel configurations and operating demands.
MOWE project experience extends from Malaysia to Nigeria, Angola to Brazil, supporting FPSO and FSO projects that continue to operate with MOWE systems.
Selected large-scale FPSO and FSO deliveries include FSO Berganding, FSO Sao Vang, FSO Benchamas, FPSO Agogo, FPSO Anna Nery and many others.
Overcoming delivery pressures, design complexities, client cleanliness requirements and long service-life commitments, MOWE Marine & Offshore continues to build its experience as a professionally committed Valve Remote Control System manufacturer and integrator.
- • CNOOC FPSO Panyu China
- • CNOOC FPSO Cao Fei Dian China
- • MODEC FPSO – Nina Singapore
- • Exxo South Angsi FSO – Deck Machinery & HPU
- • Abu Cluster FSO - Talisman
- • Orkid FSO - Talisman
- • SBM Kikeh - Single Bouy Marine
- • Ruby Princess FPSO - Petrofac
- • Cendor 2 FPSO - Petrofac
- • BP FPSO Angola - MODEC
Our experience is our strength. From installation of tubes and pipes to pressure testing, equipment supply and complete system integration, the full Valve Remote Control System can be commissioned to required cleanliness standards and other CLASS requirements.
MOWE supports marine and offshore valve control requirements from hydraulic power generation and distribution through to actuator operation, valve position feedback, control panels, hydraulic tubing and system integration.
Other vessel types include RoRo vessels, Offshore Support Vessels, Platforms, Jackup Rigs, Windmill Installation Vessels, Containers, Product and Chemical Tankers and many others.
Hydraulic VRCS Core Components
A marine offshore-grade hydraulic Valve Remote Control System is divided into functional layers covering hydraulic power generation, hydraulic distribution, valve actuation and control and feedback. Each layer is engineered to work together as an integrated valve control system.
Hydraulic Power Unit (HPU)
The Hydraulic Power Unit (HPU) is the powerhouse of the hydraulic Valve Remote Control System. It typically features redundant duty/standby positive displacement pumps driven by electric motors, a marine-grade 316SS oil reservoir, offline filtration units and a nitrogen-charged accumulator bank.
The accumulator bank stores sufficient hydraulic fluid volume to execute the required safety operating cycle for critical valves when main electrical power is unavailable, according to the project safety philosophy and system design.
The HPU interfaces with the ICSS – Integrated Control and Safety System – supporting local and remote commands and valve feedback.
HPU configurations can also incorporate an HMI touchscreen, bypass filters, hydraulic oil coolers, motor heaters and other project-specific requirements.
Nothing comes as a standard in our area of work. HPU configuration is developed around the vessel, valve quantity, operating requirements and customer specifications.
Valve Control Panels / SVC & Deck Boxes
Valve Control Panels, Solenoid Valve Cabinets (SVC) and Deck Boxes are strategically located in safe utility spaces and, where required, Zone 1 or Zone 2 hazardous areas.
These enclosures house hydraulic manifold blocks, directional solenoid valves, pressure switches and manual override hand-pumps. They bridge the gap between electronic commands and physical hydraulic fluid routing.
In special cases, Remote I/O units associated with the PLC can also be located in hazardous areas to reduce wiring requirements and improve ease of command and maintenance.
Solenoid valve arrangements can include Ex d or Ex iA protection concepts for hazardous area applications, depending on project requirements and certification.
Solenoid valve power ratings can range from approximately 8W down to 1W depending on the selected equipment and application.
Two major mechanical solenoid valve designs include Spool Valve and Poppet Valve designs. Selection can be made to support hydraulic pressure retention and reduction of potential internal oil leakage.
MOWE Hydraulic Actuators
MOWE Hydraulic Actuators are mounted directly to valve stems and translate hydraulic fluid pressure into mechanical valve movement.
- Quarter-Turn Actuators – Scotch-Yoke mechanisms for suitable valve applications.
- Rack-and-Pinion Actuators – For ball, butterfly and plug valve applications.
- Linear Actuators – Hydraulic cylinders for high-pressure gate and globe valves.
- Double-Acting – Hydraulic pressure is required for opening and closing.
- Single-Acting Spring Return – Mechanical spring action forces the valve to the required fail position upon loss of hydraulic pressure.
MOWE hydraulic actuators are manufactured in cast iron or cast steel construction with thick reinforced walls and hydraulic pressure testing up to 250 bar.
Actuators can be installed dry on deck or designed for submerged applications, including seawater or cargo oil environments, subject to material selection and suitable surface protection.
Depending on material selection and adequate surface protection, actuator designs can support long offshore service-life requirements of up to 30 years.
Control & Feedback Layer
The control and feedback layer integrates valve position indicators such as limit switches or 4–20mA HART continuous position transmitters with the vessel's Distributed Control System (DCS) or Safety Instrumented System (SIS).
Position feedback provides the control system with the operating status of the remotely controlled valve and supports centralized monitoring from the vessel control system.
Position and electrical equipment intended for hazardous areas can be selected with appropriate Ex d or Ex i protection according to project requirements.
MOWE works with Siemens, Schneider and major CLASS-approved PLC and processor manufacturers to deliver offshore and marine class processing systems.
The processor and control layer functions as the intermediate layer between vessel safety systems, automation systems and hydraulic valve control equipment.
Hydraulic Valve Control Products
As a manufacturer and system integrator, MOWE manufactures and integrates key components used in hydraulic Valve Remote Control Systems for marine and offshore applications.
Valve Remote Control System
Full hydraulic valve control systems for FPSO, FSO, FPU and offshore vessels.
Hydraulic Control Actuators
Hydraulic actuators for quarter-turn and linear valve applications.
Volume Counters
Hydraulic volume counters for valve position indication and monitoring.
Hydraulic Manifolds
Various manifold designs for hydraulic valve control applications.
Throttle & Needle Valves
Hydraulic flow control components for system regulation.
Control Blocks
Hydraulic control blocks for fluid routing and actuator operation.
Deck Boxes
Deck box designs for safe areas and hazardous area applications.
Material Options
Materials include brass, bronze, aluminium, steel and stainless steel, with other materials available according to requirements.
How the Hydraulic VRCS Works
Hydraulic Power
The HPU generates, filters and stores hydraulic power required for remote valve operation.
Control Command
Local or remote commands are transmitted through the vessel control and automation system.
Hydraulic Routing
Solenoid valves and hydraulic manifolds route hydraulic fluid to the selected actuator.
Valve Movement
Hydraulic actuator converts hydraulic pressure into mechanical valve movement.
Position Feedback
Valve position feedback is returned to the control and monitoring system.
FPSO & FSO Cargo & Ballast Valve Control
Cargo Handling & Offloading
Hydraulic remote control of cargo suction and discharge butterfly and ball valves supports controlled transfer of crude oil from storage tanks to tankers and assists tank level management during production and offloading operations.
Ballast & Bilge Control
High-capacity marine butterfly valves can be remotely operated for ballast and bilge functions supporting vessel stability, hull stress management and tilt correction.
Inert Gas & Venting
Remote control of cargo tank isolation and venting valves can support inert gas and cargo tank ventilation arrangements on FPSO and FSO vessels.
FPSO, FSO & FPU Systems
Hydraulic VRCS solutions can be configured for FPSO, FSO, FPU and other offshore vessels where centralized remote valve operation and monitoring are required.
Hydraulic VRCS Design & Engineering
Designing an FPSO or FSO hydraulic Valve Remote Control System requires careful consideration of hydraulic dynamics, valve torque, operating environment, hazardous area classification, redundancy, cleanliness and vessel control requirements.
Operating Pressure
Systems can be designed for Medium Pressure ranges of approximately 105–160 bar or High Pressure ranges of approximately 210–345 bar depending on project requirements. Higher hydraulic pressures can allow smaller actuator footprints for selected applications.
Hydraulic Fluid
Hydraulic systems may utilize synthetic, fire-resistant hydraulic fluids such as ISO VG 32/46 or suitable low-viscosity mineral oils according to equipment compatibility, customer requirements and operating conditions.
Operating Temperature
Hydraulic system design can consider operating temperature profiles ranging approximately from -20°C to +60°C according to the specified project environment and equipment selection.
Hazardous Area Compliance
Electrical components such as solenoids, junction boxes and sensors installed in hazardous areas require appropriate explosion protection and certification such as ATEX, IECEx or applicable regional Class/Division requirements.
Redundant HPU
Critical HPU systems can incorporate redundant electrical motors and pumps to improve system availability and support continued operation during equipment failure.
Solenoid Control
Solenoid blocks can be arranged according to the required control and safety philosophy, including configurations such as 2oo2 or 1oo2 where applicable.
Valve Position Feedback
Valve position can be monitored using limit switches or continuous 4–20mA HART position transmitters according to the required control philosophy.
CLASS & Project Requirements
System architecture, components, materials, testing and documentation can be configured around vessel specifications, CLASS requirements, hazardous area requirements and customer technical specifications.
Hydraulic Cleanliness
Hydraulic systems require controlled flushing and cleanliness verification before initial startup. MOWE systems can be prepared according to specified project cleanliness standards, including NAS 1638 Class 6 / ISO 4406 cleanliness requirements where specified.
Advantages & Considerations
High Power Density
Hydraulic systems provide high force and torque output from compact actuator packages, making them suitable for large marine valves and high breakaway torque requirements.
Failsafe Capability
Accumulators or spring-return mechanisms can provide stored energy for defined failsafe valve functions according to the system safety philosophy.
Reliable Offshore Operation
Hydraulic actuation can provide controlled valve movement for demanding marine and offshore operating environments.
Environmentally Sealed
Closed hydraulic circuits can protect internal mechanical components from moisture, salt spray and harsh offshore environmental conditions.
Hydraulic Fluid Leakage
Hydraulic systems require proper tubing, fittings, maintenance and oil monitoring to minimize potential fluid leakage and associated environmental or deck safety concerns. High-grade 316L compression fittings can be selected where specified.
Flushing & Cleanliness
Hydraulic systems require careful commissioning and high-velocity flushing to achieve the specified hydraulic cleanliness level before initial operation.
Centralized vs. Decentralized Electro-Hydraulic Layouts
Modern FPSO and FSO engineering can use different hydraulic architectures depending on vessel layout, valve quantity, available space, installation requirements and project philosophy.
Centralized Architecture
A single large HPU located in a safe utility space feeds hydraulic fluid through ring mains or stainless steel tube bundles across the vessel deck to individual valve actuators.
- Centralized hydraulic power generation
- Hydraulic distribution throughout the vessel
- Suitable for large numbers of remotely controlled valves
- Can require thousands of metres of hydraulic piping or tubing depending on vessel size and arrangement
- Requires careful piping design, installation, flushing and leak control
Decentralized Electro-Hydraulic Actuators
A decentralized Electro-Hydraulic Actuator (EHA) arrangement incorporates a self-contained micro-HPU directly with the actuator or valve assembly.
- Local hydraulic power at individual valves
- Reduced hydraulic distribution piping
- Electrical power and digital communication connections
- Can reduce engineering and installation requirements for selected vessel layouts
- Profibus / Modbus or other digital communication arrangements can be considered according to system design
Hydraulic Valve Remote Control System Applications
*Illustrates MOWE Hydraulic Valve Remote Control System applications for FPSO and FSO projects.*
Professionally Committed to FPSO & FSO Valve Control
MOWE Marine & Offshore provides hydraulic Valve Remote Control System engineering, manufacturing, integration, installation, testing and commissioning support for marine and offshore applications.
Our experience covers hydraulic power units, accumulator systems, valve control panels, solenoid valve cabinets, deck boxes, hydraulic actuators, manifolds, hydraulic tubing, control and feedback systems and vessel automation interfaces.
MOWE continues to develop project-specific Valve Remote Control Systems around vessel layout, valve requirements, hydraulic pressure, hazardous area requirements, cleanliness standards, CLASS requirements and long-term offshore operation.