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DOCUMENT NO : 44-LK-5100-00/J.02/0010-A4

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Issue Date


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Date : 12.08.08 Page 2 of 11 Revision No. : A



_________________________________________________________________________ DOCUMENT NO :44-LK-5100-00/J.02/0010-A4 STANDARD SPECIFICATION FOR CONTROL VALVES, SHUTDOWN VALVES & SELF-ACTING REGULATORS
1.0 PURPOSE The purpose of this specification is to define the minimum requirements of design and Manufacture of Control Valves, Shutdown valves and self acting regulators. 2.0 SCOPE The scope of work shall include design, manufacture, testing and supply of control valves, shutdown valves and self-acting regulators. The inspection requirements shall be as per the inspection plan. 3. 0 3.1 3.1.1 TECHNICAL REQUIREMENTS CONTROL VALVES, SHUTDOWN VALVES & SELF-ACTING REGULATORS Control valve type / design selection shall be made by taking special consideration of following conditions - Pressure drops, which exceed 10 bars. - Flashing or cavitating liquids. - Steam service where pressure drop exceeds 5 bar. - Corrosive fluids. - Control valves on erosive services (slurries). Control valves shall normally be globe type, single seated or double seated. Other valve types like butterfly ball, rotary plug, angle or 3 way etc., shall be selected as per service requirements. Flanged control valves shall be used. Body material, body rating shall be as per piping specifications as a minimum. The flange rating shall be 300# as a minimum or higher as per piping specifications. Valve bodies and other pressure parts, except diaphragms and housings shall be of forged or cast carbon/stainless steel conforming to grades ASTM A-181, ASTM A-216 / ASTM A-351/352, ASTM A-182 respectively, unless otherwise specified. Valve bodies of carbon/stainless steel with equivalent or better physical properties will be acceptable provided forged materials are not high manganese sulphur steels (free machining). However, higher grade materials if specified in piping specifications shall be considered accordingly. Minimum control valve body size shall be 1" in general. Reduced trims can also be considered. Body size shall be limited to 1", 1-1/2", 2", 3", 4", 6", 8", 10" and 12". Higher sizes may be used wherever necessary. Flanged connections shall conform to the dimensions and pressure temperature ratings of ANSI B16.5. The control valve shall be delivered complete with actuator and accessories preassembled. All accessories such as positioner, air filter regulator and solenoid valve shall be securely pre-tubed and mounted on the actuator such that they shall be removable for maintenance without disturbing other components. Noise from control valve during operation shall be limited to OSHA specified level or better. The noise level shall be less than or equal to 85 dBA SPL (Sound Pressure Level). Source treatment for noise, shall be preferred by using special trims like anti-noise trims, in case, noise exceeds the specified level. Other methods based on merit is permissible. For Control Valves Class V / IV shall be considered with metal seats as per process requirement or as specified in datasheets. For all shutdown valves, the leakage class shall be class VI minimum. If metal seat is not available in class VI then soft seat suitable to process service shall be considered.

Date : 12.08.08 Page 3 of 11 Revision No. : A







Date : 12.08.08 Page 4 of 11 Revision No. : A

Control valve sizing shall be carried out as per ISA S75-01. The selected valve Cv shall permit up to 150% of normal flow or 110% of maximum flow, whichever is higher. In general, control valves shall be sized so that the valve opening is as noted below: At max. flow At normal flow At minimum flow : : : about 80% open about 70% open about 15% open

Equal percentage control valves shall normally be sized between 60 & 80% open for normal flow. Linear control valves shall normally be sized to be between 50% and 70% open for normal flow. For 2-phase flow the control valve Cv shall be the computation of the Cvs of the liquid phase and the vapour phase utilising relevant correction factors based on the individual process conditions. 3.1.7 Flanged bolted type gland packing boxes shall be used, unless otherwise specified. Gland packing shall normally be self-lubricating type. Packing shall be PTFE on liquid and gas service upto 200C . and Grafoil for 200C and above. Asbestos and graphite as wetted material, either in packing or seal is not allowed. Bellows seal shall be used where it is required to isolate the packing from the process fluid or where no leakage to atmosphere can be tolerated like toxic, explosive and precious fluids. As a minimum, trim material shall be SS 316. Trim shall be with guide bushing of hardened stainless steel like 440 C, 17-4 PH all upto a pressure drop of 10 kg/cm2. For higher pressure drops or erosive and slurry services and in general for all steam services, flashing services, hard-surfacing of plug seat rings and seating area of inner valve with stellite shall be used. Special cases may require 17-4 PH seat ring and 440 C solid plugs or other materials like Hastelloy, Durimet, Monel, etc. For tight shut-off where suitable sofft seat shall be used, provided temperature limits are not exceeded. All soft seat trim valves shall be of fire safe design. For temperature above 300C stellite facing shall be used for guide posts. Guide bushing shall always be harder by a minimum of 125 Brinnel than the guide post. Trim characteristics shall be equal percentage type unless required otherwise. Control valve plugs shall be top and bottom guided for double seated valves and top guided for single-seated valves.The standard construction for globe body control valve shall be single seated with top guiding for low P applications and cage guided for high pressure drop applications generally. Hardened plug and seat rings shall be selected for erosive services, for steam services with P 5 bar or where P exceeds 10 bar Trim shall be coated with stellite 6 or colomonoy. Anti-cavitation trim shall be selected wherever cavitation is expected in the valve. 3.1.10 For liquid services in which high pressure drops occur, the application of a conventional trim with standard flow direction often results in very high velocities and cavitation. Where this is the case, preference should be given to hardened trim materials and / or, for singleseated valves, change of flow direction through the valve. If reverse flow direction is applied, special attention shall be paid to marking the correct flow direction on the valve body. Where hardened trim materials and / or change of flow direction is not adequate or feasible, valves with anti-cavitation trims shall be considered.




_________________________________________________________________________ DOCUMENT NO :44-LK-5100-00/J.02/0010-A4 STANDARD SPECIFICATION FOR CONTROL VALVES, SHUTDOWN VALVES & SELF-ACTING REGULATORS Date : 12.08.08 Page 5 of 11 Revision No. : A

The anti-cavitation valve shall be of the globe or angle-body design, the fluid velocity shall be controlled by using a valve trim having specially designed multiple orifices in series and / or in parallel. Designs other than the above require the written approval of the Consultant. For applications where valves with anti-cavitation trims are not available, i.e. miniaturetype control valves with a very low capacity (Cv factor), two valves in series should be considered, however, this procedure requires the written approval of the Consultant. 3.1.11 The allowed stroking time of the control valves shall be evaluated on the basis of the dynamic performance requirements as given below: Dynamic Performance Requirements: This section is not applicable to compressor antisurge control valves or control valves greater than 24 inches. Given below are some definitions related to speed of response of control valves: a) Dead Band: The range through which the control input signal may be varied upon the reversal of direction without initiating an observable change in valve position. b) Dead Time (Td): The interval of time between initiation of an input change or stimulus and the start of the resulting observable response. c) Overshoot: The amount by which the step response initially exceeds the final steady state value (% of step change). d) Step Resolution: The minimum step change in input signal to which the control valve system will respond whle moving in the same direction. e) Step Response Time (T63): The time after an input signal step change until the output has reached 63% of the steady state value. f) Step Response Time (T86): The time after an input signal step change until the output has reached 86.5% of the steady state value. Control valve assemblies shall meet the following dynamic requirements, this includes all valve components: valves actuator, positioner, filter / regulators, and boosters/solenoid valve when provided. a) Speed of response, as defined in the tables below, for any step change in the range of 2 to 10% of full valve travel. b) Dead Band less than 0.5% of full valve travel. c) Step Resolution less than 0.25% of full valve travel. d) Overshoot less than 10% Speed of Response for control valve assemblies in flow, differential pressure or pressure control loops: Valve (Inches) 0-2 3-6 8-12 14-20 22-24 Size Maximum dead time (Td) (seconds) 0.25 0.5 0.75 1.0 1.25 Maximum T63 step response time (seconds) 0.5 1.0 1.5 2.0 2.5 Maximum T86 step response time (seconds) 0.75 1.5 2.25 3.0 3.75



Date : 12.08.08 Page 6 of 11 Revision No. : A

Speed of Response table for control valve assemblies in temperature, level, hand or analytical control loops: Valve (Inches) 0-2 3-6 8-12 14-20 22-24 Size Maximum dead time (Td) (seconds) 0.5 1.0 1.5 2.0 2.5 Maximum T63 step response time (seconds) 1.0 2.0 3.0 4.0 5.0 Maximum T86 step response time (seconds) 1.5 3.0 4.5 6.0 7.5

3.1.12 3.1.13 3.1.14

Self actuating regulators for flow, pressure and temperature shall be used where loads are constant and requirements of precision and accurate controls are not stringent. Colour coding for all valve bodies and actuators shall be as per engineering design basis. For Butterfly valves end connections may be lug type or with flange. Normally butterfly control valve disc travel is specified as 0 to 60 for 0.2 to 1.0 signal range. The valve shall be sized so that the maximum flow is achieved at approximately 45 opening. The effect of reducers, where applicable shall be considered (i.e. Fp factor). All Shutdown valves shall be flanged Ball valves only, unless otherwise specified. Normally "floating ball" design shall be specified; where "trunnion mounting" has to be used, special check has to made for its suitability for service conditions especially for viscous and solidifying type liquids and slurries. Valves shall be full bore type. All shutdown valves shall be equipped with quick exhaust type solenoid valves / pilot valves to achieve fast closing in less than 5 seconds. All valve bodies for use on oxygen service are to be degreased and suitably protected for transit to prevent ingress of dust and grease. The body casting shall be completely machined internally to remove any casting imperfections and provide a smooth surface in order to reduce the probability of initiating metallic combustion. All valves on steam service shall comply with statutory requirements as per Indian Boiler Regulations (IBR). Vendor shall submit Form - III C of IBR duly filled. For all shutdown valves on fire safe applications, air volume tank shall be provided for storage of air volume for minimum 3 full strokes of the valves. All valve accessories such as solenoid valve, limit switches, volume tank etc shall also be enclosed in a certified fireproof enclosure. The cable used for actuation of the valve shall also be fire resistant ( Fire survival to IEC-60331). ACTUATORS Actuators shall be adequately sized to control with shut-off pressure differential applied. The maximum differential pressure for actuator sizing shall be assumed as maximum upstream pressure with valve fully closed and downstream atmosphere pressure where specifically not mentioned in the design data sheet. Valve actuator(s) shall be selected to ensure that they are capable of operating the valve(s) with out-of-balance forces as would be caused by pressure equivalent to the full static pressure upstream and normal atmospheric pressure downstream. The actuator shall be designed considering 3.5 2 Kg/cm g air pressure to deliver 25% more force / torque than the max. torque requirement




3.1.18 3.1.19

3.2 3.2.1


_________________________________________________________________________ DOCUMENT NO :44-LK-5100-00/J.02/0010-A4 STANDARD SPECIFICATION FOR CONTROL VALVES, SHUTDOWN VALVES & SELF-ACTING REGULATORS Date : 12.08.08 Page 7 of 11 Revision No. : A

to operate the valve under all operating conditions including when the valve is pressure balanced up stream and downstream with the body cavity vented. 3.2.2 Valve actuator shall be pneumatic spring opposed diaphragm type, in general. Piston type actuators may be used for very high shut off pressure requirements. Additional equipment necessary to meet fail safe condition shall also be included in case double acting piston type actuator is selected. In either case, actuator shall be able to withstand maximum shut-off pressure with the minimum instrument air pressure specified. Valve actuators of the spring opposed diaphragm type shall be furnished, with readily adjustable enclosed springs of corrosion resistant finish. The adjusting mechanism shall be designed to ensure permanence of the spring adjustment. Other types of actuators such as piston type actuators, with or with out helper springs, and/or fail safe capacity tanks, are subject to consultants approval. Double acting piston cylinder actuators , where used, shall also be provided with volume tank, safety valve, NRV, pressure gauges etc. Volume tank shall be designed for 3 full stroke operations of the valve in addition to backup for control valve operation for a preset time as indicated in project specifications. Emergency shut-off valves shall be fitted with a fail-safe spring return mechanism, the spring-opposed actuators should preferably be of the multiple spring type (redundancy). Cylinder actuators shall be provided with adjustable limit travel stops in both directions. Bolt adjustment type limit stops shall be applied with a locking facility, e.g. a locking nut to prevent tampering. Piston and Cylinder actuators shall have O-ring sealing and shall be designed for low shaft and piston friction. 3.2.4 Actuator / diaphragm cases shall be made from steel as a minimum. Yoke material shall be high-tensile strength cast, or ductile iron as a minimum. Diaphragms shall be nylon reinforced neoprene or Buna N rubber. Cooling fins and extension bonnets where fitted shall be of the same material as the body. Finned cooling and/or extensions shall be used for cryogenic and high temperature services as applicable. POSITIONERS Electro-pneumatic positioner with Foundation Fieldbus shall be used for all control valves. Valve positioners shall be fully assembled complete with all necessary tubing. Air supply, output and signal gauges of 2 (50mm) nominal diameter shall be provided as standard. All accessories shall be tubed having MOC as per project specification with double ferrule type tube fittings. All pneumatic connections shall be minimum NPT (F). However, higher size pneumatic connections shall be selected for control valves to achieve specified stroking period as per the table given above. Valve positioner shall be provided with an adjustable mechanism to vary the relationship between valve stroke and controlling air pressure span. Positioners shall be capable of providing a full stroke of the control valve, in either direction to achieve desired storking period. Separate air filter regulator shall be provided for each control valve. Fieldbus Positioners


3.3 3.3.1


3.3.3 3.3.4



Date : 12.08.08 Page 8 of 11 Revision No. : A

It should be microprocessor based with digital communication and valve diagnostics capabilities by means of Foundation Fieldbus communication. The host (DCS/PCS) with a Valve Diagnostics software, should be capable of performing Diagnostics tests remotely providing sufficient data to determine instruments and valves health enabling predictive maintenance. The positioner must have a built-in process PID controller. Able to provide Actual Valve Travel, Input current, Actuator Pressure, Instrument Temperature, Travel Deviation, Travel Alert, Travel Accumulator, Cycle Counter and Failures Alerts to be displayed on the DCS console. It must be able to provide the following diagnostics information: i) Valve Signature Test with analysed data of Seat Load, Bench set and valve friction. ii) Dynamic Error Band Test with analysed data of Dynamic Error Band and Dynamic Linearity of the Control Valve iii) Process Diagnostics capability to evaluate process performance. iv) All Diagnostics Graphs must have a 8000-point resolution and able to be superimposed for comparison When mounted on a control valve, Factory Valve Signature Test Report shall be provided to show net pressure vs. travel over the span of the assembly as well as Dynamic Error Band Test Report showing travel vs. input signal. The analysed data shall include true seat load, valve friction, and actuator bench set. The data will be the reference for future diagnostics analysis when the instrument and valve are in operations. Future enhancement of functionality can be downloaded electronically without need for change of hardware. The electrical housing shall be designed to meet NEMA 4X, IEC 529 IP65 and has certification for Intrinsic Safety and Explosion-proof from FM or CSA or Flame-proof and Intrinsic Safety from LCIE/CENELEC The operating ambient temperature limits shall be between -40F to 175F (-40C to 80C). The Vibration effect when unmounted and mounted on actuators shall be : <1.0% of output span per SAMA PMC31.1 Section 5.3, Condition (at 5%, 50%, 95% input) No significant resonance when tested per SAMA PMC31.1 Section 5.3, Condition 3. It shall have an Electromagnetic Interference (EMI) that is less than +/-0.1% when tested per IEC 801- 1 and 801-3, 27 to 1000 MHz with field strength of 30 V/m (volts per meter) It shall be in modular design to facilitate easy replacement and interchangeability when used on either single- or double-acting actuators for both sliding stem and rotary shaft valves. Printed Wiring Board shall be fully encapsulated which eliminates electrostatic discharge sensitivity and provides ruggedness in operation. The module shall include pressure and temperature sensors. It shall have Foundation fieldbus output compliant to ITK 4.6 or above. It shall employ device description to facilitate interoperability.


_________________________________________________________________________ DOCUMENT NO :44-LK-5100-00/J.02/0010-A4 STANDARD SPECIFICATION FOR CONTROL VALVES, SHUTDOWN VALVES & SELF-ACTING REGULATORS
It shall have features like EDD and FDT/DTM available. It shall not be sensitive to the polarity of the wiring connection. It shall operate on 9 to 32 V dc, with current draw capacity of 28 mA maximum. This low power consumption shall allow more devices to be connected to a segment. Vendor to specify Response time (including dead time, time constant and min damping) It shall have multiple FF compliant analog input AI, AO, PID, DO and DI blocks and VCRs (at least 12 Nos or above). VCRs used for communication between function block both within a device as well as amongst different devices shall be sufficient to execute all inter block data transfers. Execution time of PID block shall not be more than 50ms and for AI, AO blocks shall not be more than 30ms. It shall have a back up link active scheduler ( LAS) so as to improve the reliability and security of the FF network. It shall have software download capability for upgrades or product enhancement via fieldbus segment with the segment in operation. OTHER ACCESSORIES Hand wheels shall be provided as per requirement indicated in P&ID and project specifications. Handwheels shall override automatic operation. No hand wheels or bypass valve shall be provided for Shutdown valves. Valve stem position indicators shall be fitted as standard showing open, closed and incremental stroke positions. Direction of flow indication shall be permanently indicated on the valve body and shall be clearly visible in the final installed position. The limit switches for shut down valve and control valve wherever applicable shall be of intrinsically safe, proximity type. Separate switches shall be supplied for open and closed position. All the emergency shutdown valve shall have limit switches to indicate the valve position as per P&ID. The enclosure of limit switches shall be as per the respective area classification. All valve with limit switches shall also have visual indication of the valve OPEN or CLOSE conditions. Solenoid valves, wherever used, shall be 3 way universal type and shall be continuous rated type with class F coil insulation as per IEC 6085 / IS 1271. These shall be of SS body with SS316 trim, as a minimum. The solenoid coil lead wires shall be neatly terminated on the Solenoid valve terminal box. Flying leads from the solenoid valve are not acceptable. Solenoid vents shall have bug screens. All pneumatic tubing for interconnection of solenoids etc shall be as per project specification. Air lock relays of proven make and design shall be used as required. INSPECTION & TESTING Test Procedure shall include but not be limited to the following: 3.5.1 3.5.2 Dimensional /Physical Test Hydrostatic Body Test. - Duration 3 mins.

Date : 12.08.08 Page 9 of 11 Revision No. : A

3.4 3.4.1




3.4.5 3.5



Date : 12.08.08 Page 10 of 11 Revision No. : A

All valves when completely assembled shall be hydrostatically tested for a sufficient time for the body, gland and joints to be scrutinized for leakage. Parts under test shall be unpainted and shall have been processed with rust remover and protected against further rust prior to test. 3.5.3 Seat Leakage Test. - as per ANSI B16.04, 1976 / FCI 70.2 The leak test shall be conducted on the closed valve with zero diaphragm pressure for 'close on air failure' and with 18 psig (1.2 bar. g) diaphragm pressure for 'open on air failure'. The leakage test shall be carried out at both minimum and maximum pressures. 3.5.4 3.5.5 Diaphragm head test. Helium Leak Test - for control valves with bellows seal. The valve shall be stroke tested and checked for correct action on removal of supply pressure. On 300 mm valves and below, all actuators and accessories shall be completely assembled to the valve and tested at the vendors works. Assemblies shall be "type tested" under full line pressure conditions including testing under full line pressure with valve closed and body cavity vented and opening torque measured. 3.5.6 The Vendor shall provide a certified record of all tests carried out and each test record shall contain the following: - Purchase Order Number and Valve Tag Number - Valve body size and inner valve (Trim size) size - Vendor's serial number - Observations of the tests done - Bench settings for valve stroke - Date of Test Whenever fire safe requirement is specified for a shutdown valve, the valve body and actuator shall meet the testing requirements as per API 617 latest revision. Also for all valves on cryogenic service, i.e. valves installed in piping classes used for temperatures below 29 C, design and testing shall be as per BS 6364. Control valves / shutdown valves requiring certain specified operating timings, shall be tested before despatch for the operational time verification. A 316 SS nameplate shall be securely fastened to the valve in a visible and accessible place. Nameplates shall show as a minimum, the following: 4.0 Instrument Tag Number Vendor's Name Valve Model Number Order/Requisition Number Body & Trim Material Stem Packing Material Body Size and Rating Design CV (For Control valve and Regulator) Trim Characteristic or Cam Code/type as necessary Air-Fail Action Hazardous Area certifying authority certificate Number Actuator size / spring range - air supply pressure


3.5.9 3.5.10



_________________________________________________________________________ DOCUMENT NO :44-LK-5100-00/J.02/0010-A4 STANDARD SPECIFICATION FOR CONTROL VALVES, SHUTDOWN VALVES & SELF-ACTING REGULATORS Date : 12.08.08 Page 11 of 11 Revision No. : A

ANSI B16.10 ANSI / ISA S75.01 ANSI / ISA S75.02 ANSI / ISA S75.03

Control Valve dimensions Flow equations for Sizing Control Valves Control valve Capacity test Procedure Face to Face dimensions for Integral flanged globe style control valve bodies ( ANSI 125, 150, 250, 300 & 600) ANSI / ISA S75.04 Face to face dimensions of flangeless Control valves ( ANSI 150, 300 and 600) ANSI / ISA S75.05 Control Valve terminology ANSI / ISA S75.11 Inherent flow characteristics and rangeability of control valves API Std. 598 Valve Inspection and Test, 5th Edition ISA ISA Handbook of Control valves ATTACHMENTS Nil