Spec. No.

: 3700
OFFSHORE FUNCTIONAL
Rev. No.: 0
DESIGN SPECIFICATION FOR
SECTION Discipline: Instrumentation
CONTROL VALVE
Page: 1 of 13

FUNCTIONAL SPECIFICATION
FOR
CONTROL VALVE

TOTAL
PREPARED / REVIEWED
APPROVED BY No. OF DATE REV. No.
REVISED BY BY
PAGES
MC MC AC 13 25.08.2003 0

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A / B ODS/SOP/008 TO 015 01 01 15/210/2003
 Spec. No.: 3700
OFFSHORE FUNCTIONAL
Rev. No.: 0
DESIGN SPECIFICATION FOR
SECTION Discipline: Instrumentation
CONTROL VALVE
Page: 2 of 13

CONTENTS

Clause No. ITEM Page No.

1.0 Scope Of This Document 3
2.0 Standards And Specifications 3
2.1 Reference Specifications 3
2.2 Other Specifications to be followed 3
3.0 Scope Of Supply 3
4.0 Control valve. 4
4.1 Control Valve Selection & Construction 4
4.2 Control Valve Sizing 5
4.3 Actuator. 5
4.4 Positioner. 6
4.5 Material 6
5.0 Equipment Protection 7
6.0 Installation Requirement 7
7.0 Calibration, Inspection And Testing 7
8.0 Documentation 8
9.0 Tagging & Nameplates 8
10.0 Review And Approval 9
11.0 Vendor Pre-Qualification Requirements 9
12.0 Preparation For Shipment 9
13.0 Receipt And Storage 9
Annexure I Material Selection Chart For Control valve 10
Annexure II Hook-Up Drawing for Control Valve 11

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A / B ODS/SOP/008 TO 015 01 01 15/210/2003
 Spec. No.: 3700
OFFSHORE FUNCTIONAL
Rev. No.: 0
DESIGN SPECIFICATION FOR
SECTION Discipline: Instrumentation
CONTROL VALVE
Page: 3 of 13

1.0 SCOPE OF THIS DOCUMENT:

1.1 This specification describes the essential considerations in the selection, installation,
calibration and testing of Control Valve.

1.2 The Contractor shall be responsible for the selection of Control Valve suitable for its
intended application, its design, engineering, procurement, packing, calibration, testing
at yard and offshore site, shipment to site and installation and commissioning at site.

2.0 CODES & STANDARDS:

2.1 Reference Specification:

a) Specification No. 3.6: Instrumentation Design Criteria
b) Basic Bid Work
c) Project P & IDs

2.2 Other Specifications To Be Followed:

NIL

3.0 SCOPE OF SUPPLY:

3.1 The number of Control Valves to be supplied and installed shall be as per the process
requirements indicated in the Basic Bid Work and the Project P & IDs.

3.2 The scope of supply shall also include commissioning spares and two years’ spares as
required by clause 3.6.4.8 of Instrumentation Design Criteria, and as suggested by the
Manufacturer.

4.0 CONTROL VALVE:

4.1 Valve Selection & Construction:

4.1.1 The Contractor shall select control valve based upon plant capacity. The Contractor
shall select reduced trim as required to satisfy the expected flow rate range.

4.1.2 Valve selection shall consider all possible effect of erosion, cavitations and noise.

4.1.3 Maximum permissible noise level shall be 85 dBA at 1 m from valve in all direction.

4.1.4 When minimum flow would require valve to be positioned at 15% travel provision shall
be made to prevent erosion of valve trim.

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A / B ODS/SOP/008 TO 015 01 01 15/210/2003
 Spec. No.: 3700
OFFSHORE FUNCTIONAL
Rev. No.: 0
DESIGN SPECIFICATION FOR
SECTION Discipline: Instrumentation
CONTROL VALVE
Page: 4 of 13

4.1.5 Equal percentage and linear trim characteristic shall be used as applicable to process
requirement. Quick opening trim may be used for ON/OFF service only.

4.1.6 Globe valves are preferred for general service, and shall be cage guided except in dirty
or abrasive services (Produced liquids) where post guiding is preferred.

4.1.7 Ball valve may be considered on sizes above DN 100.

4.1.8 Butterfly control valves shall be used for water services only.

4.1.9 Cage type and single seated globe body valves shall be having process Fluid tending to
open the valve.

4.1.10 Shut-off leakage of valves shall be in accordance with ANSIB16.104. Generally shut-
off shall be class IV or better.

4.1.11 Body rating and flange rating and facing shall be in accordance with the piping class
specification for the associated piping.

4.1.12 Valve Packing boxes shall be flange bolted to the bonnet. Valve packing shall be spring
loaded and adjustable. Teflon V rings shall be used up to 2120C. Above this temperature
graphite shall be used with an external lubricator and isolation valve.

4.1.13 Valve bonnets shall be flange bolted to the body. Screwed bonnet s shall not be
provided. For operating temperature of 2000C or greater, a radiating finned bonnet may
be required. For temperature below 00C an extension bonnet is required. If bellows seals
are required they shall be constructed from 316SS.

4.1.14 Minimum body size shall be DN25.

4.1.15 In cases where the above conditions cannot be satisfied through control valve selection
as described above, the contractor shall present alternatives for the company
consideration.

4.1.16 Where a valve is venting to flare, soft seals are preferred. For high-pressure drop
application in gas service multiple orifice trim design shall be used. Labyrinth design
shall not be used.

4.1.17 Pneumatic connections shall be ¼” NPTF as minimum. Larger Port sizes shall be used
wherever required for larger sizes of actuators.

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A / B ODS/SOP/008 TO 015 01 01 15/210/2003
 Spec. No.: 3700
OFFSHORE FUNCTIONAL
Rev. No.: 0
DESIGN SPECIFICATION FOR
SECTION Discipline: Instrumentation
CONTROL VALVE
Page: 5 of 13

4.1.18 Termination in wiring enclosures shall be via fixed terminals. Flying leads shall not be
used.

4.1.19 Flow direction shall be stamped or cast on the body of all valves.
4.1.20 The Contractor shall provide detailed pressure temperature envelope curves for each
combination of valve body, trim and elastomer material.

4.2 Control Valve Sizing:

4.2.1 The Control valve shall be sized to pass high and low extremes of flow at no more than
80% and no less than 20% travel respectively. Butterfly valves shall be sized with 60%
representing 100% Travel.

4.2.2 The Contractor shall submit Control Valve sizing calculation performed in accordance
with ISA S 75.01 and based on Process data, Approved Process flow diagram and
material balance.

4.3 Actuator:

4.3.1 Control valve actuators shall be pneumatic, spring return type, diaphragm or piston
type. Spring shall be corrosion resistant, cadmium plated or equal. Piston type actuator
shall be used where diaphragm actuator cannot be used due to capacity limitation.
Electric actuator shall be used wherever specified.

4.3.2 Actuators shall be sized for operation under maximum shutoff pressure drop across the
valve minimum instrument air pressure or voltage to the actuator as specified in this
specification.

4.3.3 Actuators shall be selected to achieve specified valve failure positions. All accessories,
including pilot valves, relays, volume bottles etc. for double acting actuator or air block
relays for fail in position valves, shall be supplied with the valve.

4.3.4 A valve stem position indicator shall be provided. All control valve scales shall be
calibrated from 0-100 %.

4.3.5 Detachable side mounted heavy-duty hand wheels shall be provided for control valves
wherever specified.

4.3.6 Actuator action shall be field reversible.

4.3.7 Diaphragm actuators shall be multiple bolted, pressed steel with Nylon reinforced
Neoprene or Buna N Rubber Diaphragm.

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A / B ODS/SOP/008 TO 015 01 01 15/210/2003
 Spec. No.: 3700
OFFSHORE FUNCTIONAL
Rev. No.: 0
DESIGN SPECIFICATION FOR
SECTION Discipline: Instrumentation
CONTROL VALVE
Page: 6 of 13

4.4 Positioner:

4.4.1 Control valve shall be supplied fitted with positioner for all services except on/off
control.

4.4.2 On Process Complexes, the Valve positioner shall be intrinsically safe “smart” type
with integral I/P converter and shall be direct acting, with field reversible action.

4.4.3 Gauges shall be fitted to indicate both input & output pressure.

4.5 Material:

4.5.1 The material requirements for Control Valves shall in general be according to clause
3.6.4.5 of Instrumentation Design Criteria and according to the Material Selection Chart
provided in Annexure – I of this document.

4.5.2 Control valve bodies shall generally be cast or forged carbon steel to ASTM A216 Gr
WCB or A105 respectively with 316 SS trim as a minimum, however more demanding
services may require other materials as specified in the applicable piping
specification/Material selection chart. Consideration shall be given in selection of all
other valve part materials for corrosion due to process fluid and ambient conditions.

4.5.3 Accessories such as mounting bolts shall be of SS 316.

4.5.4 Tubing shall be seamless 316 SS tube 3/8” OD minimum with 316 SS double ferrule
compression fittings.

5.0 EQUIPMENT PROTECTION:

5.1 Control valve protection requirements shall in general be as per clause no. 3.6.4.4 of
Instrumentation Design Criteria.

6.0 INSTALLATION REQUIREMENT:

6.1 The installation requirements of control valve shall in general be according to clause
3.6.4.6 Instrumentation Design Criteria and as per Annexure II of this document.

6.2 Where practicable, valves shall be installed in horizontal lines with Actuator above the
valve.

6.3 Clearance shall be provided to allow in- line maintenance of valves. Adequate clearance
shall be provided above and below the valve to allow removal of the valve operator and
internal cage (trim) and valve bottom plate as applicable while not impeding access
ways.

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A / B ODS/SOP/008 TO 015 01 01 15/210/2003
 Spec. No.: 3700
OFFSHORE FUNCTIONAL
Rev. No.: 0
DESIGN SPECIFICATION FOR
SECTION Discipline: Instrumentation
CONTROL VALVE
Page: 7 of 13

6.4 Control valve assembly shall be provided with double block, double bleed and bypass
piping and valves. The bypass valve shall be a globe valve no smaller than one pipe size
than the control valve but with a CV no greater than that of the control valve.

6.5 Control valves shall be installed in the direction recommended by the manufacturer and
the valve shall not be subjected to stress due to pipeline movement or misalignment.

7.0 CALIBRATION, INSPECTION AND TESTING:

7.1 Calibration, inspection and testing requirements shall in general be as per clause 3.6.4.7
of Instrumentation Design Criteria.

7.2 All valves shall be tested in accordance with API 589, hydro-tested t ASME B 16.34
clause 7.1 and leak tested to ASME / FCI 70.2.

7.3 Contractor shall remove in line instruments and control valve and provide necessary
spool pieces/ Flanges prior to flushing/hydro testing.

7.4 All diaphragm and piston operated control valve shall be stroked pneumatically using a
pressure regulator and pressure gauge against spring range shown on name plate
Mechanical sealing and travel shall be checked against name plate. Check shall be made
in shop prior to installation.

7.5 Valve position shall be calibrated on control valve in accordance with nameplate data
and instrument specification. Split range or reverse acting positioner shall not have
bypass and shall be check carefully. Zero position shall be live zero (just off the seat at
minimum setting on seat with air). Volume bottle shall be checked for proper filling.
Signal line shall be bled to zero and failure action shall be confirmed.

7.6 Control valve accessories such as hand wheel, booster, relay etc shall be checked
operationally. Declutch able hand wheel shall be operable both with and without an air
signal to diaphragm.

7.7 All control valves shall be checked carefully against nameplate data and specifications.

7.8 Butterfly valves shall be checked carefully to see that vane moves freely into upstream
and downstream piping. Proper vane movement to stroke shall be confirmed when
specified. Multi position actuators shall be checked for proper cross ferruling and / or
piping.

8.0 DOCUMENTATION:
8.1 The documentation requirements shall in general be according to clause 3.6.6.2 of
Instrumentation Design Criteria.

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A / B ODS/SOP/008 TO 015 01 01 15/210/2003
 Spec. No.: 3700
OFFSHORE FUNCTIONAL
Rev. No.: 0
DESIGN SPECIFICATION FOR
SECTION Discipline: Instrumentation
CONTROL VALVE
Page: 8 of 13

9.0 TAGGING AND NAMEPLATES:

9.1 Tagging & Nameplate requirements shall in general be according to
clause 3.6.6.1 of Instrumentation Design Criteria.

9.2 Each Control valve shall have a 316 SS Name plate attached firmly to the body
furnishing the following information:
• Tag Number
• Body and Port size
• Stem Travel
• Action on air failure
• Spring Range
• Air supply Pressure
• Manufacturer Model Number for valve body, actuator and positioner.
• P.O. Number
• Serial Number
• Leakage Class
• Body rating and material grade
• Signal range
• Trim Characteristics
• Body Test Pressure
• Bench set Pressure

10.0 REVIEW AND APPROVAL:

10.1 Review and approval of purchase specifications and other related documents shall in
general be according to clause 3.6.6.3 of Instrumentation Design Criteria.

11.0 VENDOR PRE-QUALIFICATION REQUIREMENTS:

11.1 The Vendor pre-qualification requirements shall in general be according to clause
3.6.6.4 of Instrumentation Design Criteria.

12.0 PREPARATION FOR SHIPMENT:

12.1 The Control Valves shall be prepared for shipment in accordance to clause 3.6.6.5 of
Instrumentation Design Criteria.

12.2 All actuators, positioners, air set, air lock relays, limit switches, solenoid valves, etc.
shall be shipped factory mounted, tubed and wired in a completely assembled condition.

13.0 RECEIPT AND STORAGE:

13.1 Receipt and storage of the Control Valves shall be in accordance to clause 3.6.6.6 of
Instrumentation Design Criteria.

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A / B ODS/SOP/008 TO 015 01 01 15/210/2003
 Spec. No.: 3700
OFFSHORE FUNCTIONAL
Rev. No.: 0
DESIGN SPECIFICATION FOR
SECTION Discipline: Instrumentation
CONTROL VALVE
Page: 9 of 13

ANNEXURE – I

Material Selection Chart for Control Valves

Control Valves
S. No. Piping Class
Body Trim
A1, B1, D1, E1, F1, XF1, F1, PA1, PB1,
PD1, PE1, PXF1, PF1, A2, B2, D2, E2,
1 XG1, A1H, A3, B3, A8 CS SS 316
(EXCEPT WAT. INJ. SERVICE)

2 INJECTION WATER SERVICE CS SS 316

3 A4, A6, A9, B9, D9, E9 SS 316 SS 316

ALUMINIUM
4 A5
BRONZE
MONEL

5 A7 HASTALLOY C. HASTALLOY C.

CS SS 316
A1N, B1N, D1N, E1N, F1N, XF1N,
6 PA1N, PB1N, PD1N, PF1N, XG1N
PACKING - GRAPHOIL

SS 316 SS 316
7 A10, B10, D10, E10, F10
PACKING - GRAPHOIL

DUPLEX SS SOLID ALLOY

A11, B11, D11, E11, F11, PA11, PB11,
8 PD11, PE11, PF11
PACKING - GRAPHOIL

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A / B ODS/SOP/008 TO 015 01 01 15/210/2003
 Spec. No.: 3700
OFFSHORE FUNCTIONAL
Rev. No.: 0
DESIGN SPECIFICATION FOR
SECTION Discipline: Instrumentation
CONTROL VALVE
Page: 10 of 13

ANNEXURE – II

Hook-Up Drawing for Control Valves

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A / B ODS/SOP/008 TO 015 01 01 15/210/2003
 Spec. No.: 3700
OFFSHORE FUNCTIONAL
Rev. No.: 0
DESIGN SPECIFICATION FOR
SECTION Discipline: Instrumentation
CONTROL VALVE
Page: 11 of 13

ANNEXURE II (Contd.)

CONTROL VALVE WITH

POSITIONER AND I/P
CONVERTOR

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A / B ODS/SOP/008 TO 015 01 01 15/210/2003
 Spec. No.: 3700
OFFSHORE FUNCTIONAL
Rev. No.: 0
DESIGN SPECIFICATION FOR
SECTION Discipline: Instrumentation
CONTROL VALVE
Page: 12 of 13

ANNEXURE II (Contd.)

CONTROL VALVE (WITH POSITIONER OR PILOT VALVE)

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A / B ODS/SOP/008 TO 015 01 01 15/210/2003
 Spec. No.: 3700
OFFSHORE FUNCTIONAL
Rev. No.: 0
DESIGN SPECIFICATION FOR
SECTION Discipline: Instrumentation
CONTROL VALVE
Page: 13 of 13

ANNEXURE II (Contd.)

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
ODS/SOF/004A / B ODS/SOP/008 TO 015 01 01 15/210/2003