10080-1-SS-CI-004

J3 Program
Standard Specifications for Control Valves

Date: 28/02/2013, Rev. 1

RECORD OF REVISIONS
Date

Revision Details

Revision Number

14/07/2012

Issued for Implementation

28/02/2013

Various DECs agreed comments have been incorporated As

Marked in following sections / clauses,

9.4; 13.1.8; 14.2.5; 15.2; 19. Clauses modified.

J3 Program
Standard Specifications for Control Valves

10080-1-SS-CI-004
Date: 28/02/2013, Rev. 1

Contents
1.

Purpose........................................................................................................................... 1

2.

Scope .............................................................................................................................. 1

3.

Cost competitive engineering and design ........................................................................ 1

4.

Conflict and Deviations ................................................................................................... 1

5.

Reference ....................................................................................................................... 1

6.

Units of measurement .................................................................................................... 3

7.

Terms and Definition....................................................................................................... 4

8.

Environmental Conditions ............................................................................................... 4

9.

General Requirements .................................................................................................... 4

10.

Valve Types ..................................................................................................................... 6

11.

Valve Design and Construction ........................................................................................ 9

12.

Special Designs.............................................................................................................. 13

13.

Valve Actuator .............................................................................................................. 14

14.

Valve Accessories .......................................................................................................... 16

15.

Inspection & Testing ..................................................................................................... 20

16.

Painting ......................................................................................................................... 21

17.

Marking ........................................................................................................................ 22

18.

Preparation for Shipment.............................................................................................. 22

19.

Vendor Data Requirements ........................................................................................... 23

10080-1-SS-CI-004

J3 Program

Date: 28/02/2013, Rev. 1

Standard Specifications for Control Valves

1.

Purpose
This specification defines the minimum requirements for design, construction,
functioning and testing of control valves along with their actuators and
accessories, for throttling and on-off service.

2.

Scope
This specification together with datasheets defines the minimum requirements
for design, construction, testing, inspection, packing and documentation
requirements for control valves along with their actuators and accessories.

3.

Cost competitive engineering and design

The engineering team shall maintain the cost focus throughout all phases of the
project. This should be done without compromising any specification and design
requirements.

4.

Conflict and Deviations

SELLER shall be responsible to inform any conflicts between this specification
and other applicable specifications, industry standards and codes to Managing
Contractor / Owner. SELLER shall proceed further in concerned matter only after
conflicts are resolved in writing by Managing Contractor / Owner.
In general, order of priority of the documents shall be as follows,

Local regulatory & statutory requirement

Project specification

This specification and relevant equipment/system specification

Codes and Standards

SELLER shall be required to obtain prior approval from Managing Contractor /

Owner for any deviation from this specification.

5.

Reference
Reference shall be made to various standards and codes as listed below. The
latest issued revision to these documents shall apply unless otherwise indicated.

5.1.

Project Specification
Specification No.

Document Name

10080-1-SS-PP-038

Piping Material Specification

10080-1-SS-PP-014

Protective Coating & Painting Specification

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10080-1-SS-CI-004

J3 Program
Standard Specifications for Control Valves
5.2.

Date: 28/02/2013, Rev. 1

Codes and Standards

ASME/ANSI B16.10

Face to Face and End to End dimensions of Valves

ASME/ANSI B16.47

Large Diameter Steel Flanges

ASME/ANSI B16.5

Pressure and Temperature rating for Pipe Flanges

and Flanged Fittings

ASME/ANSI B16.34

Valves Flanged, threaded & welding ends

ASME/ANSI B46.1

Surface Texture (Surface Roughness, Waviness & Lay)

ANSI/ISA S75.01.01

Flow Equations for Sizing Control Valves

ANSI/ISA S75.08.01

Face-to-Face Dimensions for Flanged Globe Style

Control Valve Bodies (ANSI Classes 150, 300 & 600)

ANSI/ISA S75.11.01

Inherent flow characteristics and rangeability of

control valves

ANSI/ISA S75.13

Method of Evaluating the performance of Positioners

with Analog Input Signals and Pneumatic Output

ANSI/ISA S75.17

Control valve aerodynamic noise prediction

ANSI/ISA S75.19.01

Hydrostatic testing of control valve

ANSI/ISA 75.25

Test procedure for control valve response

measurement from Step Inputs

ANSI/FCI 70.2

Control Valve Seat Leakage

API 6D

Pipeline valves, end closures, connectors & swivels

API 609

Butterfly Valves: Double flanged, lug and wafer type

API 599

Metal Plug Valves-Flanged Threaded & Welding Ends.

ASTM G93

Standard Practice for cleaning methods for material

and equipment used in oxygen-enriched
environments.

BS 5155

Specification for Butterfly Valves

CGA G4.4

Practices for Gaseous Oxygen Transmission and

Distribution Piping System

IEC60079-0
(EN 50 014)

Explosive Atmospheres Equipment General

Requirements

IEC60079-1
(EN 50 018)

Explosive Atmospheres -Equipment protection by

Flameproof Enclosure d

IEC60079-11

Explosive Atmospheres - Equipment protection by

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J3 Program
Standard Specifications for Control Valves

6.

Date: 28/02/2013, Rev. 1

(EN 50 020)

Intrinsic Safety i

IEC 60534 8-3

Industrial-Process Control Valves - Part 8-3: Noise

Considerations - Control Valve Aerodynamic Noise
Prediction Method

IBR-293

Indian Boiler Regulations for Steam service over 3.5

kg/cm2.

ISA RP75.23

Considerations for evaluating control valve cavitation

ISO 5752

Metal valves for use in flanged pipe systems; Face-toface and center-to-face dimensions

NACE MR01 75

Materials Resistant to Sulfide Stress Cracking in

Oilfields

NACE MR01 03

Materials Resistant to Sulfide Stress Cracking in

Corrosive Petroleum Refining Environments

Units of measurement
Quantity

Unit

Abbreviation

Density

Kilograms per cubic meter

Kg/m3

Flow - liquid

cubic meter per hour

m3/Hr

Flow - gas and vap

normal cubic meters per hour

Nm3/Hr

Flow - steam

Kilogram per hour or Tonnes per Kg/Hr or Ton/Hr

hour

Mass

Kilogram

Kg

Mass

Tonne

te or t

Molecular weight

kilogram per kilogram mole

MWT or MW

Power

Kilowatt

kW

Pressure (gauge)

Kg/cm2 gauge / millimeter of Kg/cm2 g /

water column (gauge)
mmWC (g)

Pressure (Absolute)

Kg/cm2 Absolute / millimeter of Kg/cm2 a /

water column (Absolute)
mmWC (a)

Temperature

degree centigrade

Viscosity (dynamic)

Centipoise

Cp

Volume

Cubic meter

m3

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J3 Program
Standard Specifications for Control Valves

7.

Date: 28/02/2013, Rev. 1

Terms and Definition

The Owner / Buyer is the party which initiates the project.
The 'Managing Contractor' is the party which carries out all or part of the design,
engineering, procurement, construction and commissioning for the project.
The 'SELLER' is the party which manufactures or supplies equipment and services
to perform the function as specified by managing contractor / Owner or Buyer.

8.

Environmental Conditions

8.1.

External Conditions
Control valves and associated instruments shall in all respects be suitable for
reliable and continuous operation in the service conditions stated in the Basic
Engineering Design Data Specification". Control valves and its associated
Instruments shall be able to withstand being exposed to solar radiation and
surface design temperatures as given in the above specification.

8.2.

Control Room Conditions

Control Rooms and Plant Interface Buildings will be air conditioned.
Temperature: 22 Deg C, 1 Deg C.
Relative Humidity: 50 %, 5%.

8.3.

Hazardous Areas
All instrumentation equipment, materials and installation methods shall comply
and fully satisfy the requirements for the area classification identified on the
project Hazardous Area Drawings. All signals to and from safe to electrically
hazardous areas shall be through suitably fused galvanic isolators/Fieldbus
Barriers with status indicating LEDs.

9.

General Requirements

9.1.

SELLER shall be responsible for functional design and sizing of control valves and
its actuator with accessories to meet the requirements of the specification and
the parameters as specified on the data sheet.

9.2.

SELLER is required to complete all furnished information as indicated by an

asterisk (*) on the data sheet and submit with his proposal. The completed filled
in data sheets will be included as part of this purchase specification.

9.3.

Valve body shall not be more than two nominal sizes smaller than line size.
Reduced size trim may be used to meet this requirement.

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Standard Specifications for Control Valves

Date: 28/02/2013, Rev. 1

9.4.

Approval shall be obtained from the statutory authority (PESO) earlier known as
the Chief Controller of Explosives (C.C.O.E.), Nagpur for all valves accessories
(electrical & electronic) in explosive service Hazardous areas. The designs of
such valves must be approved by the C.C.O.E & shall be inspected by a C.C.O.E.
approved inspector.

9.5.

Valve design, body pressure temperature rating and minimum wall thickness
shall comply with ANSI B16.34.

9.6.

Control valve bodies shall be flanged suitable for insertion between pipeline
flanges. Built-in dimensions shall be according to ANSI/ISA S75.08. Separable &
slip on flanges shall not be used without prior written approval of the owner.
Flanges shall be integral to the valve for all sizes & type of valve. The body shall
be designed to have the valve flanges bolted using studs and nuts. The body
shall not be tapped for receiving the flange bolts.

9.7.

If welded end connections are specified , valves of 2 inch and smaller size shall
have socket weld ends, valves 3 inch and larger shall have butt weld ends. For
flanged valves, the valve body rating shall never be lower than the flange rating.

9.8.

The minimum body and flange pressure rating for control valves including globe
and angle valves, up to and including 6 inch size shall be ANSI 300# RF. For all
valves above 6 inches size, the end connections shall be in accordance with
piping class requirement.

9.9.

For PTFE/PFE/EPDM and other lined valves, flange rating shall be as per pipe
class requirements.

9.10.

SELLER shall size and select the control valve and actuator assembly to provide
valves with the optimum performance based on the information supplied on the
technical data sheets. Control valve sizing shall generally be based on ISA
75.01.01, Flow Equations for Sizing Control Valves.

9.11.

All valves shall be sized such that they are at approximately 80 percent of
capacity when operating under maximum flow conditions and shall be greater
than 10 percent open at minimum flow conditions. Butterfly type valves shall
normally be sized for a maximum travel of 60 deg., unless otherwise stated or
unless the valve characteristics allow control over a wider range of opening.

9.12.

Rangeability of valves shall be around 20:1 depending on valve size & trim
selection. Venting, pump and compressor minimum flow may be considered as
special cases and therefore as exceptions to this sizing criteria.

9.13.

The permitted maximum noise level measured at 1 meter from the control valve
body, shall be 85 dB (A) per ISA S75.17 or IEC 60534-8-3/60534-8-4. SELLER shall
supply noise calculations, SELLERs standard form may be used after approval.
For all gas, vapor, steam and flashing liquid valves having a pressure drop of 0.4
times upstream pressure as well as cavitating valves; a noise calculation has to

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J3 Program
Standard Specifications for Control Valves

Date: 28/02/2013, Rev. 1

be supplied. If the predicted noise level is found to exceed 85 dB(A), control

valve shall be treated for noise. Only source treatment shall be resorted to low
noise valves, diffusers may be considered as necessary. A valve supplied
together with anti-noise trim and silencer, shall be provided with a strainer on
its upstream.
9.14.

No cavitation is permissible. Anti-cavitation trim is required for all cavitating

liquids present in any portion of the valve stroke. Fluid velocities at the valve
outlet shall be limited to 40 fps for liquids and 0.3 Mach for gases or steam.

9.15.

Contoured plugs, cages, balls or disks shall be utilized to obtain the required
rangeability and flow characteristics. Minimum turndown shall be at least 20 to
1.

9.16.

The seat leakage classification and testing shall be per ANSI / FCI 70-2. If no
leakage class is specified, then class IV shall be considered as minimum and
tested with the maximum specified inlet pressure and atmospheric pressure at
valve outlet. If required, a test certificate shall be issued by the SELLER and shall
be supplied with the valve.

9.17.

Flow direction shall be clearly marked on valve body by a permanent attached or

stamped indicator of sufficient clarification so that it can be viewed after the
valve has been painted.

9.18.

Bottom flanges shall not be tapped for any flushing connection.

9.19.

Each control valve shall be provided with a local position indicator. The
indication pointer shall be directly connected to the shaft or stem. The valve
position shall be indicated on a reversible scale with clearly graduated markings
at 25% valve opening position intervals with the words OPEN and CLOSED at
the respective valve travel limits.

9.20.

All valves shall be designed for a minimum 20-year service life. Component
parts that require replacement to achieve this shall be readily available from the
SELLER and/or other market sources. All equipment and materials shall be
standard products of established SELLER.

9.21.

SELLER shall furnish the quality assurance certificate that the casting meets
these material standards.

10.

Valve Types

10.1.

Globe Valves

10.1.1.

Globe valves (linear motion) are the most common body style and shall be used
for all services except where the allowable pressure drop is so low that a globe
valve would not function.

10.1.2.

Globe valves shall be used for high pressure drop application, low flow

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Standard Specifications for Control Valves

Date: 28/02/2013, Rev. 1

application, clean fluid service particularly where cavitation, flashing, or noise

are design consideration.
10.1.3.

Single seated top guided valve bodies are the most common style. Single seated
globe or cage trim shall be used for tight shutoff applications.

10.1.4.

Double seated post guided valves shall not be used without owners approval.

10.1.5.

All Cage guided valves shall be balanced. Cage guided balanced plug type valves
bodies are normally used for higher sizes and also for severe applications.

10.2.

Rotary Valves (Eccentric-Plug/Segmented Ball)

10.2.1.

Wherever globe body is not suitable for higher capacity with lower pressure
drop applications, rotary valves shall be used. They have good rangeability,
control & shut off capability.

10.2.2.

Bodies shall be cast with integral bonnets and provided with flanged end
connections. The body shall be designed to have the valve flanges bolted using
studs and nuts. The body shall not be tapped for receiving the flange bolts.

10.2.3.

Segmented balls may be cut to provide parabolic, V, U, or other contours on

the leading edge of the ball.

10.2.4.

The ball is supported in the valve body by stub shafts that rotate in bearings or
bushings.

10.2.5.

Stuffing boxes shall have sufficient clearance to permit re-packing without

removal of the operator and without removing the valve from the line.

10.2.6.

Guide bearings shall be as close to the ball or plug as possible. Each valve shall
be equipped with thrust bearings set to hold the valve ball or plug securely in
the center of the valve seat. All shaft and linkage bearings shall be permanently
self-lubricating type.

10.2.7.

All valves shall have easily replaceable seats requiring minimal disassembly of
valve or valve components for replacement

10.3.

Butterfly Valves

10.3.1.

Butterfly valves shall be considered for the following circumstances. However,

valve type in the datasheet shall take precedence over the following guidelines:
If the required size would make it economically attractive compared to globe
valve due to lower body mass and hence lower cost of the body metal. Generally
for the body sizes above 8 inches, butterfly valves are economical (usually due to
a high flow rate with a low pressure drop).
If eccentric plug / segmented ball or globe valves are not suitable;
For corrosive services, where body lining of globe valves becomes economically
unattractive.

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10.3.2.

High performance butterfly valves are recommended over standard butterfly

valves.

10.3.3.

The actuator end of the valve stem shall be splined. Shear pins shall not be used.

10.3.4.

Shafts of butterfly valves shall be made of one piece.

10.3.5.

The shear safety factor shall be a minimum 150% at the specified shutoff
pressure drop condition.

10.3.6.

The valve stem bearing shall be designed to prevent the stem guide bushing
from rotating in the valve body.

10.3.7.

Bearing material shall be designed to prevent galling of the bearing or valve

stem.

10.3.8.

The minimum disc to pipe clearance shall be in accordance with API 609.

10.4.

Ball Valves

10.4.1.

Ball valves for use in erosive (e.g. slurry) service etc. shall be equipped with a
scraper type of seat construction.

10.4.2.

Ball valves, i.e. valves without specially designed control related internals, shall
not be selected for throttling service without the approval of the Managing
Contractor. Unless equipped with a special trim, i.e. anti-cavitation or low-noise
design, certain ball valves may be unsuitable for high differential pressures.

10.5.

Angle Valves
Angle valves may be considered for high pressure drop, slurry, flashing, choking,
solid contaminant service where a regular globe valve cannot be used. Angle
valves shall conform to the specifications for globe style valves. Angle valves
shall have full venturi throat.

10.6.

Plug Valves
Plug valves shall be considered for special applications such as throttling control
in slurry service. The use of plug valves requires the approval of the Managing
Contractor.
Plug Valves shall be in accordance with API 599.

10.7.

Self-acting pressure regulators

10.7.1.

Self-acting pressure regulators shall only be used in clean fluid services and only
in applications that need no operator intervention, such as reducing instrument
supply pressure or gas blanketing of vessels or storage tanks.
Pressure reducing regulators in gas blanketing service shall not be provided with
an internal self-relieving function.

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10.7.2.

Self-acting back-pressure regulators shall be used for maintaining a uniform back

pressure in utility (e.g. nitrogen) distribution systems or for lubrication, sealing
or control oil applications in rotating equipment.

10.7.3.

Self-acting differential-pressure regulators shall be used for secured instrument

air systems or for lubrication, sealing or control oil applications of rotating
equipment.

10.7.4.

Self-acting temperature regulators shall only be considered for simple, nonsafety related heating applications where utilities (e.g. instrument air or gas) are
not available. The use of self-acting temperature regulators requires the
approval of the Managing Contractor.

10.7.5.

Pilot operated regulator rather than self-actuated regulators shall be used where
accurate control is required.

11.

Valve Design and Construction

11.1.

Valve Body

11.1.1.

The body size of a control valve in throttling service shall at least match the
calculated trim size. The nominal sizes of control valve bodies shall be selected
from the following series: 1 inch, 1 inches, 2 inches, 3 inches, 4 inches, 6
inches, 8 inches, 10 inches,12 inches and larger. Body sizes 1 inches, 2
inches, 3 inches, 5 inches and 7 inches shall not be used. The use of body sizes
smaller than 1inch shall be subject to the approval of the Owner.

11.1.2.

All valves shall have flanged end connection. Flanges 24 inches and smaller shall
comply with ASME B16.5. Flanges 30 inches and larger shall comply with ASME
B16.47 series B. The gasket contact surface of raised faced flanges shall be spiral
finished in the range of 3.2 to 6.3 Ra in accordance with ASME B46.1.

11.1.3.

For hydrocarbon, hydrogen, oxygen, toxic, corrosive and high temperature

service like steam and boiler feed water and all process services, Butterfly valves
shall be of double flanged construction. For utility services, the same shall be
lugged construction. Wafer type construction can be used subject to owners
approval.

11.1.4.

Ball valves and rotary valves shall be of double flanged constructions for all
applications.

11.1.5.

The installed face-to-face dimensions of integral flange globe valves up to 600

class rating shall confirm to ANSI/ISA S75.08. Double flange butterfly valve shall
conform to ANSI B16.10 or ISO5752.

11.2.

Bonnets

11.2.1.

Control valves shall be furnished with bonnet cooling extension, generally above
250C or supplier standard whichever is applicable.

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Standard Specifications for Control Valves

11.2.2.

Plain extension bonnets shall be furnished with control valves for operating
temperatures 0C and below.

11.2.3.

Threaded bonnets are not acceptable.

11.2.4.

Bellows seal bonnets (alternatively double packing) shall be used for light &
hazardous gases. Valves in hydrogen or hydrogen effluent service shall have
bonnet flange or lower blind flange fitted with retained metallic or spiral wound
gasket suitable for this service

11.3.

Packing

11.3.1.

Gland Packing shall be of high performance / low emission type. Fugitive

emissions packing shall be provided for all valves in hydrocarbon, toxic and
hazardous air pollutants services as defined in the data sheets.
Packing material shall be PTFE for temperatures up to 232oC and Pure Graphite
for temperatures above 232oC up to 600oC.Packing shall not contain asbestos or
man-made mineral fibers. However, packing material recommendations are as
follows:

a.

HC service, <230oC

PTFE (fugitive emission type/live

loaded)

b.

HC service, >230oC

Graphite (fugitive emission type/live

loaded)

c.

Steam Service, <230oC

d.

Steam Service, >230 C

o

PTFE
Graphite

e.

Acid Gas, <230 C

PTFE (fugitive emission type/live

loaded)

f.

Acid Gas, >230oC

Graphite (fugitive emission type/live

loaded)

g.

Sour Water, <230oC

PTFE (fugitive emission type/live

loaded)

h.

Sour Water, >230oC

Graphite (fugitive emission type/live

loaded)

i.

Amines, <230oC

PTFE (fugitive emission type/live

loaded)

j.

Amines, >230oC

Graphite (fugitive emission type/live

loaded)

k.

Oxygen, Hydrogen, <230oC PTFE (fugitive emission type/live

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Standard Specifications for Control Valves

loaded)
o

l.

Oxygen, Hydrogen, >230 C Graphite (fugitive emission type/live

loaded)

m.

Air, Water service, <230oC

PTFE V-ring

n.

Air, Water service, >230oC

Graphite V-ring

o.

Chemicals,
<230oC

p.

All services, temperatures,

with pressure>800psig

Additives, PTFE (fugitive emission type/live

loaded)
Graphite (fugitive emission type/live
loaded)

Packing requiring external lubrication or grease shall not be used.

11.3.2.

The stuffing box shall be provided with an adjustable bolted gland flange and
gland follower. SELLER shall properly adjust the valve gland. If the valves are
delivered with a loose gland, this shall be clearly indicated on the appropriate
valve with a warning sign.

11.4.

Guiding
Globe type body pattern valves up to 3 inches size shall normally be supplied
with top guiding and above 3 inches size it will have top and bottom guiding or
cage guiding. However, SELLERs recommendations shall also be considered.
Double ported valves shall not be used without Owners approval.
Post guided, single ported valves may be used for tight shutoff applications.
Flow to open, post guided valves may be considered for dirty service.
For high pressure drop, cavitation or flashing services, the lower guide area is
required to be hardened. Also, valve plug, seat and guides shall be hard faced.
For full cavitation service, the lower guide area shall not be hardened.

11.5.

Valve Trim

11.5.1.

The term "trim" covers all those parts of the valve assembly which are in contact
with the line medium consisting of and not limited to the seat ring, plug, stem,
plug guide bushing and cage.

11.5.2.

Trim flow characteristics shall be as defined in ISA S75.11. Variations from the
specified characteristic shall be so advised by the SELLER prior to manufacture.
Equal percentage characteristic trim shall be the preferred standard for control
services, the alternative being linear characteristic.

11.5.3.

Valve sizes and trims shall be selected based on the following good control
ranges. Good operating ranges for control valves are defined as the following:

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Standard Specifications for Control Valves

Globe Valves

20% to 80% open

Ball Valves

10 to 70 degrees rotation

Butterfly Valves

20 to 50 degrees rotation

11.5.4.

The closure member form shall be solid contoured, tapered, splined or solid Vported and shall have the specified characteristic.

11.5.5.

Cage guided special trims with small holes in cage shall not be used for choking
services and also for fluid that contains solid particles, even occasional chances
of solid particles. Multistage cage shall be considered for high pressure drop
applications.

11.5.6.

Separable closure members and stems for sliding stem valves shall be connected
by tapered or proprietary thread design and be pinned. Rotary valves shall have
a shaft design that eliminates the possibility of blowout.

11.5.7.

Unbalanced, single ported globe valves shall be closure member guided. Stem
guided valves are not acceptable unless otherwise noted.

11.5.8.

Balanced, single ported globe valves shall be cage guided. Trim design, including
metallurgy shall minimize risk of galling. Special trim designs required for high
temperature service shall be so noted on SELLERs quotation.

11.5.9.

The split body globe valves closure member shall seat from the top regardless of
actuator action. Seat ring shall be of clamped-in design.

11.6.

Body Material

11.6.1.

The valve body and bonnet (including top and/or bottom flange), bolts, studs
and nuts, etc. shall be in accordance with the requirements of the piping class &
designed process conditions.

11.6.2.

The minimum body material shall be WCB or WCC carbon steel. Cast iron shall
not be used for body material.

11.6.3.

SELLER may offer different materials only if they are to a higher specification
than those defined on data sheets, subject to Managing Contractors / Owners
approval

11.7.

Trim Materials

11.7.1.

The trim material shall be as specified in data sheets but shall be of minimum
316 Stainless Steel.

11.7.2.

Trim material shall be hardened Stainless Steel construction of 440oC or 17-4PH

for corrosive, erosive, cavitation or flashing services.

11.7.3.

Austenitic Stainless Steel, Monel and nickel alloy valves shall have trim, bolting
and stem of the same nominal chemistry as of body.

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Standard Specifications for Control Valves

12.

Special Designs

12.1.

Low Noise Valves

Date: 28/02/2013, Rev. 1

Limits for the noise generated by control valves shall be below 85 dB A.

Process conditions at which the calculated noise is found to be above the
allowable limit shall be critically reviewed and validated with process engineers.
The type of noise abatement technique source treatment or path treatment
shall be selected on technical and economic merits. The most reliable and
economic solution shall be chosen by the SELLER and approved by the Owner.
12.2.

Anti-Cavitation Valves

12.2.1.

The evaluation of cavitation characteristics, parameters and the selection

guideline of valves shall be as per ISA RP 75.23. The best method of eliminating
cavitation is to select a proper location for control valve installation or change in
flow direction. If the same is not feasible, the following are the few suggested
mitigation methods of cavitation:

12.2.2.

For severe cavitation in water service, an anti-cavitation trim shall be

used.

For moderate cavitation of water and for most hydrocarbon-cavitating

services, an angle valve with hardened venturi may be used.

For minor cavitation applications, a flow-to-open standard globe valve

with hardened trim may be used. While selecting hardened trim, SELLER
shall consider the cracking that can be caused by impact of repeated
valve closures and thermal shock.

SELLER to note that, hydrocarbons and especially viscous or mixed

hydrocarbons cannot cause as much damage to valves as can water.
Because all cavitation damage prediction data use water, the calculations
can be overly conservative for these classes of services.

Rotary-style valves shall not be used in cavitating services or in erosive

services.

Flashing, Erosion and Outgassing

While sizing for two phase fluid or gas service, vendor to ensure outgassing is
avoided.
To prevent erosion, incipient cavitation, corrosion, and flashing hardened trim
shall be selected and the design shall be with streamline flow, which prevents
direct impingement upon the trim, body, or pipe.
The hardened material may be Stellite, Colmonoy coated, Tungsten Carbide or
solid Stallite. It is finally responsibility of the SELLER to select suitable material.

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Standard Specifications for Control Valves
12.3.

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Steam De-superheating Valves

Special control valves with internal water injection for de-superheating purposes
may be used for high-pressure steam reducing services. The make and type of
these valves requires the approval of the Owner.

12.4.

Anti-Surge Valves
The Anti-surge valve in general shall be a globe style valve with linear flow
characteristic, other valve styles may be used with Owner approval. The valve in
all cases shall fail open.
The E/P positioner shall be capable of fully stroking the recycle valve from the
closed position to the open position in less than two (2) sec / or as specified in
the datasheet. SMART valve positioner shall be supplied along with the valve.
The generated noise at any flow condition shall not exceed 85 dBA at one meter
distance. Noise calculations shall be carried out using IEC 60534-8-4.
Noise abatement trim in the control valve shall only be used for clean service
where there is no chance of potential plugging of the trim. Otherwise inline
downstream diffusers shall be used for noise abatement.
Anti-surge valve shall have mechanical stops for preventing over stroking of the
valve.

13.

Valve Actuator

13.1.

Design Requirements

13.1.1.

Control valve actuator shall be pneumatic. The actuator shall be springdiaphragm type unless using piston type is justified by high torque requirements.
Piston actuators may be required for long stroke and high thrust requirements.

13.1.2.

Pneumatic actuator pressure retaining parts shall be capable of withstanding the

maximum instrument design supply pressure. SELLER shall indicate Maximum
Operating Pressure (MOP) of the actuator in their offer.

13.1.3.

Piston actuators may be used for long stroke or high thrust requirements. Single
acting piston actuators shall be preferred over double acting type.

13.1.4.

All valve actuators, regardless of type shall be sized to provide sufficient power
to stroke the valve through its full travel at 1.25 times the maximum pressure
drop conditions specified for the particular valve. Any reductions in power shall
be approved by buyer.

13.1.5.

Actuator failure action shall be as stated on the Buyer's data sheet.

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13.1.6.

Pneumatic tubing shall be inch or 3/8 inch or inch OD Copper tuning PVC
covered. Covering shall be resistant to direct strong sunlight. Brass compression
fittings shall be suitable for above.

13.1.7.

Where copper tubing is not suitable in the service area, e.g. marine, sulphur,
gantry due to exposure to severe environment, Stainless Steel tubing and fittings
shall be used.

13.1.8.

Hand wheels shall be provided on control valve wherever call for in the data
sheet or otherwise valves of 6 inches sizes are generally provided with same.
Control valve shall be provided with hand wheel for manual operation if
indicated in P&ID. Control valve are not having block and bypass valve are
generally provided with hand wheel.
Hand wheels will have following features:

Manual operation with hand wheel shall override automatic operation.

Hand wheels for sliding stem valves shall be side mounted, continuously
connected, and with neutral position.

Hand wheels for rotary valves shall be suitable for intermittent manual
operation.

Diaphragm case mounted hand wheels are not recommended.

13.1.9.

Diaphragm actuators shall be used up to a maximum air pressure of 2.4 kg/cm2

(35 psi).

13.1.10.

A purpose designed vent cap or a U shaped inch OD Copper tube with

appropriate fitting to be supplied with valves where the vent is provided on the
top of actuator.

13.1.11.

The actuator shall be provided with a label that indicates SELLERs name, model
number, item serial number, size, bench spring range (as applicable), maximum
stroke and action on air failure and/or signal failure, as a minimum.

13.1.12.

Hand operated actuators: Hand wheels shall be of the non-rising type with fine
pitch threads for precise valve plug positioning. Provide stem position indicator.
Hand wheel shall be sized to provide the required thrust for valve positioning
with 40 lb. (178 N) applied to hand wheel rim.

13.1.13.

To prevent tampering, the rotating linkages between valves and their actuators
shall be of the integral type, enclosed in a protective metal housing.

13.2.

Stroking Time
Unless specified otherwise, the following stroking times for both directions shall
not be exceeded for throttling control valves under normal operating conditions:

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Standard Specifications for Control Valves

Stroking Time in general the following maximum stroking times for both
directions shall not be exceeded.
Body Size

Maximum Stroking Time

2 inch and under

10 seconds

3 inch

15 seconds

4 inch

15 seconds

6 inch

20 seconds

8 inch

25 seconds

10 inch

35 seconds

12 inch and up

45 seconds

The stroking times are applicable to the throttling mode of control valves. If
faster stroking times are required, high capacity valve positioners shall be
considered. If these are not available, additional boosters or quick-exhaust
valves shall be installed.
Compressor anti-surge valves require faster stroking times in the open direction
than shown above and the required stroking times shall be specified by the
Owner. As a general guideline, for a 1 or 2-second full stroke; volume booster,
larger tubing and quick exhaust relays may be used.

14.

Valve Accessories

14.1.

General
The accessories discussed in this section shall be supplied along with the valve.
This total supply will allow functional testing at the factory, particularly of
stroking time. The accessories may be installed on a separate mounting plate to
allow removal of just the valve and actuator, thus reducing risk of damage to the
accessories.
All electrical equipment shall be suitable for the hazardous area(s) as stated on
the data sheets and shall be certified to the full requirements of codes
applicable to project.
The performance of all accessories mounted on control valve assembly like
Positioners, Solenoid valves, Proximity switches etc. shall not be affected by line
vibrations.

14.2.

Valve Positioners

14.2.1.

All control valves shall be furnished with valve Positioners except where
precluded on on/off service.

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14.2.2.

All valve positioners shall be SMART with self-diagnostic features. Positioner

shall also have provision for full valve signature apart from self-diagnostic
features.

14.2.3.

Dead band and response time requirements of positioner shall be as per ISA
75.25

14.2.4.

Valve Positioners shall be either Foundation Fieldbus compatible or 4-20mA

SMART electro-pneumatic type as specified on the data sheet and shall be fitted
with supply, input signal(where applicable) and output pressure gauges.

14.2.5.

All positioners shall be certified EExia by a CENELEC approved certifying

authority, and be ATEX / PESO compliant.

14.2.6.

Foundation Fieldbus positioner shall be link active scheduler capable and

suitable for hosting controller functions. Link active scheduler shall be set to OFF
as standard. SELLER shall provide full Device Description and Common File
Format support files (e.g. .sym, .ffo & .cff) to ensure full compatibility with host
control system. SELLER shall support interoperability tests with host DCS.

14.2.7.

In case valve positioner is not of the same make as control valve, the control
valve, SELLER shall be responsible for correct software settings in the
configuration (i.e.: characteristic, stroke etc.) of the positioner. Hence, SELLER
shall be responsible for assembly of valve positioner and control valve.

14.2.8.

Positioners shall be easily convertible from direct to reverse action.

14.2.9.

Where a valve is not fitted with a Positioner, a 50mm dial gauge ranged to suit
the supply requirements shall be fitted to the valve assembly (Gauge to be part
of Air set).

14.2.10.

Pneumatic positioner shall have a linearity of better than 1% of span. Accuracy

including dead band, hysteresis and repeatability, shall be better than 0.5% of
span.

14.2.11.

Mechanical linkage-less coupling between the positioner and valve shall be

preferred.

14.2.12.

Positioners shall be furnished assembled and mounted on the valve, complete

with all the necessary tubing and pressure gauges.

14.3.

Limit Stops
Limit stops shall be fitted only if indicated in data sheets. Limit stops shall be
mechanical devices, mounted on the valve or actuator. They shall be
constructed so that hand wheel operation does not allow travel/rotation beyond
the limit stop setting. Limit stops shall be adjustable from outside and fitted
with a locking facility, e.g. a locking nut, to prevent tampering or loosening.

14.4.

Limit Switches

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14.4.1.

Limit switches shall be fitted for open & close position if indicated in
datasheet. They shall be of the inductive proximity type as standard. The
proximeter shall be connected to an intrinsically safe amplifier.

14.4.2.

The proximity switch shall have matching characteristics in regard to the

performance and intrinsically safe certification requirements. The amplifier units
shall be rack or de-mountable rail mounted suitable for installation in a standard
instrument equipment cabinet.

14.4.3.

The proximity switch shall have a flying lead terminated in an enclosure

mounted close to the switch. The proximity switch and enclosure shall be rated
to IP-65.

14.4.4.

The local enclosures shall be made from reinforced polyester or Stainless Steel.
Cable entries to the enclosure shall be threaded 1/2inch NPT. In cases where
1/2inch NPT is not possible or available due to certification, ISO M20 x 1.5mm
shall be used.

14.4.5.

Where inductive proximity switches cannot be used conventional contact type

mechanical action limit switches shall be used.

14.4.6.

Mechanical action switches shall be used in a fail safe mode. The spring action
shall push the follower towards the actuation device such that a sticking switch
cannot be interpreted as being in a healthy condition.

14.4.7.

Mechanical action switches shall be hermetically sealed and rated to IP-65 as a

minimum. The limit switch shall be actuated directly from the stem/shaft.

14.4.8.

Switch contacts shall be rated to 24 VDC, 500 mA, made from noble metal.

14.4.9.

All external linkages, brackets and mountings shall be Stainless Steel.

14.4.10.

Switches shall be located such that accidental actuation is not possible, including
movements caused by wear. They shall be unaffected by vibration.

14.4.11.

Adjustment facilities shall be locked after setting by drilling and pinning.

14.5.

Solenoid Valves

14.5.1.

Solenoid valves where specified, shall be mounted on brackets on the valves. For
control valves subject to vibrations the solenoid valve shall be separately
mounted and not on the valve. Solenoid valves shall be mounted between
actuator and positioner. Solenoid valves shall be direct-operated. . If a pilotoperated valve is used, the air supply to operate the pneumatic valve shall not
be derived internally from the solenoid operated pilot valve, but from an
external air supply connection

14.5.2.

Solenoid operators shall be certified Eexi (except where datasheet calls for Eex
d) from a 24 volt DC power supply.

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14.5.3.

Manual reset where called for on the data sheet shall be by a mechanical
latching device.

14.5.4.

Solenoid valves shall be provided with diode snubber.

14.5.5.

Solenoid valve shall have Stainless Steel body material.

14.6.

Filter Regulators

14.6.1.

The air filter regulators shall be of the reducing-relief valve type, with drainage
facility and bolt adjustment provided with a locking facility, e.g. a locking nut, to
prevent tampering.

14.6.2.

The air filter cartridges shall be of the rigid structure type to resist channeling,
rupturing, shrinkage or distortion and shall have a size of 5 micron.

14.6.3.

Glass (bowl-type) filter regulators shall not be used. Only metallic bowl type
filter regulators shall be used. Filter regulators shall be mounted in the vertical
position so that they are self-draining.

14.6.4.

Air filter regulators shall be fitted with small pressure gauges indicating the
output air supply pressure to the actuator and/or its components.

14.6.5.

Separate air sets shall be provided for each air consumer like I/P converter,
Positioner, etc. Pressure gauges shall be provided with each filter regulator.

14.7.

Electro-Pneumatic Transducers

14.7.1.

Transducers vibration effect shall be less than 1% of span when tested per ISA
S75.13. They shall have conformity (linearity), hysteresis and repeatability equal
to or better than 0.5% Temperature effect shall be less than 1% per 50 F (28
C).

14.7.2.

They shall have integral screwdriver adjustments for zero and span located in an
enclosure. They shall be immune to reversal of normal current supply polarity.

14.8.

Quick-Exhaust Valves

14.8.1.

Quick-exhaust valves may be provided for on/off services which require the
control valve to open or close faster than is possible with a standard actuator
configuration. Fitting quick exhaust valves to throttling services may result in
unstable operation and is therefore not recommended.

14.8.2.

Pilot-operated quick-exhaust valves shall not be used.

14.8.3.

The minimum port size in the quick-exhaust valve shall be verified and taken into
account in calculating the stroking time.

14.8.4.

Quick-exhaust valves shall be fitted directly to the port of the actuator.

14.9.

Volume Boosters

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14.9.1.

High capacity volume boosters shall only be provided if needed to achieve the
specified stroking times.

14.10.

Air Buffer Tanks

It shall be used on Piston operated control valves where there is a requirement
to provide a driven failure action.
Valves on critical service shall be
supplemented with air capacity tanks (with non-return valves, pressure gauges,
etc.). Air capacity tanks shall be sized to provide adequate air storage such that
three valve operations may be obtained between 7.0 and 4.5 kg/cm2. The tanks
shall be manufactured from Carbon Steel, painted and shall be to the pressure
vessel code applicable to the project. The accumulators shall be provided with
drain facilities. NRV, Pressure Gauge & Safety valve shall be in the SELLER scope
& to be delivered along with buffer tank in completely mounted conditions.
Safety valve shall be set between 10.0 to 10.5 Kg/cm2. Test certificate shall be
submitted. All the fittings and tubing material supplied along with air capacity
tanks shall be Stainless Steel.

15.

Inspection & Testing

All valves shall be inspected and tested as specified in data sheet, purchase
documents and approved inspection and test plan.
SELLER shall provide material certificates, test carried out at foundry and NDE
tests report for magnetic particle check or liquid penetrant, radiography and
repair procedures as applicable for the project.
Non-destructive examination of castings and material certification shall be in
accordance with piping material specification.
Where carbon steel for low temperature service is specified, impact testing shall
be carried out to the body casting, bonnet and flanges.
Valves in steam service above 3.5 kg/cm2 shall have IBR Form IIIC test
certificates completed by the manufacturer at the inspection stage.
Valves in explosive material service shall be issued with a PESO (C.C.O.E.,
Nagpur) certificate.
The following tests may be required to be carried out by SELLER, in the presence
of Managing Contractors Inspector.

15.1.

Visual Inspection & Dimensional check

The face to face dimensions & flange face finish shall be checked as per
necessary applicable ASME/ANSI standards. All dimensions (including overall
height) shall be checked as per manufactures drawing.

15.2.

Hydrostatic Test

Hydrostatic test shall be carried as per ISA 75.19.01. ASME/ANSI B16.34.

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15.3.

Date: 28/02/2013, Rev. 1

Seat Leakage Test

The Seat leakage test shall be carried out in accordance with ANSI / FCI 70.2
Latest Revision with acceptance as per specified shut-off class. If shut-off class is
not specified class IV shall be considered as minimum.

15.4.

Functional Test
The control Valve shall be completely assembled and fitted with all accessories
such as positioned, solenoid valve etc. The valve shall be stroke checked for
complete calibration of positioned and also stroke time as specified. If the
control valve fitted with Limit switch, they shall be checked for functional
operation with a proximity tester.

15.5.

Special Test Requirements

15.5.1.

Sour or Wet H2S service: Valves used in H2S or sour service shall comply with
the requirement of NACE, as applicable.

15.5.2.

Valves for Oxygen service: For valves in oxygen service, the SELLER shall submit
to the Owner for approval a detailed description of valve assembly and cleaning
procedures.
Parts for control valves specified for oxygen service shall be thoroughly deburred and cleaned of chips and foreign matter prior to assembly. Pressure
safety relieving devices shall be segregated for the assembly operation in a clean
and protected area.
All the valves shall bear the warning OXYGEN! KEEP FREE FROM OIL AND
GREASE!
Lubricants and solvents used during cleaning and assembly shall be compatible
with intended service; ensuring residues are not potential poisoning agents for
catalyst wherever applicable.

15.5.3.

Valves in Hydrogen service and if specified on requisition shall subjected to

Helium Leak Test.

15.6.

Review of Material Certificates and NDE testing certificates

15.7.

Any specific test required as per specification

16.

Painting
The painting procedure of valve body shall confirm to project painting
specification .The manufactures standard surface preparation and coating
system shall be applied to actuator and accessories. This shall apply to all valvemounted accessories in addition to the diaphragm housing and yoke.
The paint colors to be used are to RAL codes and are indicated below in
brackets.

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Standard Specifications for Control Valves

The valve body color shall be painted as below or approved equivalent

Carbon Steel body

Signal Grey

(RAL 7004)

Alloy Steel body

Traffic yellow (RAL 1023)

Stainless Steel body

No painting required

The actuator shall be painted as below or approved equivalent

17.

Direct acting (open on air failure)

Signal Red

(RAL 3001)

Reverse acting (close on air failure)

Traffic Green (RAL 6024)

Stay put

Traffic Orange (RAL 2009)

Marking
Each valve shall have a Stainless Steel nameplate riveted to the actuator yoke,
which shall be visible when the valve is in service and fully insulated. This
nameplate shall include following information:

18.

SELLERs name and trademark.

Purchase Order Number

Valve serial number/model number.

Valve tag number.

Valve type.

Maximum valve body pressure rating.

Valve body material and nominal body size.

Trim material, size and characteristics.

Stem travel in mm. (Alternative location Actuator nameplate)

Valve action on air failure. (Alternative location Actuator nameplate)

Operating signal range. (Alternative location Actuator nameplate)

Bench set. (Alternative location Actuator nameplate)

Preparation for Shipment

All valve openings shall be positively sealed by suitable blanking plates or plastic
plugs. Adhesive tape sealing of opening without blanking plates or plugs will not
be acceptable.
All exposed machine surfaces shall be protected during shipment by the
application of an easily removable Rust Preventative.
Valves shall be shipped with the stem in a vertical plane to minimize galling on

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the seat. Packaging shall be in accordance with the Project packing Specification.
Valves and components manufactured from Stainless Steel must be stored
under cover and out of contact with the ground and shall never be exposed to
wetting by salt water or salt spray.

19.

Vendor Data Requirements

The document requirements to record the valve selection process shall be as
specified in the requisition. It shall include at least:

Calculations of control valve capacity (Cv), calculations of the predicted noise

level, and, where applicable, details of the secured instrument air vessel

details of the selected actuator and torque or thrust figures

a detail data sheet for valves & accessories

Outline (GA) drawing of valve including accessories.

Bench set data for each valve for AMS configuration.

Material certificates & NDE Test results.

Inspection Test results / Certificates.

IBR, CCOE, NACE certification wherever requested.

Operation & Maintenance manual

Spare parts list & their interchangeability record.

Manufacturing record book

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