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Standard Control Valve Assemblies

This specification covers minimum requirements for the design, fabrication, inspection, testing, painting,
marking and documenting of sliding stem valves (globe).

Codes & Standards:


Control valves shall conform to all or portions of the applicable Codes and Standards listed below as
standard.
ANSI/FCI 70-2 (formerly ANSI B16.104), Control Valve Seat Leakage
ASME B16.5, Pipe Flanges and Flanged Fittings
ASME B16.11, Forged Steel Fittings, Socket-welding and Threaded
ASME B16.25, Buttwelding Ends
ASME B16.34, Valves - Flanged, Threaded, and Welding End
ISA 51.1-1979, Instrument design and testing
ISA S75.01, Flow Equations for Sizing Control Valves
ISA S75.08.01 (formerly ISA S75.03), Face-to-Face Dimensions for Flanged Globe Style Valves
(ANSI Classes 125, 150, 250, 300, & 600)
ISA S75.08.06 (formerly ISA S75.16), Face-to-Face Dimensions for Flanged Globe-Style Valve
Bodies (ANSI Classes 900,1500, & 2500)
ISA S75.19, Hydrostatic Testing of Control Valves
ISO 9000:2000, Quality Management System
MSS SP-6, Standard Finishes for Contact Faces of Pipe Flanges and Connecting End Flanges on
Valves and Equipment
MSS SP-25, Standard Marking System for Valves, Fittings, Flanges & Unions
MSS SP-55, Quality Standard for Steel Castings for Valves, Flanges & Fittings & Other Piping
Components Visual Method for Evaluation of Surface Irregularities
SSPC-SP-6, Commercial Blast Cleaning

Marking
Valve and actuator assemblies are to be marked in accordance with MSS-SP-25. Nameplates shall be
attached to the actuator using stainless steel drive screws or stainless steel wire.
Information for the valve body sub-assembly shall include:
a. Serial number
b. Type
c. Size
d. Port size
e. Rating
f. Plug/disc material
g. Stem/shaft material
h. Body material
i. Seat material
j. Manufacturers name
Information for the actuator sub-assembly shall include:
a. Serial number
b. Type
c. Size
d. Bench set
e. Travel
f. Pressure units
g. Operating range
h. Casing/cylinder maximum pressure rating
The valve body castings shall be marked with:
a. Heat/lot identification
b. Flow direction
c. Logotype
d. Bridge wall
e. Material identification
f. Foundry symbol and pattern number
g. Manufacturers symbol and die number
h. Nominal size
i. Material identification and pipe schedule
j. ANSI pressure class rating

Wherever possible, trim parts and components shall be marked with a unique identifying part number.

Control Valve Sizing and Selection


Control valve sizing shall be conducted using accepted standards and recommended practices
such as ANSI/ISA S75.01, or vendor proven proprietary methodology. Noise calculations shall be
provided for all applications, and the method should be backed up and justified with actual
testing . Noise calculations shall not include any adjustments for insulation unless clearly
identified.
Control valve selection shall follow EnTech Control Valve Dynamic Specification standards.
Noise calculations shall include influence of valve trim and valve outlet velocity induced noise.
Total calculated noise shall not exceed 90 dBA for continuous exposure and up to 110 dBA for
intermittent exposure as measured 1 meter downstream and 1 meter away from the surface of
the downstream pipe.
Minimum control valve body size shall not be less than one half of the downstream line size.
Control valves shall be sized for a minimum of three operating conditions: minimum, normal,
and maximum. The normal condition should represent normal operating conditions. The
minimum and maximum conditions should be designed to represent the expected limits of the
required control valve capacity. The minimum condition would typically include a lower flow
rate, but a higher pressure drop while the maximum condition would typically show a higher
flow rate and a lower pressure drop.

Sliding stem style control valves


Sliding stem valves may be preferred for better valve performance, low flow rates, high
temperatures, high pressure ratings, low noise or anti-cavitation trim, easier maintenance or
higher durability.
Valve size shall be the smallest one that meets the requirement that its flow coefficient (Cv) is
equal to or greater than 110 percent of the Cv calculated from the maximum specified flow rate
and conditions, taking into account the effect of piping configuration such as changes in line
size.
Control valve size shall be selected so that at the minimum specified process condition the valve
opening shall be greater than 10 percent of the total valve travel OR greater than the
manufacturer specified minimum throttling level.

Sliding stem style control valve shall follow the following requirements.
Flanged end connections are preferred and shall be integral to the valve body. Weld on or slip
on flange designs are not acceptable.
Plug stem connections must be designed to ensure positive connection to avoid separation
during operation.
Globe valves shall be of sliding stem / reciprocating design such that the valve stem and plug
travel in a linear motion.
Valve bonnets shall be bolted or clamped to the valve body as opposed to screwed or welded.

Valve Trim
Guiding shall be either cage, post, or port guided as a function of required stability, service conditions,
and capacity.
Stem guiding shall not be used on port sizes that are 1 inch or greater
Valve trim used in severe service applications (anti-noise and anti-cavitation applications, for example)
that use pressure staging to protect the internal parts from damage should be designed to insure
adequate pressure recovery between stages, which dictates that the trim feature a significant increase
in cross-sectional flow area between stages.

Packing Systems
PTFE packing is preferred for service temperatures below 232C (450F).
Graphite packing is preferred for service temperatures above 232C (450F).
Live loaded packing is preferred for all control applications in toxic service.
For applications requiring low emissions packing qualifications testing of the packing should be
conducted per EPA Method 21. To be considered low emissions packing, a leakage rate of 100
PPM or less must be achieved.
Valve stem/shaft shall have a 4 micro inches RMS surface finish in order to minimize damage to
the packing system.

Actuators
Spring and Diaphragm type actuators shall be preferred.
Spring and Diaphragm actuators with positioners shall be sized utilizing pressure ranges from 0-
18 psig to 0-50 psig output from the positioner without exceeding maximum casing pressure.
Sliding stem actuators shall be mounted in a vertical position in order to avoid side loading on
the trim and packing.
Sliding stem actuators shall provide an inherent anti-rotation design that keeps the valve plug
from rotating along the surface of the seat ring in order to minimize leak paths.
Double acting piston actuators with trip system and volume tanks shall be used in cases where
spring return actuators do not have sufficient thrust or travel to satisfy the application.
The actuator shall be sized to move the valve over its full stroke.
o It shall be sized to open and close against the customer supplied maximum pressure
drop and inlet pressure, and provide sufficient seat loading force to achieve the
customer specified, or valve design required shutoff class, whichever is the more
stringent.
o Actuator sizing shall include check for valve stem maximum allowable loading. Air supply
regulator shall be utilized if necessary to limit total force output.
o Actuators shall be without force multiplying linkages.
In the opening direction, a travel limit stop shall be engaged before the valve plug reaches its
travel limit.
The actuator shall be sized with sufficient spring and/or air stiffness to minimize any potential
control instability on modulating service applications.
Instrument air supply shall be regulated at 3 to 5 psig above required pressure to operate valve.
Positioners
General
Valve positioners shall be direct acting.
A minimum supply pressure of 20 psig (138 kpag) will be available for spring and diaphragm
actuators and 55 psig (380 Kpag) for double acting piston actuators.

Digital Valve Controllers HART Protocol


Basic Requirements
Digital Valve Controllers are required on all control valves and shall be capable of providing real
time diagnostics of the condition of the valve assembly.
Digital Valve Controllers shall be designed to accept a 4-20 mA DC control signal. In addition to
traditional function of converting a current signal to valve position pressure signal, using HART
communication protocol, should provide easy access to information critical to operation.

Hardware Requirements
Digital Valve Controller printed wiring board should be completely potted and encapsulated to
eliminate electrostatic discharge sensitivity and provide ruggedness in operation.
Components of Digital Valve Controller should be of modular design to facilitate easy
replacement and interchangeability.
Supply pressure sensor should be included for diagnostics in addition to output pressure
(Differential Pressure Sensor Not Acceptable).
Digital Valve Controller shall have a supply pressure sensor that directly measure supply
pressure and should be capable of alerting deviations in actual supply pressure.
Pneumatic relay should be mechanical beam balancing design type. Spool design not acceptable
(spool design susceptible to clogging, jamming, and sticking, which could lead to detrimental
increase in deadband and / or loss of control).
Easy access HART terminal located on device for field communication by HART Handheld
Communicator or HART modem is desired.
Digital Valve Controller should capable of mounting to both single acting (spring & diaphragm)
and double acting (piston with or w/o spring) actuators for sliding stem, rotary shaft, or quarter
turn valves. Mounting may be made directly to the actuator or remotely in hard to reach or
tough environmental applications.
Pneumatic relay motion measurement input should be provided to control algorithms to
minimize pneumatic related effects.

Functional Requirements
Future enhancement of diagnostic and algorithm-based functionality should be downloadable
electronically from wiring terminal (flash upgrade over the wire).
Microprocessor based device should be designed for functional capability upgrade (tier) in the
field, remotely electronically, without physical change of components.
The smart positioner shall have preset and user adjustable tuning sets and also a performance
tuner feature to provide flexibility in adjusting the instrument responsiveness, to identify the
optimum tuning for the total valve assembly including accessories.

Diagnostic Requirements
Digital valve controller should have remote diagnostic capability with a network via HART
interchange to facilitate on-line diagnostics and monitoring of the instruments and valves.
Digital Valve Controller should be capable (in conjunction with supporting software) providing a
FULL VALVE SIGNATURE. This full valve signature should provide full graphical analysis of the 0
to 100% travel, including seat and upper range of travel. Data should be provided for analysis,
including: Min/Max/Average Friction rates, Expected Friction, Spring Rate, Bench-Set, Actual
Seat Load, Theoretical Seat Load.

On Line diagnostics of valve, while process is running, should provide capability for checking:-
I/P and relay integrity to detect problems with plugging of nozzle, calibration shift, soft parts
failure etc.
Air mass flow rate diagnostics to detect leaks in actuator or output pressurized path
Valve Friction and Dead band measurement and trending
Supply pressure diagnostics for its adequacy and detect/quantify droop
Travel Deviation alert diagnostics for calibration shift / stuck valve
Alerts in terms of green (Everything is OK), yellow (Possible problems for future) and red light
(Need to act now), which is easy to understand by operator, is preferred method.
During performance diagnostics test, running on line, if an error is detected, it should be able to
provide its description, possible causes and recommended action for correction.

Accessories
Standard instrument tubing is 3/8 in O.D. ASTM B68 copper with a wall thickness of 0.032 in -
0.035 in. Standard fittings are NPT brass. If stainless steel tubing is specified on the control
valve data sheet, then 3/8 in O.D. ASTM A269 tubing with a wall thickness of 0.030 0.035 in
wall thickness with NPT stainless steel fittings shall be used. in O.D tubing and to NPT
pipe fittings are to be used on the high volume lines for fast stroke time applications. Tubing for
connecting volume tanks on fast stroke applications is to be furnished by the customer at the
jobsite.
Pressure-sensing trip valves are shall be used for control applications where a specific
valve/actuator action is required when supply pressure falls below a specific point.
Volume boosters shall be used in conjunction with a positioner for control valve applications
that require fast stroking speeds. In general, quick release valves should be avoided on
modulating service due their general instability.
Valves with critical stroking speed requirements should be tested before shipment to ensure
compliance.
All pneumatic actuators shall be equipped with regulator airsets on the air supply, mounted on
the valve assembly. The airset to be provided with integral relief valve and filter/drip well drain
either integral to the airset or as separate filter.
Filtered, dried, oil free compressed air will be supplied for operation of pneumatic control
valves.

Material Requirements
Pressure boundary parts such as body, bonnet, bonnet spacer, and seal protector ring shall be
procured to an ASME/ASTM specification. If neither exists a recognized industry standard or
equivalent material specification shall be used.
Chemical and mechanical properties are to be verified in accordance with the requirements of
the material specification in one of the following accepted methods.
Chemistry is verified by ladle analysis.
Mechanical properties of castings are verified from a test sample which has been heat
treated to the same procedure as the material represented.
Mechanical properties of forgings are verified from a test sample that has the approximate
working as the finished product and has been heat treated with the finished product.
As standard, pressure boundary parts are to be heat/lot traceable to certified chemical and mechanical
test reports except for the following parts/materials.
o Cast Iron
o Bronze or Brass
o AISI materials

Suppliers of steel and alloy castings and closed die forgings will be subject to an audit at 3 year
intervals or, in lieu of an audit, an annual product analysis to verify that the chemistry of the
parts is in accordance with the applicable ASME/ASTM material specification
A pilot casting from each new pattern must pass radiography to ASME B16.34, Annex B after
surface upgrading but prior to any weld repair for shrinkage. In addition, production castings
will be subject to a radiographic sampling program to assure the process remains under control.
Steel casting surface quality is to conform to MSS-SP-55, supplemented by equivalent SCRATA
Comparators.
Welding, whether repair, fabrication, or hardsurfacing, is to be performed be in accordance with
ASME Section IX and approved by a welding engineer.
Suppliers of pressure boundary parts are to be evaluated on a continuing basis in accordance
with a procedure based on the selection factors described in ISO 9000
Pressure boundary material shall conform to the following Material Specifications as applicable:
Pressure boundary and packing-flange bolting shall comply with the following material
specifications:
a. Bolts: ASTM A193
b. Nuts: ASTM A194
Non-pressure boundary parts or trim parts such as plugs, disc, ball, seat ring, cage, and stem will
be procured to an ASME/ASTM. If neither exists, a recognized industry standard or equivalent
material specification shall be used.

Inspection
Sampling inspection shall be utilized for dimensional verification and shall incorporate statistical
process control as part of a manufacturers quality plan.
Inspection, measuring, and test equipment and devices that are used to determine product
quality shall be calibrated using standards traceable to national standards such as the National
Institute of Standards and Technology or, where none exist, to industry recognized standards or
procedures.

Cleaning
Cast, forged, or plate material shall be blast cleaned to remove scale and rust; surface
cleanliness meets the acceptance criteria of commercial blast cleaning standard SSPC-SP-6.
When steel shot blasting is used on stainless material, it shall be followed by a cleaning
operation(s) to remove imbedded steel from the surface of the part.
Grinding wheels and wire brushes used on carbon steel are not to be used on stainless steel
materials unless followed by a cleaning process which will remove imbedded steel from the
surface of the part.
Machined parts are to be detergent or solvent cleaned to remove oil, grease, chips, organic
matter, loose particles and other harmful foreign matter.
Cleaning solutions in contact with austenitic stainless steel pressure boundary and trim parts
contain less than 200 ppm chlorides in the final rinse.
Testing
Hydrostatic testing shall be performed on pressure boundary parts and components per ANSI/ISA S75.19
or optionally, ASME B16.34.
The test pressure shall not be less than 1.5 times the 100 degree F rating, rounded to the next
higher 25 psi increment.
Test water shall contain a low chloride rust inhibitor.
When graphite packing is used, valve assemblies are to be tested with an o-ring gland seal in
place of the packing. Upon completion of testing and prior to installation of the packing, the
packing box shall be thoroughly dried.
Where pressure boundary parts are tested separately, the assembly shall be pneumatically
tested at the lesser of 80 psig or the pressure rating of the item to verify gasket seals.

Seat leak testing shall be performed on all valve assemblies in accordance with ANSI/FCI 70-2.
When graphite packing is used and a water seat leak test is specified, valve assemblies shall be
tested with an o-ring gland seal in place of the packing. Upon completion of the test and prior
to installation of the packing, the packing box shall be thoroughly dried.
Vlvula de globo - Como dato orientativo puede sealarce que segn la norma ANSI B 16.104-
1976 las fugas admisibles son 0,1% de caudal maximo en la vlvula de simple asiento y de 0,5%
en la vlvula de doble asiento. Asi mismo las vlvulas con obturador dotado de anillo de teflon
para cierre hermetico admiten un caudal de 1 40 burbujas de aire o N2.

Diaphragm and piston actuators shall be pressure tested at a minimum of 5 psig over the maximum
supply pressure. A leak detecting solution shall be applied around the actuator pressure joints
connections. No visible leakage shall be allowed.
Valve and actuator assemblies are to be operationally tested by cycling the valve assembly open and
closed to verify full stroke operation, bench set and, as applicable, the proper functioning of accessories
including I/P output and positioner end points.
All valve assemblies equipped with Smart Positioners, and any other valves that are considered to be
critical service, are to be tested to verify critical valve operating characteristics, such as average
dynamic error band, hysterisis and deadband, linearity, total travel, bench set, average packing friction,
and percent drive signal, as applicable. If a valve is not equipped with a smart positioner the same tests
should be run on final assembly with a portable testing device, such as the FlowScanner. In every case, a
valve birth certificate, verifying as left condition, should be generated and shipped to the customer.

Painting & Coating


Actuators, accessories, and carbon or alloy steel pressure boundary parts are to be coated per one of
the paint systems listed below.
Wet paint systems are to consist of an epoxy primer base coat and a alkyd or polyurethane top
coat. Final coating thickness shall be 2.5 to 3.0 mils.
Non-wet paint systems shall consist of an iron phosphate base coat and a polyester powder
topcoat. Final coating thickness shall be 2 mils.
Coatings referenced above shall be tested to meet the following requirements:
Minimum 300 hours salt spray resistance per ASTM B17 & D1654.
Minimum 500 hours humidity resistance per ASTM D4585 & D1735.
Comply with UV Light and Water Resistance per ASTM D4587 & G53
Comply with tape adhesion tests per ASTM D3359.
Comply with Flexibility-Conical Mandrel per ASTM D522
Standard steel fasteners such as bonnet bolting, actuator casing bolting and steel fasteners for
instruments shall have a polymer-based non-corroding finish capable of a minimum of 500
hours of ASTM B117 salt-spray test with no visible rust.
Packaging
Packaging shall provide protection for 1 year from shipment if stored in an enclosed and heated
warehouse. Flange faces and accessible interior surfaces of carbon and low alloy steel items shall be
coated with a rust preventive film. Body inlet, outlet, and instrument connections are to be covered or
plugged.

Drawings
Standard envelope dimensioned drawings shall be provided for each item.
A certified matrix of valve dimensions by Customers tag number and item number shall be
made available after shipment of the order.

Documentation
A serial record shall be provided on an per item basis describing the as-built construction and
including the information:
Heat/lot identification of pressure boundary parts.
Seat leak test pressure and results
Functional test report.
Final inspection report.
Shipment date.
Manufacturing or assembly location.
Post order documentation shall be made available on a supplier hosted website for a period not
to exceed 7 years.
o The document files will use a naming convention that includes the tag number and the
document type for easy file manipulation by the Customer.
o Preferred documentation formats are easily readable such as pdf, xls, doc, and txt.