Air Operated Control Valves.pdf

TECHNICAL SPECIFICATION AIR OPERATED CONTROL VALVES

DATE: 01 NOV 2005

ENGINEERING SERVICES BY KBR TECHNICAL SERVICES, INC.

I2210E PAGE 1 OF 7

TABLE OF CONTENTS Section 1. 1.1 1.2 2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3. 3.1 3.2 3.3 4.

Title Page No. GENERAL ......................................................................................................................................1 Scope..............................................................................................................................................1 Codes and Industry Standards .................. ............................ ................... ................... ................... ................... .................... .................... ................. ............... ..........1 ..1 DESIGN AND MATERIALS ...........................................................................................................2 General ................. ................................ ................ ................................ ................................. ................. ............................... ............... ......................................... ......................... .2 Body and Bonnet .................. ............................ ................... .................. .................. ................... ................... .................. .................. ................... ................. ................ ...............3 ......3 Control Valve Actuators .................. ............................ ................... ................... .................. .................. .................... ................... .................. ................ ................ ..............4 .....4 Bolting and Gaskets .................. ................................. ................ ................. ................................ ................ ................................. ................. .................... 5 Trim.................................................................................................................................................6 Fugitive Emissions Considerations Conside rations ................. ................................ ................ ................................. ................. ............................... ................ ...............6 6 Control Valve Accessories Accessor ies ................................ ................ .................................. .................. ................................. ................ ................. .................... .......6 TESTING ........................................................................................................................................6 Operation Operatio n and Seat Leakage. Leakag e................... .................. .................................. ................ .................. .................................. ................ .................. ................... 6 Pressure Testing............... Testing .............................. ............................... ................................ ................................ ................................ ..................................... ..................... ..........7 .......... 7 Alloy Verification Testing .................. ........................... ................... ................... .................. ................... ................... ................... ................... ............... ................ .............7 ...7 EQUIPMENT IDENTIFICATION .....................................................................................................7

1. GENERAL 1.1 Scope 1.1.1 Air operated control valves shall be supplied in accordance with an approved quality management program and in strict compliance with: Attached Data Sheets This Specification Industry Codes 1.1.2 Where special features or improvements improvements over the standard specification are required, these these shall be specified on the Instrument Data Sheets and shall be adhered to by the Supplier. 1.2 Codes and Industry Standards Standards The documents listed below are referenced referenced herein and form a part of the Order. Applicable Codes and Industry Standards are indicated below and refer to the latest issue of the referenced document in effect at placement of the initial Purchase Purchase Order. Unless approved otherwise by purchaser’s responsible responsible engineer, equipment shall be supplied in accordance with applicable requirements of these documents, as determined/clarified by same engineer. AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME) ASME Boiler Boiler and Pressure Vessel Code, including all mandatory addenda Section VIII, ASME B1.20.1, ASME B16.5, ASME B16.11, ASME B16.20, ASME B16.25, ASME B16.34, ASME B16.47, ASME B31.3,

"Pressure Vessels - Division 1" "Pipe Threads, General Purpose (Inch)" "Pipe Flanges and Flanged Flanged Fittings NPS NPS 1/2 Through NPS NPS 24" "Forged Fittings, Fittings, Socket-Welding and Threaded" Threaded" "Metallic Gaskets for Pipe Flanges - Ring-Joint, Spiral-Wound, Spiral-Wound, and Jacketed" "Buttwelding Ends" Ends" "Valves – Flanged, Threaded and Welding End" End" "Large Diameter Steel Steel Flanges NPS 26 Through NPS 60" "Process Piping"


DATE: 01 NOV 2005


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AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM) ASTM A105/A105M, A105/A105M, "Carbon Steel Forgings Forgings for Piping Applications" Applications" ASTM A182/A182M, A182/A182M, "Forged or Rolled Alloy Alloy and Stainless Stainless Steel Pipe Flanges, Flanges, Forged Fittings, Fittings, and Valves and Parts for High-Temperature Service" ASTM A193/A193M, A193/A193M, "Alloy Steel and Stainless Stainless Steel Bolting Materials for High-Temperature High-Temperature Service" ASTM A194/A194M, A194/A194M, "Carbon and Alloy Steel Steel Nuts for Bolts Bolts for High-Pressure High-Pressure and High-Temperature High-Temperature ASTM A216/A216M, A216/A216M, "Steel Castings, Carbon, Carbon, Suitable for Fusion Fusion Welding, for for High-Temperature Service" Service" ASTM A217/A217M, A217/A217M, "Steel Castings, Martensitic Martensitic Stainless Stainless and Alloy, for Pressure-Containing Pressure-Containing Parts, Suitable for High-Temperature Service" ASTM A320/A320M, A320/A320M, "Alloy-Steel and and Standard Steel Bolting Bolting Materials for for Low-Temperature Service" ASTM A350/A350M, A350/A350M, "Carbon and Low-Alloy Low-Alloy Steel Forgings, Requiring Notch Toughness Testing for Piping Components" ASTM A352/A352M, A352/A352M, “Steel Castings Ferritic Ferritic and Martensitic Martensitic for Pressure-Containing Pressure-Containing Parts Parts Suitable for Low-Temperature Service" FLUID CONTROL INSTITUTE (FCI) FCI 70-2, "Control Valve Seat Leakage" INSTRUMENT SOCIETY OF AMERICA (ISA) ISA 75.08.01 "Face-To-Face Dimensions for Integral Flanged Globe-Style Control Valve Bodies (Classes 125, 150, 250, 300, and 600)" ISA 75.08.02, "Face-To-Face Dimensions for Flangeless Control Valve Bodies (Classes 150, 300, and 600)" ISA 75.08.05, "Face-to-face Dimensions for Buttweld-End Globe-Style Control Valves (Classes 150, 300, 600, 900, 1500, and 2500) ISA 75.08.06, “Face-To-Face Dimensions for Flanged Globe-Style Control Valve Bodies (Classes 900, 1500, and 2500)" ISA 75.14, "Face-To-Face Dimensions for Buttweld-End Globe-Style Control Valves (ANSI Class 4500)" ISA 75.19.01, "Hydrostatic Testing of Control Valves" 2. DESIGN AND MATERIALS 2.1 General 2.1.1 Valve bodies shall be of the material specified on the Instrument Instrument Data Sheets. As a minimum, the the valve trim and stem shall be of stainless steel, suitable for the specified design conditions. 2.1.2 Unless otherwise specified, specified, carbon steel valves shall be painted in accordance with Supplier's Supplier's standards suitable for the environmental, operating and design conditions specified on the Instrument Data Sheets. 2.1.3 Minimum valve end connection size shall be NPS NPS 1 for valves installed in lines NPS NPS 1 and larger. 2.1.4 Valves installed in lines smaller smaller than NPS 1 shall be line size. 2.1.5 Valves that must provide tight shutoff shall have a Class IV IV seat leakage rating, as a minimum. The required shut off class will be shown on the data sheet. 2.1.6 Valves in critical applications applications that require minimum leakage shall have Class VI seat leakage rating. Class V will be acceptable if temperature limits are outside of soft seat materials.


DATE: 01 NOV 2005


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2.1.7 For Rotary valves: a.

The valve disk shall be positively attached to the shaft, and the shaft shall preferably be a one-piece, through design.

b.

The actuator end of the valve shaft shall be splined or keyed and shall not have a shear pin.

c.

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

d.

The bearing material shall be selected to prevent galling galling of the the bearing or or valve shaft.

e.

Since the disk in wafer wafer style valves valves may project beyond the valve body during part of the disk rotation, clearance shall be maintained between the disk and the pipe wall, particularly if the pipe is of heavy wall construction.

f.

For butterfly butterfly valves, the vane as a minimum minimum shall be of the same material as the valve body, unless otherwise specified.

g.

Wafer valves valves shall have centering centering holes to ensure proper alignment alignment of valve and gasket.

2.1.8 Material, end connections, and pressure rating rating of valve body shall conform to the applicable piping specification, as a minimum. 2.2 Body and Bonnet Bonnet 2.2.1 Direction of flow flow shall be indicated indicated on all valve bodies. bodies. Direction arrow must be forged, stamped, or otherwise permanently attached. 2.2.2 Cage guided valves shall have removable cages. All globe globe valves shall have removable seat rings and plugs. Threaded seat rings are not acceptable. acceptable. 2.2.3 The valve stem shall shall be sealed by means of a bolted packing box. Packing glands shall be equipped with flange style followers. followers. Packing shall be as follows unless process process fluid or conditions require others: a.

Temperature 0 to 450 F (-17.8 to 232 C) – Use TFE V-Ring.

b.

Temperature below 0 F (-17.8 C) or above 450 F (232 C) – Use Laminated graphite.

°

°

°

°

°

°

A lubricator and an isolating valve shall shall be provided when required required on the instrument data data sheet. 2.2.4 The erosive/corrosive effects effects of the controlled fluid and the design life of the plant shall be considered when deciding valve body material. 2.2.5 Ratio of nominal pipe size to body size greater than 2:1 shall be approved by Purchaser. 2.2.6 Valve end connection sizes, types, and facings shall be as specified on the Instrument Data Sheets, and shall be in accordance with the following standards:


DATE: 01 NOV 2005


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Threaded (tapered style style required) ............ ............ ASME B1.20.1 Flanged NPS 1/2 through NPS NPS 24 ............ ............ ASME B16.5 B16.5 Flanged NPS 26 and larger................... larger....................... .... ASME B16.47 ( *) Ring Joint (flat-bottom type type grooves) ........ ASME B16.20 Buttwelded .................. ............................ ................... .................. ........... .. ASME B16.25 Socket-welded.................. Socket-welded........................... .................. ................ ....... ASME B16.11 (*) Supplier to designate Type Type A or B style style flanges on quote. 2.2.7 Bonnets shall be a bolted design. 2.2.8 Single and double seated straight through valves with with flanged end connections shall have face-to-face dimensions in accordance with ISA 75.03 or ISA S75.16. 2.2.9 Unless noted otherwise and in addition to to the above requirements, all cast, forged, and fabricated steel steel valves shall be manufactured as "Standard Class" valves in accordance with ASME B16.34. 2.2.10 Unless specified otherwise, all all materials, design and fabrication fabrication of valves including any required examination, inspection, testing, and acceptance criteria, shall be in accordance with the requirements and limitations of ASME B31.3. This includes any maximum temperature temperature limitation for a material or rule governing the use of a material at a low temperature. 2.2.11 Globe valves with split body shall be used only with with prior Purchaser approval. 2.2.12 Face-to-face dimensions of the valve valve body shall conform to ISA Standards in accordance with with the following table: BODY STYLE

ISA STANDARD

Globe style

75.08.01 or 75.08.06 depending on Integral Flanges ASME Class rating

Flangeless

75.08.02

Buttweld-End Globe

75.14 or 75.08.05 depending on ASME Class rating

2.3 Control Valve Actuators Actuators 2.3.1 Unless otherwise specified, specified, valve actuators shall be pneumatic diaphragm type type or piston type. 2.3.2 Where springless type cylinder actuators are required, e.g., high thrust applications, applications, etc., the actuators shall be furnished with the necessary volume (capacity) tank and accessories to provide the correct valve action on air supply or signal failure. Tank capacity shall be capable of fully stroking stroking the valve two (2) complete cycles. 2.3.3 All volume tanks shall conform to to Part U-1 of ASME Section Section VIII, Division 1, and shall be ASME ASME Code stamped. The tanks shall be equipped with a pressure relief device, a pressure gauge, a drain valve, and support steel such as “L” shaped legs for mounting. Supplier shall make recommendations recommendations for large tank support requirements. 2.3.4 Actuator shall drive the valve to a safe position position on loss of signal or motive power. Actuator Actuator shall have an enclosed spring to achieve fail-safe action. Multispring actuators are not acceptable. acceptable.


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2.3.5 Actuator shall shall be sized: a.

By the valve supplier.

b.

To meet control, shutoff, shutoff, and leakage requirements requirements of the valve, at minimum air supply.

c.

To fail the valve to the safe position position on loss loss of air air or control signal. The valve shall return to required failsafe position using spring force only.

d.

Per the maximum differential differential pressure pressure (shutoff pressure specified specified on valve valve datasheet) or if not shown, then the maximum differential pressure shall be the maximum process upstream pressure with valve fully closed and downstream at atmospheric atmospheric pressure whichever is greater. Using process pressure to assist valve movement shall not be considered in the calculation with the spring force to maintain controllability, fail safe state and/or shutoff classification of the valve.

e.

With a 1.2 design factor for valves in a process service service where where the valve valve stems could stick.

2.3.6 Actuator case shall be rated for the maximum available available pneumatic supply pressure, or a supply regulator shall be provided. 2.3.7 Exterior of actuator shall be painted painted with Supplier’s standard paint and color, color, unless specified otherwise. 2.3.8 Actuator and associated accessories shall be completely completely assembled, piped, mounted on the control valve, aligned, tested, and shipped as a complete unit. 2.3.9 Actuator shall be capable of providing a full stoke stoke of the control valve in either direction in in not more than 20 seconds, unless specified otherwise on the Instrument Data Sheet. 2.3.10 Springs, internal parts, fasteners, fasteners, and hardware shall be resistant to corrosive corrosive effects of the environment. 2.4 Bolting and Gaskets Gaskets 2.4.1 Bolting material shall be compatible with body and bonnet material. 2.4.2 Bolts shall conform to ASTM ASTM specifications as follows: follows: Valve Body Material Carbon steel, ASTM A105 or A216-WCB LT Carbon steel, ASTM A350-LF2 or A352-LCB 1-1/4 Cr-1/2 Mo, ASTM A182-F11 or A217-WC6 2-1/4 Cr-1 Mo, ASTM A182-F22 or A217-WC9 300 Series Stainless Steel, -50 to 1000 °F 300 Series Stainless Steel, -325 to -51 °F

Bolting/Nut Bolting/Nut Materials ASTM A193-B7 / A194-2H ASTM A320-L7 / A194-4 ASTM A193-B16 / A194-4 ASTM A193-B16 / A194-4 ASTM A193-B8 CL2 / A194-8MA or 8TA ASTM A320-B8 CL2 / A194-8MA or 8TA

2.4.3 The valve Supplier shall supply supply cap screws for single flange valves in accordance with with the piping specification.


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2.4.4 Bonnet gaskets shall: a. b. c.

Be fully retained. Be made from 316 SS, unless otherwise specified. Have PTFE or graphite filler.

2.5 Trim 2.5.1 Valve stem and plug shall be pinned, welded, welded, or one-piece design. 2.5.2 Threaded trim parts shall be pinned or spot-welded to supplement threaded attachment. attachment. 2.5.2 Bonnet bolts shall not be used to attach actuators actuators or mounting brackets. brackets. 2.6 Fugitive Emissions Consideration Considerations s 2.6.1 Packing shall limit fugitive emissions. 2.6.2 Bellows seals should be considered only when no leakage across the stem can be tolerated, or cases in which excessive packing friction results in unreasonably large packing friction forces. 2.7 Control Valve Accessories 2.7.1 Side mounted handwheels, when specified specified on the Instrument Data Sheets, shall be of locking type with de-clutching mechanism. 2.7.2 Solenoid valves shall be rated for continuous continuous duty and shall have Class F high temperature encapsulated coils. Class H shall be used in high ambient temperature applications applications only. Coil voltage shall be 24 V DC, unless specified otherwise on the data sheets. 2.7.3 Solenoid valve for tripping the control control valve shall be between the positioner and the actuator or in the tubing providing the motive power to the actuator. 2.7.4 Tripping solenoid valve shall have sufficient sufficient capacity to exhaust the actuator chamber air volume volume within the time required to allow allow the valve to fail in a fail safe position. If the solenoid valve Cv is not sufficient, a pilot valve shall be provided with separate airset, which works in conjunction with the tripping solenoid valve. 2.7.5 The Supplier shall provide bonnet extension extension when necessary or when specified, to ensure proper operation of the control valve under the operating and design conditions specified on the Instrument Data Sheet. 2.7.6 If the solenoid valve vent port is open to the atmosphere, it shall have an insect screen. 2.7.7 As a minimum, the positioner shall be a “smart” positioner with 4-20 ma for signal transmission and HART data collection. collection. See the data sheets for specific project requirements. requirements. 3. TESTING 3.1 Operation and Seat Leakage Seat leakage tests shall be in accordance with FCI 70-2.


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3.2 Pressure Testing As a standard requirement, requirement, all valves shall shall be hydrostatically hydrostatically tested in accordance with with ISA S75.19.01. Unless otherwise stated on the data sheet, component testing of the pressure boundary parts is permitted; provided the valve body assembly is subsequently tested to verify the p ressure sealing integrity of gaskets. 3.3 Alloy Verification Verification Testing An alloy verification verification plan will be issued on projects where where alloy verification verification is required in accordance accordance with General Engineering Procedures. This plan will include instrument items to be alloy verified (with verification class defined), required methods of verification verification and when and where these test are to be performed. Alloy verification requirements will be noted on each valve data sheet (Example: “CLASS I ALLOY VERIFICATION VERIFICATION REQUIRED”). REQUIRED”). Supplier shall perform all required tests to meet the stated requirements. 4. EQUIPMENT IDENTIFICATION The Supplier shall provide a separate (from the valve and/or actuator nameplate) stainless steel tag attached to the valve (in a corrosion resistant manner). The valve tag number and purchase order number shall be stamped upon it.

Air Operated Control Valves.pdf

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