CONTROL VALVES Chapter 1 Page 3 Failure Open (FO) Failure Close (FC) Figure 1.2CONTROL VALVES Chapter 1 Page 4 BODY CONSTRUCTION ‘The body assembly (fig. 1.3) is build-up from the following components: + valve body [18] and bonnet [8] - valve body studs [9] and nuts [10] + valve body gasket [11] - packing washer [17], packing spacer [7] and packing [6] + packing follower [5] - packing flange [4] including studs [2] and nuts (3) - seat ring [13] and in this case a seat ring gasket [14] + valve plug [15], valve plug stem [1] and plug pin (16) - guide bushing [12] All wetted parts of the control valve, including external bolts/studs and nuts must be designed to the requirements of the relevant piping class. The piping class, see also the section ‘useful information’, provides the instrument engineer with the following information: - the composition of the material = the pressure rating at various temperatures ‘The pressure rating of a material composition is related to the operating temperature of the process fluid flowing through the piping components. The relations shown are for normal carbon steel (fig. 1.4) and AISI 316 type stainless steel (fig. 1.5) ‘The Piping classes DEPs are devided in different sections The international standard ANSI B.16.34¥ is applicable with the exception of the classes 125, 250 and 400 The following classes are used: Glass 150, 300, 600, 900, 1500 and 2500. On the PEFS's you will find the following information example: DN_100.P13001. 3309 jl DN 100 is the line size in metric units aoe I 1 1 13001 is the number of the pipeline I 3 is the rating of the piping equipment (class 300) 309 is the material composition of the piping equipment Abbreviations of the ratings: 1- class 150, 3+ class 300, 6= class 600 9= class 900, 15= class 1500, 25= class 2500 * ANSI is the abbreviation for American National Standards InstituteCONTROL VALVES Chapter 1 Page 6 BODY SIZES The control valve body size may have the same size as the calculated trim size, but oversized bodies, up to the size of the adjacent piping, may be required to reduce the outlet velocity of the fluid. The dimensions of body- and pipe sizes for metric equivalents, and imperial sizes are standardized in accordance with ANSI B36.10 i.e.: - ‘Diameter Nominal’ - sizes DN 15 to DN 600 in om and - ‘Nominal pipe sizes’ - 1/2 inch to 24 inch The control valve body size shall be selected from the following series: + DN 25, 40, 50, 80, 100, 150, 200, 300, 400, 450, 500, 600 and larger For line sizes of DN 25 and smaller,the control valve body size shall be equal to the line size. The valve nominal body size, normaly refered to as “miniature valves", must be selected from the following series: - DN 15 (1/2 inch), DN 20 (3/4 inch) and DN 25 (1 inch) For line sizes larger than DN 25, the minimum control valve body size shall be equal or larger than half che line size. END CONNECTIONS All control valves, including "miniature" types should have flanged ends. Threaded connections are not permitted for process fluids The decision is based on the fact that no reliable sealing material for temperatures above 200 degrees C is available on the market Some types of regulators for instrument air services cannot be obtained with flanges. In this case a threaded connection is permitted. Some types of control valves, such as 'Camflex valves' (fig. 1.6) and butterfly valves (fig. 1.7) do have flangeless valve bodies, which are less expensive When you intend to select a flangeless valve you have to take into account the following points - Is it permitted to use on your site flangeless valves with the exception of butterfly valves? The mechanical department can give you the answer. - What 4s the operating temperature? In some locations you are permitted to use 'Camflex' valves up to a maximum temperature of 200 degrees C for liquid service. In all cases you have to pay special attention to the material of the long bolts and very accurate alignment of the piping flangesVAL Chapter 1 Page 8 The flange rating of flanged control valves should generally be in accordance with the piping class - The minimum rating for carbon steel flanged valves is class 300. Some exceptions ar - having a large number of identical valves, e.g control valves for automatic fire protection systems, which systems are in most cases class 150 + diaphragm valves which, because of their design, can be used only on low pressure applications - teflon lined control valves capsuled in a steel body which are applied in low-pressure and corrosive fluids, e.g. for corrosive service in Demin plants ‘The end facings, i.e. the gasket contact surfaces of control valve faces, including flangeless bodies, shall be suitable for the type of gasket specified for the particular piping class - For high-vacuum services, i.e. absolute pressures of 20 mbar or lower, the valve facing shall be flat and have a super smooth facing according ANSI B46.1, The required O-ring groove shall always be in the counter flange forming part of mechanical engineering + For all other services (in Manufacturing), the facing shall have a smooth finish - In some E & P locations, the joint between piping and the control valve is standardized, for the classes 1500 and 2500, on the Ring Type Joint (R.T.J.), see Figure 1.8. The counter flanges, belonging to mechanical, are provided with identical groves. The cross section of the sealing ring is oval or octagonal and the material is soft anealed steel But-welded control valves should only be considered for special applications, such as - cryogenic service when installed in a ‘cold box’ - high-pressure hydrogenservice If a welding end control valve is selected, then special attention must be aid to * = the internal diameter of the valve body = the wall thickness of the valve body - the beveling of the welding ends of the control valve + the ordering of blind bonnet flange(s) including sufficient bonnet gaskets. Notes: 1. The blind bonnet flange(s) shall be used to blank-off the bonnet connection(s) after removal of the bonnet(s) and the internals of the control valve(s), before flushing and pressure testing starts. 2, It is not permitted to apply control valves vhich are provided with socket welding ends because of the possibility of corrosion between the outer pipe wall and the inner valve connection.ape! Page 9 ZZ 7CONTROL VALVES Chapter 1 Page 10 FACE-TO-FACE DIMENSIONS The face-to-face dimensions (fig. 1.9) of flanged globe-body control valves are standardized according ANSI/ISA $75.03" for the following sizes and ratings + sizes: DN 25, 50, 80, 100, 150, 200, 250, 300 and 400 and + ratings : class 150, 300 and 600 This standard is very important if an existing valve must be replaced by an other valve of the same size and rating, resulting in a lower overall cost since no piping modifications are required Other valve types and ratings for which standards are not yet available may be in accordance with the manufacturer's standard. It is important to reduce the different types (face-to-face dimension) to an absolute minimum. BODY MATERIALS The material selection of the body, bonnet, bolts/studs, nuts and when applicable bottom flange should normally be based on the requirements of the relevant piping class of the DEP In some cases it is for economic reasons attractive to select a control valve with a body material of a better quality A typical example is to use stainless steel instead of killed steel, which is a type of carbon steel for low temperature applications. Stainless steel is for most manufacturers a standard body material. For carbon steel bodies the carbon content shall not exeeed 0.25% to allow for possible weldrepairs. Gonsult the corrosion engineer if you intend to deviate from the DEP. Where corrosive conditions would require exotic materials, consideration should be given to a composite construction, such as an internal metallic lining of the wetted parts Split body-globe valves (fig 1.10), which are not approved for normal applications, may be considered for economic reason, e.g. where special alloys are required The inside of the valve body shall be covered with a hard facing for very severe erosive services such as - fluids containing erosive particles (slurries) + ported plugs for wet gas or wet steam services with a pressure drop across the valve above 10 bar + other services when the pressure drop is above 40 bar Reduced bore valves should not be applied for above mentioned services. If you cannot avoid this, you have to select a valve type with tapered ports * ISA is the abbreviation for Instrument Society of AmericaONTROL VALVES Chapter 1 Page 12 STUFFING BOX AND PACKING All control valves, with the exception of butterfly valves and ball valves, shall have a stuffing box. The stuffing box shall have adequate dimensions to facilitate change of packing and shall be provided with a bolted packing follover. ‘The following packing materials can be selected - PTFE impregnated asbestos such as ‘Crane 285', which has a temperature range from -30 to +200 degrees C. This is the preferred packing material. - General-purpose graphited asbestos packing such as ‘Crane 1066’ shall only be used in combination with a sealant / lubrication facility. The grease shall be free from aromatics. This type of packing requires regular maintenance and should be avoided - 'Grafoil' packing must be selected for all applications with a process temperature above 200 degrees C. The temperature limits are from -30 to +450 degrees C. For services with fluid temperatures outside the packing material temperature limits, an extended bonnet shall be applied to maintain the temperature of the stuffing box/stem sealing facility within the limits specified for the packing material For high-temperature services outside the maximum limit of the packing material an extended bonnet as per figure 1.11 shall be selected. The extended bonnet can be provided with cooling fins for very high fluid temperatures, but this type is more expensive An extended bonnet shall be selected for low-temperature services. The extended bonnet protects the stem against ice formation (fig. 1.12) This type of bonnet must also be selected for valves in which the differential pressure over the valve can result in a temperature drop which causes freezing of the stuffing box/packing and ice formation on the stem. A typical example is a control valve for depressurizing Bellows seal bonnets shall be applied for services with toxic or noxious fluids such as TEL, TML and NOX (fig. 1.13) The bellows must be of AISI 316 type stainless steel, unless an other material is required for the specified process condition. An additional aruffing how with PTFF/acheatas packing material chall he included The seal extension shall be provided with a threaded connection [1] between the bellows seal and the packed gland, for leak detection or for a vent connection to a stack GASKETS The body/bonnet and body/bottom flange gaskets shall be of the spirally wound type, of AISI 316 type stainless steel asbestos filled Other materials or types of gaskets must be specified for special applications. Consult your mechanical engineer A typical application is for vacuum services