Spec. No.

3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 1 OF 13

FUNCTIONAL SPECIFICATION

FOR

CONTROL VALVE

TKK ARD AKR 13 23. 02. 2010 4

VS SRS GRP 12 18.02.2008 3

AK BKK GRP 13 28.03.2007 2

AK BKK GRP 13 30.08.2006 1

MC MC AC 13 25.08.2003 0

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 Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 2 OF 13

CONTENTS

Page
Clause No. ITEM
No.
1.0 Scope of This Document 3
2.0 Reference Documents and Specifications 3
3.0 Scope of Supply 3
4.0 Control Valve 3
4.1 Valve selection & construction 3
4.2 Control valve sizing 4
4.3 Actuator 4
4.4 Positioner 5
4.5 Material 5
4.6 Miscellaneous Requirements 6
Annexure I Material Selection Chart 8
Annexure II Hook-up drawing 9
Annexure III Data Sheet Format 13

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 Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 3 OF 13

1.0 SCOPE OF THIS DOCUMENT:

1.1 This functional specification describes the essential design considerations for the
selection of Control Valve for the intended service.
2.0 Reference Documents and Specifications:
a) Instrumentation Design Criteria
b) Basic Bid Work
c) Project P & IDs
d) Process Design Criteria / Instrument Process Data Sheets
3.0 SCOPE OF SUPPLY:
3.1 The quantity to be supplied and installed shall be as per the requirements indicated
in the Basic Bid Work, Design Criteria and the P & IDs.
3.2 The vendor shall be responsible for the selection of the Control Valve suitable for
its intended application, its procurement, tagging, packing, stroke testing &
calibration, preparation for shipment, along with accessories, spares, and assistance
where required for its installation & commissioning at site.
4.0 CONTROL VALVE:
4.1 Valve Selection & Construction:
4.1.1 The Contractor shall select control valve based upon process flow capacity.
The Contractor shall select reduced trim as required to satisfy the expected
range of flow rate.
4.1.2 Valve selection shall consider all possible effect of erosion, cavitations and
noise.
4.1.3 Maximum permissible noise level shall be 85 dBA at 1 m from valve in all
direction. Noise mitigation by external noise reduction attachments shall be
considered where noise levels increase beyond the limits.
4.1.4 Equal percentage and linear trim characteristic shall be used as applicable to
process requirement. Quick opening type valve may be used for ON/OFF
service only.
4.1.5 Globe valves are preferred for general service and shall be cage guided for
low db application. In dirty or abrasive services (Produced liquids) post
guiding is preferred. Pressure balanced plug type valve shall be used wherever
diff. pressure across valve is high.
4.1.6 Butterfly control valves shall be used for water services, low differential
pressure high flow and non-critical applications only.
4.1.7 In general, except flare gas service, process fluid entry to Cage type single
seated globe valves shall be such as tending to open the valve (flow to open).
4.1.8 Shut-off leakage of valves shall be in accordance with ANSI B16.104. Tight
shut-off (TSO) valves shall be class VI or better with soft seating (reinforced
PTFE or similar).

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 Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 4 OF 13

4.1.9 Body rating, flange rating & facing and material of construction shall be in
accordance with PMS / FS 401 the piping class specification for the associated
piping.
4.1.10 Valve Packing boxes shall be flange bolted to the bonnet. Valve packing shall
be spring loaded and adjustable. Teflon V rings shall be used up to 2120C.
Above this temperature graphite shall be used with an external lubricator and
isolation valve.
4.1.11 Valve bonnets shall be flange bolted to the body. Screwed bonnets shall not be
provided. For operating temperature of 2000C or greater, a radiating finned
bonnet may be required. For temperature below 00C an extension bonnet is
required. If bellows seals are required they shall be constructed from 316SS.
4.1.12 Minimum body size shall be DN25.
4.1.13 Where a valve is for flare gas service, TSO valve with soft seats are required.
For high-pressure drop application in gas service, multiple orifice trim design
shall be used. Labyrinth design shall not be used.
4.1.14 Pneumatic connections shall be ¼” NPTF as minimum. Larger Port sizes shall
be used wherever required for larger sizes of actuators.
4.1.15 Flow direction shall be stamped or cast on the body of all valves.
4.1.16 The Contractor shall provide detailed pressure temperature envelope curves
for each combination of valve body, trim and elastomer material.
4.2 Control Valve Sizing:
4.2.1 The Control valve shall be selected to pass high extreme of flow at 80%
maximum opening of the valve travel and low extreme of flow at 20%
minimum opening of the valve travel. The control valve shall be sized for
required maximum diff. pressure and shut-off pressure. Butterfly valves shall
be sized to pass high extreme of flow at 60% maximum opening of the valve
travel.
4.2.2 The Contractor shall submit Control Valve sizing calculation performed in
accordance with ISA S 75.01 and based on approved Process data, Process
flow diagram and material balance.
4.3 Actuator:
4.3.1 Control valve actuators shall be pneumatic, spring return type, diaphragm or
piston type. Spring shall be corrosion resistant, cadmium plated or equal.
Piston type actuator shall be used where diaphragm actuator cannot be used
due to capacity limitation. Electric actuator shall be used wherever specified.
4.3.2 Actuators shall be sized for operation under maximum shutoff pressure drop
across the valve minimum instrument air pressure or voltage to the actuator as
specified in this specification.
4.3.3 Actuators shall be selected to achieve specified valve failure positions. All
accessories, including pilot valves, relays, volume bottles etc. for double

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 Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 5 OF 13

acting actuator or air block relays for fail in position valves, shall be supplied
with the valve.
4.3.4 A valve stem position indicator shall be provided. All control valve scales
shall be calibrated from 0-100 % of valve travel. Smart positionar transmitters
shall be considered for valve status indications in Process control room.
4.3.5 Side mounted heavy-duty hand wheels shall be provided for control valves
wherever specified. Hand wheels material shall be corrosion resistant and with
C-allowances over and above the thickness required as per design
requirements. Hand wheels shall be normally in disengaged position and
locked during normal Platform operation. These are to be used only during
maintenance / manual operation.
4.3.6 Actuator action shall be designed and sized for Failure position indicated.
4.3.7 Diaphragm actuators shall be multiple bolted, pressed steel with Nylon
reinforced Neoprene or Buna N Rubber Diaphragm and shall be corrosion
resistant / with sufficient corrosion allowances to last the life of the platform.
4.4 Positioner : (Unless otherwise specified it shall be SMART Positioner)
4.4.1 Control valve shall be supplied fitted with positioner for all services except
on/off control.
4.4.2 Wherever specified for non-smart positioner the control valve shall be
provided with integral positioner with intrinsically safe “smart” type integral
i/p converter, and shall be direct acting, with field reversible provision.
4.4.3 Gauges shall be fitted to indicate pressure of the pneumatic supply, signal and
output to the actuator.
4.5 Material:
4.5.1 The material requirements for Control Valves shall in general be according to
the Material Selection Chart provided in Annexure – I of Pressure Control
Valve.
4.5.2 Control valve bodies shall generally be cast or forged carbon steel to ASTM
A216 Gr WCB/WCC or A105 respectively with 316 SS trim as a minimum.
However, more demanding services may require other materials as specified
in the applicable valve specification/Material selection chart. Consideration
shall be given in selection of all other valve part materials for
erosion/corrosion due to process fluid and ambient conditions and valve trim/
plug shall be stellited.
4.5.3 For painting, in general, Manufacturer standard procedures shall be followed.
However, specification enclosed in the bid shall govern and shall form the
minimum requirements.
4.5.4 All mounting accessories such as mounting bolts shall be of SS 316.
4.5.5 Tubing shall be seamless 316 SS tube 3/8” OD minimum with 316 SS double
ferrule compression fittings.

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 Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 6 OF 13

4.6 MISCELLANEOUS REQUIREMENT:

4.6.1 Control valves shall be installed in horizontal lines with Actuator vertically
above the valve.
4.6.2 Clearance shall be provided to allow in- line maintenance of valves. Adequate
clearance shall be provided above and below the valve to allow removal of the
valve actuator and internal cage (trim) and valve bottom plate as applicable
while not impeding access ways.
4.6.3 Control valve assembly shall be installed with two line isolation valves. One
shall be provided at the upstream side of the control valve and the other at the
downstream side. A bypass line shall be provided across the control valve
with a line isolation (bypass) valve (globe type). Capacity of the bypass valve
shall be in line with the control valve.
4.6.4 Control valves shall be installed in the direction recommended by the
manufacturer and the valve shall not be subjected to stress due to pipeline
movement or misalignment.
4.6.5 All valves shall be tested in accordance with API 598, hydro-tested to ASME
B 16.34 clause 7.1, leak tested to ASME / FCI 70.
4.6.6 Testing and Calibration :
In accordance with nameplate data and instrument specification following
Testing and Calibration shall be carried out:
i. All diaphragm and piston operated control valve shall be stroke tested
pneumatically using a pressure regulator and pressure gauge against
spring range.
ii. Mechanical sealing and travel shall be checked.
iii. Valve position shall be calibrated on control valve.
iv. Split range or reverse acting positioner shall not have bypass and shall
be checked carefully.
v. Zero position shall be live zero (just off the seat at minimum setting with
air).
vi. Signal line shall be bled to zero and failure action shall be confirmed.
vii. Control valve accessories such as hand wheel, booster, relay, Volume
bottle etc. shall be checked operationally. Declutchable hand wheel shall
be operable both with and without air signal to diaphragm.
viii. Check shall be made in shop prior to installation.
ix. Butterfly valves shall be checked carefully to see that vane moves freely
into upstream and downstream piping. Proper vane movement to stroke
shall be confirmed when specified.

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 Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 7 OF 13

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

FORMAT No. Ref. PROCEDURE No. ISSUE No. REV. No. REV. DATE:
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 Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 8 OF 13

ANNEXURE – I
Material Selection Chart for Control Valves
Control Valves
S. No. Piping Class
Body Trim

A1, B1, D1, E1, F1, XF1, F1, PA1, PB1,

PD1, PE1, PXF1, PF1, A2, B2, D2, E2,
1 CS SS 316
XG1, A1H, A3, B3, A8
(EXCEPT WAT. INJ. SERVICE)

2 INJECTION WATER SERVICE CS SS 316

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

ALUMINIUM
4 A5 MONEL
BRONZE

5 A7 HASTALLOY C. HASTALLOY C.

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

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

DUPLEX SS SOLID ALLOY

A11, B11, D11, E11, F11, PA11, PB11,
8
PD11, PE11, PF11
PACKING – GRAPHOIL/Teflon

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 Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 9 OF 13

ANNEXURE – II
(Hook Up Drawing)

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 Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 10 OF 13

ANNEXURE II (Contd.)

AIR FAIL TO OPEN CONTROL VALVE WITH I/P AND POSITIONER

AIR FAIL TO CLOSE CONTROL VALVE WITH I/P AND POSITIONER

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 Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 11 OF 13

ANNEXURE II (Contd.)

CONTROL VALVE WITH PILOT VALVE

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 Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 12 OF 13

ANNEXURE II (Contd.)

SMART POSITIONER

AIR FAIL TO OPEN CONTROL VALVE WITH SMART POSITIONER

SMART POSITIONER

AIR FAIL TO CLOSE CONTROL VALVE WITH SMART POSITIONER

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 Spec. No. 3700
Offshore Design Section
Functional Specifications Rev. No. 4
Engineering Services
Discipline Instt
ISO – 9001:2000 CONTROL VALVE
Page: 13 OF 13

ANNEXURE – III: - TYPICAL DATA SHEET FOR CONTROL VALVE

UNITS: Flow → Liquid : M3/Hr, Gas : SM3/Hr or Kg/Hr, Steam : Kg/Hr, Pressure : Kg/Cm2 G, Temp: 0C Level / Length : MM
General 1. Tag No.
2. Inlet No.
3. Outlet No.
4. Service
5. Line Size Schedule
6. Inlet Line I.D. Outlet Line I.D
Body 7. Type of Body
8. Body Size Part Size
9. Guiding No. of Parts
10. End Conn. Type. Size & Rating
11. Facing & Finish
12. Body Material
13. Bonnet Type
14. Packing Material
15. Lubricator Isolation . Valve
16. Trim Form
17. Trim / Plug (Stellite Mat.) /Disc/Ball & Seat Mat.
18. Other Wetted Parts
19. Soft Seating Material
20. ANSI Leakage Class
Actuator 21. Type
22. Close At Open At
23. Failure Position
24. Hand wheel & Location
Positioner 25. Air Supply Pressure
26. Input Output
27. Bypass Gauges
Options 28. Solenoid Valve
29. I/P Converter
30. Filter with Gauge
31. Limit Switch
32. Smart Positioner
33.
Service 34. Fluid State
Conditions 35. Flow Liquid- Min Normal Max
36. Flow Vapour- Min Normal Max
37. Flow Water Min Normal Max
38. Inlet Pr. – Nor Min.
39. Process Flow Rate Min Normal Max
40. Pressure Shut Off
41. Temp. Oper. Max
42. Oper. S. G. Mol. Wt.
43. Cp/Cv Compress Factor
44. Flash % Visc. mPass (Oper)
45. Deg. Of Superheat
46. Vapour Pr. Critical Pr.
Valve 47. Cv Min. Cv. Max.
Data 48. Cv. Nor. Selected Cv
49. Predicted Sound Level dBA
50. Inlet Velocity m/s
Model 51. Valve Actuator
Nos. 52. Positioner Solenoid Valve
53. IBR Certification
NOTE :-
VENDOR SEAL AND SIGNATURE

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