14.

0 CONTROL VALVES AND SHUTDOWN VALVES

14.1 GENERAL REQUIREMENTS

a) For control valves and shutdown valves actuators shall be spring return
diaphragm or piston type. Necessary dedicated Air filter regulator (AFR) shall be
provided as applicable for positioners and solenoid valves, pilot valves etc. AFR
filter size shall be 5 micron.
b) Control valves sizing shall be done as per ISA standard. Noise and cavitation
check are also to be carried out by supplier for the control valves. For valves with
cavitation, cage guided valves with anti cavitation trim shall be provided. For
valves with noise exceeding 85 dBA, low noise trim shall be provided where
source treatment is not adequate, path treatment shall be provided. Inlet velocity
checks shall also be carried out and if required valve sizes to be increased.
c) End connections shall be as per below:
i. Threaded eng connections shall be to NPT as per ASME B1.20.1
ii. Flanged end connections shall be as per ASME B16.5/ 16.47B.
iii. Flange face finish shall be as per ASME B16.5. The face finish shall be
as follows:
125 AARH : 125 to 250 micro inch AARH
63AARH : 32 to 63 micro inch AARH
iv. Grooves of ring type joint flanges shall be octagonal as per ASME
B16.20.
d) Cv testing certificates for each tag of control valve shall be provided to Client
(ONGC). Software shall be provided to store and access the as-built plant data

14.2 CONTROL VALVE SELECTION

a) Normally Globe Type Valves shall be selected wherever possible.

b) In general, control valves shall be sized for maximum flow at not more than 90%
opening of the valve and normal flow around 70% opening of the valve.
c) For Two-phase flow the control valve Cv shall be the summation of the Cv of the
Liquid phase and Cv of the vapour phase. The quantities and physical properties
of liquid and vapour should be established on the outlet conditions of pressure
and temperature.
d) Valve bodies should be the maximum size required for any anticipated operating
condition.
e) Control valve sizing calculations shall be furnished for review and approval.
f) Standard control valve body sizes are 1, 1 1/2, 2, 3, 4, 6, 8, 10, 12, 14 and 16
inches.
g) Globe valves shall be used where throttling is required.
 h) Butterfly valves may be used when low pressure loss and high capacity flow is
desirable.
i) All control valves must have sound levels less than 85 dB at 1 meter from
valve. Source treatment shall be used for noise control-as far as possible. For
very high noise levels Source treatment in conjunction with Path treatment shall
be used.
j) Valve stem position indicators shall be provided for all valves. They shall be
calibrated from 0% to 100% in steps of 10%.

14.2.1 CONTROL VALVE TRIM CHARACTERSTIC

a) If a substantial increase in future flow rate is indicated, reduced valve trim shall
be used.
b) Quick Opening & Closing trim shall generally be used for on-off service.
c) Control valves used in safety shut down service shall be single seated tight
shutoff.
d) Anti cavitation trims shall be provided for valves with cavitation in liquid
service.

14.2.2 VALVE BONNETS

a) The bonnet shall be flanged bolted to the body.

b) Radiating fins or extended bonnet shall be provided when the temperature
exceeds 200°C (392° F) or below 0° C (32° F).
c) For very low temperatures, extended bonnets shall be used.

14.2.3 MATERIAL OF CONSTRUCTION

a) Valve material shall be in accordance with the line classification and Piping/
Valve material specification. Flanged end body connection shall be used for all
valves.
b) Valve plugs, seats and trim shall be AISI type 316 SS or superior material except
if the normal pressure drop exceeds 7 kg/cm2 (l00 psi) or the fluid is flashing,
hardened trim such as stellite shall be used. SS 440C and Tungsten carbide shall
be used for erosive services and very high pressure drops
c) Generally, control valves shall be furnished with bolted packing glands and
Teflon packing up to 200 deg C and Graphoil packing above 200 deg C.

14.2.4 VALVE POSITIONERS

a) Smart Electro pneumatic Valve Positioners shall be provided for all valves on
regulatory control applications in Process Platforms.
 b) The smart positioner shall be foundation fieldbus type. All engineering,
configuration, diagnostic and maintenance related data shall be provided by the
positioner. Fieldbus positioners must satisfy the requirements of the field bus
registration laboratory with applicable checkmark like Fieldbus foundation etc.
c) Fieldbus positioners shall have analog output (AO) and controller blocks (PID).
d) Fieldbus positioners must be interoperable and shall have valid interoperability
test clearance like ITK latest version for foundation field bus.
e) Fieldbus positioners shall support peer-to-peer communication with two wire
communicator and bus powered supply.
f) Fieldbus positioners shall not be polarity sensitive.
g) Fieldbus positioners in hazardous area shall be certified as per entity concept or
shall be FISCO approved.
h) In addition to operational and maintenance data provided by the positioner like
actual stem travel, input signal, pneumatic pressure to actuator etc the positioner
shall also provide cycle counting and store accumulation data to help keep the
control valve stem leakage in control.
i) The positioner shall also have built-in manual stroke button for stroke open or
close the valve for quick verification.
j) Valve's operating signatures in the form of hard/soft copy shall also be provided
for each control valve.
k) Valve positioners shall have minimum two nos. Air/Gas gauges.
l) Air/gas-filter/regulator shall be factory mounted on the control valve yoke.
m) In case of HART type positioner:
i. Smart positioner shall be a two wire device having 4-20 mA output signal
from the controller superimposed with two way digital communication in
HART protocol format. All engineering, configuration, diagnostic and
maintenance related data shall be provided by the positioner.
ii. The smart positioner shall provide HART protocol of latest version and
shall be suitable to operate with HART maintenance system (HMS).

14.2.5 ACTUATOR AND ACCESSORIES

a) Actuators shall be sized for throttling service at shut-off pressure. The actuator
shall be designed to move the valve to the failure position.
b) In general the actuators shall be sized for standard spring range of 0.2 to 1.0
kg/cm 2g.
c) Supplier shall be responsible for the sizing and selection of the correct actuator
for the specified control valve. While sizing actuator, vendor shall ensure that the
actuator is able to develop sufficient thrust to properly seat the control valve
plug/ disc at the actuator air pressure and shut-off conditions.

14.2.6 SELF –ACTUATED CONTROL VALVES

 Self Actuated Control Valve drop shall be less than 10% of set point. For regulated
pressure under 0.7 Kg/cm2g (10 psig), a pack-less valve shall be used if available.

14.3 SHUT DOWN VALVES

a) Shut down valves shall be of Flanged Full Bore Ball Valve with actuator.
b) Shut down valves shall be certified Fire safe as per API 607 or equivalent
standard by a recognized Third Party Testing agency, if specified in Datasheet.
c) All Shutdown valves shall be for Soft seated with Class A as per API 6D &
Metal seated with Class B as per ISO 5208. Metal seating shall be provided in
case of valves with high temperatures and high pressure drops exceeding the
capability of soft seats. For all other valves, fire-safe type soft seats shall be
provided.
d) Actuator type shall be spring return piston type with Quarter turn operation.
e) Body, trim & wetted parts material shall be as per Piping Material Specifications
/ Valve Material Specifications.
f) Butterfly valves shall be preferably of wafer type, suitable for mounting between
flanges. Other designs of butterfly valves may also be used, based on merit.
g) Trim shall be on-off type. Trim material shall generally be SS316 or as per
material indicated in valve material specification.
h) In case of ball-type of on-off valves;

i. The valve design shall ensure valve seat and body protection against
thermal expansion of the entrapped fluid when the on-off valve is fully
close.
ii. In case of ball-type of on-off valves for size up to 4" and rating up to
ASME Class 300, the on-off valve shall have floating ball design. For
ratings ASME Class 600 and above, floating ball is acceptable for sizes
less than 2". For higher sizes trunnion mounted ball design shall be
provide.

14.3.1 ACTUATOR

a) Type: Spring return diaphragm or piston type, Quarter turn operation.

b) Actuator torque shall be 1.5 times the valve torque required at full rated
differential pressure of valve.
c) Minimum pneumatic supply pressure for Actuator sizing shall be 4 kg/cm2-g or
as specified in Datasheet.
d) All shutdown valves shall be provided with handwheel.

14.3.2 LIMIT SWITCHES

a) Quantity : 2 nos. per valve (One each for open & close)