Control Valves & Pressure Regulators

Technical Specification

1.  Introduction ..................................................................................... 6 

1.1  Scope of Specification...............................................................6 
1.2  Definitions............................................................................. 6 
1.3  Abbreviations ......................................................................... 6 
1.4  Units ................................................................................... 7 
1.5  Supplier Exceptions ..................................................................7 
2.  Codes, Standards & Project Specifications .................................................7 
2.1  Statutory Requirements .............................................................7 
2.2  Standards .............................................................................. 8 
2.2.1  Australian / New Zealand Standards ................................... 8 
2.2.2  International Standards .................................................. 8 
2.2.3  Company Standards .......................................................9 
2.3  Order of Precedence .............................................................. 10 
3.  Approved Supplier List ....................................................................... 10 
4.  General Requirements ....................................................................... 11 
4.1  Scope of Work ...................................................................... 11 
4.2  Operation & Design Life........................................................... 12 
4.3  Interfaces ........................................................................... 12 
4.4  Utilities Requirement ............................................................. 12 
4.4.1  Instrument Air ........................................................... 12 
4.4.2  Instrument Gas........................................................... 12 
4.4.3  Electrical ................................................................. 12 
4.5  Hazardous Area Requirements ................................................... 13 
4.6  Safety Integrity Level (SIL) Requirements ..................................... 14 
4.7  EMC Compliance.................................................................... 14 
4.8  Emission Limits ..................................................................... 14 
4.9  Noise ................................................................................. 15 
5.  Technical Requirements ..................................................................... 15 
5.1  Materials............................................................................. 15 
5.1.1  General ................................................................... 15 
5.1.2  Valve Body ................................................................ 16 
5.1.3  Valve Trim ................................................................ 16 
5.1.4  Stem Packing ............................................................. 16 
5.1.5  Actuator................................................................... 17 
5.1.6  Accessories ............................................................... 17 
5.2  Material Traceability & Certification ........................................... 18 
5.3  Valve Selection Guide ............................................................. 18 
5.3.1  General ................................................................... 18 
5.3.2  Rotary Valves............................................................. 20 
5.3.3  Linear Motion Valves .................................................... 21 
5.3.4  Globe Valves ............................................................. 21 
5.3.5  Angle Valves .............................................................. 21 
Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 2 of 46

 Control Valves & Pressure Regulators
Technical Specification

5.3.6  Three Way Valves ....................................................... 21 

5.4  Body Selection Guide .............................................................. 22 
5.4.1  General ................................................................... 22 
5.4.2  Body Size.................................................................. 22 
5.4.3  End Connections ......................................................... 22 
5.4.4  Valve Dimensions ........................................................ 22 
5.4.5  Body Material ............................................................ 22 
5.5  Stuffing Box, Packing & Gaskets ................................................. 23 
5.5.1  Stem Packing ............................................................. 23 
5.5.2  Gaskets .................................................................... 23 
5.6  Trim Selection Guide .............................................................. 23 
5.6.1  Seat Leakage & Flow Direction ........................................ 23 
5.6.2  Trim Construction ....................................................... 24 
5.6.3  Trim Material............................................................. 24 
5.6.4  Severe Service Trim Design ............................................ 25 
5.7  Valve Sizing ......................................................................... 26 
5.7.1  General ................................................................... 26 
5.7.2  Two Phase Flow.......................................................... 26 
5.7.3  Viscosity Errors .......................................................... 27 
5.7.4  CV Capacity ............................................................... 27 
5.7.5  Piping Geometry Factor, FP ........................................... 27 
5.7.6  Minimum Rangeability .................................................. 27 
5.7.7  Fluid Mixture ............................................................. 28 
5.7.8  Compressor Anti Surge.................................................. 29 
5.8  Actuators ............................................................................ 30 
5.8.1  Actuator Selection ...................................................... 30 
5.8.2  Actuator Design .......................................................... 30 
5.8.3  Actuator Sizing ........................................................... 31 
5.8.4  Actuator/Positioner Performance .................................... 31 
5.9  Valve Accessories .................................................................. 32 
5.9.1  General ................................................................... 32 
5.9.2  Filter Regulators ......................................................... 32 
5.9.3  Quick Exhaust Valves / Booster Relays .............................. 32 
5.9.4  Positioner ................................................................. 33 
5.9.5  Solenoid Valves .......................................................... 33 
5.9.6  Limit Switches ........................................................... 33 
5.9.7  Mechanical Limit Stops ................................................. 34 
5.9.8  Electrical Connections .................................................. 34 
5.9.9  Electrical Cabling ........................................................ 34 
5.9.10  Junction Boxes ........................................................... 34 
5.9.11  Handwheels .............................................................. 34 
5.9.12  Lifting Eyes ............................................................... 35 
5.10  Pressure Regulators ................................................................ 35 
Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 3 of 46

 Control Valves & Pressure Regulators
Technical Specification

5.10.1  Body Size.................................................................. 35 

5.10.2  Body Construction ....................................................... 35 
5.10.3  Pressure Rating .......................................................... 35 
5.10.4  Wide Open Flowrate .................................................... 35 
5.10.5  Outlet Pressure Range & Spring Selection ........................... 35 
5.10.6  Accuracy .................................................................. 36 
5.10.7  Orifice Diameter ......................................................... 36 
5.10.8  Speed of Response ...................................................... 36 
5.10.9  Diaphragm Material ..................................................... 36 
5.10.10  Noise....................................................................... 36 
5.10.11  Freezing ................................................................... 36 
6.  Quality Assurance & Inspection ............................................................ 37 
6.1  General .............................................................................. 37 
6.2  Inspection & Testing ............................................................... 37 
6.2.1  Inspection of Actuator Welds, Castings & Steel Parts ............. 37 
6.3  Testing ............................................................................... 38 
6.3.1  General ................................................................... 38 
6.3.2  Test Requirements ...................................................... 39 
6.3.3  Functional Test .......................................................... 39 
6.3.4  Seat Leakage Test ....................................................... 40 
6.3.5  Capacity Test ............................................................ 40 
6.3.6  Hydrostatic Test ......................................................... 40 
6.3.7  Low Temperature Production Test ................................... 40 
6.3.8  Material Testing & NDE ................................................. 40 
6.3.9  Commissioning & Start-up ............................................. 41 
6.3.10  Site Support .............................................................. 41 
6.4  Quality Records .................................................................... 41 
6.5  Traceability Requirements ....................................................... 42 
6.6  Marking for Identification and Traceability .................................... 42 
7.  Nameplate ..................................................................................... 43 
7.1.1  Control Valves ........................................................... 43 
7.1.2  Pressure Regulators ..................................................... 44 
8.  Painting & Coatings .......................................................................... 44 
9.  Spare Parts, Special Tools and Special Software ........................................ 44 
9.1  Spares ................................................................................ 44 
9.2  Special Tools ........................................................................ 44 
9.3  Special Software ................................................................... 44 
10.  Documentation ................................................................................ 45 
10.1  As-Built Drawings .................................................................. 45 
10.2  Test Documentation ............................................................... 45 
10.3  Manuals .............................................................................. 45 
11.  Training ........................................................................................ 45 

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 4 of 46

 Control Valves & Pressure Regulators
Technical Specification

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 5 of 46

 Control Valves & Pressure Regulators
Technical Specification

1. Introduction
1.1 Scope of Specification
This Technical Specification details the minimum requirements for the design, supply,
configuration, factory acceptance testing, documentation and delivery of all control valves
and pressure regulators for the Company’s Coal Seam Gas (CSG), water handling and
treatment and associated infrastructure projects.
This specification shall be read in conjunction with the Requisition which details the
Supplier’s scope of supply, any project specific requirements and applicable documents
and drawings.

1.2 Definitions
Approved Means accepted by the Company or agreed representative. Such
acceptance shall not relieve the Supplier of its obligations under
the contract.
Company Origin Energy Resources Limited or Australia Pacific LNG Pty
Limited.
Supplier Supplier of works, services or goods under the Agreement
(Contract), including Subcontractors (if any).
Shall / Must / Will Mandatory requirement.
Should Recommended course of action.
May / Can One acceptable course of action.

1.3 Abbreviations
ANSI American National Standards Institute
API American Petroleum Institute
APLNG Australia Pacific Liquefied Natural Gas
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
CDTP Cold Differential Test Pressure
FAT Factory Acceptance Test
FF Foundation Fieldbus
HEM Homogenous Equilibrium Models
IPF Instrumented Protective Function
ISO International Standards Organisation
ITP Inspection and Test Plan
MAWP Maximum Allowable Woking Pressure
Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 6 of 46

 Control Valves & Pressure Regulators
Technical Specification

MDR Manufacturer’s Data Report

MML/D Megalitres per Day
MSDS Material Safety Data Sheet
MTTR Mean Time to Repair
NDE Non Destructive Examination
NDT Non Destructive Testing
NPS Nominal Pipe Size
NPT National Pipe Thread
PCB Polychlorobiphenyls
QA Quality Assurance
RF Raised Face
SAT Site Acceptance Test
SI International System of Units
TJ/D Terajoules per Day
VDRL Vendor Data Requirements List

1.4 Units
The International System of units (SI) shall be used in all documentation. Equivalent
imperial dimensions may be shown on manufacturing drawings in parenthesis following the
SI units.

1.5 Supplier Exceptions

The Supplier shall submit a list of deviations or exceptions to this Specification as part of
their tender offer. In the absence of any exceptions, it will be construed that the Supplier
fully complies with this Specification. Similarly, any exception from the Supplier’s Sub-
Supplier must be stated at this time otherwise it will be construed that they fully comply
with this specification.

2. Codes, Standards & Project Specifications

2.1 Statutory Requirements
The following Acts of Parliament and their associated Regulations are particularly relevant
to the supplied equipment.
 Queensland Workplace and Safety Act 1995
 Queensland Electrical Safety Act 2002
 Petroleum and Gas (Production and Safety) Act 2004

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 7 of 46

 Control Valves & Pressure Regulators
Technical Specification

2.2 Standards
Unless specifically designated by date, the latest edition of each publication at the issue of
this specification shall be used, together with any amendments/supplements/revisions
thereto:

2.2.1 Australian / New Zealand Standards

Number Title
AS 1200 Pressure Equipment
AS 1210 Unfired Pressure Vessels
AS 1271 Safety Valves, Other Valves, Liquid Level Gauges and Other Fittings for
Boilers and Unfired Pressure Vessels
AS 3507 Non-destructive testing
AS 60529 Degrees of protection provided by enclosures (IP Codes)
AS/NZS 60079.0 Electrical Equipment for Explosive Gas Atmospheres:– General
requirements
AS/NZS 60079.1 Electrical Equipment for Explosive Gas Atmospheres:– Equipment
protection by flameproof enclosure ‘d’
AS/NZS 60079.7 Electrical Equipment for Explosive Gas Atmospheres:– Equipment
protection by increased Safety ‘e’
AS/NZS Electrical Equipment for Explosive Gas Atmospheres:– Equipment
60079.11 protection by Intrinsic Safety ‘i’
AS/NZS Explosive atmospheres - Fieldbus intrinsically safe concept
60079.11 (FISCO)
AS/NZS 61000 Electromagnetic compatibility (EMC) - General standards - Immunity for
6-2 industrial environments
AS/NZS 61000 Electromagnetic compatibility (EMC) - Generic standards - Emission
6-3 standard for residential, commercial and light-industrial environments
AS/NZS 9001 Quality management systems – Requirements

2.2.2 International Standards

Number Title
IEC 60534 Industrial-Process Control Valves
IEC 60947-5-6 Low-voltage switchgear and controlgear - Part 5-6: Control circuit
devices and switching elements - DC interface for proximity sensors and
switching amplifiers (NAMUR)
ISA S75.01 Flow Equations for Sizing Control Valves
ISA 75.17 Control Valve Aerodynamic Noise Prediction
API 609 Butterfly Valves: Double-flanged, Lug- and Wafer-type

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 8 of 46

 Control Valves & Pressure Regulators
Technical Specification

Number Title
ISO 15848 Industrial valves - Measurement, test and qualification procedures for
fugitive emissions
ASME B16.5 Steel Pipe Flanges and Flanged Pipe Fittings
ASME B16.10 Face to Face and End-to-End Dimensions of Valves
ASME B16.34 Steel Valves, Flanges and Butt Welding Ends
ASME B31.3 Process Piping
ASME VIII Boiler and Pressure Vessel Code, Section VIII – Pressure Vessel Design
ASME IX Boiler and Pressure Vessel Code, Section IX – Welding and Brazing
Qualifications
ASTM E94 Standard Guide for Radiographic Examination
ASTM E446 Standard Reference Radiographs for Steel Castings Up to 2 in. (50.8 mm)
in Thickness
ASTM A609 Standard Practice for Castings, Carbon, Low-Alloy, and Martensitic
Stainless Steel, Ultrasonic Examination Thereof
ASTM E709 Standard Guide for Magnetic Particle Testing
ASTM E165-09 Standard Practice for Liquid Penetrant Examination for General Industry
ASTM A269 Standard Specification for Seamless and Welded Austenitic Stainless
Steel Tubing for General Service
BS EN-558 Industrial valves. Face-to-face and centre-to-face dimensions of
metal valves for use in flanged pipe systems.
BS EN-10204 Metallic Products – Types of Inspection Documents
ISO 9001 Quality management systems – Requirements
ANSI/FCI-91-1 Standard for Qualification of Control Valve Stem Seals
MSS SP-25 Standard Marking System for Valves, Fittings, Flanges and Unions
MSS SP-55 Quality Standard for Steel Castings for Valves, Flanges, Fittings and
Other Piping Components - Visual Method for Evaluation of Surface
Irregularities
MSS SP-67 Butterfly Valves

2.2.3 Company Standards

Number Title
A-1000-30-TS-1001 Protective Coating
A-1000-50-TS-1001 Piping Material Specification
A-1000-70-TS-1001 Approved Supplier List - Instrumentation

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 9 of 46

 Control Valves & Pressure Regulators
Technical Specification

2.3 Order of Precedence

Where the project specifications do not comply with the minimum requirements of the
Statutory Authorities and Standards, the latter shall prevail. Where the project
specifications exceed the minimum requirements of the Statutory Authorities and
Standards, the former shall prevail.
The Company’s approval of Supplier drawings / documents does not in any way remove the
Supplier’s responsibility to comply with Statutory Requirements, Standards and Origin
Energy Ltd. Specifications. The requirements of this specification shall not relieve the
Supplier of any responsibility to provide equipment and services that are compliant and
suitable for the intended duty.
In the case of conflict between this specification and other referenced documents, data
sheets, codes and standards, the Supplier shall bring the matter to the Company’s
attention for clarification in writing. The order of precedence shall be as follows (highest
first):
1. Applicable Legislation and Statutory Requirements
2. Equipment Purchase Order
3. Project Data Sheets
4. This Specification
5. Project Specifications and Drawings
6. Referenced Company Standards
7. Australian Standards
8. International Codes and Standards

All deviations from the requirements of this specification, its attachments and the
referenced codes and standards shall be stated in the tender. In the absence of such a
statement, Supplier’s full compliance shall be assumed.

3. Approved Supplier List

The Supplier shall use equipment marked as preferred wherever practicable, for the
purposes of equipment standardisation. Where the Supplier wishes to supply equipment
not marked as preferred, the Supplier shall submit their proposed equipment supplier for
Company approval. For the approved supplier list refer to Approved Equipment List –
Instrumentation (A-1000-70-TS-1001).

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 10 of 46

 Control Valves & Pressure Regulators
Technical Specification

4. General Requirements
4.1 Scope of Work
The Supplier’s scope includes design calculations, drawings and documentation, provision
of all materials, manufacture, inspection, non-destructive examination, assembly, testing
and delivery of control valves and pressure regulators in accordance with this specification
and associated project data sheets.
The Supplier should draw upon their existing pre-engineered or standard designs as far as
is practicable in order to satisfy the functional and technical requirements described
within this specification and referenced documentation.
The Supplier must liaise and work closely with control valve actuator Sub-Suppliers to
ensure a fully integrated design that satisfies the applicable parts of the specification is
achieved.
Control valves shall be provided as integral units, each comprising:
 valve body assembly
 actuator assembly
 controls and accessories

Units are to be assembled and tested in the Suppliers works.

The Supplier shall ensure that workmanship, materials and quality control are to the
highest standards for all delivered equipment and that only proven techniques and design
are utilised.
The Supplier shall confirm that they are able to fully support the testing and servicing of
the control valves and pressure regulators and to offer specialist assistance where
appropriate.
Each control valve and pressure regulator shall consist of a complete factory assembled
unit. The unit shall be suitable for the duty as detailed on the appropriate project data
sheet, fully tested and ready for installation.
Each unit shall be complete with, but not limited to the following equipment and
requirements:
 Control valve/actuator assembly or pressure regulator (as applicable)
 Tagging
 Packaging and marking for transport
 Inspection and Testing
 Documentation, drawings and certification
 Start up and Commissioning Spare Parts
 Protective Coating
 Special Tools

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 11 of 46

 Control Valves & Pressure Regulators
Technical Specification

4.2 Operation & Design Life

All equipment shall have a minimum design life of 30 years.

4.3 Interfaces
The equipment shall be required to fall within the parameters defined in the project data
sheets supplied by the Company. These parameters may include but are not limited to the
following:
 Maximum overall equipment dimensions and weight, including accessories
 Pneumatic tie-in locations
 Electrical and Instrument signals tie-in locations

4.4 Utilities Requirement

4.4.1 Instrument Air
Motive power shall be supplied from an instrument air distribution system, which under
normal conditions shall be reticulated at 700 kPag. Under regulator failure or other
unusual conditions that air pressures increase, the actuator assembly must be designed for
a maximum 850 kPag air supply pressure @ 45°C. Where actuators cannot meet this
requirement, the actuator supplier shall clearly and specifically state this and suitable
safety air reduction and venting designs for the actuators shall be provided, subject to the
purchases approval.

4.4.2 Instrument Gas

Remote applications may use instrument gas as the motive force when an instrument air is
not practical. Instrument gas will be nominally 200 kPag, although all actuator sizing shall
use 140 kPag as the minimum supply pressure. Instrument gas will be coal seam methane
gas saturated at 140 kPag.
Where instrument gas is used a “low bleed” positioner shall be used to reduce the fugitive
emissions from the positioner. Positioners used on with instrument gas service shall be
specifically rated for that service.

4.4.3 Electrical
Digital valve positioners shall be fitted to all of the control valves. Details of the basic
specification are shown on the actuator data sheets. The full specification shall be
confirmed by the Supplier based on the type of valve / actuator used and the valve
positioner manufacturer’s recommendations. The control signal will generally be either 4-
20mA with HART or Foundation Fieldbus.
Foundation Fieldbus is an industry standard communications protocol that replaces the
more traditional 4–20 mA type electrical signal. The Foundation Fieldbus interface allows a
Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 12 of 46

 Control Valves & Pressure Regulators
Technical Specification

large number of engineering values, diagnostics and alarms to be communicated to and

from the valve positioner.
The Supplier will require a Foundation Fieldbus compatible communicator device and a
Fieldbus compatible power supply unit in order to communicate with the Fieldbus
positioner. This communication will be necessary for carrying out testing of the complete
valve actuator assembly and for FAT (Factory Acceptance Testing). The Supplier will also
require knowledge of this interface unit, the operating system and the positioner, or utilise
the services of a third party.
Each valve/actuator assembly shall be supplied with the positioner configured with the
valve Tag number, the service description as detailed on the actuator data sheet.
Additionally the positioner shall be configured with a custom configuration that will be
supplied by the Company.
The Supplier shall provide all of these Fieldbus related services and equipment as part of
the scope of supply.
All Foundation Fieldbus (FF) devices shall be powered from its respective FISCO segment.
All other Instruments shall be suitable for 24V dc operation.

4.5 Hazardous Area Requirements

Instruments for use in hazardous areas shall comply with the requirements of AS/NZS
2381.1 or AS/NZS 60079.14. All hazardous area equipment shall be certified for the
required area classification under IEC Ex, ANZ Ex or AUS Ex. If suitable equipment cannot
be obtained with acceptable certification then equipment certified under alternative
standards may be acceptable. The justification for use of such equipment will be in the
form of a Conformity Assessment Document (CAD) (refer to Annex ZD of AS/NZS 60079.14)
and the supply of the CAD shall be by the Supplier.
Foundation Fieldbus transmitters shall be certified to meet FISCO. Analogue (4-
20mA)/HART transmitters shall be certified as Intrinsically Safe (IS).
The following table shows the preferred method of protection for electrical equipment and
devices and instrumentation installed in hazardous and non-hazardous areas:

ZONE / EPL ORDER OF PREFERENCE ORDER OF PREFERENCE

0 / Ga Ex ‘i(a)’
1 / Gb 1 Ex ‘i(a)’ or Ex ‘i(b)’
2 Ex ‘d’, Ex ‘e’ or Ex ‘me’
2 / Gc 1 Ex ‘i(a)’ or Ex ‘i(b)’
2 Ex ‘d’, Ex ‘e’ or Ex ‘me’
3 Ex ‘n’
Non hazardous N/A
areas

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 13 of 46

 Control Valves & Pressure Regulators
Technical Specification

Note that there may be exceptions to the preferences described above. For example, at
well heads Ex d or Ex n may be used in preference to Ex i(a).

4.6 Safety Integrity Level (SIL) Requirements

Control valves shall not be used as both a control and shutdown valve or as a primary
isolation means, however they may have a shutdown initiated trip position. Control Valves
used as part of a shutdown function may only be used in SIL 1 applications when there is no
tight shut off requirement.
Control valve assemblies that are part of a safety instrumented function shall be certified
to AS/IEC 61508 part 2 and meet the specified SIL. Were applicable, the SIL will be
specified on the valve data sheet. Certification shall be by a 3rd party and shall include the
following information on the certificate:
 Whether equipment is Type A or B
 Failure rate λSD (safe detected)
 Failure rate λSU (safe undetected)
 Failure rate λDD (dangerous detected)
 Failure rate λDU (dangerous undetected)

High inherent start-up and operational reliability is required, the valve assembly shall be
able to perform its duty for 48,000hrs without overhaul.

4.7 EMC Compliance

All electrical / electronic equipment shall be compliant with the following standards.
 Emissions shall comply with the Residential Commercial and Light Industry
Standard, AS/NZS 61000-6-3.
 Immunity shall comply with the Industrial Standard, AS/NZS 61000 6-2.

4.8 Emission Limits

Instrument design shall minimise fugitive emissions. All valves on hydrocarbon service shall
be fitted with low fugitive emission stuffing boxes. Fugitive emissions shall comply with
the requirements of ANSI/FCI-91-1 Standard for Qualification of Control Valve Stem Seals
to meet EPA Emission Guidelines for Volatile Organic Compounds or similar with written
approval of the Company.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 14 of 46

 Control Valves & Pressure Regulators
Technical Specification

4.9 Noise
The Supplier shall supplier shall detail the noise level generated by each assembly. Specific
data sheets shall be provided where the noise level equals or exceeds 85 dB at a distance
of 1m.

5. Technical Requirements
5.1 Materials
5.1.1 General
All materials shall be as detailed on the project data sheets and referenced specifications.
When materials are not specified the Supplier may offer the standard material suitable for
the environment and operating/design conditions.
The Supplier and type of installation materials shall be standardised to the maximum
extent possible. The type and grade of installation materials shall be subject to approval
by the Company. All materials shall be new, unused and free of defects.
Special attention shall be paid to all o-rings and seals to ensure that the materials selected
are compatible with the process conditions and the materials will not be subjected to
explosive decompression.
All materials (including gaskets and sealants) shall be free from the following hazardous
substances:
• Asbestos
• Ceramic Fibre
• Chlorofluorocarbons
• Polychlorobiphenyls (PCB) and their isomers
• Radioactive Materials
• Mercury
Dangerous goods shall be labelled and identified in accordance with the Australian
Dangerous Goods Code 7th Edition (ADG7). All fluid materials shall be supplied with a
Material Safety Data Sheet (MSDS).
The minimum valve body material shall be carbon steel with 316 SS trim. The use of brass
or copper bearing alloys shall not be permitted. Aluminium shall not be used for any part
of the equipment that may come into contact with the process fluid. Aluminium for
housings/casings shall only be permitted if coating is applied.
All bolting materials shall be compatible with the intended design/service requirements
and valve materials of construction.
As a minimum, tubing shall be 316L. Other grades of non-molybdenum austenitic stainless
steel e.g. 302, 303, 304, 305 are forbidden.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 15 of 46

 Control Valves & Pressure Regulators
Technical Specification

5.1.2 Valve Body

Materials of construction of the valve shall be in accordance with or superior to those
identified on the applicable datasheets.

5.1.3 Valve Trim

5.1.3.1 General
Consideration shall be given as to the effects of wear, galling, erosion and corrosion as
these are more pronounced on valve trim than of on the valve body. The control valve trim
shall include the plug, seat ring and stem.
For general service 316 SS trims shall be selected as a minimum. Where valves are to be
used in cavitating or flashing services, those containing erosive or solid bearing fluids, or
for those in high pressure or temperature applications, suitable hardened alternate trims
shall be selected.

5.1.3.2 Material Overlays

When hard seats (such as stellite seats) are specified, the base material shall be at least as
corrosion and erosion resistant as the material specified for these parts unless the hard
material covers the entire surface exposed to the corrosive or erosive action of the
medium.
Severe service valves shall use hard facing materials which include stellite No. 6 (CoCr) and
or tungsten carbide.

5.1.3.3 Other Materials

Type 17-4 PH SS shall be used as minimum for components such as valve stems.
Valve trim selection shall take into account the valve body geometry. For example
streamlined bodies having high pressure recovery coefficients are more likely to exhibit
cavitation. Valves having high pressure recovery coefficients, such as rotary valves, could
require special or hardened trim.

5.1.4 Stem Packing

Each valve shall be provided with a bolted gland type or spring tension type low fugitive
emission stuffing box. Fugitive Emissions shall comply with the requirements of Section
4.8.
Packing material type will depend on the service conditions. The preferred packing
material for services from -200°C to 200°C is PTFE (Teflon). Flexible graphite packing that
has temperature limits from -200°C to 450°C shall be used for temperatures above 200°C.
The Supplier shall in all cases propose packing materials appropriate to the service
conditions indicated on the project data sheets.
Valves requiring packing lubrication shall not be used.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 16 of 46

 Control Valves & Pressure Regulators
Technical Specification

Bellows seals shall not be used unless approved by the Company.

5.1.5 Actuator
Materials of construction of the actuator shall be selected to prevent galvanic corrosion
with the valve and accessories.
High grade carbon steel shall be used for all pressure retaining parts of the actuator. No
cast iron, malleable iron, aluminium, plastic or copper bearing alloys shall be used for any
components without prior approval by the Company.
The Supplier shall identify all material used in the construction of the actuator.
All welding (including casting repair) shall be performed in accordance with written
procedures and by welders qualified in accordance with ASME IX.

5.1.5.1 Anti-corrosion Measures

The Supplier shall state in the bid that the actuator meets the requirements for
anticorrosion measures stated below:
 Protective compounds and durable coatings shall be used to prevent corrosion in
the event of water condensing inside the various housings, in addition to protection
of external parts.
 Paint shall be in accordance with A-1000-30-TS-1001 – ‘Protective Coating’.
 Carbonising/nitrating surface treatment processes may be used on internal parts
such as piston rods, tie bars etc. but not on the inside surfaces of cylinders.

5.1.6 Accessories
Except where specified otherwise on the project data sheets, 316L SS shall be used as the
material of construction for control accessories (wetted and non wetted parts) including all
brackets, mounting plates and nuts and bolts.
The effects of galvanic corrosion between dissimilar metals shall be mitigated by use of
the same materials, or suitable isolation, separation or barriers. i.e. PTFE barriers.
For wetted parts, aluminium shall not be used as a construction material unless authorised
in writing by the Company.
In general, all instrument tubing shall be stainless steel to ASTM A269 TP316L as a
minimum. The tube shall be cold drawn, seamless, fully annealed and pickled. Tube
surface hardness should be between 70 and 74 but shall be no more than 80 on the
Rockwell B scale (Rb80). The use of polished tubing should be avoided as this technique is
used to cover up surface imperfections and can also work harden the tube surface, leading
to poor fitting make-up.
Compression fittings shall be Swagelok double compression type with front and back
ferrules in imperial sizes only and shall be shall be made from stainless steel as per ASTM
A132 F316/F316L. All threads shall be NPT. All thread connections shall use Stainless Steel
PTFE/ Teflon thread sealant tape approved to UL340-M1979 (AGA) 3226.
Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 17 of 46

 Control Valves & Pressure Regulators
Technical Specification

5.2 Material Traceability & Certification

Pressure retaining and wetted parts shall have full chemical analysis and mechanical test
certification and shall be identifiable by means of certified markings relating to the
available authentic material certificates. Material certification requirements shall be in
accordance with BS EN 10204/ISO 10474 type 3.1 certificates
All chemical analyses shall be certified by product check analysis with the exception of
Carbon Steel (Non-NACE) and Bronze for which ladle analysis will be acceptable.
Certification for bolting shall be to Standard Designation 3.1B unless stated otherwise.
Where supplementary requirements or impact testing in excess of the product specification
are specified, the Supplier shall provide certification proving that bolting meets the
specified requirements.
The Supplier shall keep available suppliers reports etc., for examination by the Company
or their representative, for a minimum period of five (5) years. Minor components for
which the materials are not specifically designated shall have physical and chemical
properties consistent with that of the major components.
Materials for use in cold service (0°C and below), alloy steel materials, and materials 6 mm
thick or less shall not be hard stamped or pop marked. All markings shall be by vibro-
etching or by Company approved paint.
Where the equipment operates in a corrosive service (e.g. carbon dioxide dissolved in 'wet'
hydrocarbon gas) all process wetted materials shall be suitable for corrosive service.

5.3 Valve Selection Guide

5.3.1 General
The type of control valve shall be selected to satisfy the process conditions stated on the
project data sheet. The following is a guide to the preferred valve style for different
applications. The most appropriate valve for a given application shall be determined by
the Supplier on a case by case basis.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 18 of 46

 Control Valves & Pressure Regulators
Technical Specification

APPLICATION VALVE STYLE

General Purpose Liquids and Gases Globe Body with contoured trim
Double seated trims should be top and bottom
guided. Single seated trims may have plug or
stem guiding

Noise Avoidance Globe body with cage trim

Local fixed gain control of utilities e.g. Self acting valves

Fuel systems
Large volume flows and high shut-off Full-bore ball valves or characterised ball
differential pressures valves

Large volume flow and low pressure drop Butterfly valves or eccentric rotating plug
valves
Flashing, solids in suspension or where Angle valves, Cage type globe valves or severe
high-pressure drops are encountered service valves may be considered but where
solids are expected, the risk of blocking small
orifices in multi stage cages and severe service
valve designs shall be considered.
Rotary valves shall offer straight flow paths
with a minimum fluid direction change.
Valves with expanded flow area downstream
to reduce velocities.
Severe Service Applications : Severe service valves with multistage trims
Applications where unacceptable noise, and low pressure recovery characteristics may
vibration, cavitation or erosion would be used. Refer to Section 5.6.4 for specific
result if the above more conventional requirements for valves in severe service
valve types were used. applications. Account shall be taken of the
effects of any particulate matter likely in the
process fluid which may result in blockage of
small orifices within low noise/anti-cavitation
trims.

Control valves shall be capable of handling the end points of the flow range at no less than
20% and no more than 80% of travel. For control out side of these limits, approval in
writing must be obtained from the Company.
Only valves referenced within this section shall be considered for use as control valves.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 19 of 46

 Control Valves & Pressure Regulators
Technical Specification

5.3.2 Rotary Valves

5.3.2.1 Butterfly Valves
High performance valves shall be selected over standard butterfly valves, where detailed
on the project data sheets. These valves will be either double or triple offset type. These
valves may be considered in applications where tight shutoff (Class V or VI in accordance
with IEC 60534-4) is required.
For butterfly valves, the trim should preferably be of a balanced, low torque, 90° rotation
type.
The shaft and disc shall be capable of withstanding a pressure drop across the valve of at
least 1.25 times the maximum shut off differential pressure specified on the project data
sheets.
The shaft bearings shall preferably be mounted externally. All pivots, shaft bearings and
the lower guide bushing of the actuator stem shall be properly sealed and lubricated and
dust boots (gaiters) provided around the actuator stem.
Butterfly valves shall have a minimum rating of Class 300 RF.
Butterfly valves shall have a primary resilient seat and a secondary metal to metal seal.
The seals shall provide a minimum leakage class rating under non-fire condition in
accordance with the appropriate project data sheet.
The valve steam bearing should be designed to prevent stem guide bushing from rotating in
the valve body. Bearing material should be selected to prevent galling of the bearing or
valve stem.
Butterfly valves have a high valve coefficient and thus a high pressure recovery. There high
pressure recovery coefficient makes flashing and cavitation more likely than in a globe
valve of comparable capacity, and shall be considered during selection.

5.3.2.2 Ball Valves

Full Ball
A full ball valve has a water way or port through a solid complete sphere. Full port valves
shall have an opening the same diameter as that of the pipe inside diameter. Reduced ball
valves commonly have one size smaller than the flange size and have a lower Cv value than
the equivalent full port valves.
Full Ball valves shall only be considered for on on/off applications, unless specified on the
project data sheets.

Segmented Ball
Segmented Balls may be cut to provide parabolic, V or U or other contours on the leading
edge of the ball.
Ball valves exhibit a higher potential for flashing and cavitation than do comparably sized
globe valves. Special anti-cavitation trims shall be used where required to overcome this
issue.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 20 of 46

 Control Valves & Pressure Regulators
Technical Specification

Where Pipe reduction is used within the ball valve assembly care shall be taken to apply
appropriate pipe reduction factors during sizing.

5.3.3 Linear Motion Valves

5.3.4 Globe Valves
Post Guided
Post guided, single seated valves shall be used for tight shutoff applications; however,
because these valves are unbalanced the actuator will require more force from the
actuator to achieve shutoff if the flow is under the plug. Double ported valves shall not be
used for tight shutoff applications.
Post guided valves shall be considered for dirty service where the fluid or fluid particles
would adhere to the guiding surface or would clog the plug vent holes.
In high pressure drop, cavitating or flashing applications the lower guide area shall be
hardened and shall have one port and a single seat assembly.

Cage Guided
Cage guided valves shall be considered for high pressure drop, high noise and anti-
cavitation applications.
Unbalanced cages shall be used as a default, however balanced trims can be selected on
clean services only as the balanced style allows the plug to be vented such that process
pressure interacts with the top and bottom of the plug. As a result, relatively small
pressure differentials exist across the plug throughout the valve stroke, thus lower plug
positioning forces are required from the actuator.
Careful consideration shall be given where solid particles are present as to prevent
blocking of the tortuous paths.
Cage guided valves shall achieve flow characterisation by either:
• The cage port being contoured and the plug being cylindrical
• Rectangular ports and a contoured plug

5.3.5 Angle Valves

Side and bottom connections shall be inlet and outlets, respectively. On high velocity
fluids containing erosive solids and extra sleeve manufactured out of hardened material on
the inlet throat may need to be considered.

5.3.6 Three Way Valves

Three way valves can either have converging or diverging port configurations. A single
valve assembly shall be used at all times, use of two valves and one actuator connected via
a mechanical linkage shall not be used. In high pressure drop, cavitation or flashing
services, the lower guide area shall be hardened.
Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 21 of 46

 Control Valves & Pressure Regulators
Technical Specification

5.4 Body Selection Guide

5.4.1 General
Valve bodies shall be manufactured as one piece cast forged assemblies and shall not be
fitted with bottom drains.
All control valves shall be provided with integral flanges, Separable flanges shall not be
used unless approved by the Company.
Valve bonnet assemblies shall be of bolted flange construction and provided with suitable
sealing arrangements via a gasket between the bonnet flange and valve body and by
packing around the valve stem between the bonnet and yoke clamp.
Valve Actuators shall be of bolted construction attached direct to the valve yoke.
The direction of flow through a valve shall be permanently marked on the body or flanges.

5.4.2 Body Size

The minimum size of globe and ball valve bodies shall be NPS 1 (DN 25). Body sizes
corresponding to NPS 1¼ (DN 32), NPS 2½ (DN 65), NPS 3½ (DN 90). DN 125, DN 550, DN
650, DN 700, DN 800 and DN 580 shall not be used.
The minimum nominal sizes of eccentric plug valves shall be NPS 2 (DN 50) and of butterfly
valves NPS 4 (DN 100).
The pressure ratings of globe valves and ball valves with bodies up to NPS 8 (DN 200) shall
be at least Class 300, or otherwise stated in the data sheet.
5.4.3 End Connections
The flange finish shall be serrated spiral with the finish between 3.2 and 6.3 μm. The face
to face dimensions shall comply with ASME B16.10 or BS EN 558.
All flange faces shall be Raised Face (RF), unless specified on the project data sheet.
Valve bodies with flanged ends shall have pressure-temperature ratings to ASME B16.34 as
a minimum.
Wafer type valves (butterfly type) with through body lugs may only be supplied with prior
approval from the Company.
Butt welds joining valve bodies to hubs or flanges shall be fabricated in strict accordance
with ASME B31.3.

5.4.4 Valve Dimensions

Butterfly valve face to face dimensions shall be in accordance with API 609 and MSS-SP-67.

5.4.5 Body Material

The body material selected shall be in accordance with the applicable datasheet.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 22 of 46

 Control Valves & Pressure Regulators
Technical Specification

Internal linings shall not be used other than for additional protection against corrosion or
erosion within angle valve throats.
All castings shall be true to form, free from shrinkage, strains, scale, lumps, blisters,
sandholes or other defects. All machining operations shall be performed so that all parts of
valves of the same size, type and pressure rating are interchangeable.

5.5 Stuffing Box, Packing & Gaskets

5.5.1 Stem Packing
Each valve shall be provided with a bolted gland type or spring tension type with a low
fugitive emission stuffing box. Fugitive Emissions shall comply with the requirements of
Section 4.8.
Packing material type will depend on the service conditions following the guidelines of
ASME B16.34 which specifies acceptable pressure temperature limits for pressure retaining
materials. The preferred packing material for services from -200°C to 200°C is PTFE
(Teflon).
Flexible graphite packing that has temperature limits from -200°C to 450°C shall be used
for temperatures above 200°C. The Supplier shall, in all cases, propose packing materials
appropriate to the service conditions indicated on the project data sheet.
The stem packing shall be designed such that contamination between the wiper packing
set and the upper packing of the valve stem is prevented.
All valves shall be selected as not to require packing lubrication.
Extended bonnets shall be used if the operating differential pressure across the valve could
cause freezing of the stuffing box, packing and/or ice formation on the yoke. Materials of
construction shall be compatible with the body and bonnet material as to minimise
galvanic corrosion effects between dissimilar metals.
The stuffing box shall be provided with an adjustable bolted gland flange and gland
follower.

5.5.2 Gaskets
Valve body gaskets are to be retained in a full captive joint.
The Supplier is to furnish valves with standard gasket material compatible with process
fluid and operating conditions, unless otherwise specified by the Company.
Body to bonnet and if required body to bottom flange gaskets shall be selected by the
manufacturer for the process conditions and reviewed by the Company.

5.6 Trim Selection Guide

5.6.1 Seat Leakage & Flow Direction
Unbalanced valves selected for throttling applications shall be designed for “flow tending
to open” in order to avoid large unstable forces in the virtually closed position.
Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 23 of 46

 Control Valves & Pressure Regulators
Technical Specification

Balanced type single seated valves shall only be selected for high pressure drop
applications where the process fluid is clean, as to reduce the thrust necessary to stroke
the plug by reducing the trim off balance area. As a minimum valves shall be specified
with a leakage class ANSI/FCI Class IV, unless stated otherwise on the project datasheet.
The seat load (the force necessary to provide valve shutoff) will be dependant on valve
port size and shutoff classification. Seat loading shall be based on meeting the following
criteria:

Leakage Class Nominal Pipe Size <5" Nominal Port Size <5"
Class IV Metal Sheet 50lb per Linear Inch 80lb per Linear Inch
Class IV Soft Seat 50lb per Linear Inch 50lb per Linear Inch
Class V Metal Seat 250lb per Linear Inch 400lb per Linear Inch
Class V Soft Seat 50lb per Linear Inch 50lb per Linear Inch
Class VI Soft Seat 50lb per Linear Inch 100lb per Linear Inch

5.6.2 Trim Construction

Multistage trims shall have a minimum hole size of 3mm to minimise the chances of
blockage.
The valve stem connection to the actuator stem shall be adjustable with positive locking of
the adjustment.
Stem protectors should be considered for linear motion valves if the surrounding
atmosphere causes the stem to foul.
Trims shall be designed to provide equal pressurization around the plug in order to
minimise vibration and prevent the potential for binding.
The Supplier shall provide as a minimum five (5) years experience with any proposed
control valve trim design.
If a reduced trim valve is specified, the diameter of the seat ring opening shall be reduced.
The body shall be capable of having full size trim installed unless specifically noted
elsewhere.
Reductions in trim size shall normally be to 40% trim but shall not be more than two port
sizes, except where body size is only 1 inch NPS.

5.6.3 Trim Material

The control valve trim shall be corrosion resistant. If used on fluids that become corrosive
when in contact with the atmosphere, suitable valve stem material shall be considered or
precautions shall be taken to prevent contact with air.
The Supplier shall indicate the selected trim number with reference to the applicable
valve design code.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 24 of 46

 Control Valves & Pressure Regulators
Technical Specification

5.6.4 Severe Service Trim Design

5.6.4.1 General
Where severe service trims are to be selected, the use of small passages to gradually
reduce pressure shall be considered. The design of these passages shall mitigate the
potential for fouling during normal and abnormal operating conditions.
Two types of trims shall be evaluated:
 Self Cleaning – Where the passages will be widened as the valve travels in the open
direction, thus providing some degree of self cleaning
 Non Self Cleaning – Where the number of passages will increase when the valve
travels in the open direction.
In general, self cleaning trims shall be selected. Deviation from this requirement will
require approval from the Company. For critical applications, i.e. anti-surge, fouling etc.
self cleaning trims shall be selected.

5.6.4.2 Noise Abatement

Noise abatement shall be treated at source. The Supplier shall advise the noise levels
radiated to the surrounding area and downstream piping.
The noise predication calculations and testing shall be in accordance with the relevant
sections of IEC 60534-8-3 or IEC 60534-8-4. Refer to Section 4.9.

5.6.4.3 Anti-Cavitation Service

Should cavitation be predicated, the following techniques shall be considered during valve
selection to reduce or eliminate these effects, (i.e. reduction in valve capacity, generates
high noise and vibration)
 Managing pressure drops to eliminate cavitation
 Pressure drops across the valve to be controlled such that the local pressure never
drops below the vapour pressure of the process fluid
 Select a valve with a high liquid pressure recovery factor FL (IEC 60534-2-1)
 Select a different flow direction trough the control valve
 Apply hardened trims to prevent internal damage, if severe provide anti cavitation
trims
 Size for two (or more) control valves in series.

5.6.4.4 Flashing Service

Rotary valves shall be selected with hardened trims with flow to close port configuration.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 25 of 46

 Control Valves & Pressure Regulators
Technical Specification

5.7 Valve Sizing

5.7.1 General
In general valves shall not be sized less than half the line size or more than the line size.
All control valves shall be sized in accordance with IEC 60534-2-1 and IEC 60534-2-3. All
control valves shall be sized to ensure that the exit velocity for wet gas (with or without
noise abatement trim) does not exceed 0.3 Mach.
The Supplier shall verify the project data sheet valve size, type and material for each
application in accordance with the information furnished to determine the most suitable
valve for each application. This shall include evaluating each application for cavitation,
flashing conditions and noise levels.
Calculations shall be submitted to the Company recording the minimum, normal and
maximum flow coefficients (CV), as appropriate for the operating fluid and operating cases
and shall record the maximum possible flow through the control valve with the selected
flow coefficient.
Noise calculations shall also be submitted showing maximum noise levels for each
operating case. Refer to Section 4.9.
Valve characteristics shall be as specified on the project data sheets.
The effect of any reduced inlet and outlet pipe sizes and valve pressure recovery shall be
taken into account when sizing control valves.

5.7.2 Two Phase Flow

Special consideration is required when sizing valves handling a mixture of liquid and gas or
liquid and vapour. The equation for required Cv for liquid-gas or liquid vapour is;

Cvr = (Cvl + Cvg) (1 + Fm)

Nomenclature
Cv = Standard liquid sizing coefficient
Cvr = Cv required for mixture flow
Cvl = Cv for liquid phase
Cvg = Cv required for gas phase= Cg/C1
Cg = Coefficient for gas phase
C1 = Valve recovery coefficient
Fm = Cv correction factor.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 26 of 46

 Control Valves & Pressure Regulators
Technical Specification

5.7.3 Viscosity Errors

A viscosity correction factor shall be used for liquid sizing applications, as published CV
values are based on test data using water as a test medium. This value shall be applied to
the standard CV coefficient to determine the corrected coefficient.

5.7.4 CV Capacity
The selected control valve trim capacity (CV selected) shall meet the following criteria.
Butterfly Valves, except for high performance types with low-torque disc designs, should
be sized to control between 10° and 60° of disc opening.
All high performance butterfly valves should be sized to control within 15° to 75° of disc
opening. Certain High performance butterfly valves can be selected to permit operation
with the disc as much as 90° open, subject to the suppliers recommendations.
Control valves shall be designed to operate within 10-90% of their stroke. Where this is not
achievable, two valves in parallel may be used.
All valves with equal percentage flow characteristics shall be sized on the basis of the
normal flow not exceeding 75% of valve capacity, and a maximum flow not exceeding 85%
of valve capacity.
All valves with linear percentage flow characteristics shall be sized on the basis of the
normal flow not exceeding 80% of valve capacity, and a maximum flow not exceeding 90%
of valve capacity.
The valve shall be sized for 110% of the design flow rate (Qd) to ensure that the flowrate
through a fully open control valve shall be equal to or greater than the maximum
controllable flowrate.

5.7.5 Piping Geometry Factor, FP

Valves that are mounted between pipe reducers or other pipe fittings shall be calculated
with corrected for a decrease in valve capacity inline with ISA S75.01. The piping geometry
factors FP, control valve correction factors, calculated FLP and/or XTP factors shall be
specified by the Supplier.

5.7.6 Minimum Rangeability

The actual available rangeability of each control valve shall meet the requirements of the
project data sheet. Calculations shall be submitted to the Company recording the
minimum, normal and maximum flow coefficients (CV), as appropriate for the operating
fluid and operating cases and shall record the maximum possible flow through the control
valve with the selected flow coefficient.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 27 of 46

 Control Valves & Pressure Regulators
Technical Specification

5.7.7 Fluid Mixture

5.7.7.1 Special Liquid Application Requirements
For liquid applications, the following limitations shall apply:
 The trim exit velocity shall not exceed 30m/s or Supplier recommended limits,
whichever is lower.
 For flashing service trim exit velocity shall not exceed 22.5m/s or the Supplier
recommended limits, whichever is lower.

The Supplier shall provide calculations demonstrating satisfactory compliance to the above
trim exit velocity requirements.
The Supplier shall calculate the required number of discrete pressure drop turns to ensure
the elimination of vibration, erosive action and cavitation.
Flow direction shall be a flow to close (over-the-plug) configuration.
For liquid applications the total composite density shall be used to calculate the CV.

5.7.7.2 Specific Gas Application Requirements

For gas applications, the following limitations shall apply:
 The velocity head in the trim shall be less than 480 kPa in order to eliminate
vibration and erosion and to reduce noise.
The velocity head is defined as:

2
Where:
Density = kg/m3
Vh=Velocity head pa
V= Valve exit velocity m/s
g = acceleration due to gravity 9.81 m/s2

The Supplier shall provide calculations demonstrating that valves meet the above trim
velocity head requirements.
The Supplier shall specify the number of discreet pressure drop stages required and
provide body and trim exit velocity head calculations.
The Supplier shall calculate the required number of discrete pressure drop turns to ensure
the elimination of vibration and erosive action.
For gas applications the total composite density shall be used to calculate the CV.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 28 of 46

 Control Valves & Pressure Regulators
Technical Specification

5.7.7.3 Liquid Gas Applications

For two phase applications, the following limitations shall apply:
The effective density shall be used for calculating the CV value of a fluid mixture. The
sizing formulae for incompressible fluids shall be used if the liquid weight factor is 5% or
greater. The sizing formulae for compressible fluids shall be used if the liquid weight
factor is less than 5%.
Cavitation, Choked flow and flashing
ISA S75.01 and the supplier’s valve cavitation index data shall be used for determining the
severity of cavitation, choked flow and flashing conditions.
Selection of the valve shall be in line with the requirements of Section 5.6.4.3. The
following shall also be considered during trim selection:
 Reduce the pressure in multiple stages
 Direct the flow away from the valve body and pipe walls
 Break the flow into many small streams
 Force the flow through multiple turns or torturous paths
The design shall provide a sufficient number of discrete pressure drop stages to maintain
the trim exit velocity below 22.5m/s for cavitating or flashing service. For multi-
constituent fluids, special consideration shall be given to the potential for cavitation of the
minor components in the fluid.
Contingencies on the minimum required control valve cavitation index shall be applied to
compensate for inaccuracies in process data and inaccuracies in the Suppliers control valve
cavitation index data.

Noise
Refer to Section 5.6.4.2.

5.7.8 Compressor Anti Surge

The Supplier shall select and size the anti surge valve in conjunction with the Company and
the Compressor Supplier. The Company shall be responsible for liaising between all parties.
Subject to approval by the aforementioned, the Supplier shall use the following as a basis
to calculate the valve CV, and as detailed on the project data sheet:
 The point on the surge control line which yields the highest value for that
coefficient (i.e. surge condition at maximum speed). This is usually at the
intersection between the surge limit line and the maximum performance curve. An
adequately sized valve will yield a ration in the range of 1.8 to 2.2. If the ratio is <
1.8, the proposed valve may be too small, making the performance of the anti
surge loop marginal. If > 2.2, dynamic adjustment of the system may prove difficult
(approaching compressor stonewall when the valve is 100% open).

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 29 of 46

 Control Valves & Pressure Regulators
Technical Specification

 The valve shall be sized to operate at 130% design volumetric flow, i.e. @ 100%
open the valve capacity is 130% of the design volumetric flow.
 Start up (stonewall)
 Shutdown (surge) – Sized to provide adequate anti-surge protection in all operating
regimes and for worst possible disturbances.
 Sized to avoid choked flow
 Provide flow peaks greater than what is required in steady state to operate on the
Surge Control line.
 Not to be oversized from a controllability point of view.
 Anti surge valve must have a speed of response adequate for anti surge protection.
 Closing time needs to be the same order of magnitude to assure the same loop gain
in both directions (open and closed). The trim shall have linear characteristics to
ensure this. Refer to Section 5.8.3.

5.8 Actuators
Refer to the data sheet for the actuator minimum, maximum and design supply pressure.
Also refer to Section 4.4.

5.8.1 Actuator Selection

Pneumatic spring opposed piston actuators may be used for operating valves where long
strokes or high forces are required. The spring shall be capable of supplying 100% of the
required actuator force. Reverse-acting spring diaphragm actuators incorporating seals or
glands shall be avoided.
All pressure retaining parts shall be capable of withstanding the maximum instrument air
design pressure as stated in Section 4.4.1. Where this is not possible a suitable pressure
relieving device to prevent actuator overpressure should the air filter regulator fail, shall
be provided. The method used shall be subject to the Company’s approval.

5.8.2 Actuator Design

The design of the actuator shall ensure that the action of the control valve on failure of
the control signal or operating medium shall be to a predetermined safe position.
All control valves shall be provided with a travel indicator and scale to show the position of
the valve, whether under the action of the control signal or handwheel.
Springs shall be corrosion resistant and fully enclosed in a suitable housing and stamped or
colour coded for identification of characteristics.
The actuator shall be capable of being rotated to change the location of the positioner.
Actuators shall have o-ring sealing and shall be designed to minimise shaft and
piston/cylinder friction. Actuators shall be equipped with a direct-coupled adjustable

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 30 of 46

 Control Valves & Pressure Regulators
Technical Specification

travel or position indicator for local status indication marked with the words “open” and
“closed” at the travel limits.

5.8.3 Actuator Sizing

The Supplier shall determine actuator size and force/torque output requirements based
upon the operating conditions and leakage classification specified in the project data
sheets to ensure correct operation of the valve.
If maximum valve ΔP at shutoff is shown, the actuator shall be sized for this pressure plus
any additional thrust required, ensuring the maximum leakage specified is not exceeded. If
maximum ΔP at shutoff is not specified, actuators shall be sized for a ΔP equal to 110% of
the maximum operating pressure specified.
For pneumatic diaphragm actuators the normal actuator operating range should be 0.2 to
1.0 barg or 0.4 to 2.0 barg, but shall not exceed 4.0 barg. For piston actuators, the
actuator shall be sized on the basis of the minimum design pressure of the air supply.
The actuator shall be designed to re-seat the valve after opening, to keep the valve
closed, and to break it away and subsequently stroke it from the closed position under
minimum instrument air pressure conditions with the maximum ΔP in the forward and
reverse direction.
The actuator shall be capable of operating down to the low design pressure. All pressure
containing parts of the actuator and positioner shall be designed to safely withstand the
maximum design pressure of the actuating medium. Protection by PSV shall not normally
be acceptable and shall be subject to approval by the Company on a case by case basis.
Valve fail action shall be achieved by spring action only, without the use of local
accumulators.
For flow-tending-to-close valves the actuator shall be capable of opening the valve against
the full upstream pressure and for flow-tending-to-open valves the actuator shall be
capable of closing the valve against the full upstream pressure.
Refer to the project data sheets for any special requirements on stroke time. Where
specified the supplier shall fit quick exhaust valves to the actuator.
The total maximum inaccuracy of the valve travel position due to any limitation
(repeatability, deadband, resolution, hysteresis etc.) shall be less than 2%.

5.8.4 Actuator/Positioner Performance

The Supplier shall state the following for each control valve assembly nominated for
testing.
Refer to Section 6.3.2.
 Maximum deadband (includes stiction, backlash and deadband). This shall not
exceed 2% of the rated (full scale) input signal.
 Speed of response including:
o Dead time before any response is visible (Td)

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 31 of 46

 Control Valves & Pressure Regulators
Technical Specification

o Time to reach 63% of travel response for a 10% step change in input signal (T63)
o Time to reach 98% of travel response for a 10% step change in input signal (T98)
 Hysteresis. The hysteresis shall not exceed 1% of the maximum valve stroke and
shall be limited to 0.5% on critical services, such as compressor surge control.
Critical service valves shall be identifiable by their high performance requirements
such as rapid control action or tight control tolerance as indicated on the project
data sheets.
 Positioner overshoot (% overshoot for a 10% change in input signal).

5.9 Valve Accessories

5.9.1 General
Control valves shall be furnished complete with all accessories and equipment necessary to
operate the valves as described in this specification and on the project data sheets.
All accessories shall be factory mounted on the valve/actuator, adjusted and calibrated in
accordance with the project data sheets with all tubing connections complete.
Mounting of accessories shall not interfere with the operation of the control valve.
Accessories shall ensure the required actuator stroking times are achieved as specified on
the project data sheets.
Materials shall be in accordance with Section 5.1.

5.9.2 Filter Regulators

All pneumatic control valves shall be fitted with in-line filter regulator to suit the specified
utility supply.

Filter / Regulators shall:

 Have setpoints as determined by the Supplier
 Reducing relief valve type with drainage facilities and bolt adjustment provided
with locking facilities.
 Have 5 micron Filter Element
 Be of full metal constructed

5.9.3 Quick Exhaust Valves / Booster Relays

Quick exhaust valves and / or booster relays shall be provided where necessary to meet
the required stroking times for the control valve as specified on the project data sheet.
The quick exhaust vent line shall tie into the closed loop vent. Pilot operated quick
exhausts shall not be used.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 32 of 46

 Control Valves & Pressure Regulators
Technical Specification

5.9.4 Positioner
A digital valve positioner shall be supplied on all valves unless indicated otherwise on the
project data sheet.
The positioner shall be set up so that on loss of instrument air or electrical signal the valve
fails to its fail safe position.
The positioner shall have sufficient capacity for pressurising and venting the actuator in
order to maintain the response time specified on the project datasheet. If this is not
possible then quick exhaust valves and/or booster relays shall be used.
The positoner shall not form part of the actuator design and shall be able to be
reorientated without disassembly of the control valve topworks (bonnet, yoke and
actuator).
Both the follower arm and travel arm shall be of proven secure design with zero slop
linkages.
The positioner shall be preconfigured as per the project FF parameter list datasheet.
When used on instrument gas service, the positioner shall include a “low bleed” relay and
be rated for use with instrument gas.

5.9.5 Solenoid Valves

Where specified on the project data sheet, solenoid valves shall be installed in the
actuator supply line between the positioner and actuator.
Solenoids valves shall be suitable for a hazardous area classification (if applicable).
Hazardous area requirements are detailed in Section 4.5.
To suppress voltage spikes upon energisation/de-energisation, solenoid valves operating on
direct current shall be provided with reverse diodes.
Solenoid valves shall operate from a nominal 24Vdc Supply. Tolerance on this supply will
be ±10%.
Solenoids shall be of the low powered type (typically less than 4W).
Solenoid valves shall be 3 port, 2 position or 5 port, 2 position, spring return type, air
connection 3/8" NPT minimum. Larger valves may be supplied as required to meet stroking
times. Pilot operated valves are unacceptable.
Solenoid valves shall be tubed up so that on power or operating media failure the valve
moves to the failure position specified on the project data sheets.

5.9.6 Limit Switches

Where specified on the project data sheet, limit switches indicating open and/or closed
positions shall be fitted to the control valve. The switches shall be terminated within a
single interface junction box.
Limit switches shall be NAMUR (inductive) proximity type to IEC 60947-5-6 standards,
hermetically sealed.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 33 of 46

 Control Valves & Pressure Regulators
Technical Specification

5.9.7 Mechanical Limit Stops

Externally adjustable mechanical stops shall be fitted to the actuator to adjust individually
the opening and closing stroke. This shall be independent of any valve travel stops
specified on the project data sheet. The purpose of actuator stops shall be to compensate
for the manufacturing tolerance of both the valve and actuator.
Each Limit stop shall be adjustable by at least +/- 2.5° at both the 0° and 90° positions.
Limit stops shall be easily field-adjustable without dismantling the actuator from the
valve.

5.9.8 Electrical Connections

Electrical connections shall be made to the instruments via ISO M20 x1.5mm² cable
entries, or as indicated on the project data sheets. Instruments shall include an integral
terminal box.
Flying leads are not acceptable except for limit switches.

5.9.9 Electrical Cabling

With the exception of any limit switches, all cabling shall be supplied by the Company. The
Supplier shall provide suitable cable entries to electrical devices as detailed on the project
data sheets.

5.9.10 Junction Boxes

Instrument junction boxes shall be Ex’e’ certified.
Preferred junction box construction shall be epoxy coated 316L SS, but solid GRP is also
acceptable. Other materials may be used subject to Company approval provided durability
and robustness are not compromised.
Cable entries to enclosures to junction boxes shall be preferable from the bottom. Top
entry is forbidden. Unused entry holes shall be plugged with metallic (Ex rated if required)
blanking plugs.

5.9.11 Handwheels
Handwheels shall be provided where specified on the project data sheets.
Handwheels shall:
 Be declutchable
 Be side mounted
 Be of an all metal design but hand wheels made from plate material are not
acceptable

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 34 of 46

 Control Valves & Pressure Regulators
Technical Specification

 Have an operating force, under maximum design conditions, not exceeding 350N on
the rim of the handwheel
 Allow changeover from actuator operation to handwheel operation in all stem
positions
 Be provided with an instruction plate, explaining how it is to be used

5.9.12 Lifting Eyes

Where necessary, the actuator shall be fitted with suitably located lifting eyes. These shall
be in accordance with local statutory requirements if applicable and otherwise guaranteed
by the Supplier. The Supplier shall confirm that these are suitable for mounting and
demounting the actuator in-situ with the specified valve orientation.
The Supplier shall provide detailed calculations to prove that the lifting eyes are adequate
for the intended use in lifting the actuator.
All lifting eyes should be designed to be removable once actuator is installed.

5.10 Pressure Regulators

5.10.1 Body Size
The regulator body size shall never be sized to be larger than the interconnecting
pipework.

5.10.2 Body Construction

The body material shall be of the same as the interconnecting pipework.

5.10.3 Pressure Rating

The body and the spring/diaphragm housing shall be designed and tested to meet the
interconnecting pipework pressure rating. Should the spring/diaphragm not be able to
meet this requirement, suitable means of relief shall be provided as to mitigate over
pressurisation. The selection of the relief device shall be subject to Company approval.

5.10.4 Wide Open Flowrate

The regulator wide open / breakdown flowrate shall be provided by the Supplier.

5.10.5 Outlet Pressure Range & Spring Selection

If two or more springs can be selected to meet the outlet pressure setpoint, the spring
with the lower range shall be selected as to provide greater accuracy. Spring selection
shall not be based on selecting a spring range that allows the set pressure to operate at
50% of the spring range.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 35 of 46

 Control Valves & Pressure Regulators
Technical Specification

5.10.6 Accuracy
The accuracy of the regulator shall be based on process requirements. Regulators shall be
selected based on acceptable droop (proportional band or offset,), as detailed below.
Rough Cut - Direct Operated Regulators which typically have high droop (10 to 20% change
is typical).
Close Control – Pilot Operated Regulators which provide high accuracy over a large range of
flows and shall only be used for clean service and high flowrate applications.

5.10.7 Orifice Diameter

The smallest orifice that matches the flow capacity shall be selected as to avoid process
instability / seat wear, reduce downstream relief valve sizing and as to reduce pressure
lockups.

5.10.8 Speed of Response

Direct operated regulators shall be selected for fast acting applications. Where speed is
critical, suitable techniques shall be used to decrease stroke times, subject to Company
approval.

5.10.9 Diaphragm Material

Diaphragm materials shall be selected as to meet the process requirements, including fluid
composition, design pressure and temperature. Where elastomer diaphragms are selected
consideration shall be given to the expected leakage rates as the materials are porous.
Material approval shall be sought by the Company.

5.10.10 Noise
Regulators shall not be used for high flow, high pressure drop application, unless
specifically requested by the Company. Noise reduction shall be achieved by staged
reduction through regulator pairs. Noise shall not exceed the requirements of Section 4.9.

5.10.11 Freezing
Consideration shall be given to prevent freezing downstream of the pressure reducing
regulator due to the Joule-Thomson effect. This may include reducing the size of the
pressure drops or increasing the tubing lengths between pressure drops. This clause applies
especially to pipeline main live valve actuation where instrument gas is taken from high
pressure pipelines.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 36 of 46

 Control Valves & Pressure Regulators
Technical Specification

6. Quality Assurance & Inspection

6.1 General
The Supplier shall demonstrate that they operate a Quality Assurance (QA) system in
accordance with AS/NZS 9001. The effectiveness of the quality system and the Supplier's
compliance with it shall be subject to monitoring by the Company and may be audited
following an agreed period of notice.
The Supplier shall submit a quality control program for Company review at the time of
tender.

6.2 Inspection & Testing

The Supplier shall perform inspection and testing activities in accordance with the
requirements of this specification and Company approved Inspection and Test Plan (ITP).
The ITP shall be submitted to the Company for approval as defined in the Vendor Data
Requirements List (VDRL) attached to the material requisition.
A Company provided set of check records shall be supplied to the Supplier. They shall be
completed in conjunction with the Supplier, Company representatives and Supplier ITP.
These records once completed shall feed back into the Company overall electronic
completion certification system, as part of the project wide quality and audit
documentation.
Any equipment deficiencies or carry over shall be recorded in the documents. These items
will be recorded in the project completions punch list system, for actioning in the next
phase of the project.
The Company or its authorised representatives shall be permitted at all times free access
to all parts of the Supplier’s workshops that concern the construction and testing of the
control valves assemblies or pressure regulators.
Inspection by the Company shall not relieve the Supplier of any guarantees, responsibilities
or obligations to furnish equipment/materials to this specification and the appropriate
project data sheets.
The Supplier shall also comply with the specific inspection and testing requirements given
in the project data sheets and equipment specifications.

6.2.1 Inspection of Actuator Welds, Castings & Steel Parts

The Supplier shall perform all the necessary inspections to ensure correct and safe
operation inline with ISO 10474/EN 10204 & IEC 60534-4.

6.2.1.1 Inspections
The actuator shall be assembled under clean conditions acceptable to the Company. No
loose materials, swarf or burrs shall be left in the actuator.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 37 of 46

 Control Valves & Pressure Regulators
Technical Specification

Pressure-retaining castings, e.g. cylinders, shall be 100% radiographed in accordance with

ASTM E94 and the radiographs shall be judged against ASTM E446. Defects in categories A,
B or C shall not exceed a severity level of Class 2. There shall be no defects in categories
D, E, F or G.
Radiography is not required on the actuator gearbox housing.
Pressure-containing welds shall be radiographed in accordance with ASME B31.3.
Ultrasonic examination shall be performed in accordance with ASTM A609 on all pressure
retaining and torque-transmitting steel parts. The acceptance criterion shall be Quality
Level 1.
Magnetic particle examination (in accordance with ASTM E709) or liquid penetrant
examination (in accordance with ASTM E165) shall be performed on the following, and
there shall be no relevant indications:
 Sealing areas within the actuator body
 The mounting boss of the actuator gearbox housing
 Pressure-retaining and torque-transmitting steel parts and welds

The Supplier shall provide copies of all inspection certificates to the Company.

6.3 Testing
6.3.1 General
The Supplier shall supply an Inspection and Test Plan (ITP) with the tender. All testing shall
be carried out in accordance with written procedures.
All testing shall be carried out at the supplier’s test facility. All stages of testing may be
subject to witness and approval by the Company and/or a third party verifier as identified
by the Company. The Supplier shall provide the Company with at least 14 days advance
notice to witness tests performed in either the Supplier’s works or any Sub-Suppliers
works.
Test equipment shall be supplied by the Supplier. All test equipment used shall have a
current certification of accuracy from an approved test authority and shall be used in
accordance with the Suppliers QA system.
The Supplier shall maintain up-to-date documentation at all times reflecting the
inspection/testing status of the equipment. The Company may wish to inspect retained
documentation such as internal test results, equipment logs and fault/correction records.
Certificates shall be issued recording satisfactory completion of all tests and signed by the
Suppliers and/or Company’s quality representative. The Company and/or Verifier shall
review test records and certification prior to accepting the equipment.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 38 of 46

 Control Valves & Pressure Regulators
Technical Specification

6.3.2 Test Requirements

In general, the Supplier’s standard works test procedures shall be followed and shall
include the following:
 Visual checking (All valves)
 Dimensional checking (All valves)
 Flange face finish checking (All valves)
 Hydrostatic testing, to IEC 60534-4 (All valves)
 NDE (All valves)
 Material Test and traceability reports shall be provided (All valves)
 Function Testing (All valves)
 Hysteresis and Dead Band Test (Random sample – Company to advise numbers)
 Speed of response, overshoot & non-linearity.(Random sample - Company to advise
numbers)
 Fugitive Emissions Test (it shall be demonstrated that the level of fugitive emissions
measured on the valves under test are representative for all valves supplied.
Supplier to advise number of valves to be tested based on variations in
packing/valve style) Inline with ISO 15848-1/2.
 Seat leakage test - Class V or VI (All valves), Class IV Random sample (Random
sample – Company to advise numbers)
 Capacity test (Random sample – Company to advise numbers)
 Low temperature test (Random sample – Company to advise numbers)
 The positioner shall be preconfigured as per the agreed FF / HART Parameter list
 Service/leak test of all tubing, fittings and equipment, installed as part of the
motive gas assembly.

6.3.3 Functional Test

The control valve and actuator shall be completely assembled and fitted with all
accessories. Functional tests shall include the following as a minimum:
 Positioner shall be checked for correct calibration and shall have the valve
signature recorded using a valve link software. All FF parameters shall be checked
and a valve link report produced.
 Stroking Times shall be checked
 Check the correct operation of the handwheel where fitted
 Correct operation of limit switches and position transmitters where fitted
Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 39 of 46

 Control Valves & Pressure Regulators
Technical Specification

 Hysteresis check
 Stem position error shall not exceed +/- 5% of rated travel
 Deadband check

For definition of test procedures refer to IEC 60534-1 and IEC 60534-4.
The hysteresis test shall consist of measuring the valve stem position in response to the
following sequence of input signals 50%, 75%, 100%, 75%, 50%, 25%, 0%, 25% and 50%.
The deadband expressed as a % of the input span shall be measured of the 5%, 50% and 95%
of the input span.

6.3.4 Seat Leakage Test

The valve leakage class shall comply with the minimum requirements specified in the
instrument datasheet. Leakage class is defined in ANSI/FCI 70-2 and IEC 60534-4.

6.3.5 Capacity Test

The actual Cv value shall comply with accordance with IEC 60534.

6.3.6 Hydrostatic Test

The inlet pressure retaining parts shall be hydrostatically tested at a pressure 1½ times the
maximum set pressure of the valve for a minimum of 90 seconds. No leakage shall be
permitted.
The hydro test shall be executed with potable water containing 1% by volume of
biodegradable wetting agent.
The water shall contain not more than 30 ppm of fluorides and chlorides and shall have a
pH value between 6.0 and 8.0. Equipment shall be thoroughly drained and air-blown or
otherwise thoroughly dried upon completion of testing.

6.3.7 Low Temperature Production Test

Testing shall be performed under atmospheric conditions (at zero differential pressure and
ambient temperature) and with the minimum specified air supply pressure/ instrument gas
pressure.

6.3.8 Material Testing & NDE

Castings shall be subject to 100% inspection of internal and external surfaces by magnetic
particle or dye penetration methods as per ASME B16.34.
Acceptance criteria shall be as per ASME B16.34. All defects identified as cracks or hot
tears shall be rejected irrespective of length.
Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 40 of 46

 Control Valves & Pressure Regulators
Technical Specification

All foundries shall hold on file NDT reports confirming that the casting methods have been
properly assessed, and shown to produce acceptable results consistently. These results
shall be available to the Company upon request.
Castings for valves supplied shall be radiographed in the critical areas as described in ASME
B16.34 annexure B and also in the valve necks directly behind the flanges for a width of
1.5 times the wall thickness or 50mm minimum, whichever is the greater.
The radiographic technique shall be X or gamma radiation. Cobalt 60 shall not be used as a
source of gamma radiation. The use of Type 2 film is acceptable. Interpretation of the film
shall be done using a quartz halogen type viewer. The radiographic method shall meet the
requirements of AS 3507.
Acceptance criteria for radiography shall be as per ASME B16.34 annexure B. Ultrasonic
testing in accordance with ASME B16.34 may be substituted for radiography at complex
changes of section.
The Supplier shall inspect all Materials at their premises prior to dispatch. All items shall
be identified with Line Item number and Tag number as per the Bill of Material (BOM)
attached to the Purchase Order. The Supplier shall compile a dossier of all material
certification. One copy of the dossier shall be delivered to site with the materials
consignment; a second copy shall be delivered to the Company. This level of inspection
shall not relieve the Supplier of their responsibility to comply with the codes, drawings,
calculations, standards and specifications.

6.3.9 Commissioning & Start-up

The Supplier, in their tender, shall identify any special requirements or recommendations
for Supplier support during commissioning and start up of the equipment supplied. The
Company's final acceptance of the equipment will be subject to a performance test once
the equipment has been installed and commissioned.
The Supplier shall confirm that they are able to fully support the installation, testing and
servicing of the valve assemblies and to offer specialist assistance where appropriate.

6.3.10 Site Support

The Supplier shall provide details of their after sales support capability. Suppliers shall
advise the location of their nearest service representative and nearest service facility.

6.4 Quality Records

The supplier shall generate quality records from the inspection and test activities listed in
this specification and in accordance with the approved ITP. Documents and drawings shall
be submitted as agreed in the VDRL.
The records shall be compiled and reviewed by the Supplier following the completion of
each inspection and test.
Quality records to be included in the Manufacturer’s Data Report (MDR) are nominated in
the VDRL contained within the Material Requisition. Those records not nominated for

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 41 of 46

 Control Valves & Pressure Regulators
Technical Specification

inclusion in the MDR shall be available for Company review throughout the contract period
and thereafter retained in accordance with industry standards. The MDR shall be compiled
as inspection and testing progresses. Quality records requiring Company review and or
endorsement shall be forwarded to the Company progressively throughout the contract
period.
Quality records requiring traceability as detailed in the Material Requisition shall bear an
identical marking to the item inspected or tested.
In addition to the above:
A Company provided set of check records shall be supplied to the Supplier. They shall be
completed in conjunction with the Supplier, Company representatives and Supplier ITP.
These records once completed shall feed back into the Company’s overall electronic
completion certification system, as part of the project wide quality and audit
documentation. Any equipment deficiencies or carry over shall be recorded in the
documents. These items will be recorded in the project completions punch list system, for
actioning in the next phase of the project.

6.5 Traceability Requirements

Supplier shall maintain a traceability system and establish documented means of:
 Locating and uniquely identifying the item at all stages of processing
 Locating the quality records generated from inspection and testing of the item
 Providing permanent marking (such as hard stamping) to maintain the traceability
throughout the life of the product

The Supplier is to submit details of the proposed traceability system, addressing specific
levels of traceability for each item to the Company for approval.
Specific traceability and marking requirements shall be identified within the Package
contents list documents.

6.6 Marking for Identification and Traceability

The Supplier shall mark items for identification and traceability in accordance with the
following requirements:
 Markings to facilitate identification and traceability during processing are generally
temporary in nature (such as paint marking) and shall be maintained throughout the
manufacture and fabrication stages. The Supplier shall propose the method for
identification marking during processing for Company approval.
 Markings covered in final assembly and/or coating shall be first transferred to as-
built traceability quality records. The transfer of markings to traceability quality
records may be subject to Company verification.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 42 of 46

 Control Valves & Pressure Regulators
Technical Specification

 Markings to facilitate permanent identification and traceability shall be in

accordance with the Material Requisition and shall remain visible for the life of the
item.

The above items should be determined based on criticality evaluation of

equipment/package.

7. Nameplate
In addition to any international code requirements, each control valve and pressure
regulator shall be equipped with a permanently attached primary nameplate manufactured
from 1.5mm thick 316SS. Text and numbering shall be clearly engraved, paint filled and a
minimum of 5 mm high.
In addition to any International Code nameplate requirements, namely ASME UG-129, all
valves assemblies shall be supplied tagged in accordance with the project data sheets.

7.1.1 Control Valves

All control valves assemblies shall be clearly and permanently marked by securely
attaching a stainless steel nameplate with the pertinent information required by the
applicable international codes, including:
 Manufactures /Suppliers Name and or Trademark
 Control Valve serial number
 Valve/Actuator tag number
 Valve Characteristic, e.g. 'equal percentage'
 Action, e.g. 'fail open'
 Maximum Working Pressure
 Body Material
 Actuator Size
 Pressure Rating
 Purchase Order Number
 Trim Size
 Date of Manufacture

The tag number shall be additionally furnished in 6 mm high (minimum) lettering on a

separate tag permanently attached to the valve with stainless steel screws. Tag numbers
shall be issued by the Company during detail design.
Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 43 of 46

 Control Valves & Pressure Regulators
Technical Specification

7.1.2 Pressure Regulators

All pressure regulators shall have a label identifying operating set pressure. This label shall
be a warning label with red text and stating that the operating pressure must not be
exceeded.

8. Painting & Coatings

Painting and coating of all external surfaces shall as a minimum meet the requirements of
the Protective Coating Technical Specification A-1000-30-TS-1001. Where the
manufacturer’s standard painting and coating specification exceeds A-1000-30-TS-1001
then the manufacturer’s standard may be used.

9. Spare Parts, Special Tools and Special Software

9.1 Spares
The Supplier shall identify the following spares:
 Pre-commissioning, commissioning and start-up spares
 Recommended spares list for two years operation

Spares shall be itemised and priced with the Tender.

9.2 Special Tools

The Supplier shall identify at the tender stage all necessary special tools and calibration
equipment required to perform both routine maintenance and specialised procedures.
Special tools shall be itemised and priced with the tender. The Company shall agree the
special tools to be included in Purchase Order.

9.3 Special Software

The Supplier shall identify at the tender stage any necessary special software that is
required to remotely calibrated and record performance valve performance.
Special Software shall be itemised and priced with the tender.The Company shall agree the
special software to be included in the Purchase Order.

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 44 of 46

 Control Valves & Pressure Regulators
Technical Specification

10. Documentation
The Supplier shall be responsible for providing all documentation in accordance with the
VDRL included in the Requisition Package.
Fabrication of equipment shall not commence until the Company has reviewed and
approved the relevant design documentation.

10.1 As-Built Drawings

As-built revisions shall be prepared and submitted no later than two (2) weeks before the
Factory Acceptance Test (FAT). Any information or data revised during the FAT tests shall
be updated prior to the Site Acceptance Test (SAT). Each drawing shall be clearly marked
As-Built and signed and dated. All documentation shall be revised with the As-Built
information incorporated. A final copy with the As-Built information shall be provided by
the Supplier.

10.2 Test Documentation

The Supplier shall provide comprehensive Inspection and Test Plan (ITP) and check sheets
for both the FAT and SAT. The Supplier’s shall provide one test report at the end of the
FAT and another at the end of the SAT.

10.3 Manuals
The Supplier shall provide electronic and hard copies of their standard technical, operating
and maintenance manuals for all hardware within their scope of supply. This requirement
includes documentation from the Supplier’s Sub-Suppliers.
All manuals shall be complete and contain sufficient detail so as to convey to field
personnel, proper operation and maintenance information without the need for outside
reference. This shall apply to all equipment including ancillary items such as calibration
equipment, indicators, etc.
All manuals shall be provided along with the complete system upon delivery.

11. Training
The Supplier shall identify training for operators, technicians and engineering personnel for
all equipment supplied. The Supplier shall provide all equipment, instruction materials and
other documentation associated with the training. Training courses shall be conducted at
stages during the project execution phase to enable Company personnel to effectively
participate during the execution and testing activities. The following topics should be
provided within the training courses:
 Calibration and operation.
 Performance monitoring and optimisation
Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 45 of 46

 Control Valves & Pressure Regulators
Technical Specification

 Periodic corrective and preventative maintenance tasks

Fault diagnosis and correction

Printed copies are not controlled unless issued under a transmittal.

A-1000-70-TS-1008 Rev 1 Page 46 of 46