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Materials System Specification

34-SAMSS-711 Control Valves Instrumentation Standards Committee Members


Al-Juaib, Mohammed Khalifah, Chairman Tuin, Rienk, Vice Chairman Al-Dakhil, Tareq Khalil Al-Faer Al Sharif, Hisham Mohammed Al-Harbi, Ahmed Saad Al-Jumah, Yousif Ahmed Al-Khalifa, Ali Hussain Al-Qaffas, Saleh Abdal Wahab Al-Sahan, Fawaz Adnan Al-Saleem, Hesham Salem Chetia, Manoj Ell, Steven Tal Fadley, Gary Lowell Falkenberg, Anton Raymond Grainger, John Francis Mahmood, Balal Mathew, Vinod Qarni, Mahdi Ali Trembley, Robert James

26 January 2009

Saudi Aramco DeskTop Standards


Table of Contents Scope............................................................. 2 Conflicts and Deviations................................ 2 References..................................................... 2 Environmental Conditions.............................. 6 Information Required with Quotation............. 6 Materials, Design, Fabrication and Assembly......................................... 7 7 Noise Level Requirements........................... 21 8 Marking and Name Plate.............................. 22 9 Painting........................................................ 22 10 Documentation............................................. 22 11 Inspection and Testing Requirements.......... 23 12 Requirements for Shipment.......................... 25
Previous Issue: 9 September 2008 Next Planned Update: 4 May 2013 Revised paragraphs are indicated in the right margin Primary contact: Al-Juaib, Mohammed Khalifah on 966-3-8730222
CopyrightSaudi Aramco 2009. All rights reserved.

1 2 3 4 5 6

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Document Responsibility: Instrumentation Issue Date: 26 January 2009 Next Planned Update: 4 May 2013

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Scope This specification, together with the Purchase Order, Instrument Specification Sheet (ISS) Form 8020-711-ENG, Form 8020-712-ENG or Form 8020-713-ENG, NMR-7925, and Inspection Requirements Form 175-340100 or 175-340150 define the minimum mandatory requirements for general service pneumatically operated steel control valves up to and including Class 2500 ratings. This specification is not applicable to on/off valves.
Commentary Note: Some control valves are used in on/off service or interlock applications. Such valves are part of the scope of this standard.

Conflicts and Deviations 2.1 Any conflicts between this specification and other applicable Saudi Aramco Materials System Specifications (SAMSSs), Engineering Standards (SAESs), Standard Drawings (SASDs), or industry standards, codes, and forms shall be resolved in writing by the Company or Buyer Representative through the Manager, Process & Control Systems Department of Saudi Aramco, Dhahran. Direct all requests to deviate from this specification in writing to the Company or Buyer Representative, who shall follow internal company procedure SAEP-302 and forward such requests to the Manager, Process & Control Systems Department of Saudi Aramco, Dhahran.

2.2

References Material or equipment supplied to this specification shall comply with the latest edition of the references listed below, unless otherwise noted. 3.1 Saudi Aramco References Saudi Aramco Engineering Procedure SAEP-302 Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

Saudi Aramco Engineering Standards SAES-A-206 SAES-J-700 Positive Material Identification Control Valves

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Document Responsibility: Instrumentation Issue Date: 26 January 2009 Next Planned Update: 4 May 2013

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Saudi Aramco Forms and Data Sheets Form 8020-711-ENG Form 8020-712-ENG Form 8020-713-ENG Form SA NMR-7925 ISS - Globe/Angle Control Valves (sheets 1 & 2) ISS - Ball Control Valves (sheets 1 & 2) ISS - Butterfly / Rotary Plug Control Valves (sht 1 & 2) Non-Material Requirements for Valves - All Types

Saudi Aramco Inspection Requirements Form 175-340100 VALVES: Control, Steel, General Service, Pneumatic Operated Up to and including Class 2500 ratings VALVES: Control, Non-General Service

Form 175-340150

Saudi Aramco Standard Drawing AB-036386 3.2 Industry Codes and Standards American National Standards Institute/Fluid Controls Institute, Inc. ANSI/FCI 70-2 (1991) American Petroleum Institute API STD 6D API STD 607 API STD 609 Pipeline Valves Testing of ValvesFire Type-testing Requirements Butterfly Valves, Double Flanged Lug and WaferType Control Valve Seat Leakage (Formerly ANSI B16.104) Hardness Testing for Welding Procedure Qualifications

American Society of Mechanical Engineers ASME B1.20.1 ASME B16.5 ASME B16.10 ASME B16.34 ASME B31.3 Pipe Threads, General Purpose (Inch) Pipe Flanges and Flanged Fittings Face-to-Face and End-to-End Dimensions of Valves Valves Flanged, Threaded and Welding End Process Piping

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34-SAMSS-711 Control Valves

ASME B46.1 ASME SEC VIII D1

Surface Texture (Surface Roughness, Waviness, and Lay) Rules for Construction of Pressure Vessels American Society for Testing and Materials

American Society for Testing and Materials ASTM A105 ASTM A182 Standard Specification for Carbon Steel Forgings for Piping Applications Standard Specification for Forged or Rolled Alloy and Stainless Steel Pipe Flanges, Forged Fittings, and Valves and Parts for HighTemperature Service Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High Temperature Service Standard Specification for Steel Castings, Martensitic Stainless and Alloy, for PressureContaining Parts, Suitable for HighTemperature Service Standard Specification for Carbon and Low-Alloy Steel Forgings Notch Toughness Testing for Piping Components Standard Specification for Castings, Austenitic, for Pressure-Containing Parts Steel Castings, Ferritic and Martensitic for Pressure Containing Parts, Suitable for LowTemperature Service Qualification of Procedures for Welding Castings Standard Reference Radiographs for Steel Castings up to 2 inch (51 mm) in Thickness

ASTM A216

ASTM A217

ASTM A350

ASTM A351 ASTM A352

ASTM A488 ASTM E446

The Instrumentation, Systems and Automation Society - ISA


Commentary: IEC standards equivalent to the ISA standards referenced herein are also acceptable.

ANSI/ISA 51.1 ANSI/ISA 75.01.01

Process Instrumentation Terminology Flow Equations for Sizing Control Valves


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ANSI/ISA 75.05.01 ANSI/ISA 75.08.01

Control Valve Terminology Face-to-Face Dimensions for Integral Flanged Globe-Style Control Valve Bodies (ANSI Classes 125, 150, 250, 300 and 600) Face-to-Face Dimensions for Flangeless Control Valves (ANSI Classes 150, 300 and 600) Face-to-Face Dimensions for Flanged Globe-Style Control Valve Bodies (ANSI Classes 900, 1500 and 2500) Inherent Flow Characteristic and Rangeability of Control Valves Hydrostatic Testing of Control Valves Face-to-Centerline Dimensions for Flanged Globe-Style Angle Control Valve Bodies ANSI Classes 150, 300 and 600 Control Valve Response Measurement from Step Inputs

ANSI/ISA 75.08.02 ANSI/ISA 75.08.06

ANSI/ISA 75.11.01 ANSI/ISA 75.19.01 ANSI/ISA 75.22

ANSI/ISA TR75.25.02 European Norm EN 10204

Inspection Documents, Metal Products, Steel, Nonferrous Metals, Material Testing

International Electrotechnical Commission IEC 60529 IEC 60534-2-5 Degrees of Protection Provide by Enclosures (IP Code) Industrial Process Control Valves, Part 2-5: Flow Capacity Sizing equations for Fluid Flow through Multistage Control Valves with Inter-Stage Recovery Industrial Process Control Valves, Part 3-2: Dimension Face to Face Dimensions for Rotary Control Valves, except Butterfly Valves Electromagnetic compatibility (EMC) Part 4-3: Testing and Measurement Techniques Radiated Radio Frequency Electromagnetic Field Immunity Test

IEC 60534-3-2

IEC 61000-4-3

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International Organization for Standardization ISO 15156 Petroleum and Natural Gas Industries - Materials for Use in H2S Containing Environments in Oil and Gas Production

Manufacturers Standardization Society MSS SP-55 Quality Standard for Steel Castings - Visual Method

National Fire Protection Association NFPA 70 National Electrical Code

Scientific Apparatus Manufacturer Association SAMA PCM 31.3 3.3 Vibration Testing

All engineering units shall be in the International System of Units (SI). Equivalent values in conventional units enclosed in parentheses may follow the SI units. When not critical, the equivalent conventional values may be rounded to their nearest practical values. The terminology and nomenclature used in ISA 51.1 and ISA 75.05.01 apply to this specification.

3.4

Environmental Conditions 4.1 Relative Humidity: Minimum 5%, maximum 95% (condensing) Temperature: Minimum 0C, maximum 65C Wind: Steady wind velocities up to 130 km/h and gusts up to 160 km/h. 4.2 The normal air-borne dust concentration shall be considered as 1 mg/m. During sand storms dust concentrations may reach 500 mg/m. The dust particle size distribution is 95% smaller than 20 micrometers and 50% smaller than 1.5 micrometers. The dust contains salts of sodium, magnesium, aluminum and calcium, which are critically corrosive when wet. Control valves and accessories installed offshore, including nearshore locations within 1 km inland from the shoreline, shall be protected against above conditions and also against air-borne sea water spray and wet salt accumulation.

4.3

Information Required with Quotation The following information shall be supplied with the quotation:
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Valve capacity, noise prediction, and body exit fluid velocity calculations for each specified operating condition; Actuator sizing data; Manufacturers control valve specification sheet; ISS marked-up (i.e., completed and/or corrected) to represent the quoted valve; Sketch with outline dimensions of valve and actuator with approximate weight; Air consumption data; Valve capacity data as a function of travel, either in graphical or tabular form; Valve trim performance data as a function of travel, including liquid pressure recovery factor, cavitation index and pressure drop ratio factor; Confirmation that all electrical equipment and installation of each valve will meet the NEC requirements for the electrical area classification specified on the ISS; Confirmation for each quoted valve that it fully meets the specified process services for trouble free operation; Additional Documentation covered by SA NMR-7925 Non-Material Requirements (NMR) for Valves - All Types, as specified to be submitted with the quotation.

This information is necessary and will be used to complete the technical evaluation of the quotation. The quotation will be considered technically unacceptable if any of the information requested is not included. 6 Materials, Design, Fabrication and Assembly 6.1 General The manufacturer is responsible for the design, construction and the durability of the control valves for the specified process services. If there is no valve body style specified, the manufacturer shall recommend a control valve body style fully meeting the specified process services. Control valves are classified into two main categories based on Application as defined in SAES-J-700. These categories are: General Service and Non-General Service. 6.2 Material The materials specified are minimum requirements and the manufacturer needs to verify and re-confirm that the selections fully meet the specified process services, including anticipated effects of corrosion and erosion.
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Materials specified on the ISS shall be in accordance with the subject standard covered by the following abbreviations, unless otherwise specified in the Purchase Order: 105 F5 F9 F11 F304 F316 F347 WCB WCC WC6 WC9 WC12 LF3 CF8M CF3M CF8C LCB LCC LC2 LC3 A6 A12 A20 CER COB DUPL HAST M400 ASTM A105 ASTM A182 Gr. F5 ASTM A182 Gr. F9 ASTM A182 Gr. F11 ASTM A182 Gr. F304 ASTM A182 Gr. F316 ASTM A182 Gr. F347 ASTM A216 Gr. WCB ASTM A216 Gr. WCC ASTM A217 Gr. WC6 ASTM A217 Gr. WC9 ASTM A217 Gr. C12 ASTM A350 Gr. LF3 ASTM A351 Gr. CF8M ASTM A351 Gr. CF3M ASTM A351 Gr.CF8C ASTM A352 LCB ASTM A352 LCC ASTM A352 LC2 ASTM A352 LC3 Alloy 6 (Solid Stellite No. 6) Alloy 12 (Solid Stellite No. 12) Alloy 20 Ceramic Cobalt Duplex Stainless Steel Hasteloy C Monel 400
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M500 NIT50 TC 17-4 304 316 316L 410 416 420 440 600 625

Monel 500 Nitronic 50 (Nitraded Stainless Steel) Tungsten Carbide 17- 4 PH Stainless Steel AISI 304 Stainless Steel AISI 316 Stainless Steel AISI 316L Stainless Steel AISI 410 Stainless Steel AISI 416 Stainless Steel AISI 420 Stainless Steel AISI 440-C Stainless Steel Inconel 600 Inconel 625

The following materials shall not be used for control valve bodies and bonnets: ASTM A217 Gr. C5 and ASTM A216 Gr. WCA. Requirements for other material standards are covered in the Purchase Order. Material Certificates or Material Test Reports, signed by the manufacturer, shall be provided as minimum for all body and trim materials. Material Test Reports shall be furnished for body and bonnet materials (and bolting materials when ISO 15156 service is specified on the ISS) in accordance with EN 10204, 3.1. Material Test Reports for trim materials and all other materials in contact with wetted components shall be furnished per EN 10204, 2.2. 6.3 Body and Bonnet 6.3.1 Valve design, body pressure-temperature rating and minimum wall thickness shall comply with ASME B16.34. Where pressure containing parts are of a forged material and the non-destructive testing of the welds joining the parts results in a joint efficiency of 1 per ASME B31.3 Table 302.3.4 then the specified minimum wall thickness can be reduced by 25%. The body rating shall be equal to or higher than the flange rating. Welding procedures, performance of welders and welding operators at the foundry and manufacturer shall meet the requirements of ASTM A488 and other ASME codes if applicable.

6.3.2

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Certificates for castings shall include weld repair data including extent of repair, WPS, welder qualifications, post weld heat treatment and NDE following the repair(s). Repair welding shall be performed as per ASME B16.34 using a properly qualified and approved procedure and shall conform to the material specification of the casting including requirements for post weld heat treatment. A repair procedure must include a method statement regarding the excavation, NDT, and welding requirements. All welding procedure specifications, performance qualification records and weld map documents must be available for the purchaser inspector upon his request. The control valve shall be re-hydrotested after any welding or weld repair and any post weld heat treatment on the body or bonnet. For non-general service valves, repair of major defects shall not be performed without the knowledge of the Company. Welding, NDE and heat treatment procedures for major weld repairs of non-general service valves require submittal and approval by the Company prior to affecting the repairs. Weld repairs shall be considered major if any of the following conditions apply: a) b) c) 6.3.3 Castings leak during hydrostatic testing The depth of the repair cavity prepared for welding exceeds 20% of the wall thickness or 25 mm (1 in), whichever is smaller The surface area of the repair cavity exceeds 65 cm (10 in).

Flanged connections shall be raised face (RF) conforming to ASME B16.5. Separable flanges, flanges with tag welds, slip-on flanges or flanges with partial penetration welding are not acceptable. Flangeless valves shall have centering means (e.g., lugs, holes, or equal) to ensure proper alignment of valve and gasket. Dimensions of flanges over 24 inch size shall conform to the standard drawing(s) specified in the Purchase Order. The gasket contact surface texture of raised-face flanged valves and flangeless valves shall be smooth machine-finish between 3.2 to 6.4 micrometers Ra conforming to ASME B46.1. For hydrogen services, when specified on the ISS, the gasket contact surface texture shall not exceed 3.2 micrometers Ra. Face-to-face dimensions of control valves shall conform to one of the following standards as applicable, unless otherwise specified on the ISS: ANSI/ISA 75.08.01, ANSI/ISA 75.08.02, ANSI/ISA 75.08.06,
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6.3.4

6.3.5

Document Responsibility: Instrumentation Issue Date: 26 January 2009 Next Planned Update: 4 May 2013

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ANSI/ISA 75.22, API STD 6D, API STD 609, IEC 60534-3-2. Flanged control valves not covered by any of the above references, shall comply with ASME B16.10 unless otherwise specified on the ISS. 6.3.6 In wet sour services all parts, welds and heat-affected zones of welds exposed to the process fluid shall meet the hardness and heat treatment requirements as per ISO 15156. Welding procedures for welds exposed to the process fluid shall be hardness tested in accordance with Standard Drawing AB-036386 with a maximum allowable hardness of VHN 250 or Rockwell C 22. Austenitic stainless steels and nickel based alloys are not required to be hardness tested, however they shall comply with the ISO 15156 requirements. To prevent sulfide stress cracking (SSC) the fabrication shall be strictly in accordance with the heat treatment requirements and hardness limitations of ISO 15156, including materials under overlays, platings or coatings. In wet sour services the bolting for body, bonnet and cover shall be in accordance with ISO 15156. Inspection reports and Material Certificates or Material Test Reports, shall be furnished to confirm that materials comply with the ISO 15156 requirements. 6.3.7 6.3.8 6.4 Threaded connections shall be NPT and comply with ASME B1.20.1. Bonnets shall be of the integral or bolted type construction with fully retained gasketing. Threaded bonnets are not acceptable.

Sliding Stem Valves 6.4.1 6.4.2 6.4.3 Straight globe valves shall be single or double ported, as specified on the ISS. Angle globe valves shall be single ported. Globe valves shall be top and bottom guided, double top-stem guided or stem and cage guided. Axial flow valve body shall be single piece. Piston is to be guided over the full stroke. Piston is to be permanently locked to the piston rod.

6.5

Rotary Valves The trim position shall be indicated by an engraved mark on the end of the shaft. The shaft design of rotary control valves shall prevent blowout.
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The shaft design of rotary control valves shall prevent excessive shaft deflection for the process conditions specified on the ISS. 6.5.1 Ball Valves The seat ring and seat joint area of the ball valve, or segmented ball valve, shall be designed for continuous throttling control of the process service. Stem seals shall be resistant to vibration. 6.5.2 Butterfly Valves 6.5.2.1 Conventional flat disc/vane type butterfly valves shall be sized for a maximum travel of 60 degrees opening. Travel in excess of 60 degrees opening may only be applied when the disc/vane is specifically designed for control services up to 90 degrees opening, under low dynamic torque requirements. Butterfly valve trims enabling stable control beyond 60 degrees opening include a fishtail disc/vane, angular offset disc/vane, cambered disc/vane, fluted disc/vane and S-disc designs. The actuator end of valve stem shall be splined or keyed. Shear pins are not acceptable. The shear safety factor shall be minimum 150% at the specified shut-off pressure drop condition. The valve stem bearing shall be designed to prevent the stem guide bushing from rotating in the valve body. Bearing material shall be selected to prevent galling of the bearing or valve stem.

6.5.2.2

6.5.3

Plug/Disc Valves Plugs and discs shall be a single casting to form the seating surface, joining arm and hub. Valve body seat shall consist of a removable seat ring with a seat retainer ring. If a stub shaft construction is furnished, each stub shaft shall be inserted into the disc hub for a distance of at least 1 times the shaft diameter.

6.6

Trim 6.6.1 Trim materials shall be selected to withstand corrosion, erosion and wear. Material combinations, especially for cage/piston type trims, shall be selected for maximum galling resistance of mating surfaces by
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means of necessary hardness differentials or galling resistant material combinations. 6.6.2 6.6.3 AISI 300- and 400- series stainless steel shall be used as a minimum. Carbon steel or plated carbon steel trims are not acceptable. Trim materials, or trim hard facing materials, with a hardness of at least 38 HRC shall be provided for control valves in erosive, cavitating or flashing services. Hard faced trims, or solid Stellite or Colmonoy type trims shall be used in erosive type services, including steam and water applications with pressure drop conditions exceeding 350 kPa (51 psi) and all other applications with pressure drop conditions exceeding 4000 kPa (508 psi). The manufacturer shall use harder materials, including Tungsten Carbide where appropriate to ensure acceptable service life. Solid tungsten carbide trim materials shall be specified for sales gas and fuel gas containing the so-called "black powder". Monel, nickel, titanium or Hastelloy trim materials are recommended for corrosive type services to ensure acceptable service life. Trim design shall be suitable to withstand the specified shut-off pressure drop condition. Seat leakage shall meet the ANSI/FCI 70-2 class specified on the ISS.

6.6.4

6.6.5 6.6.6 6.6.7 6.6.8 6.7

Packing System 6.7.1 General Control valve manufacturer shall provide packing systems to effectively maintain minimum leakage and travel performance within the inaccuracy limits specified in paragraph 6.9.2. If necessary, oversized actuators shall be used. The manufacturer is responsible for the quality and performance of the packing system for the process fluid conditions specified on the ISS. A safety margin of 15C shall be applied on the manufacturer's upper and lower temperature limits to cater for abnormal operations outside the specified temperature conditions. 6.7.2 Use of elastomer packing such as PTFE or glass filled TFE shall be limited to 230C (450F) service temperature. Above 230C, graphite

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compound type packing materials or manufacturer's recommended packing shall be used. 6.7.3 Packing systems shall not require lubrication. Asbestos materials shall not be used. Coiled packing and split-ring packing systems shall not be used for new control valves. The use of sealing compounds is not acceptable. 6.7.4 6.7.5 Packing gland studs and nuts shall facilitate precise adjustments of the packing load. Corrosion resistant alloy materials compatible with the process fluid shall be used for the gland studs and nuts, packing follower and packing flange (i.e., carbon steel is not acceptable). Low Emission Packing Low Emission Packing (LEP) designed to reduce fugitive emissions shall be supplied when specified on the ISS for applications including VOC services and components that are in Hazardous Air Pollutant service (e.g., including benzene, toluene and xylene). 6.7.7 6.7.8 6.7.9 The LEP shall limit the fugitive emissions of to a maximum of 500 ppmv. Bellows welded to both the bonnet and stem provided with a back-up packing system shall be supplied when specified on the ISS. Stem and Extension Bonnet Stem materials and sizes shall be selected to prevent corrosion, pitting, scoring and bending of the stem. Valve stems shall have a finish of 0.1 micrometer Ra or less. Packing gland followers and/or bushings shall be provided to maintain the stem precisely centered. An extension bonnet or cooling fin may be provided when the packing life can be increased or when the valve travel dead band can be reduced. However, no extended temperature operating range shall be allowed for PTFE packing material. The manufacturer is responsible for selecting the quality and performance of the packing system for the specified process fluid conditions. Requirement for extended or finned bonnet shall be as specified on the ISS.

6.7.6

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6.8

Sizing and Selection 6.8.1 The manufacturer is responsible for the valve flow capacity sizing, noise calculations and actuator sizing. Control valve sizing shall generally be based on ISA 75.01.01 or IEC 60534-2-5 as applicable. Manufacturer may deviate from the ISA and IEC formulas provided that the reason and the formula used are detailed in the technical quotation. Manufacturer to specify all applicable capacity calculation correction factors addressed in these standards (i.e., piping geometry factor, FP, for valves mounted between pipe reducers or other pipe fittings, calculated FLP and/or XTP factors, Reynolds number factor, FR, etc., to be specified in the calculation or on the ISS). Manufacturer shall provide capacity and noise calculations for all operating conditions specified on the ISS. 6.8.2 Control valve bodies with reduced trims shall be quoted as an alternative for the following applications: a) b) c) d) e) pressure drop applications in excess of 5170 kPa (750 psi); choked flow services; flashing services with downstream vapor content exceeding 10% weight; erosive services; services where future capacity increase is anticipated.

Body sizes 1-inch, 2-inch, 3-inch", 5-inch or higher odd numbers shall not be used. 6.8.3 Body outlet velocity, defined as the fluid velocity at the discharge flange of a control valve, shall not exceed: 0.15 Mach 0.2 Mach 0.3 Mach 0.4 Mach 0.5 Mach for gas containing black powder for gas, vapor and steam services containing any particulate matter for wet gas, vapor and saturated steam services for dry clean gas and superheated steam services for dry clean gas in infrequent services (i.e., services where the control valves are operated for less than 1 hour and closed for more than 7 hours during an 8-hour shift)

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6.8.4

An equal percentage trim shall operate below 93% stem travel at maximum flow condition. A linear trim and quick opening trim shall operate below 90% stem travel at maximum flow condition. A modified parabolic trim shall operate below 90% stem travel at maximum flow condition.
Exception: Anti-surge control valves shall operate below 55% travel at any surge flow condition. Commentary Note: The specified travel percentages apply to both linear and rotary control valves and need to be converted to degrees opening for rotary type control valves.

6.8.5

The installed rangeability (i.e., the actual available rangeability) of each control valve in the process system shall meet all flow conditions specified on the ISS. The specified minimum flow condition shall be fully controllable and shall operate above 10% travel for globe, angle and axial flow type control valves, 5 degrees for ball type control valves, and 10 degrees for butterfly, rotary plug/disc and cammed type control valves. Manufacturer's control valve characteristic shall conform to ISA 75.11.01.

6.9

Positioners 6.9.1 General The control valve manufacturer shall be responsible for packaging and guaranteeing the whole control valve assembly. Each control valve shall be provided with a digital positioner, unless otherwise specified. Type of positioner shall be as specified on the ISS. For fast stroke speed requirements it is preferred to use a high air capacity positioner rather than a positioner with booster(s). The required stroke time shall be met. A double acting positioner shall be used for double acting type actuators (e.g., a single acting positioner with a reversing relays shall not be used).
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Positioners shall be electromagnetic compatible and be certified to IEC 61000-4-3, Level 3 (10 volts/meter). Positioners shall be vibration resistant up to 0.75 inch/sec. RMS minimum and be tested conform to SAMA PCM 31.3. Manufacturer shall test, record and submit control valve signatures, or tested hysteresis data in tabular form, as part of the documentation submittals, in soft copy format. Positioners shall be fully configured with all user information. Following criteria apply for the subject positioners: 6.9.2 Digital Positioners 6.9.2.1 Foundation Fieldbus (FF) positioners shall: have passed all tests of the latest Interoperability Test Kit (ITK) and accordingly be certified by Fieldbus Foundation; be field proven for at east one year; have passed all function block tests with the host control system and be certified by host control system vendor; enable user to download function blocks to the positioner; be capable to perform continuous diagnostic tests, including self-test functions, and to provide specific diagnostic information at the Man-Machine-Interface (MMI); include menu's and methods (wizards) to facilitate easy set-up and to enable calibration from the MMI; be certified as Non-Incentive by FM or CSM for installation in a Class I, Division 2 (Zone 2) area; store all configuration data in non-volatile memory (e.g., no configuration data may be lost during a power loss).

6.9.2.2

HART positioner A 2-wire loop powered 4-20 mA signal HART protocol smart positioners shall be locally configurable by push buttons and a HART handheld terminal and remotely by a HART handheld terminal and thru the DCS.

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6.9.3

Analog Positioners Conventional electro-pneumatic and pneumatic positioners, if specified, shall be selected and guaranteed by the control valve manufacturer.

6.10

Actuator System 6.10.1 Type of actuator shall be as specified on the ISS. The manufacturer is responsible for correctly sizing the actuators based on this specification and the ISS. Actuator systems shall be suitable for non-lubricated air or sweet gas as specified on the ISS. Actuators shall operate on the signal specified on the ISS. Actuators shall develop sufficient force to operate the valve against the shut-off pressure drop specified on the ISS. Actuator force/torque requirements shall be determined for the worst case service requirements. If no shut-off pressure drop is specified then the actuator sizing shall be based on the maximum inlet pressure specified in the ISS with atmospheric pressure at the outlet. Actuator sizing shall be based on a minimum available instrument air pressure of 415 kPag (60 psig), including worst-case requirements for maximum force/torque. Air supply design pressure conditions are generally 862 kPag (125 psig) at 82C. Maximum inaccuracy of the valve travel position versus control signal shall be less than 1.5% for valves with a positioner and less than 2.5% for valves without a positioner. Pneumatic tubing and fittings shall be AISI 316 stainless steel minimum. Carbon steel, copper, bronze, brass, and AISI 304 stainless steel materials shall not be used. Fittings shall be as specified on the ISS, but be limited to Swagelok, Parker A-lock, Hy-Lok, Gyrolock, CPI or other equivalent manufacturer approved by Saudi Aramco. The minimum Size of pneumatic connectors, fittings, unions and nipples shall be 0.25 inch NPT provided that the stroke speed requirements are met. Teflon ribbon shall not be used for sealing threaded connections. All vents shall be directed downwards to prevent ingress of dust and sand. All control valves shall be provided with a suitably sized air filter regulator set. 6.10.4 When the air failure open (AFO) or air failure close (AFC) action mode of a single or double piston-operated actuator system can not be accomplished due to insufficient spring force then a volume tank with fail-safe trip valves shall be provided. The specified air failure mode
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6.10.2

6.10.3

Document Responsibility: Instrumentation Issue Date: 26 January 2009 Next Planned Update: 4 May 2013

34-SAMSS-711 Control Valves

movement of the control valve shall be prompt in the event of either control signal failure or air supply failure. The tripping pressure shall be 350 kPa (50 psig) and normal valve operation shall be automatic on restoration of air supply pressure. The required air failure mode shall be accomplished without the aid of process pressure. Air failure modes shall be testable during inspection and during plant commissioning when piping systems are de-pressurized. 6.10.5 When an air failure lock (AFL) action mode is required, also referred to as "air failure steady" (AFS), lock-up valves shall be provided to maintain the actuator in the last operating position. Actuators shall meet the control stroke time specified on the ISS for all specified operating conditions (e.g., stroke time in modulating modes of operation). Boosters may be applied, as required but stroke movements shall remain stable at 20%, 50% and 80% control signal step changes (i.e., overshoot to be less than 120% of the input step change and be dampening) as defined in ANSI/ISA 51.1 and addressed in ANSI/ISA TR75.25.02. Overshoot shall be less than 110% for compressor AntiSurge applications. Stroke times shall be met on a 50% control signal step change (i.e., the resulting 50% stroke change needs to be performed within 50% of the total stroke time specified on the ISS). When specified on the ISS, actuator shall also meet the air failure mode stroke time. Quick-exhaust valves commonly used to meet this requirement shall not interfere with the normal control operation of the actuator. Connection of the shaft or stem to the actuator linkages shall be adjustable with positive locking and be of an anti-rotating type. Actuator springs shall be minimum of carbon steel with manufacturer's standard factory applied corrosion resistant coating or hot oil dipping, unless other wise specified in the P.O.

6.10.6

7.10.7

6.10.8 6.10.9

6.10.10 Materials of actuator cylinders and diaphragm cases shall be steel, cast iron or copper free aluminum (i.e., non-metallic, epoxy or fiber glass type materials are not acceptable). For emergency de-pressurizing control valves only steel or cast iron cylinder type actuator systems are allowed to be used. 6.11 Accessories 6.11.1 Manufacturer shall supply the accessories specified on the ISS and Purchase Order. Accessories shall be installed on the control valve and
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Document Responsibility: Instrumentation Issue Date: 26 January 2009 Next Planned Update: 4 May 2013

34-SAMSS-711 Control Valves

actuator assembly. Accessories shall operate from the power supply specified on the ISS or Purchase Order. Enclosures of accessories and junction boxes shall be die-cast aluminum copper free max. 0.4%, to meet minimum NEMA 4X or IP 65 (IEC 60529) weather proof and shall be certified for Class I, Division 2 (Zone 2) installations. 6.11.2 The pneumatic positioner and I/P transducer shall be supplied from the same air supply connection. A 5 micron air supply filter shall be supplied for each control valve. A large capacity regulator, capable to provide a constant pressure under all operating conditions, shall be provided. Positioners shall be provided with gauges to indicate the air supply and signal pressures and positioner pneumatic output. For a double acting actuators both top and bottom pressure gauges should be provided on the positioner. A positioner bypass valve shall only be provided for direct acting positioners with a 3-15 psig pneumatic signal output to spring-loaded actuators (e.g., only when the input signal range is the same as the valve positioner output range). A bypass valve shall not be installed on reversed- or reversible-type positioners. If a handwheel is specified on the ISS, manual operation of the handwheel shall override automatic operation. Handwheel mechanism shall not add significant friction to the actuator. The handwheel operation shall be clockwise to close the valve and anti-clockwise to open the valve. Handwheel shall not be used as mechanical travel stop. The neutral position shall be clearly indicated. Discrete limit switch shall be of the mechanical, proximity or magnetic sensor type, as specified on the ISS. Limit switch enclosures shall be hermetically sealed. Switch contact outputs shall be minimum, SinglePole, Double-Throw (SPDT). Contact rating shall be minimum, 0.5 Amp inductive @ 125 VDC and 2 Amp resistive @ 120 VAC unless otherwise specified in the Purchase Order. A solenoid valve shall move the valve to the fail-safe position when de-energized. Solenoid valves shall be certified to Class I, Division 2 (Zone 2). The solenoid valve shall have Viton internal soft parts. The minimum solenoid valve size shall be 0.25 inches. Solenoid operated valves shall have class H insulation, stainless steel body and be selected from the manufacturers specified on the ISS or Purchase Order. Provided the solenoid valve meets ambient temperature

6.11.3

6.11.4

6.11.5

6.11.6

6.11.7

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Document Responsibility: Instrumentation Issue Date: 26 January 2009 Next Planned Update: 4 May 2013

34-SAMSS-711 Control Valves

requirements, Class F coil insulation may also be used in low power applications, i.e., 24 volts. 6.11.8 Volume tanks shall be mechanically designed to withstand a maximum pressure of 930 kPag (135 psig) at 82C. Volume tanks shall be manufactured in accordance with ASME SEC VIII D1 (stamped UM) or PED requirements. Volume tanks shall have a minimum capacity for two complete strokes of the control valve at the minimum available instrument air pressure of 415 kPag (60 psig). The I/P transducer shall also be supplied from this volume tank. Travel stop adjustment must be lockable or be equipped with a jam-nut arrangement. Travel stop arrangements through the hand wheel mechanism are not acceptable.

6.11.9

6.11.10 Each control valve shall be provided with a valve position indicator. The indicating pointer shall be directly connected to the stem or shaft. The valve position shall be indicated on a reversible scale, with clearly graduated markings at the 25, 50 and 75% valve opening position and the words OPEN and CLOSED at the valve travel limits. 6.11.11 Requirement for analog valve travel position transmitter shall be as specified on the ISS. The total maximum inaccuracy of the signal versus travel position due to any limitation shall be less than 1.5%. 7 Noise Level Requirements The maximum noise level emission from each control valve measured 1 m downstream of the valve and 1 m away from the valve shall not exceed the limit specified in SAES-J-700 and the ISS under any specified operating condition. The maximum noise levels are specified in terms of equivalent continuous A-weighted Sound Pressure Levels (SPL) with a maximum inaccuracy of + 5 dB(A). Manufacturers shall include inaccuracies of their quoted noise levels and shall guarantee that the noise emission from control valves shall not exceed the specified limit for any specified operating condition. Manufacturer shall provide a noise calculation, including the maximum inaccuracy, for each specified operating condition. Manufacturer shall include noise reduction proposal(s) for any calculated noise level exceeding 85 dB(A).

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Document Responsibility: Instrumentation Issue Date: 26 January 2009 Next Planned Update: 4 May 2013

34-SAMSS-711 Control Valves

Marking and Name Plate 8.1 The direction of flow shall be marked on the valve body for all valves which have been designed or selected for a specific flow direction. Marking shall normally be cast or steel stamped. Alternative marking may be accomplished by a stainless label permanently fixed to the body by rivets. The trim position of rotary valves shall be engraved on the shaft end. 8.2 A permanently fastened stainless steel name plate shall be provided on each control valve (e.g., by stainless steel rivets) with the following information: Tag number specified on the ISS; Manufacturers name, model number and valve serial number; Body material, valve size and flange rating; Trim material; Actuator model, size and bench set.

Painting Finish, priming and painting of the control valve and accessories may be as per the manufacturer's standard provided that the coatings are suitable for the environmental conditions and can be maintenance coated.

10

Documentation Following documentation shall be provided: Documents to be submitted with the quotation covered by the Purchase Order; Documents covered by Form NMR-7925 Non-Material Requirements (NMR) for Valves - All Types; Documents covered by the applicable inspection requirements.

11

Inspection and Testing Requirements 11.1 General Manufacturer is responsible for ensuring conformance to the applicable specifications and standards and for demonstrating this to the Contractor and Saudi Aramco inspection representatives.

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Document Responsibility: Instrumentation Issue Date: 26 January 2009 Next Planned Update: 4 May 2013

34-SAMSS-711 Control Valves

As part of their QA program, Manufacturer shall implement a qualification procedure for all pressure containing steel castings. As a minimum, the manufacturer shall have qualified each foundry's casting patterns by radiographic or other NDE examination of the initial casting. Records of these qualifications shall be made available upon request. For Capital Projects, Manufacturer shall propose an inspection and testing plan and schedule (ITPS) for each control valve order. The manufacturer may use his own ITPS format provided that all Saudi Aramco requirements are included. 11.2 Visual Inspection All castings shall be visually inspected in accordance with MSS SP-55. A casting shall be rejected if any surface irregularity exceeds example b for General Service valves or example a for Non-General Service valves of any defect type as per MSS SP-55. 11.3 Inspection and Testing Forms The following inspection and testing requirements apply to this specification: SA Form 175-340100 for General Service Control Valves SA Form 175-340150 for Non-General Service Control Valves 11.4 Specific Tests and Procedures Proposed repair method of major weld repairs shall be approved by Company prior to welding. Welds shall be 100% radiographed and evaluated in accordance with of the applicable ANSI/ASME standard with a minimum casting quality factor of 0.95. 11.4.1 Positive Material Identification (PMI) Requirements Positive Material Identification (PMI) shall be performed on alloy steel material control valves. PMI shall be performed in accordance with SAES-A-206. PMI alloy verification is required on body and bonnet materials (100%). Alloy verification for trim parts is not required unless specified in the purchase order. 11.4.2 Post Weld Heat Treatment Castings and test bars shall be heat treated together. For carbon steel, the Brinnel hardness of heat-treated castings shall not exceed 225.

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Document Responsibility: Instrumentation Issue Date: 26 January 2009 Next Planned Update: 4 May 2013

34-SAMSS-711 Control Valves

11.4.3

Non-Destructive Testing When required by the applicable 175 Form, critical body and bonnet casting sections, typically defined by ASME B16.34, shall be radiographed and shall meet ASTM E446 (up to 2 inches thick). NDE of pressure retaining parts shall be completed before machining.

11.4.4

Hydrostatic Testing Hydrostatic shell testing shall be performed at factory after assembly of the control valve as per ISA 75.19.01. The water shall contain a corrosion inhibitor.

11.4.5

Leakage Tests Leakage test shall be based on ANSI/FCI 70-2. The water shall contain a corrosion inhibitor.

11.4.6

Mechanical Operation Test Mechanical operation tests shall be performed with the packing system tightened under the same load as during the hydrostatic test. The valve stem may not be lubricated. The test shall consist of measuring the valve stem position for increasing and decreasing input signals at every 10% travel interval. The manufacturer shall demonstrate that the maximum acceptable inaccuracy levels will not be exceeded. If a handwheel is specified then the fully open and closed positions of the valve need to be achieved with handwheel operation taking over from actuator at mid-position. Stroking speed in control mode shall meet the ISS.

11.4.7

Impact Tests Charpy impact testing at the design temperature shall be performed on the body and bonnet materials for services below -46C.

11.4.8

Fire Tests Certified Fire Tests Report shall be provided for each type of control valve specified to be fire-safe. Packing systems of fire proof control valves shall meet API STD 607 fire test leakage performance requirements.
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Document Responsibility: Instrumentation Issue Date: 26 January 2009 Next Planned Update: 4 May 2013

34-SAMSS-711 Control Valves

11.4.9

Certificates Manufacturer shall issue material certificates and certified test reports as specified on the appropriate SA Form 175 or P.O.

11.4.10 Storage Control valves shall be stored in an enclosed building that provides protection from blown dust, mud and rain, etc. The Contractor is responsible for any damage or malfunctioning due to inadequate storage of the control valves. 12 Requirements for Shipment All machined or threaded surfaces subject to atmospheric corrosion during shipment, or subsequent outdoor storage, shall be treated with an easily removable rust preventive. Flange protectors shall fully cover the gasket contact surfaces. Pneumatic tubing systems shall be adequately protected to prevent any damage during shipment. Pneumatic end connections shall be sealed or closed by a plastic plug or PVC tape.

4 May 2008 9 September 2008 26 January 2009

Revision Summary Major revision. Minor revision to delete the mandatory requirement of the drain provision and plug for control valve bodies. Editorial revision to delete the reference to ATEX as a certifying agency for electrical equipment to be used in classified areas.

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