ENGINEERING STANDARD

Title: CONTROL VALVES Standard No. : 406

Page : 1 of 11
Issue Date : August, 2006
Director, Control Systems Director, Specialty
Approvals: Sponsor & Electrical Engineering Engineering

Name J. Salom M. A. Tibbitts M. R. Hoffman

Signature ON FILE ON FILE ON FILE

Date 09/12/06 10/10/06 10/31/06

TABLE OF CONTENTS

Page

1.0 SCOPE................................................................................................................................... 2

2.0 CODES, STANDARDS AND REFERENCES................................................................... 2

3.0 GENERAL REQUIREMENTS........................................................................................... 2

4.0 CONTROL VALVE STYLES............................................................................................. 4

5.0 CONTROL VALVE CHARACTERISTICS ..................................................................... 6

6.0 MANIFOLD BLOCK AND BYPASS VALVES ............................................................... 6

7.0 CONTROL VALVE SIZING AND RATING ................................................................... 6

8.0 CONTROL VALVE ACTUATORS................................................................................... 7

9.0 POSITIONERS AND RELAYS .......................................................................................... 8

10.0 ELECTRICAL ACCESSORIES......................................................................................... 8

11.0 ELECTRICAL MOTOR-OPERATED VALVES............................................................. 9

12.0 HYDRAUICALLY OPERATED VALVES....................................................................... 9

13.0 SELF-ACTUATED REGULATORS ................................................................................. 9

Table 1 - Block and Bypass Valve Sizes ............................................................................................... 10

RECORD OF REVISIONS................................................................................................................... 11
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1.0 SCOPE

1.1 This Standard, in conjunction with the Vendor Preference List and Specifications for the specific
project, shall define the minimum Lyondell requirements for control valves.

1.2 API Recommended Practice 553 shall be used in conjunction with and be considered part of this
Standard.

1.3 Where approvals are indicated in this Standard, this refers to Lyondell or its designated
representative.

1.4 Any discrepancy between this Standard and other contract or procurement documents or
specifications, unless specifically indicated as an exception, shall be submitted by the
Contractor/Manufacturer/Supplier to the Buyer for a written ruling.

1.5 All measurements are expressed in the U.S. Conventional System of Measurement, followed by,
in parenthesis, the equivalent SI units (metric). All SI units are for reference only and shall not
be interpreted as a precise conversion.

1.6 Any proposed deviation from this Standard shall be submitted in writing to Lyondell for review
and approval. It is the responsibility of the individual(s) who requests a deviation to submit a
request form in a timely manner and in accordance with Lyondell Procedure SEP 107B,
Preparation of Addenda and Deviations to Lyondell Engineering Standards.

2.0 CODES, STANDARDS AND REFERENCES

The latest editions of the following Codes and Standards in effect on the date of contract award
shall be used, except as otherwise specified.

2.1 Lyondell Engineering Standards

ES 320 Piping
ES 325 Valves

2.2 American National Standards Institute (ANSI)

ANSI B 16.10 Face-to-Face and End-to-End Dimensions of Valves

ANSI/FCI 70.2 Control Valve Seat Leakage

2.3 American Petroleum Institute (API)

API RP 553

2.4 Instrument Standard of America (ISA)

ISA-S75.04-1992 Face-to-Face Dimensions for Flangeless Control Valves

(ANSI Classes 150, 300, and 600)

3.0 GENERAL REQUIREMENTS

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3.1 Accessibility

All control valves shall be installed such that they are accessible for maintenance purposes. If a
handwheel is provided, sufficient clearance shall be provided for accessibility to, and for
operation of, the handwheel.

3.2 Location

Within reasonable design considerations, the control valve shall be located at grade, preferably
near the piece of operating equipment that must be observed while on manual control. When
local process measurement indicators are provided, they shall be located so that they can be seen
by an operator standing next to the control valve.

3.2.1 Control valves that handle combustible fluids shall be located a safe distance from hot pumps,
lines, or equipment to prevent the fluid from contacting such equipment or lines when the valve
manifold is drained, or if leaks develop.

3.2.2 Precautions

3.2.2.1 Control valves used in process lines or fuel lines to fired heaters shall be located such that the
manifolds can be drained and the valves removed without danger of flashback. In addition, the
drain or bleed connection, as required, shall be piped a safe distance from the heater.

3.2.2.2 Control valves shall be located such that the maximum permissible ambient temperature is not
exceeded, because high temperatures cause premature failure of diaphragms and electrical or
electronic components.

3.2.2.3 Certain rotary motion-type control valves use low-friction, plastic-lined bearings that are
susceptible to static electricity and therefore shall be grounded. The valve manufacturer shall be
consulted for recommendations when this type of valve is used.

3.3 Installation Clearances

Sufficient clearance must be provided above, below, and on the side of the control valve to allow
removal of the valve trim and actuator from the valve body for maintenance, if required.

3.4 Face-to-face dimensions shall comply with ANSI B16.10, for flanged control valves, and ISA-
S75.04-1992, for flangeless control valves.

3.5 Handwheels, when specified, shall be the side-mounted type, except on butterfly and ball valves,
which shall have shaft-mounted declutchable handwheels.

3.6 All control valves shall have a permanently affixed stainless steel tag listing the valve tag
number, body material, body size, end connection style and rating, trim size and material, flow
characteristics, valve coefficient, fail action, spring range, manufacturer and model number. No
wire or glue is permitted.

3.7 Shut-off characteristics, when specified, shall comply with ANSI/FCI 70.2 Standards.
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3.8 Standard bonnet with TFE V-ring packing material is recommended for temperature limits of -
40°F to +450°F (-40°C to +232°C). If the encountered service temperature is in excess of 450°F
(232°C), laminated graphite packing shall be considered, for which the suitable temperature
range is from cryogenic temperatures to +1200°F (649°C); however, an extension bonnet or steel
yoke shall be used when packing box temperature exceeds 800°F (427°C).

3.9 Extension bonnets shall be used below -30°F (-22°C).

3.10 Detailed control valve specifications shall be furnished on Standard ISA S20 specification sheets.
Any deviation must have the express approval of Lyondell. All variables used in calculating
valve size (Cv) shall be shown on the specification sheet.

3.11 The overall noise level shall not exceed 85 dBA at a predetermined point (48 in. [1220 mm]
downstream of the valve outlet and 29 in. [740 mm] from the pipe surface). The predicted noise
levels shall be determined and furnished to Lyondell for review and approval.

3.12 The flow direction shall be shown with an arrow on the valve body.

3.13 Three-way valves shall have the permanently open port stamped as “common.”

3.14 The use of Variable Frequency Drives for pump flow control in acutely toxic applications as
defined in ES 320 (in lieu of control valves) shall be evaluated due to the inherent personnel
hazard during control valve decontamination and maintenance.

4.0 CONTROL VALVE STYLES

4.1 Globe-type body valves shall generally be used. The selection of cage-guided, as opposed to
other guiding, must be made on the basis of process fluid characteristics and pressure drop
conditions. In general, cage-guided valves will be used on relatively clean fluids, gases, or where
pressure drop across the control valve dictates the use of a balanced trim. Other types of guiding
should be considered when the process fluid, gas, pressure drop, etc., would allow the use of a
more economical valve.

4.1.1 For high-pressure drop service, use of tortuous path or controlled stage-type valves must have the
approval of Lyondell.

4.2 For low-pressure drop service or where high-pressure recovery is required, an eccentric disk or
high-performance butterfly valve shall be used. Ball valves with characterized ball shall also be
considered.

4.2.1 Butterfly valves, when approved for use in throttling applications, shall be high-performance
butterfly valves.

4.3 Split body, flangeless body, or plastic-lined body valves shall only be used where process
requirements, such as corrosive conditions, make use significantly more economical and when
approved by Lyondell. Split body, flangeless body, or plastic-lined body valves are typically not
specified for acutely toxic applications and must be approved by Lyondell.
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4.4 Use of special valves, such as Saunders type, angle body, plastic body, high-pressure let down
valves, p in. valves, etc., are subject to approval by Lyondell.

4.5 Materials of Construction

4.5.1 Valve body material will be determined by the process fluid, corrosion/erosion characteristics,
and ES 320. Fire safety also shall be considered when selecting materials of construction. In this
case, the valve body shall be made of a material that will not deform or leak during a fire.
Copper bearing alloys are not permitted.

4.5.1.1 Ductile or cast iron shall not be used.

4.5.2 Trim materials for normal service shall consist of proper combinations of 316 SS, 17-4 PH,
440C SS, and 416 SS. Hardened surface requirements, such as stellite, shall be dictated by
service conditions. No copper bearing alloys are permitted. Trim material for control valves in
Phosgene or Chlorine service shall typically be Hastelloy C unless prior experience with another
material (such as Monel or 316ss) dictates otherwise. The applicable piping specification may be
referenced for additional guidance on material selection.

4.5.3 TFE V-rings shall be used for general service. Laminated graphite packing shall be considered
for all temperatures above 450°F (232°C); however, the stem shall have a very smooth finish (2-
4 micro-inches RMS) to seal properly. Any packing material containing asbestos is not
acceptable.

4.5.4 A lubricator and isolating valve shall be supplied, only if recommended by the manufacturer.

4.5.5 Bonnet gasket and seat ring gasket shall be graphite. On oxygen service, gasket material shall be
Teflon.

4.6 Fugitive Emissions

4.6.1 Valves that are identified as the source of Hazardous Air Pollutants (HAP) shall be equipped
with the valve seals to meet the EPA’s latest fugitive emissions (FE) requirement. On control
valves with vertical-rising stems and on quarter-turn control valves, a special packing ring
material suitable for FE application shall be used for stem seals, to minimize leakage. Valve
stem finish and finish on the bore of the bonnet shall be RMS 4 or better. Fugitive Emissions
(FE) packing systems shall be utilized at a minimum on all control valves in acutely toxic
service. On valves where zero emissions are mandated by certain codes or are highly desirable to
minimize health hazards, metallic bellows seal valve with secondary stem packing shall be used.
When used on a rising stem valve in acutely toxic service, the metallic bellows shall be
constructed of Hastelloy C or Inconel. “Hydroformed” bellows (as opposed to diaphragm or
welded bellows) shall be utilized. Process fluid and pressure shall be on the outside of the
bellows which prevents any solids from accumulating inside between bellows and stem.

4.6.2 Valves that handle the listed pollutants that are subject to a FE monitoring/leak detection and
repair (FEM/LDAR) program shall have a permanent stainless steel tag attached, identifying the
valves as under the FE monitoring program.

4.7 When Ball or Plug valves are specified as shut-off valves, the ball or plug must be vented in the
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appropriate direction. Reference the applicable piping specification for guidance.

4.8 Valves used in Chlorine service shall be cleaned and degreased per Chlorine Institute
requirements and shall utilize appropriate lubricant and packing materials. Valves used in
Phosgene service shall be evaluated to determine if they must meet Chlorine Institute cleaning
requirements.

4.9 Valves in liquid Phosgene or Chlorine service must not have any threaded plugs or set screws
(typically used to facilitate assembly/disassembly) which penetrate the valve body and are
exposed to the process. If so, they must be backwelded or otherwise eliminated. For valves in
vapor Phosgene or Chlorine service, every effort shall be made to eliminate these threaded plugs
or set screws. Consider specifying an alternate valve design.

5.0 CONTROL VALVE CHARACTERISTICS

5.1 Characteristics will normally be equal percentage. Linear and quick-opening characteristics shall
be used only where process control requirements dictate their use.

6.0 MANIFOLD BLOCK AND BYPASS VALVES

6.1 Unless otherwise specified or required, block valves size shall be the same as the line size.
Bypass valves shall be the same size as the control valves.

6.1.1 Globe valves shall be used in bypass sizes through 4 in. and gate valves in bypass sizes 6 in. and
up. (Refer to Table 1 and ES 325).

6.2 A single drain connection, 3/4 in. (19 mm) minimum size, shall be provided upstream of the
control valve. For hazardous chemical service, drain connections shall be provided on both
upstream and downstream side of the control valve.

6.3 With the approval of Lyondell, bypass and block valves shall be treated as special, or eliminated
if the requirements are dictated by: noncontinuous or batch operation, use of exotic alloys,
availability of low differential pressure, slurry service where bypass lines are likely to plug, etc.

6.4 Elimination of block valves and bypass requires the use of a side-mounted handwheel, unless
specifically exempted by Lyondell.

6.5 Reducers and swages upstream and downstream of the control valve shall be concentric, unless
otherwise specified.

6.6 Supports at control valve manifolds shall be located such that the assembly is self-supporting
with the control valve removed.

6.7 Control valves and the associated bypass shall be installed per API RP 553.

7.0 CONTROL VALVE SIZING AND RATING

It is the responsibility of the Contract Engineer to calculate the total system pressure drop and
then to assign a pressure drop to the control valve as a percentage of the total system pressure
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drop. The minimum guideline shall be to allow 30% of the total system dynamic drop or 10 psig
(0.068 MPa), whichever is greater. Another important consideration is selection of a maximum-
flow figure for control valve-sizing purposes.

As a rule, engineering schedules are such that control valves are sized, specified, and purchased
prior to receipt of certified pump data. Therefore, the following guidelines shall be used for
assignment of maximum flow for control valve sizing purposes.

7.1 Guidelines

7.1.1 When normal flow is given, in all cases except steam service:

Computed Cv Based on normal flow (design flow at 100% production rate)

Sizing Cv Based on 1.3 x normal flow

7.1.2 When maximum flow is given:

Computed Cv Based on 0.7 x maximum flow

Sizing Cv Based on maximum flow

7.1.3 Control valves in centrifugal compressor suction and discharge lines shall be reviewed with
Lyondell.

7.1.4 Control valves in steam lines to turbines, reboilers, and process vessels shall be allocated a 10%
pressure drop of the design absolute pressure of the steam system or 5 psi (0.034 MPa),
whichever is greater. The valve shall be sized for twice the normal flow rate.

7.1.5 In using the above guidelines, it is required that the Contract Engineer, upon receipt of certified
pump data, recheck control valve capacity and pressure drop as related to actual pump discharge
pressure and flow. If a difference exists, such as the control valve being too large or too small
based on actual pump data, the control valve shall be modified prior to installation.

7.1.6 Control valve connections shall be flanged. Screwed valves or flangeless valves may be used
when approved by Lyondell. Acceptable control valve body sizes are 1 in. (25 mm), 1-1/2 in.
(40 mm), 2 in. (50 mm), 3 in. (80 mm), 4 in. (100 mm), 6 in. (150 mm), etc. All control valves in
acutely toxic service shall be flanged to match the piping specification requirements.

7.1.7 Minimum rating for valve flanges shall be 150# ANSI R.F. Minimum rating for screwed valves
shall be 600#.

Butterfly valves and ball valves are excluded from the required minimum rating. The rating for
these valves shall be in accordance with service conditions.

8.0 CONTROL VALVE ACTUATORS

8.1 Topworks or operators, including valve springs, shall be sized to fully stroke the valve against
the unbalanced force (i.e., force due to pressure drop across the control valve, force required to
provide seat load, and force to overcome packing friction) to provide the shutoff, required per
ANSI class, upon loss of instrument air.
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8.2 Spring and diaphragm actuators or double-acting cylinder actuators shall be used. Valve springs
shall have a 3-15 psig (0.2-1 kg/cm2 spring range. A spring range of 6-30 psig (0.4-2 kg/cm2)
may be used only when combined with a positioner. Written approval is required for use of a 6-
30 psig (0.4-2 kg/cm2) spring range.

8.3 Where double-acting pneumatic piston type actuators are required, an air failure spring shall be
used. Other types require the approval of Lyondell.

8.4 An air supply regulator used for common service of more than one control valve shall not be
acceptable.

8.5 As a minimum, the actuator shall be sized to provide ANSI Class IV shutoff, unless the
application calls for a tighter shutoff.

9.0 POSITIONERS AND RELAYS

9.1 Digital (Smart) valve positioners shall normally be used except where specifically exempted by
Lyondell.

9.2 All positioners shall be equipped with a three-gauge manifold and bypass, except for split range
applications, piston operators, and electro-pneumatic positioners or applications where 3-15 psig
(0.02-0.1 MPa) will not fully stroke the valve. Electro-pneumatic positioners shall be equipped
with two gauges.

9.3 A 2 in. (50 mm), 0-30 psi (0-0.2 MPa) gauge shall be mounted on each diaphragm-actuated
control valve where a positioner is not furnished.

9.4 Accessories, such as limit switches, air sets, and solenoid valves, shall be rigidly mounted and
bracketed to the valve. Three-eighths inches (9.5 mm) 316 SS tubing shall be furnished to pipe
air users integrally mounted on the control valve.

10.0 ELECTRICAL ACCESSORIES

10.1 Three-way direct-acting solenoid valves shall normally be used to actuate control valves when
interlocked with failsafe or shutdown circuits. Solenoid valves shall be piped directly to the
valve actuator (i.e., if a positioner is installed, piping between the positioner and the actuator
diaphragm port). The vent port of the solenoid valve shall be piped so that moisture does not
enter the valve. Vents shall have bug screens. If a manual reset solenoid valve is used, it shall
incorporate a lever-type latch. Outdoor installations shall be weatherproof. Pilot-operated
solenoids shall not be used without written approval of Lyondell.

10.1.1 Molded coils for solenoid valves shall be specified for continuous operation at 110% of rated
voltage and suitable for operating temperatures up to 220°F (105°C). The coil housing shall be
compatible with the electrical area classification in which it is installed. DC coils shall be rated at
24 volts. AC coils shall be rated at 110 volts.

10.1.2 Valve bodies for solenoid valves shall be in accordance with ES 320, when used in process lines.
The Manufacturer’s standard brass shall be used on air service.
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10.1.3 Valve action shall be determined such that, when the coil is de-energized, the control valve will
move in the failsafe direction, except where interlock requirements dictate otherwise. Universal
(reversible ports) shall be used.

11.0 ELECTRICAL MOTOR-OPERATED VALVES

11.1 A torque limit switch shall be used as a backup switch to stop the motor when the valve is at full
limit. Limit switches shall be furnished for stopping the motor and controlling lights, which
indicate the limit of the valve stroke.

11.1.1 Field activation, if required, shall consist of two illuminated push buttons for local control of
each motor operated valve. Their nameplates shall be marked “OPEN” and “CLOSED” colored
green and red respectively.

11.1.2 Enclosures shall be in accordance with area electrical classification.

12.0 HYDRAULICALLY OPERATED VALVES

12.1 Use of hydraulically operated valves shall be approved by Lyondell.

12.2 If a hydraulic manifold is rigidly piped, it shall be connected to the hydraulic fluid supply and
return headers by a flexible hose.

12.3 A parallel oil filter/strainer that is suitably piped and valved shall be provided so that either can
be removed and cleaned without shutting off the supply of hydraulic fluid.

12.4 Vent valves shall be provided at high points in the hydraulic fluid system.

12.5 Automatic fluid-trapping valves shall be provided to lock the fluid in the cylinders to prevent
valve movement in the event of hydraulic system failure.

13.0 SELF-ACTUATED REGULATORS

13.1 Self-actuated control valves shall usually be limited to a maximum regulated pressure of 600 psig
(4.1 MPa) and a maximum valve size of 6 in.

13.2 Self-actuated valves shall only be used for the following services:

a. Where a variation of 5% above or below the setpoint is not objectionable.

b. For governors on steam-driven reciprocating pumps.
c. Reducing the pressure of fuel gas to heaters.
d. Gas blanketing.
e. Vapor recovery.
f. For instrument and plant air system.

13.3 Due to the presence of threaded sensing ports typically found on self-actuated regulators, they
shall not be applied to Phosgene or Chlorine service without approval by Lyondell.
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RECORD OF REVISIONS
(as compared to March, 2000 issue)

3.14 Added new paragraph.

4.3 Revised paragraph.

4.5.2 Revised paragraph.

4.6.1 Revised paragraph.

4.7 Added new paragraph.

4.8 Added new paragraph.

4.9 Added new paragraph.

7.1.6 Revised paragraph.

13.3 Added new paragraph.