Air Control Valve

7/29/2019 Air Control Valve

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NATIONAL AEROSPACE LABORATORIES

BANGALORE

SPECS: NAL/PR/HSCTF-AUG-CV_AIR/JAN-2008

Specifications for the

Control Valvefor

High Pressure Air


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CONTENTS

1. Standard Specification2. Deviation list

3. List of commissioning spares4. List of 2 years spares5. Data sheet for pressure & flow6. Data sheet for control valve7. Schematic of the air supply & regulation system8. Control time


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1.0 INTENT OF SPECIFICATION

This specification is intended to cover the design, manufacture, assembly,testing at vendor's works; delivery including packing, crating in road, freight,insurance, all taxes & duties and other charges as applicable for the globe typecontrol valve and all accessories specified in the scope of supply and as

required for safe and trouble free operation for the NAL Combustor TestFacilities, NWTC, NAL, Bangalore560 037, Karnataka, India.

It is not the intent to completely specify all the details of design and constructionherein. Nevertheless, the control valve shall conform to high standards ofengineering, design and workmanship in all respects and shall be capable ofperforming satisfactory in continuous operation under the specified operatingcondition.

2.0 SCOPE OF SUPPLY AND EXCLUSIONS

This specification together with the data sheet enclosed herewith covers thebasic requirement of design and supply of the control valve.

a. Supply of the control valve with actuator and its accessories such aselectronic position transmitter, positioner, solenoid valve, I/P converter,manual hand wheel, air filter regulator, companion flanges, gaskets, nuts,bolts etc. as specified in this specification sheet/data sheet and any othertechnical attachment sheet herein.

b. Engineering and submission of documents as mentioned in clause.8.0

c. Supply of two year's operational spares for trouble free operation as perFORMB with unit price of each item.

d. Supply of commissioning spares as per FORM - C.

e. Suggestion/ Supervision for erection and commissioning, site testing andcalibration of equipment supplied under this specification is optional.

f. Installation at site is excluded.


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2.0 CODES AND STANDARDS

The following codes and standards are for design, construction, testing &qualifications

1. ISA 75.01.01, 75.02, 75.03, 75.08.06, 75.11.01, 75.13, 75.19.01, 75.25.01and 75.25.02

2. ASTM F1985-99 (2005)

3. ANSI B 16.34, B 16.5

4. BS 6755

5. OSHA

6. NEC

7. IEC

8. NEMA

3.0 VENDOR'S RESPONSIBILITY

a) Proper sizing and selection of valve with suitable capacity (CV) andrangeability for the process conditions specified in the data sheets. Sizingcalculation shall be submitted with the offer.

b) Actuator to meet operational and shut-off differential pressure. Calculation,for selection to be given with the offer.

c) The data sheet indicates the materials of construction for various items likebody, trim, packing and other parts. However, this does not absolve thevendor of the responsibility for proper selection of materials for wetted partsand accessories so as to be compatible with the process fluids and its

operating conditions. Reasoning is to be given if deviated from specification.

d) Checking and proper treatment for noise and ensuring that the body velocityis within the permissible limits.

e) The control valve and its accessories to be supplied under this specificationh ll t th t d f ifi d i th l d d t


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4.0 VALVE CONSTRUCTION

4.1 GENERAL

The control valve shall be supplied complete with actuator and accessories(such as positioner with pressure gauges, position transmitter, solenoid valve,air filter regulator with pressure gauges, hand wheel, etc.) in assembled

condition. Accessories shall be securely mounted and easily removable formaintenance works.

Control valve shall be provided with SS valve stem travel indicator (0-100%graduation with open and close marking).The control valve on failure will moveto safe end position as per process requirement.

Quantity, type and service conditions of the control valve to be supplied under

this specification shall be as per the enclosed data sheet.

The schematic of the air supply & regulation system along with the control valveis shown in Fig -01.

4.2 BODY

The valve body rating should be equal to or better than the flange ratingspecified in the data sheet. Castings shall be free from injurious blowholes,porosity shrinkage faults, cracks and other faults. Repairs of any nature on suchdefects are not acceptable. Bonnets shall be of the same material as the valvebody and integral or bolted type construction. Threaded bonnets are notacceptable.

The flow direction shall be clearly marked on the valve body.

The Air line size on which the valve is to be mounted is 219.1 mm OD (8), schXXS (22.2 mm thick).

End connectionsa) Flanged end connections shall be as per ANSI B16.5

b) Flanged face finish be serrated concentric to ANSI B 16.5


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4.3 TRIM

The valve is sized on the basis of being installed "flow tending to open".(preferred). Wherever stelliting of trim is specified in data sheet, it stands forstelliting of the complete plug unless otherwise mentioned.

Guide bushing shall be of a sufficiently hard material to resist side thrust on plug.

Metal to metal seating shall be used when drop tightness is required. Packingmaterial of Teflon seal shall generally be used if the operating temperature isless than 200 C.

4.4 ACTUATOR

Linear actuator, piston/ diaphragm type, single acting, spring return, fail safe toclose position shall be used. The actuator shall be normally closed which willopen on actuation.

Actuator sizing shall be such that it must be capable to generate power to strokethe valve through its full travel at 125% of maximum pressure drop condition

within specified stroke time. The response time shall be 4 s for 8 valves fromzero position to a specified position including 100% opening.

End connection for command gas test where Instrument Air at 10 bar is used,shall be

NPT(F) to ANSI B 1.10.1.

Nylon reinforced neoprene shall be used as diaphragm material. Piston rod shallbe of SS. Valve actuators shall be capable of operating at 50 C ambientcontinuously. Castings shall be of the type to suit individual area environments.

Vendor shall guarantee that the size of the actuator is adequate to meet theoperating thrust requirement for the control valve under extreme condition.Calculation for selection of actuator size shall be submitted along with the offer.

SS304L/ SS316L tubes of size " OD shall be used for pneumatic tubing. Allthe fittings shall be made of SS304L/ SS316L and double compression type.


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Actuator shall be of removable type for maintenance work.

The control time tcontrol shown in Fig-2 must be less than 8seconds.

5.0 SIZING AND NOISE CALCULATION

Control valve sizing shall be based on ISA S 75.01 or Vendor's sizing formula.And the sizing calculation shall be submitted along with the offer.

In general control valve shall be sized to obtain the valve opening as belowAt maximum flow about 90% openAt normal flow about 75% open

At minimum flow about 20% open

Vendor shall calculate the predicated noise level in a weighted sound levelmeasured at a point, which is one metre downstream of the valve and one metrefrom pipe surface. Maximum noise level shall be limited to 85 dBA as per OSHAguide line. Necessary diffusing device shall be used to achieve this noise level.

If predicted noise level exceeds 85 dBA, noise reduction treatment shall be

carried out. Only source treatment for noise shall be carried out, no pathtreatment is acceptable.

6.0 ACCESSORIES

All the electronic accessories shall have explosion proof enclosure.

6.1 POSITIONER and I/P CONVERTER

I/P CONVERTER:


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SL Item Details

1.

2.

3.

4.

5.

Command gas supply at inlet

Excitation signal

End connection for commandgas

End connection for electricalconduits

Safety

Instrument quality Air at 10 bar (Suitablepressure regulator with filter shall beincorporated)

4 20 mA with digital signal super-imposed

HART protocol.

NPT(F) to ANSI B 1.20.1


All the electronic components are to beintrinsically safe compatible for Kerosene/Gasoline environment in conformation withEex ia IIC T1, Zone 1, EN 50020 of IEC/CENELEC.

Pneumatic positioner shall be of force balance type and shall be side mounted onthe yoke of the valve. The valve shall be operated on 0.2 Bar to 1.0 Bar controlsignal. Positioner shall be easily field convertible from direct to reverse acting.Positioner shall be provided with bypass where output signal to valve actuator issame as input signal.

Every positioner shall have three nos. of 2" pressure gauges mounted on it, oneeach for air supply, control signal and output to actuator. Overall accuracy shall be+ 1.0% of stroke. Dead band shall be 0.5% of the signal range. Input, output andair supply pressure gauges, bypass valve, cam to modify the valve characteristics

shall be supplied in assembled condition.

This shall be reputed make. Make shall be indicated in the offer.

6.2 ELECTRONIC POSITION TRANSMITTER


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not be of variable resistance type. This shall be reputed make. Make shall beindicated in the offer.

The valve shall employ a position transmitter to indicate the percentage status ofthe valve.

Item Details

1.

2.

3.

4.

Power supply input

Signal output

Safety

End connections for electricalconduits

24 V dc

4 20 mA with digital signalsuperimposed HART protocol.

Same as that of I/P converter as above.


Apart from the provision for the remote position transmission, a local positionindicator (with a pointer and a graduated scale) shall be provided.

6.3 HAND WHEEL

Removable/ lockable hand wheel shall be provided for manual operation. Thisshall be either of continuous connection type (bell crank lever) or the helical geartype in relation to the efforts necessary to operate the valve. Clockwise rotation ofthe valve will close the valve. A hand wheel disconnecting system or thepossibility to operate manual control shall be provided. A blocking device for thehand wheel in any position shall be provided. Hand wheel diameter shall beappropriately chosen.

6.4 AIR FILTER REGULATOR

Vendor shall provide air filter regulator with 2" size outgoing air pressure gaugesuitable for reduction in air pressure from 6 12 bar to valve spring range fordiaphragm actuator. Regulation shall not be less than 97%.


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6.5 SOLENOID VALVE

Solenoid valve shall be provided in the instrument air supply line to positioner,which will be required for interlocking/ emergency operation. The service gas shallbe Instrument Air at 10 Bar. The solenoid configuration shall be 3 port, 2 way,direct acting type. Solenoid Excitation voltage shall be 24 V dc. The solenoid shallbe suitable for Maximum operating differential pressure of 10 Bar and safe staticpressure of 20 bar.

Electrical connection shall be terminated in a explosion proof junction box.Terminal connection of 1.5 sq. mm and cable entry of " NPT (F) shall beconsidered. Internal termination type coil shall have a power rating of 12 W percoil.

Mounting shall be on the actuator's body. End connection for gas shall be NPT(F) to ANSI B 1.20.1. End connections for electrical conduit shall be NPT (F) to

ANSI B 1.20.1. Material of the body shall be of brass. Diameter of the hole shallbe sufficient to guarantee the stroke time of the valve. Port size of the solenoidvalve for pneumatic valves shall be adequate capacity for quick operation of thevalve. This shall be reputed make. Make shall be indicated in the offer.

7.0 NAME PLATE

The control valve shall have a SS nameplate attached firmly to it at a visible place

furnishing the following information.

a. Tag No.b. Manufacture's name/trade mark.c. Manufacture's model No. and serial No.d. Pressure and temperature designe. CVf. Body material and sizeg. Trim material and sizeh. Valve characteristicsi. Stem travelj. Valve action on air failure.k. Operating signal range.


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physical and chemical properties, of the principal pressure-bearing parts shallbe provided.

Visual inspection for quantity, conformity with specification, supply ofaccessories etc. and dimensional check as per vendor's drawing.

Body mount leak test as per vendor's standard

Actuator leak test Air at 1.5 times the maximum working pressure Seat leakage test as per ANSI

Calibration test with positioner for stroke linearity, hysteresis etc.

Test on accessories for proper operation.

CV test to be carried out if specially called for in the specification.

Inspection shall be carried out by agencies like Lloyds, Beuro Veritas, BIE,

TUVs or equivalent competent authority with ISO certification for inspection.The inspection shall be carried out by the inspection agency as per approvedQAP. The QAP is to be generated and submitted to NAL for approval. QAPshall list clearly all stages of inspection of third party and NAL.

Material certificates:

The material certificates, detailing the physical and chemical properties, of the

principal pressure-bearing parts as well as all the parts shall be provided.

Welding joint test:

Any butt welding joint in the valve shall be subject to radio-graphic test with X-raysto 2-T sensitivity.

Soundness test for casting:

All the castings shall be subject to soundness test with radiographic or ultrasonictechnique for flaw detection.

Hydraulic shell pressure test:

Th l i t bl ith th b ll i ti ll iti h ll b


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Pneumatic shell pressure test:

The valve, upon final assembly including the bellows, in partially open position,shall be subjected to the pressure test by dry air or GN2 at 1.1 times themaximum rated working pressure of the particular pressure rating class of thevalve. The test procedure and acceptance criterion shall be as per Rate A of BS6755 Part 1 / equivalent

Hydraulic seat pressure test:

The valve, in closed position, shall be subject to pressure test with water (withsuitable corrosion inhibitor) at 1.1 times the maximum rated working pressure ofthe particular pressure rating class of the valve. The test procedure and theacceptance criterion shall be as per ISA-75.19.01-2001 orRate A of BS 6755 Part1 / equivalent

MSLD shell leak test:

The globe leak rates across body shall be measured with GHe MSLD to establishthe leak tightness values specified above by hood technique as per article 10,section V, ASME. The leak test shall be performed by shrouding the entire outsidesurface of the valve with a plastic bag to hold GHe at a positive pressure and byevacuating and connecting the inlet/ outlet port to MSLD. Leak test by detectorprobe or tracer probe technique is not acceptable.

MSLD seat leak test:

The global leak rates across seat shall be measured with GHe MSLD to establishleak tightness values, specified above by hood technique as per article 10, section5, ASME. The leak tests shall be performed by pressurizing the inlet with GHe,and by evacuating and connecting the outlet to MSLD. Leak test by detectorprobe or tracer probe technique is not acceptable.

Functional Tests:

The valve with all accessories mounted shall be subject to functional test tovalidate the performance.


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Permissible leak rate across seat

Class IV for hard seated valves as per ANSI

Marking:

All the valves are assigned tag numbers for the sake of identification. The tag

number for each valve, as indicated above besides size, pressure rating class,material of construction etc., shall be legibly and indelibly engraved on the body ofthe valves.

Vendor shall complete all tests as above and submit internal inspection/testreports to NAL, at the time of intimation for inspection. All the items shall beinspected at vendor's work by NAL or their authorised representatives. Vendorshall provide all facilities/ assistance for inspection and testing by NAL

The valve shall be Globe type suitable for air service. The valve shall be suitablefor operating at 210 bar pressure and 50 Deg C. The valve shall be of Equalpercentage characteristic. End Connections shall be flanged as per ANSI B16. 5

8.0 INFORMATION REQUIRED WITH BID

8.1 Vendor's quotation shall include a Cv sizing calculation and detailed

specification sheet for the control valve which shall provide all the detailsregarding type, material of construction, range and accessories etc. Vendorshall submit calculation basis for selection of valve sizing, actuator size,noise level, relevant to process condition indicated in the data sheets.

8.2 Vendor shall bring out all the deviations, if any, from the specification andshall furnish in Deviation list. Vendor shall provide reason for the deviationswherever possible.

8.3 Vendor shall furnish catalogues/ literature for all models of valve, actuator,positioner and all accessories including CV curves, actuator sizing, and liftv/s flow charts.

8.4 Vendor shall also quote for Commissioning spares and Two years'


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c. Detailed dimensional drawings with bill of material and materials ofconstruction

d. Valve sizing calculations

e. QA/QC plan

f. Test certificate, inspection report, material test reports.

g. Installation drawing showing end connections, Operation and maintenancemanual.

8.6 Inspection will be carried out by NAL Engineer or their authorizedrepresentative at vendors place

9.0 DELIVERY

Tenderer shall indicate the delivery schedule along with the offer.

10.0 GENERAL REQUIREMENTS

The vendor shall provide following ordering information to order consumables andspare parts as required:

Description of item

Vendor's reference No.

Standard quantities recommended for start-up and normal operation.

Spare parts interchangeability records (SPIR) procedures.

The tenderer shall indicate a list of tools and tackle ( if any) which may berequired for maintenance, overhaul and replacement of needle valves.

11.0 GUARANTEE AND WARRANTY

The supplier shall give warranty for 2 years from date of commissioning forreplacing/ repairing of control valves from any kind of defect, material orworkmanship or malfunctioning within 14 days of observing the defect. The

li h ll i f f h bl f i f


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DEVIATION LISTFORM - A

SL SPEC./CLAUSE/ TAGNO.

SPECIFICATIONREQUIREMENTS

DEVIATION AND REASONFOR DEVIATION AND ITS

EFFECT ONPERFORMANCE/ALTERNATIVE SOLUTION

NOTES:


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LIST OF COMMISSIONING SPARESFORM-B

SL PART NO DESCRIPTION QTY UNIT RATE

NOTES:

1.


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LIST OF TWO YEARS SPARES

FORM-C

SL.NO. PART NO. DESCRIPTION QTY UNIT RATE

NOTES:

1.


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1. Data Sheet for the Required Pressure & Flow rates

Electro-pneumatic control valveSize 8Pressure Class #1500 (PN250)Leakage Class IV

Sl. Medium Type Line Size

Qty Pressure (bar) FlowRatekg/s

Inlet Outlet(regulated)

1. Air Globe

(With equalpercentage flowCharacteristics)

219.1

mm OD;22.2 mmthick

(8, schXXS)

1 No. 210

60

40 (max)

20 (min)

60

30

1.The valve is mounted on 8 sch XXS line. The outlet of the valve isconnected by an 8x 10 expander to 10 sch 40 line. The distancefrom control valve to the required injection point is about 40 m; theline size is 273 mm OD dia & 9.3 mm thick; the corresponding volume

available for air flow is ~2 m3

.

2. During a test of about 120 secs, the Control Valve upstream pressurefalls from 200 bar to 60 bar. The control valve must control the downstream pressure to the specified set value in the range 40 to 20 bar. For

l if th t th i 25 b th t l l h ld


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INSTRUMENT TAG NO. FCV-AIR-01

SERVICE FCV IN AIR FLOW LINE

LINE/EQUIPMENT NO. 219-AIR-CV-01

O FLUID AIR

P FLOW UNITS SERVICE SI MODULATING

E FLOW NORM FLOW MAX 30 kg/s 60 kg/s

R TEMP NORM TEMP MAX 33 C 50 C

A Pressure Class #1500 (PN 250)

T Pin NORM Pout NORM

I Pin MAX Pin MIN 210 Bar 20 Bar

O Pout MAX 40 Bar

N PR. DROP SHUTOFF DIFF

DIFF.PR allow DIFF PR MAX 190 Bar

Cv NORM Cv MAX * *

VALVE Cv LEAK CLASS * Class IV

D HYDROSTATIC TEST RQD.

A SEAT TIGHTNESS TEST RQD.

T FUNCTIONAL TEST RQD.

A IBR CERTIFICATION NOT RQD.

RADIOGRAPHIC TEST RQD.

PENETRANT LIQUID TEST RQD.

LINE SIZE/SCHED. SOUND LEVEL219.1 mm OD; 22.2 mm thick/

8" sch XXS


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Please see next two pages for Fig-01 and Fig-02


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SPECS: NAL/PR-HSCTR-AUG-CV_AIR/JAN-2008219 mm (8)_210 bar

21

PT

Fig-01: Air supply & Regulation system

210 bar; 2.5 cubic-m12 nos

TT PT

PT

P I D

30 to 60 kg/s;20 - 40 bar

PT PT PT


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SPECS: NAL/PR-HSCTR-AUG-CV_AIR/JAN-2008219 mm (8)_210 bar

22

Fig-02

PsetP

tt_control

Error< 0.8%P

t_control < 8 seconds

Documents

Air Control Valve