COMPLETE REVISION

March 2003

Process Industry Practices

Process Control

PIP PCCCV001
Selection of Control Valves
 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these
technical requirements into a single set of Practices, administrative, application, and
engineering costs to both the purchaser and the manufacturer should be reduced. While
this Practice is expected to incorporate the majority of requirements of most users,
individual applications may involve requirements that will be appended to and take
precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or engineering
situations should not be made solely on information contained in these materials. The
use of trade names from time to time should not be viewed as an expression of
preference but rather recognized as normal usage in the trade. Other brands having the
same specifications are equally correct and may be substituted for those named. All
Practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these Practices or guidelines
should conflict with OSHA or other applicable laws or regulations, such laws or
regulations must be followed. Consult an appropriate professional before applying or
acting on any material contained in or suggested by the Practice.

This Practice is subject to revision at any time by the responsible Function Team
and will be reviewed every 5 years. This Practice will be revised, reaffirmed, or
withdrawn. Information on whether this Practice has been revised may be found at
www.pip.org.

© Process Industry Practices (PIP), Construction Industry Institute, The

University of Texas at Austin, 3925 West Braker Lane (R4500), Austin,
Texas 78759. PIP member companies and subscribers may copy this Practice
for their internal use. Changes, overlays, addenda, or modifications of any
kind are not permitted within any PIP Practice without the express written
authorization of PIP.

PIP will not consider requests for interpretations (inquiries) for this Practice.
PRINTING HISTORY
October 1995 Issued
March 2003 Complete Revision
Not printed with State funds

Process Industry Practices
Process Control
PIP PCCCV001
Selection of Control Valves
Table of Contents
1. Introduction................................. 2
1.1 Purpose ............................................. 2
1.2 Scope................................................. 2
2. References .................................. 2
2.1 Process Industry Practices ................ 2
2.2 Industry Codes and Standards .......... 2
2.3 Government Regulations ................... 3
3. Definitions ................................... 4
4. Body - General ............................ 5
5. Globe Valves ............................... 7
6. Rotary Valves.............................. 9
7. Trim............................................ 10
8. Bonnet ....................................... 11
8.1 General ............................................ 11
8.2 Gaskets............................................ 12
8.3 Packing ............................................ 12
8.4 Bolting .............................................. 13
9. Sizing Considerations.............. 14
9.1 General ............................................ 14
Process Industry Practices
COMPLETE REVISION
March 2003
9.2 Pressure-Drop Determination for
Nonpumped Systems ...................... 14
9.3 Pressure-Drop Determination for
Pumped Systems............................. 15
9.4 Secondary Control Valves ............... 15
9.5 Operating Range ............................. 15
10. Noise Considerations .............. 15
11. Actuator .................................... 17
11.1 General ............................................ 17
11.2 Diaphragm Actuator......................... 19
11.3 Piston and Vane Actuators .............. 20
11.4 Volume Tank ................................... 20
12. Positioner/Current-to-Pneumatic
Transducer (I/P)........................ 21
13. Accessories .............................. 21
13.1 Handwheel Operator........................ 21
13.2 Limit Switches and Solenoid Valves 22
14. Marking, Identification, and
Nameplate ................................. 23
Page 1 of 24
PIP PCCCV001 COMPLETE REVISION
Selection of Control Valves March 2003

1. Introduction

1.1 Purpose
This Practice provides designers and vendors the requirements for the selection and
sizing of control valves.

1.2 Scope
This Practice specifies requirements for selection and sizing of pneumatically
actuated control valves, including requirements for body, bonnet, trim, actuator,
accessories, and noise considerations. This Practice, along with a completed
PIP PCSCV001, PIP PCECV001, and the individual control valve data sheets (i.e.,
ISA20 or equivalent), defines the minimum requirements for selection, materials,
construction, and installation of control valves. This Practice does not cover
requirements for motor-operated valves, on-off valves intended for emergency
isolation, or valves with hydraulic actuators.
Comment: The intention is that the owner will fill out the PIP PCSCV001
control valve specification sheet to define company and location
generic requirements for control valves.
This document is a complete revision of PIP PCCCV001, and therefore, revision
markings are not provided.

2. References
Applicable requirements in the latest edition (or the edition indicated) of the following
standards shall be considered an integral part of this Practice. Short titles will be used herein
when appropriate. The owner shall be informed if portions of this Practice do not comply
with referenced codes, standards, and regulations.

2.1 Process Industry Practices (PIP)

– PIP PCECV001 - Guidelines for Application of Control Valves
– PIP PCSCV001 - Specification of Control Valves
– PIP PCSIP001 - Instrument Piping and Tubing Systems Specifications

2.2 Industry Codes and Standards

• American Society for Mechanical Engineers (ASME)

– Boiler and Pressure Vessel Code, Section VIII, Division 1
– ASME B16.5 - Pipe Flanges and Flanged Fittings
– ASME B31.3 - Process Piping
• Fluid Controls Institute Inc. (FCI)
– ANSI/FCI 70-2- Control Valve Seat Leakage

Page 2 of 24 Process Industry Practices

COMPLETE REVISION PIP PCCCV001
March 2003 Selection of Control Valves

• The Instrumentation, Systems, and Automation Society (ISA)

– ISA20 - Specification Forms for Process Measurement and Control
Instruments, Primary Elements, and Control Valves
– ISA75.03 - Face-to-Face Dimensions for Integral Flanged Globe-Style
Control Valve Bodies (ANSI Classes 125, 150, 250, 300, and 600)
– ANSI/ISA75.04 - Face-to-Face Dimensions for Flangeless Control Valves
(ANSI Classes 150, 300, and 600)
– ANSI/ISA75.05.01 - Control Valve Terminology
– ANSI/ISA 75.08 - Installed Face-to-Face Dimensions for Flanged Clamp or
Pinch Valves
– ISA 75.08.04 - Face-to-Face Dimensions for Buttweld-End Globe-Style
Control Valves (Class 4500)
– ISA 75.08.07 - Face-to-Face Dimensions for Separable Flanged Globe-Style
Control Valves (ANSI Classes 150, 300, and 600)
– ANSI/ISA 75.15 - Face-to-Face Dimensions for Buttweld-End Globe-Style
Control Valves (ANSI Classes 150, 300, 600, 900, 1500, and 2500)
– ANSI/ISA 75.16 - Face-to-Face Dimensions for Flanged Globe-Style Control
Valve Bodies (ANSI Classes 900, 1500, and 2500)
– ISA 75.17 - Control Valve Aerodynamic Noise Prediction
– ANSI/ISA 75.22 - Face-to-Centerline Dimensions for Flanged Globe-Style
Angle Control Valve Bodies (ANSI Classes 150, 300, and 600)
• International Electrotechnical Commission (IEC)
– IEC 60534-8-3 - Industrial-Process Control Valves, Part 8, Noise
Considerations, Section 8: Control Valve Aerodynamic Noise Prediction
Method
– IEC 60534-8-4 - Industrial Process Control Valves, Part 8, Noise
Considerations, Section 8: Prediction of Noise Generated by Hydrodynamic
Flow

2.3 Government Regulations

• U. S. Environmental Protection Agency (EPA) Code of Federal Regulations

(CFR)
– EPA 40 CFR, Part 60, Appendix A, Attachment 1, Reference Method 21 -
Determination of Volatile Organic Compound Leaks
– EPA 40 CFR, Part 61 - Monitoring Requirements
– EPA 40 CFR, Part 63, Subpart H - National Emissions Standard for Organic
Hazardous Air Pollutants from Synthetic Organic Chemical Manufacturing
Industry Equipment Leaks
• U. S. Occupational Safety and Health Administration (OSHA)
– OSHA 1910.95 - Occupational Noise Exposure

Process Industry Practices Page 3 of 24

PIP PCCCV001 COMPLETE REVISION
Selection of Control Valves March 2003

3. Definitions
The following terms and their definitions are derived from ANSI/ISA75.05.01:

ball valve: a valve with a rotary motion closure member consisting of a full ball or a
segmented ball

butterfly valve: a valve with a circular body and a rotary motion disk closure member,
pivotally supported by its stem

closure member: the movable part of the valve that is positioned in the flow path to modulate
the rate of flow through the valve. Examples include the plug for a plug valve, the disk for a
butterfly valve, and the ball for a ball valve.

eccentric rotary disk: a spherical segment in a rotary motion valve that is not concentric with
the disk shaft and moves into the seat when closing

equal percentage characteristic: an inherent flow characteristic, which, for equal increments
of rated travel, will ideally give equal percentage changes of the existing flow coefficient
(Cv)

flangeless control valve: a valve without integral line flanges, which is installed by bolting
between companion flanges, with a set of bolts, or studs, generally extending through the
companion flanges

full ball: a closure member having a complete spherical surface with a flow passage through
it. The flow passage may be round, contoured, or otherwise modified to yield a desired flow
characteristic.

globe body: a valve body distinguished by a globular-shaped cavity around the port region,
wherein the closure member motion is linear and normal to the plane of the port

lugged body: a thin annular section body with lug protrusions on the outside diameter of the
body, having end surfaces mounted between the pipeline flanges or attached to the end of the
pipeline without any additional flange or retaining parts, using either through bolting and/or
tapped holes

plug valve: a valve with a closure member that may be cylindrical, conical, or a spherical
segment

segmented ball: a closure member that is a segment of a spherical surface, which may have
one edge contoured to yield a desired flow characteristic

travel: the movement of the closure member from the closed position to an intermediate or
the rated full open position

wafer body: A thin annular section butterfly body having end surfaces located between the
piping flanges and clamped there by bolts extending from flange to flange

Page 4 of 24 Process Industry Practices

COMPLETE REVISION PIP PCCCV001
March 2003 Selection of Control Valves

4. Body - General
4.1 Material, end connections, pressure rating, gaskets, and packing of valve body shall,
as a minimum, conform to the applicable piping specification. The materials
engineer shall approve any deviation from the piping specification.
Comment: Special alloy bodies that differ from the piping specification may be
required in conditions such as high temperature, severe
erosion/corrosion, or critical applications such as oxygen.
4.2 Valves shall not be cast iron. Carbon steel shall be the minimally acceptable material
on control valve bodies.
4.3 Control valves in flashing water service require harden body material such as
5 Cr-1/2 Mo.
4.4 Ratio of nominal pipe size to body size shall not be greater than 2:1.
4.5 Valves 1 inch and larger shall not be screwed.
4.6 Valves with welded end connections shall be approved by the owner.
Comment: Welded valves are often used in high-pressure steam applications
and in high-temperature applications.
4.7 Flanged connections shall be required in the following services:
• Flammable, toxic, or lethal services
• Services above 400ºF
• Where subject to deep thermal cycling
• Where steam pressure is greater than 50 psig
• Where fire-safe design is required
4.8 Control valve body size shall not exceed the line size.
4.9 Body sizes 1-1/4, 2-1/2, 3-1/2, 5, or higher odd numbers shall not be used. If valve
calculations indicate a requirement for such sizes, reduced trim shall be used in
standard size valve bodies, i.e., NPS 3 valve with 2-1/2-inch trim.
4.10 Face-to-face dimensions of valve body shall conform to ISA standards in accordance
with the following Table 1:
Table 1 - Valve Body Face-to-Face Dimensions
Body Style ISA Standard
Globe-style with integral flanges ISA75.03 or ANSI/ISA75.16
depending on ANSI class rating
Globe-style with separable flanges ISA75.08.07
Flangeless ISA75.04
Buttweld-end globe ISA75.08.04 or ANSI/ISA 75.15
depending on ANSI class rating
Globe-style angle flanges ISA75.22

4.11 Flanged connections shall be raised face (RF), conforming to ASME B16.5.

Process Industry Practices Page 5 of 24

PIP PCCCV001 COMPLETE REVISION
Selection of Control Valves March 2003

4.12 Flanges with tag welds or flanges with partial penetration welding are not
acceptable.
4.13 Flangeless valves shall have centering means (e.g., lugs, holes, or equivalent) to
ensure proper alignment of valve and gasket. Valve body gasket surface areas shall
be the same as that of the mating flanges.
4.14 Separable flanges must be approved by the owner. The manufacture shall supply a
permanent, yellow tag on the valves with separable flanges that can rotate when the
bolts are loosened. The tag shall be inscribed with the following statement:
“Warning - This valve has separable flanges and may rotate when bolts are
loosened. The actuator must be supported before loosening the bolts.”
4.15 If separable flanges are specified, the flange-retaining ring shall be zinc-plated or
shall be made of stainless steel.
4.16 Welding procedures, performance of welders, and welding operators shall meet the
requirements of ASME B31.3.
4.17 Only valves in critical applications that require minimum leakage shall have
ANSI Class VI seat leakage rating. Valves with this seat leakage rating shall be
submitted to the owner for approval before they are incorporated into the design.
4.18 Flow direction, where applicable, shall be permanently marked on the valve body.
4.19 Mechanically linked valves shall not be used for split process flows in lieu of three-
way valves.
4.20 Severe service valves (e.g., globe or angle with hardened trim, specially designed
multi-hole/path cavitation trim, or noise abatement trim) shall be used for
applications where conventional valves (globe, ball, butterfly, etc.) are not
appropriate because of loss of control characteristics over time. Examples of
conditions where severe service valves shall be considered are as follows:
• Liquid valves
Cavitation potential exists: (P1-P2)/(P1-Pv) > 0.6
Application is a flashing service: (P2 < Pv)
• Gas valves
(P1-P2)/P1 > 0.5
where
P1 is the upstream pressure;
P2 is the downstream pressure;
Pv is the vapor pressure of the process fluid at flowing temperature.

Page 6 of 24 Process Industry Practices

COMPLETE REVISION PIP PCCCV001
March 2003 Selection of Control Valves

4.21 Severe service valves shall be used in the following service applications:
• Intermittent letdown (e.g., high-noise, errosive service) in daily service
• Recirculation in daily service where cavitation is predicted
• Where high vibration and/or high noise is expected from the application
• Where history of valve failures or need for severe service trim exists

5. Globe Valves
5.1 Globe valves are acceptable for all applications and pressure classes listed in
Table 2, as follows.

Process Industry Practices Page 7 of 24

PIP PCCCV001 COMPLETE REVISION
Selection of Control Valves March 2003

Table 2 - Acceptable Applications for Valve Body Types

Body Type (Note 1)
Valve ANSI
Flange Wafer Rotary
Process Rating Globe Globe Eccentric E-Disc / Ball and
Characteristic (Note 2) (Straight) (Angle) Disc Segmental Plug
Ball
A. Process Gas or Liquid
1. Clean service = 150 M,S,O --- M,O M,S,O S,O
(liquid - no = 300 M,S,O --- M,O M,S,O S,O
cavitation or
= 600 M,S,O --- --- M,S,O ---
flashing)
> 900 M,S,O --- --- --- ---
(Note 4)
B. Process Liquid
1. Clean service = 150 M,S,O M --- --- ---
(cavitation or = 300 M,S,O M --- --- ---
flashing
= 600 M,S,O M --- --- ---
condition)
> 900 M,S,O M --- --- ---
2. Suspended = 150 --- M,S --- M,S S,O
solids (Note 6) (Note 7)
(erosive) = 300 --- M,S --- M,S S,O
(Note 3) (Note 6) (Note 7)
= 600 --- M,S --- M,S ---
(Note 6)
> 900 --- M,S --- --- ---
3. Corrosive = 150 M,S,O --- --- M,S,O M,S,O
(Note 8)
= 300 M,S,O --- --- M,S,O M,S,O
(Note 8)
= 600 M,S,O --- --- M,S,O ---
> 900 M,S,O --- --- --- ---
4. Viscous or = 150 --- --- --- M,S,O M,S,O
nonerosive = 300 --- --- --- M,S,O M,S,O
slurry
= 600 --- --- --- M,S,O ---
> 900 --- --- --- --- ---

Notes:
1. "M" indicates valves that are acceptable for modulating service;
"S" indicates valves that are acceptable for shutdown service;
"O" indicates valves that are acceptable for on/off service.
2. The ANSI flange rating relates to the pipe flanges for flangeless valves.
3. Valve selection for nonerosive suspended solids service is the same as that for process gas or liquid
(A1).
4. Utility (steam, air, water) valve selection is the same as that for process gas or liquid (A1 and B1).
5. Control valves used in streams that have a combination of the above process characteristics or
process characteristics not listed shall be selected according to project requirements.
6. Valve must be installed in accordance with the manufacturer's recommendation.
7. Full port valves only.
8. Plug valves are acceptable in corrosive service. Ball valves are not typically available in corrosion-
resistant materials.

Page 8 of 24 Process Industry Practices

COMPLETE REVISION PIP PCCCV001
March 2003 Selection of Control Valves

5.2 Single-seated globe valves are required unless otherwise approved by the owner.
5.3 Cage guiding shall not be used in applications with suspended solids. Globe valves
shall be used for high-pressure-drop applications, low-flow applications, clean liquid
and gas service applications (corrosive and non-corrosive), and clean liquid service,
particularly where cavitation, flashing, or noise are design considerations.
5.4 Globe valves with split bodies shall not be used unless otherwise approved by the
owner.
5.5 To reduce the exit velocity of the valve and to dissipate energy, control valve bodies
in the following applications shall be no smaller than one size less than line size.
Comment: The proper reduced trim size must also be specified in these severe
service applications:
• To reduce the valve body liquid flow velocity below a
maximum of 33 ft/sec
• To reduce the valve body gas/vapor outlet velocity below a
maximum of 0.3 Mach
• When the calculated noise not including special noise trim or
other noise reduction methods exceeds the maximum
continuous operating noise level entered on PIP PCSCV001
data sheet.
Comment: Velocity must be below 0.3 Mach for
effective noise treatment.
• Choked flow services
• Flashing services
• Erosive services maximum velocity shall not exceed 20 ft/sec

6. Rotary Valves
6.1 Rotary valves include all types of ball or plug valves (e.g., ball, segmented ball) and
butterfly valves (e.g., eccentric disk). Rotary valves are acceptable for all
applications and pressure classes listed in Table 2.
6.2 Rotary valves in applications where cavitation or high-noise conditions are present
require approval by owner. These applications normally use a globe valve.
6.3 Flangeless valves shall have centering guides to ensure proper alignment of valve
and gasket.
6.4 Flangeless and wafer-style valves shall not be used in toxic and/or highly corrosive
services.
6.5 Flangeless valves that exceed a body width of 5-1/2 inches shall be subject to owner
approval. Lugged body flanges shall be through-bolted. Threaded lugged flanges
require owner approval.
6.6 Unless otherwise specified, the valve shaft shall be oriented in the horizontal plane.

Process Industry Practices Page 9 of 24

PIP PCCCV001 COMPLETE REVISION
Selection of Control Valves March 2003

6.7 Rotary valves shall be designed such that a mechanical failure will not expel the
shaft of the stem from the valve body.
Comment: When the stem breaks and is expelled from the valve, a leak path
develops that is equal to the cross section of the stem. This failure
scenario has caused considerable damage to plants. Since
maintenance may remove the actuator while under pressure, the
preferred mechanism to retain the stem should be independent of the
actuator. If the actuator is used to retain the stem, the valve shall
have a tag that states this possibility as a warning statement.
6.8 The actuator end of the valve stem shall be the spline or keyed design. Shear pins are
not acceptable. Shafts shall be made of one piece. The shear safety factor shall be a
minimum of 150% at the specified shutoff-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.
6.9 The valve shaft bearing shall be designed to prevent the shaft guide bushing from
rotating in the valve body.
6.10 Bearing material shall be selected to prevent galling of the bearing or valve shaft and
to operate at the maximum and minimum process temperatures.
6.11 The valve disk and shaft for lined, carbon steel, and stainless steel valves shall be
made of stainless steel. Other trim parts shall also be made of stainless steel, as a
minimum, or of material that meets the process requirements.
6.12 Because the disk in wafer-style valves may project beyond the valve body during
part of the disk rotation, clearance shall be maintained between the disk and the pipe
wall, particularly if the pipe is of heavy wall construction.

7. Trim
7.1 For maximum allowable control valve seat leakage, refer to PIP PCSCV001 control
valve specification sheet. On individual valves, the maximum allowable seat leakage
ANSI/FCI 70-2 Class shall be stated on the individual control valve data sheet.
7.2 Control valves that must provide a tight shutoff (TSO) shall be an ANSI/FCI 70-2
Class V or better. The actual leakage rate shall be communicated to the process
engineer for approval.
Comment: This requirement does not pertain to isolation valves and safety
valves. Leakage requirement for these valves must be defined
individually by process requirements.
7.3 Because of close tolerances between the cage and plug, cage trim valves shall be
used only in clean liquid, vapor, or gas service.
7.4 Cage-guided trim in dirty services shall be subject to owner approval.
7.5 Trim shall be 13 Cr (400 series SS) as a minimum for control valves with cage-
guided design and for other valves where such metallurgy is of standard
construction.

Page 10 of 24 Process Industry Practices

COMPLETE REVISION PIP PCCCV001
March 2003 Selection of Control Valves

7.6 Trim for valves in services that contain erosive or solids-bearing fluids shall be
hardened with a minimum hardness of 38 Rockwell C.
7.7 Trim material shall meet the requirements of Table 3 as a minimum.
Table 3 Hardened Trim Applications
Flowing dP psid Gases Steam Water HC Liquids
0-100 1 2 1 1
100-200 1 2 4 2
200-400 1 2 4 4
500-600 1 3 4 4
600-800 1 3 4 4
800-up 1 3 4 4

1 = Manufacture’s standard valve trim (316 or 400 series

stainless minimum)
2 = 400 series stainless minimum
3 = Stellite trim (alloy 6 or 316/alloy 6 overlay for the seat
ring and plug)
4 = Standard trim 400 series stainless or hard-faced stellite
unless valve is cavitating or flashing.
• If cavitating, use anti-cavitating trim or harden trim
according to the manufacturer’s
recommendation.
• If flashing, use harden trim (stellite, 440C, or
Colmonoy® 6)

7.8 Valve stem and plug shall be pinned and welded or be of a one-piece design.
7.9 Threaded trim parts, except seat rings, shall be pinned or spot-welded to supplement
the threaded attachment.
7.10 In erosive or corrosive services, self-flushing valves shall be preferred instead of
permanent flushing connections built into the control valve.
7.11 Permanent flushing connections shall be subject to owner approval.
7.12 Valves that require cavitation or noise trim shall be submitted to the owner for
approval. Do not use small passage cavitation/noise trim on processes that contain
particulates, solids, or plugging material.
Comment: To avoid plugging, conical strainers shall be considered for
installation upstream of valves with anti-noise or anti-cavitation
trim.
7.13 If operating temperature exceeds 700°F, guide post areas and rings shall be hard-
faced stellite or equivalent.

8. Bonnet

8.1 General
8.1.1 The bonnet shall have a bolted design.
8.1.2 Extended or finned bonnet shall be used for service temperatures below 0°F
and above 750°F.

Process Industry Practices Page 11 of 24

PIP PCCCV001 COMPLETE REVISION
Selection of Control Valves March 2003

Comment: Extended bonnets may be avoided in processes above 400°F

and below 750°F if graphite-based or other high-temperature
packing is used.
8.1.3 Bonnet bolts shall not be used to attach actuators or mounting brackets.

8.2 Gaskets
8.2.1 Default bonnet gasket material shall be as specified on the PIP PCSCV001
control valve specification sheet.
8.2.2 Bonnet gasket shall be compatible with the process, the maximum
temperature, and maximum pressure. The gasket material shall be in
compliance with the piping specification.
8.2.3 Gaskets containing asbestos are unacceptable.
8.2.4 If the valve is required to be fire safe, the following materials are considered
fire safe:
• Metal gaskets
• Flexible graphite gaskets

8.3 Packing
8.3.1. Packing material shall be compatible with piping specification.
8.3.1.1 Packing shall not require lubrication.
8.3.1.2 The cooling effects from use of an extended bonnet shall not be
taken into account when selecting the packing.
8.3.1.3 Packing material containing asbestos is unacceptable.
8.3.1.4 For applications in temperatures above 750°F, an extended bonnet
shall be used to protect the positioner and actuator from heat.
8.3.1.5 See the PIP PCSCV001 control valve specification sheet for packing
type for non-fugitive emission and fugitive emission versus process
temperature.
8.3.1.6 Packing shall conform to vendor’s sizing and selection criteria for
temperature/pressure curves. The packing material shall be in
compliance with the piping specification.
8.3.1.7 For fire-safe applications, graphite-based packing shall be used.
8.3.1.8 Bellow seals shall require owner approval.
8.3.2 Fugitive emissions considerations are as follows:
8.3.2.1 Packing shall limit fugitive emissions. Fugitive emissions of any
substance containing more than 5% by weight of volatile hazardous
air pollutant as defined in the EPA 40 CFR, Part 63, shall be limited
in accordance with the applicable local regulation or limited to a
maximum of 500 parts per million, whichever is more stringent.

Page 12 of 24 Process Industry Practices

COMPLETE REVISION PIP PCCCV001
March 2003 Selection of Control Valves

8.3.2.2 Determination of leaks and monitoring requirements shall comply

with EPA 40 CFR, Parts 60 and 61, respectively.
Comment: Methods of meeting the above-mentioned
requirement include application of twin packing
designs, live-loaded packing, and bellows seals.
Bellows seals, while relatively expensive, should be
considered for cases in which no leakage across the
stem can be tolerated or for cases in which excessive
packing friction results in unreasonably large
packing friction forces.
Comment: Increased emphasis on limiting packing leaks has
resulted in the development of new packing
materials and methods. Valve vendors are offering
increasingly effective designs, and they should be
consulted for recommendations on specific fugitive
emission control applications.
Comment: To meet fugitive emissions, the stem should be
finished to a maximum of 8 microinches RMS.
Smooth finish assists in reducing fugitive emissions
over service life of control valve.
8.3.2.3 Packing design shall be approved by the owner before
implementation.
8.3.2.4 Control valves shall be designed, selected, and installed to permit
easy access of monitoring packing areas prone to fugitive emissions
without removing equipment or devices.
8.3.2.5 PIP PCSCV001 control valve specification sheet, which indicates
the testing criteria, identifies whether fire-safe packing is required.

8.4 Bolting
8.4.1 Vendor-recommended bonnet bolts shall be used unless owner specifies
differently.
8.4.2 Valve bonnets shall be bolted type with a retained-type gasket.
8.4.3 Plated bolting material shall not be used for pressure-containing parts.
8.4.5 The following valve components shall be 304 or 316 SS minimum:
• Gland studs and nut (e.g., packing bolts)
• Packing flange and follower
8.4.6 Packing glands and followers shall be bolted for valves larger than 1 inch.
8.4.7 Carbon steel screwed packing followers shall not be acceptable.

Process Industry Practices Page 13 of 24

PIP PCCCV001 COMPLETE REVISION
Selection of Control Valves March 2003

9. Sizing Considerations

9.1 General
9.1.1 Valve-sizing procedure shall address the full range of expected flow
conditions. Appropriate differential pressure shall be applied as load
changes. Flow equations specified in PIP PCSCV001 control valve
specification sheet shall be used.
9.1.2 When sizing a valve, only the characteristcs of the plug shall be considered
for an accurate understanding of the plug stroke at the various conditions. A
positioner with characterization such as equal percentage may be used on
trim with an inherent linear characterization to enhance control.
9.1.3 Linear trim design shall be preferred if pressure drop across valve does not
vary more than 20% between maximum flow and minimum flow; i.e.,
dP(max flow) – dP(min flow)/dP(min flow)<20%. This practice typically
achieves an installed linear characteristic. If the linear valve does not have
sufficient rangeablilty to meet the minimum and maximum conditions, an
equal percentage valve is prefered.
9.1.4 The manufacturer shall be consulted in sizing of a two-phase, liquid-vapor
mixture.
9.1.5 Body outlet velocity, defined as the fluid velocity at the discharge flange of a
control valve, shall not exceed the following:
• 0.3 Mach for gas, vapor, and steam services except in vacuum services
• 0.4 Mach for infrequent services (i.e., services for which the control
valve is closed for more than 4 hours during an 8-hour shift, including
emergency vent and emergency depressurizing services)
• 33 ft/sec for liquid services other than water
• 18 ft/sec for water service
• 20 ft/sec for erosive fluid (e.g., those that contain errosive particles)
Comment: Oversized control valve bodies with reduced trim may be
required to meet these limits.
Comment: If manufacturer’s plug guiding or construction governs
maximum allowable velocities, manufacturer’s
recommended lower velocities shall be used.
9.1.6 Final valve sizing shall be confirmed by valve manufacturer and shall be
approved by owner.

9.2 Pressure-Drop Determination for Nonpumped Systems

Control valves shall be sized for a minimum pressure drop of 20% of variable system
pressure drop, excluding drop across control valves.

Page 14 of 24 Process Industry Practices

COMPLETE REVISION PIP PCCCV001
March 2003 Selection of Control Valves

9.3 Pressure-Drop Determination for Pumped Systems

9.3.1 The pressure drop shall be adequate to provide control at all process
conditions including start-up.
9.3.2 Primary control valves shall have a minimum pressure drop that is the
greater of the following:
• 15 psi
• A minimum of 30% of the total system pressure drop (defined as
system frictional pipe losses) excluding the pressure drop across the
control valve at pump-rated flow

9.4 Secondary Control Valves

9.4.1 Secondary control valves (e.g., temperature control valve at inlet to
exchanger) shall have a minimum pressure drop that is the greater of the
following:
• 5 psi
• 20% of exchanger pressure drop in fouled condition at maximum
operating flow rate
Comment: The “secondary” control valve is defined as the valve that
individually controls sub-systems of a major system such as
streams to multiple exchangers, streams to multiple heaters,
or boilers. Typically, the primary and secondary control
valves will be in series with a header or similar
configuration. As an example, the main pump discharge
feeds into a header via a “primary” control valve, and the
flow is split into multiple streams via a “secondary” control
valve.

9.5 Operating Range

9.5.1 Operating ranges for linear motion and rotary valve types shall comply with
the following:
• The Cv of control valve through all conditions shall be sized to operate
within 15% through 80% of maximum rated Cv of the control valve.
• Stem travel/rotation at normal design flow conditions shall be within
40% through 65%.

10. Noise Considerations

10.1 Noise level produced by control valves shall conform to the limits identified on the
in PIP PCSCV001 control valve specification sheet. The noise level is based on
1 meter downstream and 1 meter from the surface of the attached piping. These
calculations shall include all process conditions as stated on the data sheet for
maximum, normal, and minimum flow.

Process Industry Practices Page 15 of 24

PIP PCCCV001 COMPLETE REVISION
Selection of Control Valves March 2003

Comment: OSHA 1910.95 defines a maximum allowable equivalent noise dose,

which is based on the noise level and the length of exposure time to
this level during an operating shift.
10.2 Control valve noise calculations shall be performed for all control valves. For
aerodynamic noise of gases, steam, or vapor, ISA 75.17 or IEC 60534-8-3
calculations shall be used. For hydrodynamic noise, the vendor method or
IEC 60534-8-4 shall be used.
10.3 For the noise calculations to be valid, the maximum valve body exit velocity must be
below 0.3 Mach.
10.4 Noise emissions shall not exceed the limits stated on PIP PCSCV001 control valve
specification sheet for the following conditions, which are the definitions of terms
used in the noise section of PIP PCSCV001 control valve specification sheet:
• Continuous: Operation is for more than 2 hours per shift.
• Infrequent: Each occurrence is less than 30 minutes in duration. Total
cumulative effect of each occurrence shall be less than 2 hours per year (e.g.,
emergency and relief conditions).
• Intermittent: Each occurrence is no more than 2 hours per shift or includes
startups and shutdowns.
• Remote: These are areas in which personnel are not normally present during
periods of higher noise emission (e.g., tank farm, flare line).
• Normally attended: These include fence line areas to publicly travel areas,
areas bordering residential areas, and normally traveled areas within the plant.
More stringent noise criteria may need to be applied to these applications on a
case-by-case basis.
10.5 The control valve vendor shall advise the owner if the calculated noise level exceeds
the 85 dB(A) value as stated on the PIP PCSCV001 control valve specification sheet.
10.6 Calculated noise level shall not exceed 110 dB(A). The control valve manufacturer
shall be consulted to verify that the control valve will perform correctly for the
expected duration with no damage at noise greater than 100 dB(A).
10.7 Control valve noise shall be treated at the source except as noted below. The
provision of low-noise multipath-multistage trim designs is required because it
reduces noise at multiple operating points. Diffusers, baffle plates, and silencers,
either inside the valve body or downstream of the valve, shall not be permitted for
the following applications:
• Process control/feed regulation
• Continuous letdown
• Intermittent letdown in daily service
• Recirculation in daily service
Comment: For other applications, special attention shall be given to the
possible limited flow ranges of these devices (i.e., noise reduction

Page 16 of 24 Process Industry Practices

COMPLETE REVISION PIP PCCCV001
March 2003 Selection of Control Valves

from these devices is generally reduced at low-flow conditions).

Noise generated by diffusers or baffle plates shall be calculated with
ISA 75.17 or with IEC 60534-8-3 as a separate system from the
valve trim and included in the overall noise source. If a diffuser is
being considered, then the noise level shall be calculated at half the
design flow.
10.8 Hardened materials in trim design shall be used to assist in prolonging the life of the
control valve.

11. Actuator

11.1 General
11.1.1 Unless otherwise specified, valve actuator shall be pneumatic diaphragm-
type or piston-type. Vane and other type actuators may be appropriate for
rotary-type valves.
Comment: Use of electric motor or electro-hydraulic actuator may be
considered for special applications, particularly if pneumatic
power is not available or if very high thrust forces are
required.
11.1.2 The actuator shall drive the valve to a safe position on loss of signal or
motive power. The actuator shall have an enclosed spring to achieve fail-safe
action. Valve failure position shall comply with owner-approved P&IDs and
the control valve data sheet. When sizing the spring, the process pressure
shall not be considered if this pressure assists in achieving the fail-safe
position.
Comment: Using an actuator having an enclosed spring design provides
the most reliable fail-safe operating parameter. If fail-safe
position cannot be ensured by an enclosed spring, volume
tanks may be used with prior owner approval to provide the
necessary motive power.
11.1.3 The actuator shall be sized to meet control, shutoff, and leakage class at the
minimum instrument air pressure identified on the PIP PCSCV001 control
valve specification sheet
Comment: Valves that must shut off against reverse flow shall be
identified on the individual control valve data sheet, and the
actuator shall be sized appropriately.
11.1.4 PIP PCSCV001 control valve specification sheet identifies the shutoff
criteria for valves on the loss of motive force (e.g., air supply) as follows:
• The shutoff classification must be met with spring force only. The
spring must be sufficient to maintain shutoff classification at
maximum delta P on loss of motive force.
• On loss of motive force, the valve shall return to required end position
using spring force only. Air assistance may be used in conjunction

Process Industry Practices Page 17 of 24

PIP PCCCV001 COMPLETE REVISION
Selection of Control Valves March 2003

with spring force to maintain shutoff classification at maximum

delta P.
• On loss of motive force the valve shall return to required end position
using spring force only. Process pressure assistance may be considered
in conjunction with spring force to maintain shutoff classification at
maximum delta P.
11.1.5 Sufficient actuator thrusts, tubing diameter, and accessories sizes shall be
provided to minimize the dead band, hysteresis, frequency response, and
speed of response at all process conditions.
11.1.6 Actuators shall be sized for positioning the closure member against a
minimum of the maximum differential pressure at all process conditions
unless otherwise specified in PIP PCSCV001. Maximum differential
pressure shall be considered the maximum upstream pressure with the
control valve fully closed and downstream pressure at atmospheric pressure.
If there is a vacuum on the control valve outlet, then the maximum vacuum
pressure on the valve outlet shall be used to determine the maximum
differential pressure
11.1.7 Valves in services that cause the control valve stem to stick shall have the
actuator sized with a 1.25 design factor.
11.1.8 For rotary valve actuator, the vendor shall confirm the breakout torque
requirements and the maximum percentage opening limit for stable
operation.
11.1.9 The actuator case shall be rated for the maximum available pneumatic
supply pressure.
11.1.10 The actuator material of construction shall be the vendor’s standard material.
11.1.11 Valve yokes shall be nodular iron, high-tensile-strength cast iron, or steel
unless specified otherwise in the individual control valve data sheet.
11.1.12 Springs, internal parts, fasteners, and hardware shall be resistant to the
corrosive effects of the environment.
11.1.13 The actuator exterior shall be painted with the vendor’s standard paint and
color, unless specified otherwise.
11.1.14 The sliding stem actuator shall have a valve position indicator that shows
position of valve stem against a full travel linear scale.
11.1.15 A travel indicator, graduated in opening percentages, shall be attached to the
rotary valve actuator end of the shaft.
11.1.16 The actuator and associated accessories shall be assembled, piped, and
mounted on the control valve and aligned, tested, and shipped as a complete
unit.
11.1.17 The designer shall coordinate the installation and orientation of valve
accessories with the vendor before final assembly and shipment.

Page 18 of 24 Process Industry Practices

COMPLETE REVISION PIP PCCCV001
March 2003 Selection of Control Valves

11.1.18 Refer to PIP PCSIP001 for piping and tubing specifications. Tubing shall be
sized to meet the required valve stroke response time.
11.1.19 The actuator shall have a permanently attached stainless steel tag. The tag
shall be stamped with the vendor’s standard data and the owner’s item
number.
11.1.20 The valve vendor shall supply filter or filter/regulator, whichever is
applicable according to the control valve data sheet.

11.2 Diaphragm Actuator

11.2.1. Nominal diaphragm spring ranges shall be 3 to 15 psig or 6 to 30 psig.
Comment: Although some applications will allow the use of actuators
that stroke over the input range of from 3 to 15 psig, higher
diaphragm pressures often will be required. Generally, the
valve should be specified to control and provide the
necessary shutoff force with a 6- to 30-psig diaphragm
pressure range.
11.2.2 If the control valve is not provided with a positioner, instrument air supply
shall be regulated in accordance with the following:
• Instrument air supply shall be minimum of 10 psi above spring range
(bench set) of actuator.
• The 10-psi requirement may be increased if additional instrument air
supply pressure may reduce actuator size or provide more force to
achieve the ANSI-class leakage shutoff requirement.
• All devices in the instrument air loop for control valve assembly shall
be rated/designed for this regulated pressure, including air supply
filter, air supply regulator, I/P, diaphragm, actuator housing, and
solenoid valves.
• If 10 psi above spring range exceeds rated/designed pressure of any
component, pressure for instrument air shall be regulated at the design
pressure of the component having the lowest design pressure.
11.2.3 If the control valve is provided with a positioner, the instrument air supply
shall be regulated at a minimum of 5 psig above the actuator-required
pressure to achieve fully open or closed positions (e.g., if actuator requires
6-30 psig, then the supply pressure will be set at a minimum of 35 psig).
• All devices in the instrument air loop for control valve assembly shall
be rated/designed for 50 psig, including air supply filter, air supply
regulator, I/P, positioner, diaphragm, actuator housing, and solenoid
valves.
11.2.4 If 50 psig exceeds rated/designed pressure of any component, pressure for
instrument air shall be regulated at design pressure of the component that has
lowest design pressure.

Process Industry Practices Page 19 of 24

PIP PCCCV001 COMPLETE REVISION
Selection of Control Valves March 2003

11.3 Piston and Vane Actuators

11.3.1 Piston and vane actuators shall be used in the following situations:
• when valve stem or shaft loading is high
• where fast valve action response is require
• where a compact physical installation is required
11.3.2 The actuator shall be designed to meet control and shutoff requirements with
the minimum available air supply.
11.3.3 Air exhaust connections shall be oriented and/or equipped to exclude or
minimize the entry of water, dirt, and insects.
11.3.4 Valves with piston operators shall be sized at the minimum instrument air
pressure stated in PIP PCSCV001 control valve specification sheet. Only a
filter shall be provided.
11.3.5 The following shall apply for control valves:
• All devices in the instrument air loop for the control valve assembly
shall be rated/designed for instrument air header pressure, including
air supply filter (required), positioner, actuator housing, actuator
internals, and solenoid valves.
Comment: Typically the I/P requires a separate filter/pressure
regulator set at a pressure compatible to the device.
• If the instrument air header pressure exceeds the rated/designed
pressure of any component (e.g., solenoid valve), the instrument air
pressure shall be regulated at the design pressure of the component
that has the lowest design pressure.

11.4 Volume Tank

11.4.1 Use of volume tank shall be approved by owner.
11.4.2 Volume tank shall be sized to fully stroke the valve through two travel
cycles.
11.4.3 If the volume tank, by virtue of size, pressure rating, or local regulation must
conform to Part U-1 of Section VIII, Division 1, of the ASME Boiler and
Pressure Vessel Code, capacity tank shall be ASME Code stamped and be
equipped with a pressure relief device.
11.4.4 Volume tank shall be equipped with the proper accessories (tubing, fittings,
pressure transmitters, solenoid valves, etc.) to ensure that the valve fails in
the safe position.
Comment: The pressure transmitter is required only if identified on the
PIP PCSCV001 control valve specification sheet.

Page 20 of 24 Process Industry Practices

COMPLETE REVISION PIP PCCCV001
March 2003 Selection of Control Valves

12. Positioner/Current-to-Pneumatic Transducer (I/P)

12.1 A positioner shall be used on all valves unless its use would be detrimental to good
process control. Local pneumatic loops do not require a positioner.
12.2 The positioner shall be mounted on plates or bosses on the valve dedicated for that
purpose.
12.3 The positioner shall be mounted, piped, and aligned by the vendor to provide a
complete control valve assembly.
12.4 The positioner shall be equipped with the manufacturer’s standard supply, input, and
output gauges unless otherwise specified.
12.5 A positioner bypass shall be provided only if specified by the owner.
12.6 Pneumatic boosters shall be used in conjunction with positioners in applications such
as pressure control to achieve the required response time.
12.7 Positioners shall
• Use two-wire loop power.
• Provide pneumatic output signal in which range is as required by actuator.
• Meet electrical area classification where they are installed.
12.8 Digital positioners shall
• Use standard digital communication and 4-20 mA as input signal.
• Provide diagnostic functions and information through hand-held
communicator, laptop computer, or computer console.
12.9 Electropneumatic transducers (I/P) shall
• Convert 4 to 20 mA DC electronic signal to 3 to 15 psig output signal.
• Be configured to be direct acting rather than reverse acting.
• May be integrally mounted on control valve, with owner approval, if
transducers are rated for operating conditions, such as maximum temperature
and vibration.
• Have minimum air flow rating of 0.25 scfm.
• Meet area classification and NEMA 4X.

13. Accessories

13.1 Handwheel Operator

13.1.1 Control valves shall have a handwheel operator only if specified by the
owner.

Process Industry Practices Page 21 of 24

PIP PCCCV001 COMPLETE REVISION
Selection of Control Valves March 2003

13.1.2 The handwheel operator shall be continuously connected and shall operable
through an integral declutching mechanism.
Note: Declutchable means a shaft-mounted worm gear that can be
detached from the power of the actuator.
Comment: Handwheel operator may be side mounted, lockable, or
screw or gear driven if accessibility is not a consideration.
13.1.3 The handwheel operator on a rotary valve shall be mounted directly on the
shaft, and the clutch shall be installed so that it can be declutchable.
13.1.4 Top-mounted jacks or handwheels shall not be used unless approved by
owner.
13.1.5 A valve-to-open direction arrow shall be permanently marked on the
handwheel.
13.1.6 Handwheels shall not be used to eliminate block and bypass valves
13.1.7 Handwheels shall not be used as limit stops.
Comment: When handwheels are used as limit stops, the adjustment
can be changed inappropriately.

13.2 Limit Switches and Solenoid Valves

13.2.1 General
13.2.1.1 All accessories shall be suitable for the electrical area
classification.
13.2.1.2 Solenoid valves and limit switches shall be mounted and tubed by
the valve vendor unless directed differently by the owner. For
instruments without terminal strips, the valve vendor shall provide
a terminal strip and housing.
13.2.2 Limit Switches
13.2.2.1 Unless otherwise specified, limit switches shall be hermetically
sealed.
13.2.2.2 Unless otherwise specified, limit switches shall be proximity types.
13.2.2.3 Limit switches shall be enclosed in watertight, dust-proof housings.
13.2.3 Solenoid Valves
13.2.3.1 Solenoid valves shall be rated for continuous duty and shall have a
minimum of Class F high-temperature encapsulated coils; Class H
coils are preferred.
13.2.3.2 The solenoid coil shall be molded in epoxy.
13.2.3.3 The solenoid coil shall be rated for continuous duty.
13.2.3.4 The solenoid valve for tripping the control valve shall be between
the positioner and actuator or in the tubing that provides the motive
power to the actuator.

Page 22 of 24 Process Industry Practices

COMPLETE REVISION PIP PCCCV001
March 2003 Selection of Control Valves

13.2.3.4 Tripping the solenoid valve shall provide sufficient capacity to

exhaust the actuator chamber air volume within the time required to
allow the valve to fail in a safe position. If solenoid valve Cv is not
sufficient, a “quick exhaust” valve shall be provided that works in
“conjunction” with the tripping solenoid valve if needed.
13.2.3.5 If the solenoid valve vent port is open to the atmosphere, it shall
have an insect screen.
13.2.3.6 The solenoid valve shall be capable of switching under conditions
of maximum and minimum operating differential pressure.
13.2.3.7 Instrument air supply piping must be of adequate size to stroke the
valve in the time specified.
13.2.4 Boosters and Quick Exhaust
13.2.4.1 Boosters shall be provided when necessary to achieve the required
stroke time. A volume booster shall be used only if approved by
owner.
13.2.4.2 Instrument air supply piping to boosters must be of adequate size
not to limit the supply to the boosters. The piping size selection
must also include drops across filters and regulators. Normally,
pipe is used for supplies. Larger pipe may be required for extensive
pipe runs. The flow through the boosters must not be restricted. In
some cases, connections in the actuators must be enlarged.
13.2.4.3 Conditions may exist making it desirable for the valve to move
rapidly in one direction but slower in the other. This can be
accomplished by selectively restricting one side of the booster or
boosters.
13.2.5 Air Sets and Auxiliary Equipment
13.2.5.1 Air sets that are required at valves shall be rigidly mounted to valve
yoke if mounting pads are provided.
13.2.5.2 Pressure gages supplied with positioners that are not enclosed in
positioner housing shall have stainless steel cases.
13.2.5.3 If approved by owner, auxiliary solenoid valves, position switches
and transmitters, and pneumatic relays associated with control
valves may be integrally mounted on control valve.
13.2.5.4 Air sets shall not be supported by pipe nipples from positioners. Air
sets for positioners bolted to control valve yoke shall be permitted.

14. Marking, Identification, and Nameplate

14.1 The direction of flow shall be marked on the valve. The flange rim of three-way
valves shall be identified.
14.2 The trim position of rotary valves shall be engraved on the shaft end.

Process Industry Practices Page 23 of 24

PIP PCCCV001 COMPLETE REVISION
Selection of Control Valves March 2003

14.3 A permanently fastened (e.g., by stainless steel rivets) stainless steel nameplate,
showing the following information, shall be provided on each control valve:
• Tag number specified on the individual control valve data sheet
• Manufacturer’s name, model number, and valve serial number
• Body material, valve size, and flange rating
• Trim material, trim size, and Cv
• Trim characteristic type
• Stem travel distance in inches
• Actuator model, size, and bench set and actuator serial number
• Actuator failure position
• Actuator maximum allowable case pressure
• Operating range (air signal to operator with valve under pressure)
• Bench setting (air signal to operator with no pressure in valve body); applies
only to diaphragm-actuated valves

Page 24 of 24 Process Industry Practices