GP 15-09-01 Control Valves December 2012

Control Valves
GP 15-09-01

Scope
1) [I] This Global Practice (GP) covers the design and inspection of all types of valves used for control,
in both throttling and on-off services. Gate valves are specifically excluded.
2) [I] Diaphragm and piston actuators, positioners, and ancillaries for control valves are covered by this
GP. Motor actuators are covered by GP 15-09-02.
3) [I] Slide valves are not covered by this GP.

Refining/Chemicals,
© ExxonMobil 2012 Version 3.0.0 Page 1 of 23
Downstream Imperial Oil

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without the express written consent of ExxonMobil.
 GP 15-09-01 Control Valves December 2012

Table of Contents
1. Required References ............................................................................................ 4
1.1. Global Practices–ExxonMobil Engineering Practices ................................... 4
1.2. API–American Petroleum Institute................................................................ 4
1.3. ASME–American Society of Mechanical Engineers ..................................... 4
1.4. CFR–U.S. Code of Federal Regulations ...................................................... 4
1.5. FCI–Fluid Controls Institute, Inc. .................................................................. 4
1.6. IEC–International Electrotechnical Commission ........................................... 4
1.7. ISA–The International Society of Automation ............................................... 4
1.8. ISO–International Organization for Standardization ..................................... 5
1.9. MSS–Manufacturers Standardization Society of the Valve and Fittings
Industry......................................................................................................... 5
1.10. NACE International ....................................................................................... 5
2. Additional Requirements ...................................................................................... 5
2.1. Global Practices–ExxonMobil Engineering Practices ................................... 5
2.2. ASTM International ....................................................................................... 6
3. Accessibility and Precautions ............................................................................. 6
3.1. Accessibility .................................................................................................. 6
3.2. Precautions .................................................................................................. 6
4. Control Valve Selection ........................................................................................ 6

5. Materials................................................................................................................. 7

6. Valve Design .......................................................................................................... 9

6.1. General......................................................................................................... 9
6.2. Characteristics............................................................................................ 11
6.3. Sizing ......................................................................................................... 12
6.4. Additional Requirements ............................................................................ 13
6.5. Self-Acting Regulating Valves .................................................................... 13
6.6. Environmental Protection ........................................................................... 13
6.7. High Performance Control Valves .............................................................. 14
7. Actuators, Positioners, and Valve Ancillaries .................................................. 14
7.1. Actuators .................................................................................................... 15
7.2. Stem and Shaft Linkages ........................................................................... 15
7.3. Handwheels................................................................................................ 16

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 GP 15-09-01 Control Valves December 2012

7.4. Positioners.................................................................................................. 16
7.5. Transducers ............................................................................................... 16
7.6. Air Locks..................................................................................................... 17
7.7. Volume Boosters/Quick Exhaust Vents ...................................................... 17
7.8. Limit Switches ............................................................................................ 17
7.9. Solenoid Valves .......................................................................................... 17
8. Inspection and Testing ....................................................................................... 18

9. Identification ........................................................................................................ 18

10. Documentation .................................................................................................... 19

Record of Change ....................................................................................................... 20

Attachment: Purpose Code Definitions.................................................................... 23

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 GP 15-09-01 Control Valves December 2012

1. Required References
[I] This Section lists the Practices, codes, standards, specifications, and publications that shall be used
with this document. Unless otherwise specified herein, use the latest edition.

1.1. Global Practices–ExxonMobil Engineering Practices

GP 16-01-01 Area Classification and Related Electrical Design for Flammable
Liquids, Gases, or Vapors

1.2. API–American Petroleum Institute

API STD 609 Butterfly Valves: Double Flanged, Lug- and Wafer-Type

1.3. ASME–American Society of Mechanical Engineers

ASME B16.34 Valves - Flanged, Threaded, and Welding End

1.4. CFR–U.S. Code of Federal Regulations

40 CFR 61-V National Emission Standard for Equipment Leaks (Fugitive Emission
Sources)

1.5. FCI–Fluid Controls Institute, Inc.

FCI 70-2 Control Valve Seat Leakage
FCI 91-1 Standard for Qualification of Control Valve Stem Seals

1.6. IEC–International Electrotechnical Commission

IEC 60534-8-3 Industrial-Process Control Valves - Part 8-3: Noise Considerations -
Control Valve Aerodynamic Noise Prediction Method

1.7. ISA–The International Society of Automation

ISA 75.01.01 Industrial-Process Control Valves - Part 2-1: Flow Capacity - Sizing
Equations for Fluid Flow under Installed Conditions
ISA 75.17 Control Valve Aerodynamic Noise Prediction

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 GP 15-09-01 Control Valves December 2012

1.8. ISO–International Organization for Standardization

ISO 15848-1 Industrial Valves Measurement, Test and Qualification Procedures for
Fugitive Emissions - Part 1: Classification System and Qualification
Procedures for Type Testing of Valves

1.9. MSS–Manufacturers Standardization Society of the Valve and

Fittings Industry
MSS SP-25 Standard Marking System for Valves, Fittings, Flanges, and Unions

1.10. NACE International

NACE MR0103 Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum
Refining Environments
NACE MR0175/ISO Petroleum and Natural Gas Industries Materials for Use in H2S-
15156 Containing Environments in Oil and Gas Production

2. Additional Requirements
[*] [I] This Section lists the additional Practices, codes, standards, specifications, and publications that
shall be used with this document only where specified. Unless otherwise specified herein, use the latest
edition.

2.1. Global Practices–ExxonMobil Engineering Practices

GP 02-01-01 Facility Sound Level Design Criteria
GP 03-06-02 Piping at Control and Protective System Valve Stations
GP 03-06-04 Vents and Drains, Flushing and Cleaning Connections
GP 03-09-01 Winterizing and Protection Against Ambient Temperatures
GP 03-12-01 Valve Selection
GP 15-06-01 Electronic and Pneumatic Instruments
GP 15-06-02 Environmental Protection for Instrumentation
GP 15-07-02 Protective Systems
GP 15-09-02 Electric Motor Operators for Valves
GP 18-03-04 Pressure Casting Quality and Inspection
GP 18-10-01 Additional Requirements for Materials

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 GP 15-09-01 Control Valves December 2012

2.2. ASTM International

ASTM A 320/A 320M Standard Specification for Alloy-Steel and Stainless Steel Bolting for
Low-Temperature Service

3. Accessibility and Precautions

3.1. Accessibility
All control valves shall be installed so that the valve and associated accessories and indicators are readily
accessible to maintenance and readable from normal personnel access paths. Control valves may be
mounted above grade if a platform for access is provided.

3.2. Precautions
1) Control valves shall be so located that topworks, accessories, or other applicable components are not
in close proximity to high-temperature sources. The actuator and accessories shall have a minimum
clearance of 600 mm (24 in.) from surfaces exceeding 260°C (500°F). Where this clearance is not
available, thermal shielding shall be used.
2) Control valves shall be removed from the piping system during flushing and hydrotesting after initial
installation. Refer to GP 03-09-01 for details.
3) All electrical equipment and circuits for instrumentation and controls shall be designed, furnished,
and certified to meet the electrical area classification in which they are to be installed. All electrical
instrumentation shall be suitable for the applicable electrical area classification, as defined by the
requirements of GP 16-01-01.

4. Control Valve Selection

The Flow Chart shown in Figure 1 provides an overview of control valve selection workflow and key
decisions to be made in accordance with following Sections 5 through 7 of this GP.

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 GP 15-09-01 Control Valves December 2012

Figure 1 Control Valve Selection Workflow

START

Determine service conditions A

(P1, dP, Q, T1, Fluid Properties, Allowable Noise, etc.)

Verify that the ratio of the pressure from across the CV

Select appropriate pressure class required for valve to the pressure drop of the entire system is acceptable
body and trim (typically between 0.2 and 0.5)

Calculate required Cv preliminary Select body and trim materials to meet application

Control Valve Sizing (Refer DP Section XII-F Table 5) Consider options on shutoff, stem packing, etc.
Check cavitation and flashing levels
END

Cavitation or Choose appropriate standard

No
flashing? trim

Yes

Determine appropriate trim and type (e.g., Angle valve

with multi-staged pressure drop trim)

Calculate outlet velocity

Size up valve body or consult

Under * Velocity Limits
No valve supplier for specific
Velocity limit*? Gas or steam: 0.3 MACH
application
Liquid: 5 m/s

Yes

Calculate noise

Under
No Anti-noise measure
Noise limit?

Yes

5. Materials
1) [S] [R] Body Class and materials shall meet or exceed the line piping classification and materials
requirements.
2) [R] Low alloy valve castings in hydrogen service and austenitic stainless steel valve castings in high-
pressure hydrogen service shall meet the requirements of GP 18-03-04.
3) [R] All control valves shall have a casting quality level assigned per GP 18-03-04.

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4) [R] Impact requirements for valves in low-temperature service shall meet the requirements of GP 18-
10-01.
5) [R] Trim materials shall be per the Manufacturer's standard for the specified service conditions,
except as modified below:
a) Exposure to wet H2S service (as defined in GP 03-12-01). The material for the valve trim
components such as the Plug, Seat, and any Guide/Guide bushing shall be 304 or 316 stainless
steel with Hardfacing Alloy 6 (Stellite) or solid Stellite. The complete valve assembly shall meet
NACE MR0103/NACE MR0175/ISO 15156 requirements for material hardness, etc.
b) Nitrided valve components should be avoided where sulfidation due to H2S is a concern due to
experience with fouling and sticking of control valves. Stellite-lined internals should be
satisfactory where surface hardening is required.
c) Hardened trim, such as hardened stainless steel [S44004 (440C) or S17400 (17-4PH)], are
required for the following severe services:
i) Steam pressure reduction where the pressure drop may exceed 700 kPa (100 psi).
ii) Condensate from boiler where the pressure drop may exceed 700 kPa (100 psi).
iii) Where more than 3 percent of the inlet fluid by weight may vaporize in the valve together
with a pressure drop exceeding 1000 kPa (150 psi).
iv) Any pressure reduction greater than 1700 kPa (250 psi).
v) For fluids containing solids, and services above 315°C (600°F), unless higher grade materials
are required for process conditions.
vi) [*] Unless otherwise approved by Owner's Engineer, tungsten carbide trim shall be used for
the oil and water level control streams from the first stage crude oil production separation and
from test separators.
d) [*] [A] For other severe services such as catalyst slurry service and all others that are not listed
above, the trim material shall be approved by Owner's Engineer.
6) [R] Austenitic stainless steel, Monel, and nickel alloy valves shall have trim, bolting, and stem of the
same nominal chemistry as the body except when Alloy 6 trim has been specified. Where Alloy 6 is
specified, all surfaces shall be covered with a minimum thickness of 1.3 mm (0.05 in.) and a
maximum of 2 mm (0.08 in.). If undercutting of Alloy 6 covered surfaces is anticipated, then
centrifugally cast solid Alloy 6 shall be used instead of overlay methods.
7) [S] Control valve packing glands shall meet the following criteria:
a) [A] Control valve packing glands shall be the bolted type. Exceptions may be made, with
Company approval, for sizes NPS 2 and smaller used in low-pressure service.
b) Packing follower and packing gland bolts shall be Grade B8M (as reflected in ASTM A 320/A
320M) stainless steel when installed in condensing (sweating conditions) or cold [less than 0°C
(32°F)] environments.
c) The packing gland bolt torque specified by the valve Manufacturer shall be included as part of the
valve specification sheet information.
d) Valve stuffing box arrangements shall use anti-extrusion rings to minimize extrusion, which
causes loss of packing material, and shall use a minimum amount of packing to reduce effects of
thermal expansion.
e) Valve stem shall be retained in a centrally aligned position via a bushing system.

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 GP 15-09-01 Control Valves December 2012

f) The recommended packing for general service with moderate packing box temperatures to 230°C
(450°F) is TFE V-ring. Alternative packing material such as graphite type compounds may be
used.
g) Asbestos packing is prohibited.
h) Temperatures above 230°C (450°F) require graphite type compounds. The recommended
configuration is braided graphite rings top and bottom, with flexible graphite [minimum
uncompressed density 1360 kg/m3 (85 lb/ft3)] between them. When flexible graphite is used
alone, sealing washers are recommended for each end of the packing box to prevent excess
packing material extrusion. An alternative is to use bonnet extensions to lower the packing
temperature levels, allowing low emissions, and to lower friction packing at higher temperatures.
i) Bonnets shall be tapped and installed with a lubricator and steel isolating valve for all control
valves with packing other than TFE and graphite type compounds or for all control valves with
extended stems in hot service.
8) [S] Process-wetted gaskets shall be suitable for the line service classification.
9) [R] Tubing downstream of instrument air filters shall be stainless steel with stainless steel
compression fittings.
10) [R] Valve actuator springs shall be carbon steel with factory-applied, rust-resistant coating. For
corrosive atmospheres, alloy springs shall be considered.

6. Valve Design
6.1. General
1) [A] The selection of valve types and sizes, body, and trim materials shall be approved by Owner's
Engineer.
2) Control valve designs used in Protective System service shall meet additional requirements as
specified in GP 15-07-02.
3) [R] The pressure-temperature rating, dimensions, tolerances, materials, nondestructive examination
requirements, testing and marking for cast, forged, fabricated steel flanged, threaded, and buttwelding
end valves shall be per ASME B16.34. Additional requirements for specific valves are listed below:
a) Flanged-end and flangeless valves shall match the line serve classification rating.
b) Threaded end valves shall have a minimum Class 600 rating.
c) Butterfly valves shall match the line service classification rating.
4) [S] Wafer valves (refer to GP 03-12-01 "Valve End Connections" definition) shall not be used in any
hydrocarbon service. In addition, use of both wafer and lug-type valves (again refer to GP 03-12-01
definition) shall be restricted as follows:
a) Wafer or lug-type valves shall not be used where the design temperature is above 315°C (600°F)
or above the auto-ignition temperature of the fluid, whichever is lower.
b) Wafer or lug-type valves shall not be used where the design temperature is below 315°C (600°F)
and the service conditions meet the "dangerous" (refer to GP 03-06-04) criteria defined below:
i) Toxic materials such as phenol, hydrogen sulfide, chlorine
ii) Highly corrosive materials such as acids, caustic, and similar materials

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iii) Flammable materials (including light hydrocarbons lighter than 68 degrees API)
iv) Boiler feedwater and steam, in systems requiring ANSI Class 300 and higher flange ratings
v) Oxygen in concentrations greater than 35%
c) For design temperatures above 205°C (400°F), body material shall have the same nominal
coefficient of thermal expansion as the bolting material and adjacent flanges.
5) [S] [O] Control valves shall meet the following seat leakage criteria:
a) [A] Metal-to-metal seating with Class IV leaking rating is expected for most applications,
especially for fluids containing abrasive particles or with design temperatures above 230°C
(450°F). Leakage class lower than Class IV requires approval by Owner's Engineer.
b) Control valves used in tight shutoff and gas compressor recycle service shall be single-seated.
c) For tight shutoff, leakage class shall be at least Class V or as specified by Owner's Engineer.
d) Composition (soft) seats for shutoff valves may be used when better than Class V tight shutoff is
desired and when the seats conform to the pressure, temperature, and chemical limitations of the
process. Where required to be fire safe, composition seated valves shall be fire tested in
accordance with GP 03-12-01.
e) Worst-case process conditions shall be considered for control valve leakage class selection.
f) Actuator type and size shall be selected to provide adequate seat loads for the selected leakage
class on a conservative basis (10 percent above the minimum calculated thrust per inch of port
circumference). The primary criteria for meeting tight shutoff/low leakage requirements shall be
proper trim design configuration and materials.
g) [A] Single-seated control valves with springless top works and double-acting pistons may be
used, with Owner's Engineer's approval, for tight shutoff and where extra power is required to
overcome unbalanced forces caused by process operating pressure and shut-off pressure.
Facilities shall be provided to ensure the fail safe action of the valve.
6) [*] [A] [R] Noise calculations per ISA 75.17 or IEC 60534-8-3 shall be provided for each control
valve. A calculated sound pressure level greater than 80 dBA (reference GP 02-01-01) shall require
application of noise attenuation methods. These methods shall maximize the noise attenuation within
the valve body (to reduce possibility of valve damage) by the design of the trim before consideration
is given to the use of insulation, increased wall thickness, diffusers, silencers, or other inline devices.
Proposed noise reduction methods shall be approved by Owner's Engineer.
7) [O] [R] Control valves in plugging services (e.g., liquid sulfur) shall be steam jacketed where steam
tracing would not provide enough heat to prevent plugging.
8) [S] [R] Shafts of rotary actuated valves shall be sized for pressure drop equal to maximum upstream
design pressure.
a) [*] [A] The shaft shall be designed with a blowout prevention/protection feature to retain the
shaft in the event of a shaft failure. Shaft design shall be reviewed with Owner's Engineer.
b) As a minimum, butterfly valve disk attachment shall be done by double pinning to a solid shaft.
c) Butterfly valves in slurry service or in liquid service with entrained solids shall be mounted with
the valve shaft in the horizontal position. For other services, the mounting position shall be as per
valve Vendor recommendation.
d) The shear safety factor shall be 2:1 at maximum shutoff pressure across the valve. The limiting
value shall be taken at the weakest point, such as pins or keyways.
e) Butterfly valve shaft retention thrust collars for blowout protection shall be fitted to valve shaft
ends opposite to the actuator and open to atmosphere if the valve does not meet API STD 609,

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 GP 15-09-01 Control Valves December 2012

Paragraph 4.5.2, "The shaft and/or shaft retention shall be designed so that, if failure of the shaft
to disc connection or of the shaft occurs, no portion of the shaft can be ejected from the valve as a
result of internal pressure."
f) Ball or any rotary valve stem retention shall not depend on the packing gland. A shouldered stem
with bottom entry is normally expected.
9) [O] Radiating fins or extension pieces shall be provided if specified fluid design temperature is above
230°C (450°F) or below 0°C (32°F), unless specifically designed bonnet or packing does not require
them. Warming spools in conjunction with extension bonnets may be required for cryogenic service.
10) [E] Valve packing shall meet local fugitive emissions regulations. Special environmental packing
systems shall be provided for environmental emission control applications, keeping process emission
levels within the EPA standards defined in the National Emission Standard for Equipment Leaks
(Fugitive Emission Sources) or within levels defined by the appropriate other national regulations.
Refer to EPA document 40 CFR 61-V, which is applicable in the United States.
11) [S] Valve packing leakage shall meet requirements for personnel exposure. Control valves in toxic
(as defined in GP 03-06-04) material service shall have low emissions packing that is certified for
leakage that is less than that shown in Table 1 (or more restrictive applicable national leakage
requirement) after a minimum of 25,000 cycles and 3 thermal cycles using the testing standard
applicable per local regulations. The certification shall cover the design pressure and temperature
range of the valve application.

Table 1: Allowable Packing Leakage

Testing Standard Maximum Allowable Leakage
Teflon Packing Graphite Packing
FCI 91-1 100 vppm 100 vppm
ISO 15848-1 10-4 mg/(sec-m) 10-2 mg/(sec-m)

6.2. Characteristics
1) [A] [O] Two way control valves shall have characteristics per Table 2. Exceptions are noted in the
following subparagraphs.

Table 2: Characteristic Selection for Two-Way Control Valves

Valve Characterization Selection

Process Variable Valve ∆P

Constant OR
∆PQ MAX > 0.50 ∆PQ MIN ∆PQ MAX < 0.50 ∆PQ MIN
Level Linear Equal Percentage
Pressure Linear Equal Percentage
Flow Equal Percentage Equal Percentage
Temperature Equal Percentage Equal Percentage

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 GP 15-09-01 Control Valves December 2012

a) Valves used in pairs, as three-way valves, including rotary actuated valves, such as ball or
butterfly types, shall have linear characteristics. Where characterized positioners are used to meet
this requirement, Valve Manufacturer shall perform calibration for the required characterization.
b) [A] Gas compressor recycle control valves shall have linear characteristics. Recycle valve
applications require approval by the Owner's Engineer.
c) Typically, valves in noise reduction or anti-cavitation service have linear trims and these trim
types shall take precedence in these situations.
d) [A] In certain cases, there may be a significant valve size and cost advantage for applying an
equal percentage valve instead of an otherwise preferable linear valve due to the minimum lift
requirements of Section 6.3, Item (1b) (larger valve lift for smaller Cv values). These cases shall
require approval by Owner's Engineer.

6.3. Sizing
1) [O] Control valve sizing shall comply with the following criteria:
a) Valve size shall be the smallest one that meets the requirement that its flow coefficient (Cv) is
equal to or greater than 125 percent of the Cv calculated from the maximum specified flow rate
and conditions, taking into account the effect of piping configuration such as changes in line size.
b) [A] Control valve size shall be selected so that at the minimum specified flow rate and
corresponding pressure drop, the required lift shall not be less than 15 percent of full travel.
Proposals to use control valves at a lower lift (such as compressor surge control valves) shall be
approved by Owner's Engineer.
c) In normal valve sizing calculations where pressure conditions for valves have already been fixed
and where it cannot positively be determined by inspection that cavitation or flashing will not
occur, the choked flow equation shall be used. Refer to ISA 75.01.01.
2) [*] [A] [O] Conventional butterfly valves shall be sized for maximum angle opening of 60 degrees.
Proposals to use angles greater than 60 degrees shall be submitted for approval by Owner's Engineer.
When sized for 60 degrees, the installed travel should be restricted to 60 degrees by actuator or travel
stop and the input calibrated for 100 percent at 60 degrees.
3) [O] [R] For heat exchanger service, three-way valves or two-way valves used in pairs as three-way
valves (including rotary actuated valves such as ball or butterfly types) shall be sized in accordance
with the following:
a) For globe and characterized v-port skirt design type three-way valves, the exchanger port shall be
sized to pass the maximum design flow with a fouled exchanger and zero flow through the bypass
port.
b) For two-way valves in three-way service, the following sizes shall apply:
i) The exchanger valve shall be sized to pass the maximum design flow with a fouled exchanger
and zero flow through the bypass valve.
ii) The bypass valve shall be sized to pass the maximum design flow with zero flow through the
exchanger valve subject to the limitation that the bypass valve shall be no smaller than one
size below the exchanger valve.
c) The 125 percent factor referred to in Section 6.3, Item (1a) shall not be used in sizing three-way
valves or two-way valves in three-way service.
4) [*] Control valve sizing shall be in accordance with ISA 75.01.01. For conditions outside the scope
of the ISA standard (such as two-phase mixtures of hydrocarbons), refer to Owner's Engineer.

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5) [A] [R] Minimum body size shall be 1 in. NPS (25 mm) except for self-acting regulating valves.
Dual parallel strainers installed upstream of the control valve shall be considered for valves that
employ less than 3 mm (0.125 in.) orifice opening sizes. Owner's Engineer's approval is required.
6) [C] [M] Body sizes of 11/4 in., 21/2 in., and 5 in. NPS (32 mm, 65 mm, and 125 mm) shall not be used.

6.4. Additional Requirements

1) [S] [R] Valve plug assemblies, excluding the stem, whether single or double, shall be machined all in
one piece from bar stock or from castings. Sectional construction or hollow plugs are not permitted.
2) [M] Flanged end connections are preferred for all valves. Flange rating, facing, and finish shall be
specified.
3) [S] All valves with hollow-ball construction in liquid service shall be provided with internal pressure
relief for the body cavity. See GP 03-12-01 for complete requirements.
4) [R]Threaded end valves shall be as follows:
a) Limited to body sizes 1 in. NPS (25 mm) or smaller
b) Furnished with internally tapered threads
5) [*] Welded end valves shall be specified by Owner's Engineer.

6.5. Self-Acting Regulating Valves

1) [*] [C] Self-acting regulating valves may be used in noncritical service. The valves may also be used
in some critical services, such as major machinery lube oil systems. The following restrictions and
additions apply:
a) Where control no better than 10 percent is acceptable.
b) [A] Use of self-actuated pressure regulators for upstream pressure greater than 687 kPa (100 psi)
requires Owner's Engineer's approval.
c) [A] Pilot-operated regulators or local pneumatic controllers, rather than self-actuated pressure
regulators, shall be used where a control accuracy better than 10 percent is required. Yoke
mounted pilots require Owner's Engineer's approval.
d) The controlled output signal shall be indicated on the pilot.
2) [S] Actuators for self-acting regulating valves shall be capable of withstanding the maximum
upstream design pressure.
3) Nitrogen blanketing or inert gas blanketing systems shall be implemented with proprietary blanketing
regulator systems. Such applications shall be detailed in an application-specific specification or data
sheet.

6.6. Environmental Protection

[O] [R] Valves shall meet all environmental requirements. Mounting brackets and accessory hardware
shall be suitable for use in the environment in which the valve is to be installed. Brackets and hardware
in harsh (corrosive, marine, or tropical) environments shall be stainless steel or epoxy painted. Cadmium
coated or electroplated bolts or hardware shall not be used.

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6.7. High Performance Control Valves

1) High performance control valves are those whose performance directly and significantly impacts
plant or unit operation. It is expected that less than 3 percent of all control valves will fall into this
category. There are two criteria to be considered:
a) Reliability Performance Criteria—Severe service conditions are those which impact the valve's
reliability. Severe service conditions include the following:
i) Cavitation or flashing
ii) High pressure drop, where the pressure drop exceeds the critical pressure
iii) High piping vibration
iv) Erosion, such as solids in the fluid, liquid particles in gas stream or steam
v) High valve outlet velocity (liquids > 5 m/sec; gas/steam > 0.3 mach)
b) Process Performance Criteria—High performance operating conditions are those that impact the
valve's process performance. These operating conditions include the following:
i) High rangeability (> 100:1)
ii) Quick step response (> 4 in. travel/sec or full stroke in less than 2 seconds in either direction.
iii) Very low or zero overshoot (< 1%)
iv) Very low hysteresis (< 1%)
v) Controllability (≤ 0.5% in both directions)
vi) High sound pressure level (> 80 dBA)
vii) Very low or zero packing leakage requirement
viii) Tight shutoff Class V or VI
ix) High duty cycle (> 10 cycles/hr)
2) These high performance valves deserve special attention during the engineering, procurement,
installation, and maintenance process. The following are examples:
a) These valves should be handled separately engineered products, as opposed to off-the-shelf
products.
b) Special attention should be paid to the accuracy of process data in the sizing and selection of
these valves. This includes noise prediction and valve characteristic selection.
c) These valves should be identified as high performance valves early in the project schedule and
should retain that designation throughout the life of the valve.

7. Actuators, Positioners, and Valve Ancillaries

1) [A] Valve ancillaries such as limit switches, positioners, relays, and solenoid valves shall be furnished
mounted on the control valve, unless approved by Owner's Engineer
2) [M] [R] Valve ancillaries shall meet the area classification and environmental requirements of GP 15-
06-01 and GP 15-06-02.
3) [R] Open vent ports on pneumatic components (e.g., solenoid vents, I/Ps, Positioners) shall be
provided with screens (bug screens) to prevent blockage, and installed to prevent the buildup of ice on
the screened ports. Screens shall be manufactured from corrosion resistant material consistent with

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 GP 15-09-01 Control Valves December 2012

normal plant atmospheric conditions and shall be of a design (e.g., screw-fit) to prevent blow out
when the solenoid vents. This provision applies also for avoiding any obstruction of the pneumatic
component vent, e.g., by insulation, labeling, etc.

7.1. Actuators
1) [S] Position on actuating medium failure or control signal failure shall be specified. When piston
actuators are used, positive failure action shall be provided, such as an external volume tank and trip
system to achieve the desired failure position.
2) Either pneumatic diaphragm or piston type actuators shall normally be used to operate the control
valve, with diaphragm actuators generally preferred.
3) [*] [A] [O] Piston type actuators applied in harsh (marine or tropical) environments shall be
configured to minimize the ingress of air from the local atmosphere. A tubing, filter, and check valve
configuration shall be used to assure the air entering the actuator is primarily from the instrument air
supply. Owner's Engineer shall review all such designs.
4) [O] Actuators shall be sized to achieve all of the following:
a) To prevent instability of the valve plug or vane over its full travel, based on a pressure drop equal
to the maximum upstream design pressure or if used in vacuum service, designed for 101 kPa (30
in. Hg) vacuum on the outlet side.
b) To overcome frictional requirement of the stuffing box packing selected.
c) To ensure shutoff against maximum line design pressure.
d) Valves without positioners operated by controllers that inherently have their output clamped at 4
mA and 20 mA shall have actuators sized and adjusted for full travel and full seating force for
this range.
e) Valve travel speed shall be considered if there are specific process requirements for either fast or
slow travel (e.g., to mitigate potential hydraulic surge, sequencing applications).
5) [R] Actuators shall not exceed travel limits. In the opening direction, a stop shall be engaged before
the valve plug reaches its travel limit. The stop shall be designed to absorb any force transmitted to it.
In the closing direction, the valve plug shall seat before the actuator reaches its travel limit.
6) [*] [O] [R] Actuators shall be rated for the maximum normal operating pressure of the instrument air
system. No other source of actuating medium shall be connected to the actuator.
7) [S] Where the actuating medium is something other than instrument air, actuators shall be either rated
for the system design pressure of that actuating medium or overpressure protection shall be provided.
8) [A] [O] [R] Control valves shall be installed in horizontal lines. Globe and angle style valves shall be
installed with the valve actuators above the valves and with the valve stems vertical. Rotary style
valves shall be installed with the shafts horizontal, except in cryogenic services where the shaft shall
be vertical. Proposals for other installation orientations shall require approval by Owner's Engineer.
Refer to GP 03-06-02.

7.2. Stem and Shaft Linkages

1) [R] The valve stem, when threaded to the valve plug, shall be pinned.
2) [M] Rotary valves (such as butterfly, ball) shall have shaft keyways or splined shafts that allow the
action of the valve actuator to be changed. In addition, rotary actuators shall not use cams, gears, or
sliding linkage in their construction or connection to the control valve.

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3) [R] Shaft thrust bearings shall be provided for rotary actuated valves in cryogenic service, preferably
installed inboard on the opposite end of the shaft from the actuator.

7.3. Handwheels
1) [*] [A] [M] When specified, handwheels, or hydraulic hand jacks, where approved by the Owner's
Engineer, shall be mounted and designed to operate in the following manner:
a) For globe valves, handwheels shall be mounted on the yoke, arranged so that the valve stem can
be jacked in either direction.
b) Neutral position shall be clearly indicated.
c) Handwheel operation shall not add friction to the actuator.
d) Clutch/linkage mechanisms for handwheels on rotary valves shall be designed such that valve
position does not change when engaging the handwheel.
e) Handwheels shall not be used as travel limit stops.
2) [O] Handwheels shall be easily operable from normal personnel access paths or platforms.
Handwheels shall face the operator access area, and the shaft center shall be 1 m to 1.5 m (3 ft to 5 ft)
above the elevation of the access area. When valve actuator configurations or piping layouts preclude
this arrangement, a supplemental platform will be required.

7.4. Positioners
1) [*] [O] Valve positioners are required on all control valves, unless waived by Owner's Engineer. The
only exception is on-off control service.
2) [S] Valve positioners shall be direct acting.
3) [R] Where one controller output adjusts more than one actuator (e.g., louvers and variable pitch fans),
positioners, boosters, or transducers shall be installed at each actuator. Isolation valves shall be
provided for each actuator. Alternatively, each actuator may be driven by its own output card
assigned and characterized by the controller.
4) [O] On new valves where a positioner is required, a smart valve positioner (SVP) shall be applied
instead of an electropneumatic (I/P) transducer plus pneumatic positioner or an integral electronic
positioner. Wherever possible, an SVP directly coupled to the valve shall be installed.
5) [O] [R] A smart valve positioner is required on both new and existing High Performance Valves.
6) [O] [R] Filter regulator sets for smart valve positioners shall have 5 micron filters.

7.5. Transducers
1) [S] Electropneumatic (I-to-P or I/P) transducers shall be direct acting.
2) [C] [M] An air output gauge is required if the electropneumatic transducer is not connected to a
positioner.
3) [R] Where two control valves with pneumatic positioners are used in three-way service, one common
electropneumatic transducer shall be used for both valves. Air supply to this transducer shall be the
same as the valve positioners. Where electropneumatic positioners are used, the split ranging shall be
performed in the control system.

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4) [O] [R] Transducers shall not be mounted on valves in vibrating service such as high-pressure drop
service and flashing/cavitating service, or on valves in locations subject to vibration from associated
equipment or adjacent piping.
5) [O] Transducers shall have sufficient loading and venting capacity so as not to degrade the response
of the valve.

7.6. Air Locks

1) [S] [R] If air locks are required, they shall be installed as close to the valve actuator as possible.
However, any trip/dump valves associated with protective systems shall be installed such that the
trip/dump valve moves to its failure state regardless of the air lock state of an associated control
valve. The air supply for the air lock shall be the same as for the valve positioner. The set point for
the air lock shall be set at a value above the minimum pressure required by the actuator for the
application.
2) [M] Control valves with an air lock feature shall have a pressure gauge indicating actual diaphragm
or piston pressure after the air lock.

7.7. Volume Boosters/Quick Exhaust Vents

1) [O] [R] Volume booster relays may be used to improve the dynamic response of a control system if
the positioners are used that do not have the capacity to operate the control valve fast enough to meet
process needs.
2) [O] The air supply system (piping and air filter) shall be capable of providing a sufficient quantity of
air for the desired stroking time.
3) [A] Owner's Engineer shall approve the use of a quick exhaust vent on a control valve.

7.8. Limit Switches

1) [*] [O] [R] Where required, positive valve movement (open/close) shall be indicated by using, as a
minimum, single pole double throw (SPDT) hermetically sealed position switches.
2) [O] [R] Magnetic, inductive, or capacitive type switches with valve position indication are preferred.
3) [O] [R] Limit switch and linkage devices used to detect valve stem position shall not have a dead
band exceeding the lesser of 10 percent of the valve travel or 3 mm (0.125 in.). Rotary valve limit
switch dead band shall not exceed 5.0 degrees rotation of the valve disk shaft.
4) [O] [R] Limit switch mounting brackets to valves shall be robust to prevent switch trip settings from
drifting.
5) [O] [R] All switch parts shall be protected from corrosion.

7.9. Solenoid Valves

[A] Solenoid Valve body material shall be specified and/or approved by the Owner's Engineer. Brass is
required as a minimum but stainless steel may be specified for corrosive environments. Site standards
shall be applied.

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8. Inspection and Testing

1) [O] Factory Acceptance Tests and Site Acceptance Tests are required for High Performance Valves.
2) [O] New High Performance Valves shall be furnished with a valve profile that documents its baseline
for future maintenance and troubleshooting.
3) Casting quality inspections shall be performed per GP 18-03-04.
4) [S] Test pressure for steel bodies shall be per ASME B16.34. For cast iron, brass, or bronze bodies,
test pressure shall be two times primary pressure rating.
5) [*] [O] Vendor shall supply documentation demonstrating that the valves meet the specified FCI 70-2
leakage Class V or above, where specified by Owner's Engineer.
6) [R] For operational testing, all valves shall be completely assembled with the packing box fully
packed and torqued to the appropriate value for the valve. The valve stem may be lightly lubricated.
The user should consider witnessing the tests if the valve is judged to be critical. The following tests
shall be performed once the valves have been stroke sufficiently to produce repeatable results:
a) Valve stem position shall be measured while applying increasing and decreasing air signals
directly to the actuator without the positioner in service. Air signal shall be consistent with the
spring range of the actuator. Performance shall meet the following requirements:
i) Stem position error shall not exceed 5 percent of rated travel.
ii) [*] [A] Hysteresis plus deadband shall not exceed 5 percent of rated travel for PTFE packing.
For graphite packing, this performance shall be specified and/or approved by Owner's
Engineer.
b) Valve stem position shall be measured while applying increasing and decreasing control signals
to the positioner. Performance shall meet the following requirements:
i) Stem position error shall not exceed 1 percent of rated travel.
ii) Hysteresis plus deadband shall not exceed 1 percent of rated travel for all packing types.

9. Identification
1) Valve body (and flanges where applicable) shall be marked in accordance with MSS SP-25.
2) The fixed-open port for three-way valves shall be steel-stamped COMMON on the flange.
3) Valves shall have the following identifying information on a nameplate fastened to the valve:
a) Equipment identification number (tag number).
b) Manufacturer name, model, serial number, operating range, materials of parts exposed to process
fluid, size (body and inner valve), type of plug, spring range, and flow capacity (Cv).
c) Packing materials and lubricant. If not included on the nameplate, provision for a separate tag is
acceptable.
d) Adhesive fastening is not acceptable.

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10. Documentation
1) Manufacturers shall furnish the following documentation:
a) Completion of mechanical sections of a provided control valve spec sheet.
b) A detailed "assembly" drawing or description of parts traceable to the serial number.
c) Identify a parts list of replacement soft goods.
d) Provide PMI record, as required.

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GP 15-09-01 Control Valves December 2012

Record of Change
Version 1.0.0 Date: 07/01
Location Action Description
Initial Publish.

Version 1.1.0 Date: 12/01

Section 1 Deletion References to Data Sheets removed.

Version 1.1.0 Date: 01/04

Global Practice version number and format updated to comply with new
process; however, original publish date remains, and no content was
modified.

Version 1.2.0 Date: 08/05

Section 1 Modification Reorganized subsections in alphabetical order.
Replaced ISA 75.01 with ISA 75.01.01.
Replaced ISA 75.03 with ISA 75.08.01.
Replaced ISA 75.04 with ISA 75.08.02.
Section 2 Modification Updated reference title.
Section 4.3 Modification Updated ISA mnemonics.

Version 2.0.0 Date: 12/05

Entire Modifications, The entire GP was reviewed. Significant changes include the following:
Standard Deletions, and
Additions • Removed unused references from Sections 1 and 2.
• Added rationale statements throughout the GP.
• Changed end connection requirement of 300# to being consistent
with the piping classification.
• Adopted several paragraphs from the Upstream GP 15-09-01,
including valve accessibility and precautions.
• Added new subsection on high performance control valves from
Best Practice on that subject.

• Clarified seat leakage paragraphs.

Upstream Upstream maintains Version 1.2.1 until review of Owner's update.
Only
Pipelines and Pipelines and Terminals maintains Version 1.2.1 until review of Owner's
Terminals update.
Only

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GP 15-09-01 Control Valves December 2012

Version 3.0.0 Date: 12/12

Entire GP The entire GP was reviewed. Significant changes include the following:
Figure 1 Addition Added control valve selection flow chart.
Section 3.2, Modification Added reference to GP 03-09-01and Rationale.
Item (2)
Section 4 Addition Added section on Control Valve Selection. Subsequent sections
renumbered.
Section 5, Addition Added requirements that all control valves have casting quality levels
Item (3) assigned and be inspected in accordance with GP 18-03-04.
Section 5, Item Modification Item expanded. Rationale added.
(5a)
Section 5, Item Modification Item modified.
(7)
Section 6.1, Modification Item modified.
Item (4)
Section 6.1, Modification Items modified
Item (4a), (4b)
Section 6.1, Modification Owner's Engineer's approval added.
Item (5g)
Section 6.1, Modification References added.
Item (6)
Section 6.1, Modification Review by Owner's Engineer added.
Item (8a)
Section 6.1, Modification Item modified.
Item (10)
Section 6.1, Addition Added requirement for leakage certified low emissions packings for
Item (11) control valves in toxic material service.
Section 6.2, Modification Modified guidance for selection of control valve characteristics. Table 2
Item (1) added.
Section 6.2, Modification Added need for approval by Owner's Engineer.
Item (1b)
Section 6.2, Modification Items replaced.
Item (1c) and
(1d)
Section 6.4, Addition Added requirement for valves with hollow balls to have internal pressure
Item (3) relief in alignment with GP 03-12-01.
Section 6.7, Modification Changed 90 dBA to 80 dBA.
Item (1b-vi)
Section 7, Addition Items added.
Items (2), (3)
Section 7.1, Modification Owner's Engineer's approval added.
Item (3)

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GP 15-09-01 Control Valves December 2012

Section 7.1, Addition Item added.

Item (4e)
Section 7.1, Addition Added guidance on required actuator pressure ratings where the actuating
Item (6) medium is instrument air.
Section 7.1, Addition Added guidance on actuator design for cases where the actuating medium
Item (7) is something other than instrument air.
Section 7.1, Modification Modified.
Item (8)
Section 7.4, Addition Item added.
Item (6)
Section 7.7, Addition Item added.
Item (3)
Section 7.9 Addition Added subsection on solenoid valves.
Section 8, Item Addition Item added.
(3)
Section 9 Modification Item (3b) modified
Item (3d) added.
All Global Modifications To standardize the format of the Global Practices and to meet other
Practices requirements, the following changes have been implemented:
"For ExxonMobil Use Only" has been replaced with "For Company Use
Only."
A copyright waiver has been added in the first page Footer.
The definition of asterisks in the Scope has been deleted. The asterisk is
now defined in the Purpose Code attachment and is used within brackets
as other Purpose Codes.
Multiple paragraphs within a Section have been numbered.
The standard text for Required References has been modified.
The standard text for Additional Requirements has been modified.
The [S] Purpose Code has been modified.
The following Purpose Codes have been added:
[*] for additional information or decision required of Owner's
Engineer.
[A] for approval requirements before beginning work or finalizing
design.
DIOL Only DIOL accepts Version 3.0.0 as of 12/13. DIOL previously used Version
2.0.0.

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GP 15-09-01 Control Valves December 2012

Attachment: Purpose Code Definitions

Code Description
[*] Assigned to paragraphs that require the Owner's Engineer to provide additional information or
make a decision.
A Assigned to paragraphs that require approval from the Owner's Engineer before the work may
proceed or the design is finalized.
C Assigned to paragraphs whose primary purpose is reduced costs. Reduced cost in this context
refers to initial investment cost and does not include life cycle cost considerations. Life cycle
cost considerations are captured under reliability, maintainability, or operability purpose codes.
E Assigned to paragraphs whose primary purpose is driven by environmental considerations.
Environmental considerations typically include specifications intended to protect against
emissions/leakage to the air, water, and/or soil. Deviations from the specifications contained
in such paragraphs require formal review and approval according to local environmental
policy.
I Assigned to paragraphs that provide only clarifying information, such as Scope statements,
definitions of terms, etc.
M Assigned to paragraphs whose primary purpose is to provide for maintainability of equipment
or systems. Maintainability provisions are those that facilitate the performance of maintenance
on equipment/systems either during downtimes or during onstream operations.
O Assigned to paragraphs whose primary purpose is to assure operability of equipment or
systems. Operability is the ability of the equipment/system to perform satisfactorily even
though conditions are off-design, such as during start-ups, process swings, subcomponent
malfunction, etc.
R Assigned to paragraphs whose primary purpose is to improve or assure the reliability of
equipment or systems. Reliability is a measure of the ability of equipment/systems to operate
without malfunction or failure between planned maintenance interventions.
S Assigned to paragraphs containing specifications/guidance where the primary purpose is the
avoidance of incidents impacting personnel safety, process safety, and the public in general
and/or involving responses to emergency situations. Any deviation from the specifications
contained in such designated paragraphs requires formal review and approval according to
local safety policy.
Personnel Safety: Refers to the prevention of incident-related personnel injuries or illness,
e.g., burns, cuts, abrasions, inhalation of or exposure to dangerous
substances, etc., that could result in medical treatment, restricted work,
lost-time incidents, or fatalities.
Process Safety: Refers to the prevention and control of process releases, fires, and/or
explosions that could result in damage to equipment, process disruption,
or personnel injury or illness.

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