Control Station Piping Layout

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Control valves are located as single items in piping systems or are furnished with
up and downstream block valves and a bypass valve. These multi-valve
arrangements are called control stations.

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#Control_Station

Flanged Control Valves

The blocks and bypass valves are used so that the system can continue to operate
during maintenance work on the control valve.

Threaded Control Valves

In the most common control valve arrangement, the block valves are located in the
vertical section of the assembly, with the control and bypass valve in the horizontal
section.

The globe valve can be used to regulate line flow manually while the control valve
is out of service.

Basic Arrangement of Control Station

Arrangement for Angle Control Valves

Arrangement (a) and (c) are suitable for sediment free fluids in lines carrying
sediments. Place the bypass valve at the highest level than the control valve to
reduce the risk of bypass line becoming plugged.
Control Stations for Steam
For other arrangements (e.g. for steam control valve station), the upstream bloc
valve is also located in horizontal leg of the piping to accommodate adequate
condensate removal.

Station suitable for turbine and other steam users.

Continuously operating station suitable for all conditions including
freezing.
Station for intermittent use suitable for open air use in freezing
climate.
Low point drains and trunion based supports are also furnished at control valve
stations.

Stations for liquids harmful to personnel

Locating Control Stations
1. Control valve stations are preferably located at grade for the inline unit and
at main operating levels for the vertical arrangements.
2. It is not absolutely necessary to locate control valve stations in such a way
that pneumatic or electrical interconnections are kept to a minimum; however,
usually, the control valve is located in the same area as its source of control – for
 example, to facilitate the connection between the vessel level controller and its
associated control valve.
3. The prime considerations, however, are cost and for the more expensive
piping systems, accessibility.
4. Control valve stations are located within process areas for ease of operation
and maintenance, preferably on either side of the access aisles, adjacent to
equipment and structural columns.
5. When locating control valves with valve positioners, the plant layout
designer must allow adequate clearance between structural columns and vessels.
6. In case of fail to open valve, only one drain upstream of control valve is
required.
7. In Case of Fail to Close valve, two drains on both sides of control valve are
required.

Control Valves Piping Layout

Control valves, block and by-pass valves shall be sized on the PID. Control valves
shall be accessible from grade or platforms unless otherwise approved for
good process or economic reasons on an individual item basis.

Control valves shall be located in sight of instruments or indicators showing the

variables they control. Unless otherwise approved by Owner, control valves shall
be located high enough to permit valve stem removal, but not higher than 900 mm
above grade or platform.

Where vaporization occurs in control valves, they shall be placed as close as

practical to the destination of the stream. Control valve bypass piping shall provide
sufficient clearance for the removal of the control valve from the loop.

All control valves shall be provided with block valves and bypass valves rated for
the same design pressure as the upstream piping. Bypass valves shall be designed
for a capacity at least equal to the capacity of the control valve. Flanged spools
shall be used between flanged control valves and block valves. The length of the
spools shall be sufficient to permit removal of bolts and the installation of drain
or vent connections.

Valved 3/4″ drains shall be provided on the isolatable spool upstream of control
valves.
All control valves in socket weld piping shall be flanged. The only devices which
may be mounted on control valves shall be valve positioners, volume boosters,
lock-up relays and pressure controllers. These devices shall be installed so as to be
easily accessible for servicing. These devices shall not be mounted when vibration
may cause malfunction.

Supporting of Control Stations

Control station groups and by-pass, when located at grade adjacent to rack columns
or other structures, are normally supported from grade to avoid additional loads not
foreseen during structural design. Groups weighing less than 2500 N may be
supported from structure beams.

The use of spring supports at ground is to be minimized..