valves testing procedure (internet)

DOC. NO.: KVT-P0707-1

REV. NO.: 0 Fluid flow &

Valve specialist

TEST AND INSPECTION PAGE 1 OF 13

TEST AND INSPECTION PROCEDURE

FORGED & CAST STEEL VALVES

99. 07. 07 최 초 작 성

개정 일자 REV. DATE

내 용 DESCRIPTION

작 성 PREPARED

검 토 CHECKED

검 토 CHECKED

승 인 APPROVED

FORM P1003-1(0) KEY VALVE TECHNOLOGIES LTD.



Valve specialist


1. SCOPE

This procedure covers inspection and pressure test requirements of forged steel valves and cast steel valves to be supplied for the customers.

1. 1. APPLICABLE STANDARDS The following standards shall be applied : ANSI B16.34 : STEEL VALVE, FLANGE AND WELDING ENDS ISA S75.19 : HYDROSTATIC TESTING OF CONTROLS VALVES IEC STD IEC-534-4 : INDUSTRIAL PROCESS CONTROL VALVES, PART 4 ANSI/FCI-70-2 : AMERICAN NATIONAL STANDARD FOR CONTROL VALVE SEAT LEAKAGE API 600 : STEEL GATE VALVES, FLANG AND BUTT- WELDING API 602 : COMPACT STEEL GATE VALVE. API 598 : VALVE INSPECTION AND TEST MSS SP-55 : QUALITY STANDARD FOR STEEL CASTINGS-VISUAL METHOD. 1.2 . TEST AND INSPECTION ITEMS

The following tests and inspections shall be conducted.

MATERIAL INSPECTION NON-DESTRUCTIVE EXAMINATION(If performs) * RADIOGRAPHIC EXAMINATION(RT) * LIQUID PENETRANT EXAMINATION(PT) VISUAL AND DIMENSIONAL TEST PRESSURE TEST * SHELL TEST * BACK SEAT TEST (For manual globe & gate valve only) * SEAT TEST(SEAT LEAKAGE TEST PER ANSI/FCI 70-2 FOR CONTROL VALVES) * LOW - PRESSURE SEAT TEST (PNEUMATIC SEAT TEST) FUNCTIONAL(OPERATION) TEST RUST PREVENTION AND PAINTING INSPECTION QUANTITY AND IDENTIFICATION INSPECTION

2. TEST AND INSPECTION 2. 1 Material inspection 2.1.1. Identification of material to be inspected * (1) BODY * (2) FLANGE * (3) BONNET * (4) COVER 2.1.2. Material certificates for asterisked (*) items are to be submitted to the customer 2.1.3. Material to be used shall be identified as the materials in approval drawings. 2.1.4. The charge number put on the material shall be identified as the charge number referred to the

relative material certificate and the contents of with applicable material standard / code.




Valve specialist


3.0 NON-DESTRUCTIVE EXAMINATION 3.1. Liquid penetrant examination 3.1.1. Extent of examination Liquid penetrant Examination (PT) shall be carried out on the valve as per the following items. Parts / area to be applied with Liquid Penetrant Examination

-. AII Butt Weld Ends of Valve Body. -. Welded area of Body to End flange

3.1.2. Time of Examination The examination shall be carried out on raw material or after rough-machining process and shall

be done on finish-machined surface after finish-machining process. 3.1.3. Procedure for examination and acceptance criteria shall be as follows APPLICABLE PART AND

AREA CRITERIA PROCEDURE ACCEPTANCE CRITERIA

* Butt Welded Ends * Welded area of Body to End flange

ANSI B16.34 ANNEX D.

ANSI B 16.34 ANNEX D.

3.1.4. Recording

Records shall be made for the following items: a. Date of examination b. Manufacturer’s Job No. c. Name of interpreter d. Materials e. Judgment f. Time of Examination

4. VISUAL INSPECTION 4.1 External and internal surfaces of castings be free from harmful defects, such as blow holes, fins, sand

inclusion burning and cracks. 4.2. Castings shall be identified by visual inspection as that they are in accordance with MSS SP – 55. 4.3. Machined surfaces shall be from harmful defects. 4.4. Seat surfaces shall be free from blowholes and other harmful defects. 4.5. Corners and fillets without specified dimensions shall be properly chamfered or rounded. 4.6. Flow path portions shall be properly finished and cleaned. 4.7. Valve bodies shall have specified markings on the surface (trade marks, rating, size, flow direction,

material identification and others.) 4.8. Forging shall be free from laps, fullering scars and cracks.





Valve specialist


5.0 PRESSURE TESTS 5.1 Tests required Items

The following pressure tests shall be made on each valves. Shell test - all valves Backseat test – all manual globe and gate stop valves except swing check Low pressure seat and seal weld seat - all valves except swing check for low pressure seat test.

5.2 Test fluid

For shell and backseat test, fluid shall be water. For the low pressure seat test, fluid shall be air. Water used for any test may contain a water soluble oil or a rust inhibitor. Test fluid viscosity is no higher than that of water.

5.3 Test pressure

Test pressure shall be as per TABLE-3 and TABLE-2. 5.4 Test duration

Test duration shall be as per TABLE-3 and TABLE-4. 6.0 SHELL AND BACKSEAT TEST PROCEDURE 6.1 Backseat The backseat test is made by applying the pressure inside the assembled valve

with the valve ends closed. the valve fully open and the packing gland loose. 6.2 Shell

The shell test shall be made prior to any painting of the shell. The shell test is made by applying pressure to the assembled valve internal with the valve ends closed. During shell testing the valve must be opened. And the packing gland sufficiently tight to maintain the test pressure, thereby testing the packing chamber also.

Acceptance standard : no visible leakage 6.3 Seat Leakage Test 6.3.1 Hydrostatic test

The test shall be made by applying the test pressure specified in para 5.3 and maintaining the pressure for a duration specified in para 5.4 to check any sign of leakage from the seating portion and inside the valve. When a small amount of leakage is allowed for the valve, the amount of leak shall be measured by maintaining the test pressure for a duration sufficient to permit the measurement of leak. The method of applying the test pressure for each type of valve shall be as follow.




Valve specialist


- For gate valves, the pressure shall be applied to the inlet side with the gate closed so that the body and bonnet may retain the teat pressure. Examination shall be made to check any sign of leakage from the outlet side. Valves with no indication of flow direction shall also be tested on the seat of the other side, or both valve seat faced shall be simultaneously tested under condition of both flanged ends opened after giving pressure to inside of valve body and bonnet / cover and closing valve. - For globe valves and angle valves, the pressure shall be applied from upstream of the seat with the valve closed. - For lift and swing check valves, the pressure shall be applied, with back- pressure side filled with water. - For control valves, the pressure shall be applied from upstream of the seat with the valve closed in according to control valve specification(data sheet). <Acceptance criteria > Allowable seat leakage for gate and globe valves shall be less than the value in Table 5. Allowable seat leakage for lift and swing check valve shall be less than 3 cubic centimeter per minute per inch of diameter of nominal pipe size. Allowable seat leakage for control valves shall be meet the value in Table 5-1.




Valve specialist


7.0. LOW PRESSURE SEAT AND SEAT SEAL WELD TEST PROCEDURE 7.1. Gate Valves

The air pressure is applied successively to each side of the closed valves with the other side open to the atmosphere and covered with water to check leakage of the downstream side of the seat closure. Air must be blown in so that it is trapped inside the valve cavity. Leakage through the seat of the valve shall be detected by observation of bubbles when the seat is covered with water. Later cover with water seat seal weld area to check for leakage. Permissible leakage through the seat shall be following Table 5 and no leakage is allowed through the seal weld.

7.2. Globe Valves

The pressure is applied from below the closed disc through the valve end clamped to the air test fixture with the other side open to the atmosphere to check leakage of the downstream side of the closure including the seat seal weld. Any leakage at the seat on the open end of the valve shall be detected by observation of bubbles when the seat and weld is covered with water. Acceptance standard for seat shall be following Table 5, and leakage through seal welds not permitted.

7.3. Check Valves

Air Pressure Seat Seal Weld Test Procedure. The pressure (5.6barG air) is applied from below the closed disc through The valve and clamped to the air test fixture with the other side open to the atmosphere to check the seal weld. Any leakage shall be detected by observation of bubbles when the weld is covered with water. A device that holding clapper in closed position can be used on seat. Leakage through seal welds not permitted.

8. 0 FUNCTIONAL(OPERATION) TEST

Assembly functional inspection shall be carried out of valve as follows. 8.1. General requirements 8.1.1. Serial number of each part, material, outside appearance, clean shall be in accord-

ance with the instructions. 8.1.2. Sealing agent, lubricant, seize inhibitor shall be applied as per the Instructions. 8.1.3. Outside appearance, dimensions and position of assembled valves shall be as

per the instructions. 8.1.4. Easy operation shall be obtained without any irregular torque when the valve is

closed. 8.1.5. Valve lift shall be obtained as specified.




Valve specialist


8.1.6. Nameplate and markings shall be as per the instructions. 8.1.7. Valve indicator shall be kept to indicate correct position of valve travel. 8.1.8. Gland packing shall be equally fastened, not to be fastened one side. 8.2. Gate valve 8.2.1. when the valve has been fully closed, the center of seating surface of the wedge shall be located at the upper position for the center of seating surface of the valve body. 8.2.2. When the valve has been fully opened, the bottom of the wedge shall be not intrude into the passage of fluid. 8.3. Globe valve 8.3.1. Disc and seat are on the same concentric circle and disc shall perfectly fit on seat when valve has been fully closed. 8.3.2. Valve lift shall be enoughly obtained and disc shall smoothly lotate. 8.4. Lift and Swing check valve 8.4.1. Check by manually operation that function for opening and closing disc up to the stopper positioned on valve body or cover shall be smoothly obtained. 8.4.2. Open and close of disc shall be easily obtained with its weight. 8.5. Electric Motor Operated Valves 8.5.1. Test items and time of test. All of the electric motor operated valves shall be tested upon assembling. 8.5.2. Test method and acceptance standards. 8.5.2.1. All wiring of the motor and other equipment shall be checked to assure conformance to the drawing. 8.5.2.2. Limit switches and torque switches shall function properly and correctly in the full open closed positions. 8.5.2.3. It shall be verified that the change from manual operation to motor operation, and vice versa, may be accomplished smoothly. 8.5.2.4. No-load operation (with no pressure applied in the valve) Operate the valve from the full open position to closed position over three times to verify that the maximum current, operating current, starting current are within the specified values. The starting current shall be the design current of motor.




Valve specialist


8.5.2.5. Loaded operation. (operation under the design pressure applied toward the inlet of the disc) Opening / closing shall be motor operated more than three times, and make sure that start up current, in-operation current are respectively within specification. However, start up current shall be under motor design current value. 8.5.2.7. Make sure opening / closing times conforms with the specification . Acceptance criteria shall be as follows. Acceptance criteria : To be within 110% of planned. But, to be maintained for three seconds if duration is specified within three seconds and below. 8.5.2.8. Make sure that valve lift conforms with the specification. Acceptance criteria shall be as per TABLE-6. 8.5.2.9. The full open bad closed positions of valves shall conform respectively, to those indicated by the position indicator of motor actuator. 8.5.2.10 Seat leakage Test Manual operation To be the same procedure as clause 7 and seat seal weld test shall be done in accordance with clause 8. Motor operation Pressurize closing-off differential pressure (hydraulic pressure) specified in the specification after disc has been fully closed. And when test pressure is higher than the closing differential pressure, after clamped additionally by hand and test shall be performed. ( C) Acceptance criteria : To be as per TABLE-5. Performance test of equipment as electrical components. Insulation resistance shall be tested by 500 voltmegger to assure it least 30 Mega-ohms. The dielectric strength tests at specified voltages shall be made by equipment manufacturer and it shall be verified on the test report that no abnormality exists in pressure retaining parts. Records Results of inspections and tests specified in paragraphs 3 to 9 shall be recorded on test reports, which shall be submitted. DIMENSIONAL INSPECTION The main dimensions such as face - to -face, end flanges and drilling shall be measured in comparison with applicable drawings. Allowable dimension is to be shown in TABLE-7 to TABLE-9.




Valve specialist


Allowable valve for internal diameter “D” of socket for socket welded area shall be defined as an extent from minimum dimension to maximum dimension specified as per ANSI B16.11 (as shown in approval drawings.) The dimension shall be taken on the completed valve each type and size by 20% sampling or 5 sets max. But the purchaser keeps the right to require to increase a percentage of the check if necessary. The surface finish of end flange shall be checked in comparison with applicable drawings. RUST PREVENTION AND PAINTING INSPECTION The procedure for Paint shall be as per the manufacturer’s standard. The procedure for Rust Prevention shall be as per the manufacture’s standard. QUANTITY AND IDENTIFICATION TEST Quantity shall be visually confirmed according to the specification in accordance with the supply list. CONFIRMATION FOR PACKING AND MARKING. For Packing and Marking, the following points shall be visually checked.

Shipping Marks

Identification Marks

Plant Marks

Care Marks

Volume, style And Type of Package

Fixation of Goods

Material of Package

Condition of Package

FORM P1003-1(0) KEY VALVE TEDHNOLOGIES LTD.



Valve specialist


TABLE-1 Test Pressure (Gate & Globe Valve) UNIT : BarG TABLE-2 Test Pressure (swing & Check Valve ) UNIT : BarG TABLE-3 Test duration (Gate and Globe valve )


SHELL TEST PRESSURE HIGH PRESSURE SEAT & BACK SEAT TEST

CLASS WCB

A105

WC6

F11

CF8 CF3 F304

LOW PRESSUR

E

SEAT

WCB

A105

WC6

F11

CF8 CF3 F304

150 31.1 31.1 29.4 5.6 21.8 22.1 21.1

300 77.6 77.6 75.9 5.6 56.2 56.9 54.9

600 153.5 155.2 150.0 5.6 112.4 113.8 109.3

800 207.0 207.0 206.9 5.6 152.O 152.O 145.9

1500 384.4 387.9 372.4 5.6 281.4 284.5 273.1

SHELL TEST PRESSURE HIGH PRESSURE SEAT

CLASS WCB

A105

WC6

F11

CF8 CF3 F304

WCB

A105

WC6

F11

CF8 CF3 F304

150 31.1 31.1 29.4 21.8 22.1 21.1

300 77.6 77.6 75.9 56.2 56.9 54.9

600 153.5 155.2 150.0 112.4 113.8 109.3

800 207.0 207.0 206.9 152.0 152.0 145.9

VALVE SIZE SHELL (SEC.) BACKSEAT(SEC.) SEAT (SEC.)

2” & SMALLER 15 15 15

2-1/2” TO 6” 60 60 60

8” TO 12” 120 60 120

14” & GERATER 300 60 120



Valve specialist


TABLE-4 Test Duration (Check valves ) TABLE-5 Maximum allowable leakage rates for closure tests.

* 1 milliliter is considered equivalent to 16 drops.

Warning : Air must pass through filter to prevent the deposit of foreign particles on seating faces.

TABLE-6 Tolerance For Motor Operated Valve Lift

Note (a) For gate valve, the bottom of a disc shall not be at flow

passage when a disc has been fully opened. (b) To be as 2mm, when tolerance of ±15% is shown as below 2mm.


VALVE SIZE SHELL (SEC.) SEAT (SEC.)

2” & SMALLER 15 15

2-1/2” TO 6” 60 60

8” TO 12” 120 120

14” & GERATER 300 120

VALVE SIZE (NPS) SHELL (SEC.) SEAT (SEC.)

2” & SMALLER 0 ( * drop ) 0 ( bubble )

2-1/2” TO 6” 12 ( * drop ) 72 ( bubble )

8” TO 12” 20 ( * drop ) 120 ( bubble )

14” & GERATER 28 ( * drop ) 168 ( bubble )

SPECIFIED LIFT (mm) TOLERANCE

GATE VALVE GLOBE VALVE

up to 20 ± 15 %

over 20 up to 40 ± 10% ± 10 %

over 40 up to 100 ± 5 % ± 5 %

over 100 up to 200 ± 3 % ± 3 %

over 200 up to 350 ± 2.5%

over 350 ± 2 %



Valve specialist


TABLE -7 Dimensional Tolerances of Flange Unit : mm


Designation of Dimension

Surface Condition

Dimensional Divisions Tolerance

Black Skin up to 300 +4 -2

over 300 up to 600 +5 -2

over 600 up to 1000

+6 -2

over 1000 +8 -3

Finished up to 300 ±1

over 300 up to 600 ±1.5

over 600 up to 1000 ±2

Outside Dia. D

over 1000 ±2.5

Black Skin up to 100 ±2.0

over 100 up to 250 ±2.5

over 250 up to 450 ±3.0

over 450 up to 500 ±4.0

Inside Dia. d

over 500 ±5.0

C ±1.6 Bolt Hole P Drilled ±0.5

up to 20 ±0.8 g Finished

over 2 ±0.5 Gasket Facing

f Finished ±0.5

up to 20 +1.5 0

over 20 up to 40 +3.0 0

Finished, One Face

over 40 up to 100 +4.8 0

up to 20 +1 0

over 20 up to 50 +1.5 0

Thick. Of

Flange t

Finished, Both Faces

over 50 up to 100 +2 0



Valve specialist


TABLE-8 Dimensional Tolerance for Butt Welding End TABLE-9 Tolerances for Face to Face Dimension, Parallelness and Squareness of Valve Unit : mm


Face to Face Dimension Parallelness Nominal size

Globe, Gate and Check Valves Angle Valves and Squareness

up to 4B ±30 °

5B to 10B ±1.5 ±0.8

±20 °

12B and over ±3.0 ±1.5 ±15 °

valves testing procedure (internet)

Documents