INTRODUCTION FOR QUALITY

AND TESTING ASPECTS FOR

SERVICE & AUTOMATED VALVES .
QUALITY & TESTING ASPECTS
TEST DESCRIPTION AS PER
REFERENCE ISO 17292,RECORD
DOCUMENTS API 6D,SYSTEM
API 598.
DIMENSION GENERAL ARRANGEMENT IR
DRAWING
HYDRO-STATIC TEST FOR HYDRO-STATIC TEST IR
SHELL (applicable for soft PACK (GAD, ITP, P&ID)
& metal seated valves)
HYDRO-STATIC TEST FOR GAD, ITP, relevant IR
SEAT (metal seated valves) STANDARDS
PNEUMATIC TEST FOR GAD & ITP IR
SOFT SEATED VALVES
FET ITP & relevant IR
SPECIFICATIONS
LTT ITP & relevant IR
SPECIFICATIONS
VISUAL APPEARANCE ASME Sec V IR
PAINTING (DFT check, NACE IR
WFT check)
DOCUMENTS REVIEW MTC’s & CALIBRATION DATA SHEET
TC’s
PERFORMANCE & GAD, ITP, relevant Manufacturer’s equipment
FUNCTIONAL TEST specifications certificate
TAGGING & MARKING GAD IR
PPE ( Personal Protective Equipment)
• PRODUCTION IS MUST BUT
QUALITY COMES FIRST
•ON BEHALF THIS SLOGAN THE
PERSSONEL SHOULD ALSO
FOLLOW THE PPE FOR HAVC
HAZARDS
•BOILER SUIT FOR COMFORT AND
FIRE HAZARD
•SAFETY SHOES FOR PROTECTION
OF ALL TOE FINGERS OF LEG
•HELMET OR HARD HAT FOR
PROTECTION FROM HEAVY ITEM
COMING IN DOWNSTREM IN HIGH
FORCE .
•GOGGLE TO PROTECT SENSIBLE
PART OF HUMAN BODY CALLED
EYES.
•GLOVES FOR PROTECTION OF
FINGERS AND PALM
VALVES TYPES

GATE VALVE

GLOBE VALVE

PLUG VALVE

BUTTERFLY VALVE

CHECK VALVES

BALL VALVE

NEEDLE VALVE
 GLOBE VALVE
•Consist of a movable disk type
element and a stationary ring seat
in a generally spherical body.
• the plug is connected to
a stem which is operated by screw
action using a hand wheel in
manual valves.
•Provided with back seat.
 GATE VALVE
•Gate valves shall have an obturator
that moves in a plane perpendicular to
direction of flow.
•Provided with backseat or secondary
stem sealing feature in addition to
primary stem seal.
 PLUG VALVE
• Plug valve shall have a cylindrical or
conical obturator that rotates about an
axis perpendicular to the direction of
flow.
•Plug valves are designed to operate
with a lubricant / sealant.
•The lubricant provides an integral
sealing and corrosion preventative
film.
• As the plug is covered by the
lubricant over all surfaces, a smooth,
controlled actuation is achieved over
extended maintenance periods.
 BUTTERFLY VALVE
•A butterfly valve is a valve which can be used
for isolating or regulating flow.
•The closing mechanism (Obturator) takes
the form of a disk.
•metal disc is mounted on a rod.
• Operation is similar to that of a ball valve,
which allows for quick shut off.
CHECK VALVE

Check valve shall have an obtuator which responds automatically to block fluid in one
direction.

Also known as non-return valve or one-way valve.

Cracking pressure in check valve - the minimum upstream pressure at which the valve will
operate.
Swing CV
Piston CV

Check valves
Dual-plate CV
Non-slam CV
BALL VALVES

Ball valves shall have a spherical obtuator that rotates on an axis perpendicular to
direction of flow.

Ball valves are durable and usually work to achieve perfect shutoff even after
years of disuse.
 Floating BV Trunnion
BV

Full Bore type BV Reduced Bore type

BV
Slim line
DBB

Mono Flange
DBB
NEEDLE VALVE
Instruments Inside & outside
caliper
Vernier caliper

Micromete
Serration r
comparator

Thread gauge

Measuring
tape
 Pressure Gauges

All pressure
measuring devices must
have an accuracy within
±2% of the full scale
reading.

Pressure
measurements shall be
made between 25% &
75% of the full pressure
range of the measuring
device.

Calibration of the
gauges should be
carried out in specific
intervals.
FAT (Factory Acceptance Test)

Hydro seat Pneumatic

Shell test
test seat test

•Valve ends must be •Valve is at full •Valve is full

closed off and the closed position closed position
obturator placed in with hydro with air pressure.
partially open pressure.
position during the •Test pressure
test. should not be less
•No visible leakage than 1.1 times test
permitted. pressure rating
•Test pressure to be 1.5
times or more test
pressure rating.
Dimensional Inspection
CRITICAL DIMENSIONS TO BE CARRIED OUT AFTER
ASSEMBLY OF VALVES
 Torque Testing

•The maximum torque or thrust

required to operate ball , gate or plug
valves shall be measured at the specified
hydrostatic seat pressure
•Torque test shall be carried out with
bare stem (Where fitted with Gear box,
the measured torque value shall
include Mechanical Advantage)
• The electrical resistance between the obturator and the
valve body, & between the stem and valve body which is
measured using a direct current power source not more
than 12V.
•The resistance value obtained should not exceed 10
Ω(Ohms) & it be measured before pressure testing.
 FUNCTIONAL TEST
•The valve shall be tested for
proper operation, by cycling the
actuator from the normal
position to
the fully stroked position, a
minimum Closed
of 3 times. position
•The valve shall operate smoothly
in both directions.

Open position
 FET (Fugitive Emission Testing)
• Leakage rate shall be detected using
sniffer probe technique, and shall be
consistently measured in either
atm·cm3/s or Pa·m3/s.
• The valve flange joints shall be sealed
with an adhesive foil type with max
thickness of 40μ with a hole at
highest
point to sniff the leakage.
• Leakage shall be measured with valve
at half open position.
• FE shall be measured at:
1. Valve stem/stuffing box,
2. Body/bonnet/flange seals.
DAILY TESTING REPORT
• All internally tested valves data is entered in this document.
• This document is maintained on a daily basis.
• Data such as Valve description, its Internal testing result, pressure applied
while testing, etc are added with respective date of testing.
DPTR (Dimensional & Pressure Test Report

• In DPTR, data regarding

Dimension & Pressure is
entered.
• All dimension required
are entered such as Face to
Face, Flange OD, Flange
thickness, etc.
• Pressure used while
testing valve is entered
with the respective
holding time.
• Data regarding valve
such as work order
number, PO Item no, Tag
no, material used, Drg no.
etc is also present.
HEAT NUMBER & SERIAL
NO.

Material
Heat No.

Serial No.
Thank You….