Manual Valves, Control Valves Inspection and Testing

VALVE FUNDAMENTALS & INSPECTION
VALVE
A valve is a mechanical device that controls the flow and pressure of fluid within a
system or process. They are also known as regulators and are used in a wide variety
of applications. A valve controls system or process fluid flow and pressure by
performing any of the following functions:
1. Stopping and starting fluid flow

2. Varying (throttling) the amount of fluid flow
3. Controlling the direction of fluid flow
4. Regulating downstream system or process pressure
5. Relieving component or piping over pressure
2
VALVE
Valves can be broadly categorized based on their function as.
1. Stop (Isolation) Valves
2. Regulating Valves
3. Back-Flow Prevention Valves
4. Pressure Relief Valves
Stop (Isolation) Valves
These valves are used to stop the flow or isolate a portion of the system until it is
desirable to achieve flow downstream of the valve. The basic design requirement of
stop valves is to offer minimum resistance to flow in the fully open position and to
exhibit tight shut-off characteristics when fully closed.
Valves commonly used as stop valves are gate, globe, ball, butterfly, plug & diaphragm
valves etc.
3
VALVE
Regulating Valves
As the name indicates, these valves are used extensively in piping systems to regulate
the flow of fluid. The flow regulation is accomplished by increasing or decreasing the
flow through the valve in response to a signal from a pressure, flow or temperature
controller.
The primary requirement of a flow control valve is to predictably regulate the flow
with respect to its open position and impart the required pressure drop without
sustaining damage. Specially designed globe, needle, butterfly, ball, plug & diaphragm
valves etc.
4
VALVE
Back Flow Prevention Valves
Generally, check valves are used for the prevention of back-flow in piping system. The
valves are most self-actuating. The valve’s disk is kept open by the forward flow of
fluid and quickly closed by the reverse flow. In certain application, pneumatic
actuators may be used to help in the rapid closure of the valves on flow reversal.
Pressure Relief Valves
Pressure relief valves are used to protect piping and equipment from being subjected
to pressures that exceed their design pressure. Safety valves and relief valves
primarily serve this requirement. Generally, the seating of these valves is
accomplished by a compressed spring, which exerts a force on valve disc, pressing it
against the valve seat. When the force exerted by the fluid on the valve disc exceeds
the spring force; the valve automatically opens to release the excess pressure.
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Types of Valves
Types of Valves
Manual Valves Control Valves
© Intertek Group 6
Manual Valves
Gate Valve
Globe Valve
Check Valve
Plug valve
Ball Valve
Butterfly Valve
Needle Valve
Pressure Relief Valve
Diaphragm Valves
Control Valve
Steam Traps
Strainers
© Intertek Group 7
Gate Valve
Gate valve is the most common type of valve in any process plant. It is a linear motion valve used to
start or stop fluid flow. In service, these valves are either in fully open or fully closed position. Gate
valves are used in almost all fluid services such as air, fuel gas, feedwater, steam, lube oil, hydrocarbon,
and all most any services. Gate valve provides good shutoff.
Rising Stem Gate Valve Non-Rising Stem Gate Valve

© Intertek Group 8
Globe Valve
Globe valve is used to stop, start, and regulate the fluid flow. Globe Valves are used in the systems
where flow control is required and leak tightness is also necessary. Globe valve provides better shut off
as compared to gate valve.
Tee Pattern Globe Valve Angle Pattern Globe Valve

© Intertek Group 9
Check Valve
The check valve prevents backflow in the piping system. The pressure of the fluid passing through a
pipeline opens the valve, while any reversal of flow will close the valve.
Lift Check Valve Ball Check Valve Swing Check Valve
© Intertek Group 10
Plug Valve
Plug valve is Quarter-turn rotary motion Valve that uses a tapered or cylindrical plug to stop or start
the flow. The disk is in plug shape, which has a passage to pass the flow. Plug valve used as on-off stop
valves and capable of providing bubble tight shutoff.
Plug Valve
Ball Valve
A Ball valve is a quarter-turn rotary motion valve that uses a ball-shaped disk to stop or start the flow.
Most ball valves are of the quick-acting type, which requires a 90° turn of the valve handle to operate
the valve. The ball valve is Smaller and lighter than a gate valve of same size and rating.
Floating Ball Valve Trunnion Mounted Ball Valve

Butterfly Valve
A Butterfly valve is a quarter-turn rotary motion valve, that is used to stop, regulate, and start the flow.
Butterfly valve has a short circular body. Butterfly Valve is suitable for large valve applications due to
Compact, lightweight design that requires considerably less space, as compared to other valves.
Flanged End Butterfly Valve Wafer Butterfly Valve

Needle Valve
Needle valves are similar to a globe valve in design with the biggest difference is the sharp needle like
a disk. Needle valves are designed to give very accurate control of flow in small diameter piping
systems. They get their name from their sharp-pointed conical disc and matching seat.
Needle Valve
Pressure Relief or Safety Valve
A pressure Relief valve or pressure safety valve are used to protect equipment or piping system during
an overpressure event. This valve releases the pressure at pre-defined set pressure.
Relief Valve Safety Valve

Diaphragm Valve
Diaphragm valves are suitable for moderate throttling applications and offer several advantages over
other valves in low pressure applications. The valve has a flexible diaphragm which forms the upper
pressure boundary of the valve. This provides for excellent leek-tight properties, even when conveying
liquids containing suspended solids.
© Intertek Group Diaphragm Valve 16

Control Valve
A control valve is a valve used to control fluid flow by varying the size of the flow passage as directed
by a signal from a controller. This enables the direct control of flow rate and the
consequential control of process quantities such as pressure, temperature, and liquid level.
Control Valve
Steam Traps
Steam traps serves to discharge condensate from steam piping or steam heating equipment without
allowing live steam to escape. Presence of condensate can reduce the operating efficiency of the
system and may also cause physical damage due to “water hammer” or corrosion.
The float steam trap is density operated and the operation is purely mechanical. They utilize a float to
determine the condensate level in the body and thereby operate a valve mechanism.
Float Steam Traps Thermostatic Steam Traps

Strainers
Piping systems are provided with strainers to protect equipment sensitive to dirt and other particles
that may be carried by fluid. During system start-up and flushing, strainers may be used upstream of
pumps to protect them from construction debris that might be left over in the pipe. Wye strainers are
generally used upstream of traps, control valves and instruments.
Wye Strainer Basket Strainer

Manual Valve Parts
Regardless of type, all valves have the following basic parts, the body, bonnet or cover, trim (internal
elements), actuator and packing.
Valve Body
The valve body, sometimes called the shell, is the primary boundary of a pressure valve. It serves as
the main element of a valve assembly that holds all the parts together.
The body, the first pressure boundary of a valve, resists fluid pressure loads from connecting piping. It
receives inlet and outlet piping through threaded, bolted or welded joints.
Valve Bonnet or Cover

The cover for the opening in the body is the bonnet, and it is the second most important boundary of a
pressure valve. A bonnet acts as a cover on the valve body, is cast or forged of the same material as the
body. It is commonly connected to the body by a threaded, bolted, or welded joint.
Manual Valve Parts
Valve Trim
The removable and replaceable valve internal parts that in contact with the flow medium are
collectively termed as Valve trim. These parts include valve seat(s), disc, stem, glands, spacers, guides,
bushings, and internal springs etc.
A Valve's trim performance is determined by the disk and seat interface and the relation of the disk
position to the seat. Because of the trim, basic motions and flow control are possible. In rotational
motion trim designs, the disk slides closely past the seat to produce a change in flow opening. In linear
motion trim designs, the disk lifts perpendicularly away from the seat so that an annular orifice
appears.
Valve trim parts may be constructed of assorted materials because of the different properties needed
to withstand different forces and conditions. Flow-medium properties, chemical composition,
pressure, temperature, flow rate, velocity and viscosity are some of the important considerations in
selecting suitable trim materials. Trim materials may or may not be the same material as the valve
body or bonnet.
Valve Pressure Class Ratings
The pressure rating (also known as pressure class) is the maximum pressure a pipe, fitting or valve
should be capable of withstanding at given temperature in normal conditions.
Pressure-temperature ratings of valves are designated by class numbers. ASME B16.34. Valves-
Flanged, Threaded, and Welding End is one of the most widely used valve standards. It defines three
types of classes: standard, special and limited. ASME B16.34 covers Class 150, 300, 400, 600, 900,
1500, 2500 and 4500 valves.
Valves – Inspection & Test Requirements
➢ Chemical Analysis and Mechanical Properties as per the applicable ASTM Code
➢ Non-destructive Tests
➢ Visual & Dimensional Test
➢ Hydrostatic Test
➢ Hydrostatic Seat Leakage Test
➢ Pneumatic Seat Leakage Test
➢ Other Special Tests like FET, Cryogenic Test, Fire Safe Test etc.
➢ Final Inspection
Applicable pressure testes to the valves as per API 598 & API 6D
Shell Test
The shell test shall be made by applying the pressure inside the assembled valve with the valve ends
closed, the valve partially open, any packing gland tight enough to maintain the test pressure prior to
protective coatings inside of the valve.
Back Seat Test

Valves which have the backseat feature and shall be performed by applying pressure inside the
assembled valve with the valve ends closed. The valve fully open and the packing gland loose or
packing not installed. If the backseat test is performed after the shell test, the packing shall be
installed and / or packing glands retightened after the backseat test.
Low-Pressure Closure Test

The low-pressure closure test shall be performed with the seat sealing surface interface clean and free
from oil, grease, and sealant. If necessary to prevent galling, the sealing surfaces may be coated with a film of oil
that is not heavier than kerosene. This requirement does not apply to a valve that uses a lubricant as its primary
seal (e.g. lubricated plug valves).
Any leakage at the seat sealing surface interface, behind the seat ring, or through the disc on the open
side of the valve shall be detected when bubbles are observed coming from the closure (disc, seat, and seat ring),
covered with water or leakage that is channeled to a volumetric device for measurement.
High-Pressure Closure Test

The procedure for the high-pressure closure test shall be the same as the procedure for the low-
pressure closure test except that, in the case of a liquid test, leakage shall be detected when drops, not
bubbles.
Double Block and Bleed High-Pressure Closure Test

For a DBB valve, the pressure shall be applied successively to each side of the closure through the
valve bore leakage into the body cavity shall be checked through as opening in the bottom of the valve.
Where operational considerations do not allow for an opening in the bottom of the valve, an
alternative opening location may be specified by the purchaser, and the valve shall be DBB tested in a
positions that results in the alternative opening location being at the bottom of the valve during test.
Testing in all positions and specifically in alternative positions will require procedures that meet the
requirements, test duration shall be no less than twice the required test pressure.
Testing Duration as per API 598
Valve Size Minimum test duration in seconds
Back seat as Closure Check Closure Other

DN NPS Shell
applicable valves Valves
≤ 50 ≤2 15 15 60 15
65 to 150 2½ to 6 60 60 60 60
200 to 300 8 to 12 120 60 120 120
≥ 350 ≥ 14 300 60 120 120
Testing Duration as per API 6D
Valve Size Minimum test duration in minutes
Back seat as Closure Check Closure Other

NPS DN Shell
applicable valves Valves
≤4 ≤ 100 2 2 2 2
≥6 ≥ 150 5 5 5 5
6 to 10 150 to 250 5 5 5 5
12 to 18 300 to 450 15 5 5 5
20 and larger 500 and larger 30 5 10 10
Valves - Various ASTM, ASME, API, BS & MSS Standards
ASTM ASTM material standard (widly used)
ASTM A105 Standard Specification for Carbon Steel Forgings for Piping Applications
ASTM A182 Standard Specification for Forged or Rolled Alloy and Stainless-Steel Pipe Flanges, Forged Fittings, and Valves and Parts for High Temperature Service
ASTM A216 Standard Specification for Steel Castings, Carbon, Suitable for Fusion Welding, for High Temperature Service
ASTM A217 Standard Specification for Steel Castings, Martensitic Stainless and Alloy, for Pressure Containing Parts, Suitable for High Temperature Service
ASTM A350 Standard Specification for Carbon and Low-Alloy Steel Forgings Notch Toughness Testing for Piping Components
ASTM A351 Standard Specification for Castings, Austenitic, for Pressure-Containing Parts
ASTM A352 Steel Castings, Ferritic and Martensitic for Pressure Containing Parts, Suitable for Low Temperature Service
ASTM A488 Qualification of Procedures for Welding Castings

ASTM A494 Castings, Nickel and Nickel Alloy
ASTM A995 Castings, Austenitic-Ferritic (Duplex) Stainless Steel, for Pressure-Containing Parts
Standard Specification for Alloy-Steel and Stainless-Steel Bolting Materials for High Temperature or High-Pressure Service and other Special Purpose
ASTM A193
Applications
ASTM A194 Standard Specification for Carbon and Alloy-Steel Nuts for Bolts for High-Pressure or High Temperature Service, or Both
ASME ASME Standard Name
ASME A961 Standard Specification for Common Requirements for Steel Flanges, Forged Fittings, valves, and Parts for Piping Applications
Standard Specification for Forged or Rolled UNS N08020, UNS N08024, UNS N08026, UNS N08367, and UNS R20033 Alloy Pipe Flanges, Forged Fittings, and Valves and Parts for Corrosive High-Temperature
ASME B462
Service
Standard Specification for Pressure Consolidated Powder Metallurgy Iron-Nickel- Chromium-Molybdenum (UNS N08367) and Nickel- Chromium Molybdenum Columbium (NB) (UNS N06625) Alloy Pipe Flanges,
ASME B834
Fittings, Valves, and Parts
ASME D5500 Standard Test Method for Vehicle Evaluation of Unleaded Automotive Spark-ignition Engine Fuel for Intake Valve Deposit Formation
ASME F885 Standard Specification for Envelope Dimensions for Bronze Globe Valves NPS 1/4 to 2 El-1996 R (1996)
ASME F992 Standard Specification for Valve Label Plates El-1997 R (1997)
ASME F993 Standard Specification for Valve Locking Devices El-1997 R (1997)
ASME F1020 Standard Specification for Line-Blind Valves for marine Applications El-1996 RI'1996)
ASME F1098 Standard Specification for Envelope Dimensions for Butterfly Valves - NPS 2 to 24 EI-1993 R (1993)
ASME F1271 Standard Specification for Spill Valves for Use in Marine Tank Liquid Overpressure Protections Applications EI-1995 R (1995)
ASME F1370 Standard Specification for Pressure Reducing valves for Water Systems, Shipboard
ASME F1508 Standard Specification for Angle Style, Pressure Relief Valves for Steam, Gas, and Liquid Services
ASME F1565 Standard Specification for Pressure-Reducing Valves for Steam Service
ASME F1792 Standard Specification for Special Requirements for Valves Used in Gaseous Oxygen Service
ASME F1793 Standard Specification for Automatic Shut-Off Valves (Also Known as Excess Flow Valves, EFV) for Air or Nitrogen Service
ASME F1794 Standard Specification for Hand operated, Globe-Style Valves for Gas (Except Oxygen Gas), and Hydraulic Systems
ASME F1795 standard Specification for Pressure-Reducing Valves for Air or Nitrogen Systems
ASME A230 Standard specification for steel wire oil - tempered carbon valve spring quality
ASME A232 Standard specification for chromium - vanadium alloy steel valve spring quality
ASME A350 Standard specification for forged or rolled carbon and alloy steel flanges forged fittings and valves and parts for low - temperature service
ASME A338 Standard specification for ultrasonic examination of heavy steel forgings
ASME A694 Standard specification for forgings carbon and alloy steel for pipe flanges fittings valves and parts for high - pressure transmission service
ASME A404 Standards specification for forged or rolled alloy - steel pipe flanges forged fittings and valves and parts specially heat treated for high temperature service
ASME A522 Forged or rolled 8% and 9% nickel alloy steel flanges fittings valves and parts for low - temperature service
API API Standard Name
API SPEC6D Supplement 1 to API spec 6D (sixteenth edition) specification for pipeline valves
API STD6D Steel gate plug ball and check valves for pipeline service
API STD6D API Specification for flanged steel gate and plug valves for drilling and production service
API SPE14D API Specification for wellhead surface safety valves for offshore service
API 526 Flanged steel safety relief valves
API 527 Commercial seat tightness of safety relief valves with metal - to metal seats
API 528 API standard for safety relief valve nameplate nomenclature
API 529 Cast - forged Steel plug valves flanged ends
API 594 Wafer - type check valves
API 595 Cast - iron gate valves flanged ends
API 597 Steel venturi gate valves flanged or butt-welding ends
API 598 Valve inspection and test
API 599 Steel plug valves flanged or butt-welding ends
API 600 Flanged and butt - welding - end steel gate and plug valves for refinery use
API 602 Compact design carbon steel gate valves for refinery use
API 603 150 - pound light - wall corrosion - resistant gate valves for refinery use
API 604 Ductile iron gate valves flanged ends
API 607 Fire - resistant testing of ball valves with soft contact faces
API 609 Butterfly valves to 150 psig and 150 F
API SPEC 6FA Specification for fire test for valves
API SPEC 6FC Specification for fire test for valves with automatic backseats
API BULL 6RS Bulletin on referenced standards for committee 6, standardization of valves and wellhead equipment
API RP 11V6 Recommended practice for design of continuous flow gas lift installations using injection pressure operated valves first edition
API RP 11V7 Recommended practice for repair, testing, and setting gas lift valves
API RP 520 PT 1 Sizing, selection and installation of pressure relieving devices in refineries part 1- sizing and selection
API RP 574 Inspection of piping, tubing, valves and fittings first edition, replaces guide for inspection of refinery equipment Chapter XI
API RP 576 Inspection of pressure-relieving devices first edition
API STD 608 Metal ball valves-flanged, threaded and welding end
BS British Standard Name
BS 1212 Ball valves (Portsmouth type) excluding floats
BS 1123 Specification for safety valves, gauges and other safety fittings for air receivers and compressed air installations
BS 1414 Specification for steel edge gate valves (flanged and butt- welding ends) for the petroleum, petrochemical and allied industries
BS 1552 Control plug cocks for low - pressure gases
BS 1570 Specification for Flanged and Butt - welding ends steel plug valves for the petroleum industry (excluding well - Head and flow - line valves)
BS 1735 Specification for Flanged cast iron outside - screw - and - yoke edge gate valves class 125, size 1.5 in to 24 in for the petroleum industry
BS 1868 Specification for steel check valves (flanged and butt-welding ends) for the petroleum, petrochemical and allied industries
BS 1873 Specification for Steel globe and globe stop and check valves (flanged and butt-welding ends) for the petroleum, petrochemical and allied industries
BS 1952 Specification for copper alloy gate valves for general purposes
BS 1953 Copper alloy check valves for general purposes
BS 1968 Floats for Ball valves (copper)
BS 2060 Copper alloy screw - down stop valves for general purposes
Specification for Face - to - face, centre - to - face end - to -end and centre - to - end dimensions of flanged and butt-welding ends steel valves for the petroleum, petrochemical and allied
BS 2080
industries
BS 2591 PT.1 British standard glossary for valves and valve parts (for fluids) part 1. screw - down stop, check and gate valves
BS 2591 PT.2 British standard glossary for valves and valves parts (for fluids) part,2 safety valves and relief valves
BS 2591PT.3 British standard glossary for valves and valve parts (for fluids) part 3, Plug valves and cocks
BS 2591PT.4 British standard glossary for valves and valves (for fluids) part4, butterfly valves
BS 2591PT.5 British standard glossary for valves and valve parts (for fluids) part5, Ball valves
BS 2995 Specification for cast and forged steel wedge gate, glove, check and plug valves screwed and socket - Welding sizes 2 in and smaller for the petroleum industry
Manufacturers Standardization Society
MSS SP-6 Standard finishes for contact faces of pipe flanges of valves and fittings
MSS SP-9 Spot facing for bronze, iron and steel flanges
MSS SP-25 Standard marking system for valves, fittings, flanges and unions
MSS SP-42 Class 150 corrosion resistant gate, globe, angle and check valves with flanged and butt weld ends
MSS SP-45 Bypass and Drain connections
MSS SP-53 Quality standard for steel castings - Magnetic particle Inspection method for valves, flange, fittings and other piping components
MSS SP-54 Quality standard for steel castings - Radiographic inspection method for valves, flange, fittings and other piping components
MSS SP-55 Quality standard for steel castings - Visual inspection of valves, flanges and fittings and other piping components
MSS SP-60 Connecting flange joint between tapping sleeves and tapping valves
MSS SP-61 Hydrostatic testing of steel valves
MSS SP-67 Butterfly valves
MSS SP-70 Cast iron gate valves, flanged and threaded ends
MSS SP-71 Cast iron swing check valves, flanged and threaded ends
MSS SP-72 Ball valves with flanged or butt - welding ends for general service
MSS SP-78 Cast iron plug valves
MSS SP-80 Bronze Gate, globe angle and check valves
MSS SP-82 Valves pressure testing methods
MSS SP-84 Steel valves socket welding and threaded ends
MSS SP-86 Metric data in standards for valves, flanges and fittings
MSS SP-88 Diaphragm Valves
MSS SP-91 Guideline for Manuel operation of valves
MSS SP-93 Quality standard for steel Castings & Forgings - Liquid Penetrant Inspection method for valves, flange, fittings and other piping components
MSS SP-94 Quality standard for Ferritic and Martensitic steel Castings - Ultra sound Inspection method for valves, flange, fittings and other piping components
MSS SP-99 Instrument valves
MSS SP-110 Ball valves Threaded, Socket-Welding, Solder Joint, Grooved and Flared Ends
BS British Standard Name
BS 3464 Specification for cast iron gate valves for general purposes
BS 3808 Specification for cast and forged steel flanged, screwed and socket - welding Wedge gate valves (compact design) sizes 2 in and smaller for the petroleum industry
BS 3948 Specification for cast iron parallel slide valves for general purposes
BS 3952 Specification for cast iron butterfly valves for general purposes
BS 3961 Specification for cast iron screw - down stop valves and stop and check valves for general purposes
BS 4090 Cast Iron check valves for general purposes
BS 4133 Flanged steel parallel slide valves for general purposes
BS 4312 Flanged steel screw - down stop valves and stop and check valves for general purposes
BS 4460 Steel Ball valves for the petroleum industry
BS 5146 Specification for inspection and test of steel valves for the petroleum petrochemical and allied industries
BS 5150 Cast iron wedge and double disk gate valves for general purposes
BS 5151 Cast iron gate (parallel slide) valves for general purposes
BS 5152 Cast iron globe and globe stop and check valves for general purposes
BS 5153 Cast Iron check valves for general purposes
BS 5154 Copper alloy globe stop and check, check and gate valves for general purposes
BS 5155 Cast iron and carbon steel butterfly valves for general purposes
BS 5156 Screw down diaphragm valves for general purposes
BS 5157 Steel gate (parallel slide) valves for general purposes
BS 5159 Specification for cast iron and carbon steel ball valves for general purposes
BS 5160 Specification for Flanged steel globe valves, globe stop and check valves and lift type check valves for general purposes
BS 5351 Steel ball valves for the petroleum petrochemicals and allied industries
BS 5417 Testing of general-purpose industrial valves
BS 5418 Marking of general-purpose industrial valves
CONTROL VALVE
A control valve is a valve used to control fluid flow by varying the size of the flow
passage as directed by a signal from a controller. This enables the direct control of
flow rate and the consequential control of process quantities such as pressure,
temperature and liquid level. They accomplish this by opening the valves partially or
completely after receiving signals from controllers (Automatic controllers are used as
per application).
The opening or closing of automatic control valves is usually done by electrical,

hydraulic or pneumatic actuators.
Control valves are classified based on several
attributes and feature
1. Based on the pressure drop profile
2. Based on the movement profile of the controlling element
3. Based on the functionality
4. Based on the actuating medium
1.Based on the pressure drop profile.
High recovery valve
These valves typically regain most of static pressure drop from inlet to vena contract
at outlet. These valves are characterised with lower recovery coefficient. Examples of
high recovery valve - butterfly valve, ball valve, plug valve, gate valve etc.
Low recovery valve
These valves typically regain very less of static pressure drop from inlet to vena
contract at outlet. These valves are characterised with higher recovery coefficient.
Example of low recovery valve – globe valve, angle valve
2.Based on the movement profile of the
controlling element
Sliding stem
Here the valve stem / plug moves in a linear straight-line motion Examples - Globe
valve, angle valve, wedge type gate valve.
Rotary valve
Here the valve disc undergoes a rotary motion Examples - Butterfly valve, ball valve
3.Based on the functionality
The valve controls flow parameters proportional to input signal received from central
control system. Example - globe valve, angle valve, ball valve - Shut-off / On-off valve.
These valves regulate the pressure and temperature profile of inlet media to required
parameters at outlet.
4.Based on the actuating medium

The valve is actuated by hand wheel, Pneumatic valve. The valve is actuated using
compressible medium like air, hydrocarbon, nitrogen, spring diaphragm type, piston
cylinder type or piston-spring type, hydraulic valve. The valve actuated by non-
compressible medium like water or oil Electric valve
An automatic control valve consists of three main parts in which each part exists in
several types and designs.
Valve actuator: Which moves the valve's modulating element, such as ball or
butterfly.
Valve positioner: Which ensures the valve has reached the desired degree of
opening. This overcomes the problems of friction and wear.
Valve body: Which the modulating element, a plug, globe, ball or butterfly is
contained.
Valve Actuator
There are applications where is not possible or desirable to actuate the valve
manually by hand wheel or lever. Large valves that must be operated against high
hydrostatic pressure, those valves must be operated from a remote location when the
time for opening, closing, throttle or manually controlling the valve is longer, than
required by system-design criteria, these valves are usually equipped with an
actuator.
An actuator in the broadest definition is a device that produces linear and rotary
motion of a source of power under the action of a source of control.
Basic actuators are used to fully open or fully close a valve. Actuators for controlling
or regulating valves are given a positioning signal to move to any intermediate
position. There a many different type of actuators, but the following are some of the
commonly used valve actuators are
• Gear Actuators
• Electric Motor Actuators
• Pneumatic Actuators
• Hydraulic Actuators
• Solenoid Actuators
Valve positioner
A valve Positioner is a device used to increase or decrease the air load pressure
driving the actuator until the valve's stem reaches a “POSITION” balanced to the
output SIGNAL from the process variable instrument controller. Valve positioners are
used on controlling valves where accurate and rapid control is required without error
or hysteresis.
Positioners are generally mounted on the side-yoke or top casing of the pneumatic
actuator for linear sliding stem control valves, and at/near the end-of-shaft for
rotary control valves. For either basic design type, “mechanical feedback linkage”
connected directly to the valve’s stem provides feedback to controller. The process
controller tells the positioner to “change” position; the feedback linkage reports back
to the positioner confirming that a change has occurred and gives a “sense” of the
magnitude of the change in position.
Valve Positioner’s Principle of Operation
The valve positioner is a force-balanced instrument, with pneumatic module installed
on a double-acting actuator for air to open action. Positioning is based on a balance
of two forces: one proportional to the instrument signal and the other proportional to
the stem position. A downward force is activated as the signal pressure acts upon the
diaphragms in the instrument signal capsule, through the follower arm and cam, the
motion of the actuator stem is transmitted to the top end of the feedback spring
resulting in the varying of tension in feedback spring as stem position changes. The
system will be in equilibrium and stem will be in the position called for by the
instrument signal when these opposing forces balance exactly. The balance will move
up or down and by means of the spool valve, will change the output pressures and
flow rate if these opposing forces are not in balance. This will lead to the piston to
moving until the tension on the feedback spring opposes exactly the instrument
signal pressure.
Valve body
For control valve body as per relevant API / ASME or other required standards.
Cage
The cage is a part of the valve that surrounds the plug and is located inside the body
of the valve. Typically, the cage is one of the greatest determiners of flow within the
valve. As the plug is moved more of the openings in the cage are exposed and flow is
increased and vice versa. The design and layout of the openings can have a large
effect on flow of material (the flow characteristics of different materials at
temperatures, pressures that are in a range). Cages are also used to guide the plug to
the seat of the valve for a good shutoff, substituting the guiding from the bonnet.
Basic out line of control valve based on operation
Coefficient of velocity in control valve
Flow coefficient (Cv) is defined as the number of gallons per minute (gpm) at 60°F
that will pass through a full open valve with a pressure drop of 1 psi.
Control valve Standards
Control valve Standard
ANSI/FCI 70-2 Control Valve Seat Leakage (Formerly ANSI B16.104)
ANSI/ISA 51.1 Process Instrumentation Terminology
ANSI/ISA
Flow Equations for Sizing Control Valves
75.01.01
ANSI/ISA
Control Valve Terminology
75.05.01
ANSI/ISA Face-to-Face Dimensions for Integral Flanged Globe-Style Control Valve
75.08.01 Bodies (ANSI Classes 125, 150, 250, 300 and 600)
Control valve Standards
Control valve Standard
ANSI/ISA Face-to-Face Dimensions for Flangeless Control Valves (ANSI Classes 150,
75.08.02 300 and 600)
ANSI/ISA Face-to-Face Dimensions for Flanged Globe-Style Control Valve Bodies
75.08.06 (ANSI Classes 900, 1500 and 2500)
ANSI/ISA
Inherent Flow Characteristic and Range ability of Control Valves
75.11.01
ANSI/ISA
Hydrostatic Testing of Control Valves
75.19.01
ANSI/ISA Face-to-Centreline Dimensions for Flanged Globe-Style Angle Control
75.22 Valve Bodies ANSI Classes 150, 300 and 600
ANSI/ISA
Control Valve Response Measurement from Step Inputs
TR75.25.02
Control valve
Pneumatic schematic
Actuator
Air fails close Schematic diagram
Air fails Open Schematic diagram
Few Parts of Control Valves
Valve Sizing & Selection Body & Bonnet assembly

Body Trim
Valve Actuator Pneumatic Positioners
Smart or Intelligent Positioner Transducers or Converters
Valve Position Indicator Valve Position Transmitter
Limit Switch Hand Wheel or Hand Pump
Solenoid Valve Limit Stops
Mechanical limit stops Volume Tanks
Volume Boosters Air Buffer Bessel’s for Lock Up Actions or
Air Receivers Lock up Relay or Valve
Quick Exhaust Valve Restrictors
Air Filters (Air Set) Air Lubricator
Tubing & Fittings Antistatic devises
Seat Leakage class
CLASS I
A modification of any Class II, III, or IV valve where design intent is the same as the
basic class, but by agreement between user and supplier, no test is required.
CLASS II
This class establishes the maximum permissible leakage generally associated with
commercial double-seat control valves or balanced single-seat control valves with a
piston ring seal and metal-to-metal seats. Use test procedure Type A.
CLASS III
Class II but with a higher degree of seat and seal tightness. Use test procedure Type
A.
Seat Leakage class
CLASS IV
commercial unbalanced single-seat control valves and balanced single-seat control
valves with extra tight piston rings or other sealing means and metal-to-metal seats.
Use test procedure Type A.
Seat Leakage class
CLASS V
This class is usually specified for critical applications where the control valve may be
required to be closed, without a blocking valve, for long periods of time with high
differential pressure across the seating surfaces. It requires special manufacturing,
assembly and testing techniques. This class is generally associated with metal seat,
unbalanced single-seat control valves or balanced single-seat designs with
exceptional seat and seal tightness. Use test procedure Type B using water at the
maximum operating differential pressure or Type B1 by using air at the specified
conditions.
Seat Leakage class
CLASS VI
This class establishes the maximum permissible seat leakage generally associated
with resilient seating control valves either unbalanced or balanced single-seat with
“O” rings or similar gap-less seals. Use test procedure Type C.
Seat leakage class as per FCI 70 – 2
Test
Leakage
Maximum Seat Leakage Procedu
Class
re
Class I by agreement between user and supplier, no test is required NA
Class II 0.5% of rated valve capacity Type A
Class III 0.1% of rated valve capacity Type A
Class IV 0.01% of rated valve capacity Type A
5x 10-4 ml per minute of water per inch of seat diameter per psi differential Type B
5 x 10-12 m³ per second of water per mm of seat diameter per bar differential Type B
Class V
4.7 standard ml per minute of air per inch of orifice diameter Type B1
11.1 x 10-6 standard m³ per hour of air per mm of orifice diameter Type B1
Basic information on Test procedure Type A, B, B1 & C in control valves
SL Test Procedure Test Procedure Test Procedure

Test Procedure Type B
No Type A Type B1 Type C – Class VI
The test medium

The test medium The test medium
The test medium shall shall be clean air
shall be clean air shall be clean air or
1 be clean water at 10-52⁰ or nitrogen gas
or water at 10- nitrogen gas at 10-
C (50-125⁰ F) at 10-52⁰ C (50-
52⁰ C (50-125⁰ F) 52⁰ C (50-125⁰ F)
125⁰ F)
Basic information on Test procedure Type A, B, B1 & C in control valves
Test
SL Test Procedure Test Procedure
Test Procedure Type B Procedure
No Type A Type C – Class VI
Type B1
The water test differential
Pressure of the test pressure shall be within ± 5
Pressure of the test
medium shall be 3- % of the maximum service
medium shall be the
4 bar (45-60 psig) pressure drop across the
Inlet pressure of maximum rated
or within +/- 5% of valve plug, not exceeding the
test medium differential pressure
2 the maximum maximum operating pressure
shall be 3.5 barg across the valve plug
operating at room temperature as
(50 psig). or 3.5 barg (50psig),
differential determined by ANSI B16.1,
whichever is the
pressure, B16.5 or ASME B16.34 or
least.
whichever is less. some lesser pressure by
individual agreement.
Seat leakage as per FCI 70 – 2
Seat Leakage for Class VI as per FCI 70-2
Nominal Seat Diameter Seat Leakage Rates
ml or cc /
Millimetres Inches Bubbles per minute
minute
< = 25 ≤1 0.15 1
38 1.5 0.3 2
51 2 0.45 3
64 2.5 0.6 4
76 3 0.9 6
102 4 1.7 11
152 6 4 27
203 8 6.75 45
250 10 11.1 NA
300 12 16.1 NA
350 14 21.6 NA
© Intertek Group
400 16 28.4 NA 65
Widely followed Control valve Mounted Instrumentation and Functional Test
Procedure as applicable excluding the Low Temperature Testing Procedure
Linearity (ISA 75.05.01)

The closeness to which a curve relating to two variables approximates a straight line.
Hysteresis Error (IEC 60534-4)

The maximum deviation between the two calibration curves of the measured
variables as obtained by an upscale going traverse and a downscale going traverse
over the full range and subtracting the value of dead band.
Dead band (IEC 60534-4)

Finite range of values within which reversal of the input variable does not produce
any noticeable changes in the output variable.
Basic Functional Acceptance tests.
Zero & Span
The Positioner is mounted on valve and as per manufacturer installation procedure,

the zero and span of the valve full stroke is calibrated to 4-20 mA (Analog
signal/HART) and 0-100% (digital signal/ FF) as applicable. The default stem lift
characteristic is Linear. For split range application, the valve stroke is calibrated for the
given range of input signal as per requirement.
Stroke positions for Linearity & Hysteresis test
The input signal is varied in both opening and closing directions in the following
sequence 50%, 75%, 100%, 75%, 50%, 25%, 0%, 25% and 50%. The actual position
against the input signal is tabulated for calculating the linearity and hysteresis error.
Linearity Error
From the recorded actual position of the valve, the deviation from the corresponding
input signal is calculated and the maximum deviation is given as Linearity error. The
value shall be within the requirement and the maximum allowable Linearity error
shall be ±1.5% of full Stroke.
Hysteresis
From the recorded actual positions, calculate the difference between the actual stem
positions in forward and reverse direction for every input. Subtracting the value of
dead band at the test position gives the hysteresis error. The value shall be within the
requirement and the maximum hysteresis error shall not exceed 2 % of full stroke.
Dead Band
Dead Band shall be evaluated by measuring and monitoring stem position in response
to signal changes at the following positions 25%, 50% & 75% Using the loop
calibrator/ Handheld communicator (FF ), stroke the valve to the test position and
change the input in lowest possible steps in opposite direction. The minimum span of
signal taken for an observable movement in valve position shall be given as the valve
dead band. The value shall be within the requirement and the maximum allowable
dead band shall be 1.5 % of input span for PTFE based packing and 2% of
input span for graphite packing.
Low band and High band
The control valve with positioner shall start to open (or close), when an input signal
between 0% and 3% of span is added to the lower value of the signal range. The valve
shall be fully open (or closed), when an input signal between 97% and 100% of the
signal range is applied. Note: For valves with digital Positioners (HART & FF enabled),
these values are optional as they can be programmed.
(Cut-off, split range, signal modification, etc.)
Supply Failure Mode
Fail open valves.
Position the valve approximately at 50% open. On disconnecting the power supply
and valve must fully open. Position the valve approximately 50% open. On
disconnecting the air supply, the valve must fully open.
Fail close valves
Position the valve approximately at 50% open. On disconnecting the power supply
and the valve must fully close. Position the valve approximately at 50% open. On
disconnecting the air supply, the valve must fully close.
Fail Stay-put valves
Position the valve at 50%. On disconnecting the air supply, the valve stem motion
shall not exceed 5% of full stroke for 5 minutes from the current position. If valves
have signal/Power fail (positioner) stay-put requirement, Position the valve
approximately at 50% open. On disconnecting the power supply the valve stem
motion shall not exceed 5% of full stroke for 5 minutes from the current position.
Limit Switches
The Limit Switches are mounted on valve and the valve is stroked to 0% and 100%.
Check the operation of the Switches at respective positions. Assure that the limit
switch is activated / deactivated as applicable within 10% of the full stroke it is
intended to monitor.
Position Transmitter
Connect a 4-20mA loop calibrator to the Positioner as input signal. Connect another
loop calibrator to the Position Transmitter module and set to “Read Mode”. Check the
readings for 0%, 25%,50%, 75% & 100% of full Stroke, the linearity error shall be
within the requirement and the maximum allowable linearity error shall be 2% of full
stroke.
Solenoid Valve
Give 100% signal to the Positioner so that the valve is fully opened / closed against
fail position. Disconnect the power supply from the solenoid valve the valve should
open/close within the time specified in the data sheet / valve specification sheet.
Overshoot
Conduct a step-input test for 25%, 50%, 75% of Stroke in both directions. The
maximum deviation from steady state value is recorded as overshoot. The valve
overshoot shall be less than 3% of full stroke.
Valve Opening Time
Position the valve at full closed position and hold for approximately 5 seconds.
Change the input signal corresponding to valve fully open position. The time taken by
the valve from fully closed position to reach full mechanical open limit after the
change of input signal is recorded as opening time. The time should be within the
specified limits if applicable.
Valve Closing Time

Position the valve at fully open position and hold for approximately 5 seconds.
Change the input signal corresponding to valve full close position. The time taken by
the valve from fully opened position to reach full mechanical close limit after the
change in input signal is recorded as closing time. The time should be within the
specified limits if applicable.
Manual override
Before operating the hand wheel, ensure the valve is in fail safe position and the
’Auto/Manual’ valve should be in manual mode. Ensure the hand wheel operation is
smooth for full stroke.
Valve Positioners
Positioners are devices used to put the valve in the correct position by increasing or
decreasing the air load pressure on the actuator. Valve positioners are used for
controlling valve where accurate and rapid control is required without error or
hysteresis. There are different types of control valve positioners.
• Force-balance pneumatic positioner

• Motion-balance pneumatic positioner
• Electro-pneumatic valve positioner
• Electronic positioner
Force Balance pneumatic positioner
The above shown is an air to open control valve. In force-balance pneumatic
positioner, a 3-15 psi control signal is used to control the pneumatic supply to the
valve diaphragm. When control signal applies the force, beam moves upwards closing
the Nozzle. The force beam is also connected to the valve stem through the spring
when the valve closes the force beam lifts to up closing the flapper nozzle.
Closing the flapper nozzle increase the pressure to the valve diaphragm starts closing
the valve. Like all force-balance systems, the force beam motion is constrained by the
balancing forces, such that its motion is negligible for all practical purposes. In the
end, equilibrium is achieved by one force balancing another, like two teams of people
pulling oppositely on a length of rope, so long as the two teams’ forces remain equal
in magnitude and opposite in direction, the rope will not deviate from its original
position.
Motion balance pneumatic positioner
In this mechanism, an increasing signal pressure causes the beam to advance toward
the nozzle, generating increased nozzle backpressure which then causes the
pneumatic amplifying relay to send more air pressure to the valve actuator. As the
valve stem lifts up, the upward motion imparted to the right-hand end of the beam
counters the beam’s previous advance toward the nozzle. When equilibrium is
reached, the beam will be in an angled position with the bellows’ motion balanced by
valve stem motion.
Electro pneumatic valve positioner
In Electro-pneumatic valve positioner, the force to close and open the nozzle is
balanced by valve stem position and by input current signal. Input current signal in
range 4-20mA is used to increase the magnetism of the coil placed in force beam
which has the same polarity to the ring magnet placed above the force beam. The
beam get away from the force beam closing the nozzle.
Electronic positioner
Electronic valve positioners, use an electronic sensor to detect valve stem position, a
microprocessor to compare that sensed stem position against the control signal by
mathematical subtraction (error = position − signal), then a pneumatic signal
converter and relay(s) to send air pressure to the valve actuator.
We have not just one, but two control algorithms working together to maintain
proper valve position: one monitoring and controlling pressure applied to the
actuator (compensating for changes in air supply pressure that might otherwise affect
the valve’s position) and the other monitoring and controlling stem position itself,
sending a cascaded control signal to the pressure control components.
The command signal tells the positioner where the valve stem should be positioned.
The positioner (PI) calculates how much air pressure at the actuator should be
needed to achieve the requested stem position.
The next controller (PID) drives the I/P(current-to-pressure) converter as much as

necessary to achieve that pressure. If anything causes the valve stem to not be at the
commanded position, the two controllers inside the positioner work together to force
the valve to its proper position.
SEAT LEAKAGE CLASS - ALTERNATIVE AIR TEST LEAKAGE SCFH.
SEAT LEAKAGE CLASS - ALTERNATIVE AIR TEST LEAKAGE SCFH.
➢NDT (Non-Destructive Testing)
Types of NDT which is recommended / used for valve components
• Visual inspection
• Radiographic Examination
• Magnetic particle Examination
• Liquid penetrant Examination
• Ultrasonic Examination.
Visual inspection
Visual inspection is very common, basic and at most first inspection for any materials in any form in industry
(castings, forging, rolling & welding, etc.), for Valves this inspection performed on valve pressure bounding
components, pressure retaining components, fasteners and other parts.
Castings: MSS – SP -55 (II to XII - A & B)
Type I- Hot Tears and Cracks.

Linear surface discontinuities or fractures caused by either internal or external stresses or a
combination of both acting on the casting. They may occur during or after solidification. In
general,
visible surface cracks and/or hot tears are not acceptable.
Type II - Shrinkage.
A void left in cast metals as a result of solidification shrinkage and the progressive freezing of
metal,
which is exposed upon cutting off risers and gates.
Visual inspection
Type III - Sand Inclusions.
Sand that becomes entrapped in the molten metal and shows on the surface of the casting.
Type IV - Gas Porosity.
Voids in cast metal caused by entrapment of gas during solidification.
Type V- Veining.
Features on the surface of castings appearing as a ridge and associated with movement or cracking of
sand.
Type VI - Rat Tails.
Features on the surface of castings appearing as a depression resulting from faulting or buckling of the
mould surfaces.
Type VII - Wrinkles, Laps, Folds, and Cold shuts.
Surface irregularities caused by incomplete fusing or by folding of molten metal surfaces.
Visual inspection
Type VIII - Cutting Marks.
Irregularities in casting surfaces resulting from burning or mechanical means used in the cleaning of
castings.
Type IX - Scabs.
Slightly raised surface blemishes that are usually sand crusted over by a thin porous layer of metal.
Type X - Chaplets.
Evidence of chaplets on surface of casting disclosing incomplete fusion, which likewise can apply to
internal chills.
Type XI - Weld Repair Areas.
Evidence of improper surface preparation after welding.
Type XII - Surface Roughness.
Surface texture due to design, pattern, gating, and sand conditions.
Visual inspection
Forgings: ASTM A961 Clause 15:
The finished parts shall be cleaned to remove all scale and processing compounds prior to the final
surface examination. The cleaning process shall not injure the surface finish, material properties, or the
metallurgical structure. The cleaned parts shall be protected to prevent recontamination. Protective
Coatings on parts subsequently subjected to socket welds or butt welds shall be suitable for welding
without removal of the coating. When specified in the purchase order, parts may be furnished in the
as-formed or as-forged condition.
Depth of Injurious Imperfections— selected typical linear and other typical surface imperfections shall
be explored for depth. When the depth encroaches on the minimum specified wall thickness of the
finished part, such imperfections shall be considered injurious.
Visual inspection
Imperfections Not Classified as Injurious—Surface imperfections not classified as injurious shall be treated as
follows:
Seams, laps, tears, or slivers not deeper than 5 % of the actual wall thickness at the point of interest or 1/16
in. [1.6 mm], whichever is less, are acceptable. If deeper, these imperfections require removal, and shall be
removed by machining or grinding.
Mechanical marks or abrasions and pits shall be acceptable without grinding or machining provided the
depth does not exceed 1/16 in. [1.6 mm]. If such imperfections are deeper than 1/16 in. [1.6 mm] but do not
encroach on the minimum wall thickness of the forging they shall be removed by machining or grinding to
sound metal.
The wall thickness at the point of grinding, or at imperfections not required to be removed, shall be
determined by deducting the amount removed by grinding, from the nominal finished wall thickness of the
part. In any case, the wall thickness shall not be less than the specified minimum value.
RADIOGRAPHIC EXAMINATION
Radiographic Examination or Testing is a non-destructive testing method used to inspect materials with the help of its short
wavelength electromagnetic radiation. From security to forensics, radiographic testing is used in a broad range of
applications. It is done by two different radioactive sources, i.e., X-rays and gamma rays. As the tests are highly radioactive,
they should be carried out under strict rules.
REF STANDARD:
ASME Section V : Non-destructive Examination

ASME Section VIII Div-1 : Rules for Construction of Pressure Vessels
ASME B16.34 : Valves—Flanged, Threaded, and Welding End
ASME SE1030 : Standard Practice for Radiographic Examination of Metallic Castings.
MSS SP-54 : Quality Standard for Steel Casting for Valves, Flanges and Fittings and Other Piping
Components -Radiographic Examination Method
ASTM E94 : Standard Guide for Radiographic Examination
ASTM E 1815 : Standard Test Method for Classification of Film Systems for Industrial Radiography
ASTM E 446 : Standard Reference Radiographs for Steel Castings Up to 2in. (50.8 mm) thickness.
ASTM E 186 : Standard Reference Radiographs for Heavy Walled (2 to 4½in. 50.8 to 114 mm) Steel Castings
ASTM E 280 : Standard Reference Radiographs for Heavy-Walled (4½ to 12-in. 114 to 305mm) Steel Castings
ASTM E 272 : Standard Reference Radiographs for High-Strength Copper-Base and Nickel-Copper Alloy
Castings
REF STANDARD:
Description Requirements
Test Standard ASTM E94 / ASME Sec V
ASME B16.34 App – I & MSS SP-54
Acceptance Standard NORSOK M-630 & ASME Sec VIII Div. 1 App – 7
API 6A Annex O Clause 7.4.2.3.15 (C)
Area of coverage 100% or Critical area as defined in ASME B16.34
Stage of Test After final heat treatment and prior to final machining operations.
IQI ASTM IQI and IQI selection to achieve 2% and a 2-2T quality level
Film Type Film equal to or finer grained than Type 2 of ASTM E94 / ASTM E1815
2 – 4T for thickness up to and including 19 mm for hole type IQI

Sensitivity
2 – 2T for thickness greater than 19 mm for hole type IQI 2% sensitivity for wire type IQI
Single film viewing: 1.5 to 4.0
Film Density Range
Superimposed viewing: 1.0 to 2.5 for each single film and maximum 4.0 for double film
REF STANDARD:
Examined thickness equal or Examined thickness over 50 mm Examined thickness over 115 mm
Discontinuity Type Category
less than 50mm. (ASTM E 446) through 115mm. (ASTM E 186) through 305mm. (ASTM E 280)
Gas A A2 A3 A3
Sand B B3 B3 B3
Shrink, Type 1 C CA2 CA3 CA3
Shrink, Type 2 C CB3 CB3 CB3
Shrink, Type 3 C CC3 CC3 CC3
Shrink, Type 4 C CD3 -- --
Hot tears and D None None None
Cracks E None None None
Inserts (chills, chaplets) F None None None
MAGNETIC PARTICLE EXAMINATION
Magnetic Particle Inspection is a technique used to detect surface and slightly subsurface flaws in most
ferromagnetic materials such as iron, nickel, and cobalt, and some of their alloys. Because it does not necessitate
the degree of surface preparation required by other non-destructive test methods, conducting MPT is relatively
fast and easy. This has made it one of the more commonly utilized NDE techniques.
REF STANDARD:

ASME B 16.34 : Valves - Flanged, Threaded, and Welding End
MSS SP-53 : Quality Standard for steel castings and forgings for Valves, Flanges and Fitting Other
Piping Components – Magnetic Particle Examination Method
ASTM E709 : Standard Recommended Practice for Magnetic Particle Examination
ASTM A275 : Magnetic Particle Examination of Steel Forgings
ASTM E125 : Reference Photographs for Magnetic Particle Indications on Ferrous Castings
ANSI/API SPEC 6A : Specification for Wellhead and Christmas tree Equipment.
REF STANDARD:
Description Raw Material (Before machining) Finished components (After Machining)
ASTM E709 for Casting / ASTM A275 for

Test Standard ASTM E709 for Casting / ASTM A275 for Forging
Forging
Acceptance ASME B16.34 App – II, MSS SP-53 & ASME

ASME B16.34 App – II, MSS SP-53 & ASME Sec VIII Div. 1 App-6
Standard Sec VIII Div. 1 App-6
No relevant rounded indication ≥ 5mm.

Acceptance No relevant linear indication. Additionally, no indication allowed in
Criteria No four or more relevant indications in a line separated by 1.5mm or less edge to edge. machined sealing surfaces
No more than ten relevant indications in any continuous 6 Sq. inch area.
All accessible machined surfaces incl.

Area of Test 100 % of all accessible internal and external surfaces
sealing surfaces of each finished parts
After final heat treatment and final

Stage of Test After final heat treatment
machining
ACCEPTANCE CRITERIA:
CASTINGS (As per MSS SP 53)
LINEAR INDICATIONS
a) 0.3 in. (8mm) long for materials up to 0.5 in. (13mm) thick.
b) 00.5 in. (13mm) long for materials 0.5 in. to 1 in. (13mm to 25mm) thick.
c) 0.7 in. (18mm) long for materials over 1 in. (25mm) thick.
ROUNDED INDICATIONS
a) 0.3 in. (8mm) dia for materials up to 0.5 in. (13mm) thick.
b) 0.5 in. (13mm) dia for materials over 0.5 in.(13mm) thick.
Four or more rounded indications in a line separated by 0.06 in. (2mm) or less edge to edge are
unacceptable. Unless the total length does not exceed the individual diameter, size allowed for the
material thickness being evaluated.
FORGINGS AND ROLLED or WORUGHT MATERIALS (As per MSS SP 53)
LINEAR INDICATIONS
a) 0.2 in. (5mm) long for materials 0.5 in. (13mm) or less thick.
b) 0.4 in. (10mm) long for materials over 0.5 in. to 1 in. (13mm to 25 mm) thick.
Linear indications must be separated by a distance greater than the length of longest, adjacent acceptable linear
indication.
ROUNDED INDICATIONS
b) 0.3 in. (8mm) dia for materials over 0.5 in. (13mm) thick.
Four or more rounded indications in a line separated by 0.06 in. (2mm) or less edge to edge are unacceptable.
Unless the total length does not exceed the individual diameter, size allowed for the material thickness being
evaluated.

Castings as per B16.34 Appendix II
Linear Indications
(1) 8-mm (0.3-in.) long for materials up to 13-mm (0.5-in.) thick
(2) 13-mm (0.5-in.) long for materials 13-mm to 25-mm (0.5-in. to 1.0-in.) thick
(3) 18-mm (0.7-in.) long for materials over 25-mm (1.0-in.) thick
For linear indications, the indications must be separated by a distance greater than the length of an acceptable
indication. A linear indication is one with length in excess of 3 times the width.
Rounded Indications
(1) 8-mm (0.3-in.) diameter for materials up to 13-mm (0.5-in.) thick
(2) 13-mm (0.5-in.) diameter for materials over 13-mm (0.5-in.) thick
Four or more rounded indications in a line separated by 1.5 mm (0.06 in.) or less edge to edge are unacceptable.
Rounded indications are those that are not defined as linear indications.

Forgings and Rolled or Wrought Material as per B16.34 – Appendix II
Linear Indications
(2) 10-mm (0.4-in.) long for materials over 13-mm (0.5-in.) to 25-mm (1-in.) thick
(3) 15-mm (0.6-in.) long for materials over 25-mm (1.0-in.) thick.
Indication. A linear indication is one with length in excess of 3 times the width.
Rounded Indications
(2) 8-mm (0.3-in.) diameter for materials over 13-mm (0.5-in.) thick.
Four or more rounded indications in a line separated by a 1.5 mm (0.06 in.) or less edge-to-edge are unacceptable.

LIQUID PENETRANT EXAMINATION
Liquid penetrant testing is a nondestructive material examination procedure used to check for deficiencies such as
cracks by spreading a thin liquid dye onto the material's surface, followed by the application of a developer. Liquid
penetrant testing is also known by several other names, such as liquid penetrant examination, dye penetrant
testing, dye penetration test, and dye penetrant inspection.
REF STANDARD:

ASME B 16.34 : Valves - Flanged, Threaded, and Welding End.
MSS SP- 93 : Quality Standard for Steel Castings and Forgings for Valves, Flanges and Fittings and
Other Piping Components – Liquid Penetrant Examination method
ASTM E165 : Standard Practice for Liquid Penetrant Examination for General Industry
ANSI/API SPEC 6A : Specification for Wellhead and Christmas tree Equipment.

REF STANDARD:
Description Raw Material (Before machining) Finished components (After Machining)
Test Standard ASTM E165 ASTM E165

ASME B 16.34 App-III, ASME B 16.34 App-III,
MSS SP-93, MSS SP-93,
Acceptance Standard
ASME Sec VIII Div.1 App-7 & 8, ASME Sec VIII Div.1 App-7 & 8,
API 6A Clause 7.4.2.2.9 API 6A Clause 7.4.2.2.9
No relevant rounded indication ≥ 5mm.
No relevant linear indication.
Acceptance Criteria Additionally, No indication allowed in machined sealing surfaces
No four or more relevant indications in a
line separated by 1.5mm or less edge to edge
All accessible machined surfaces including sealing surfaces of

Area of Test 100 % of all accessible internal and external surfaces
each finished part
Stage of Test After final heat treatment After final heat treatment and final machining
Penetrant Dwell Time Minimum 10 minutes Minimum 10 minutes
Final interpretation shall be made between 10 to 60 minutes after wet Final interpretation shall be made between 10 to 60 minutes after
Interpretation Time
developer is dry. wet developer is dry.

CASTINGS (As Per MSS SP 93)
LINEAR INDICATIONS
a) 8mm (0.3 in) long for material up to 13 mm (0.5 in) thick.
b) 13mm (0.5 in) long for material13mm to 25 mm (0.5 in to 1.0in) thick.
c) 18mm (0.7 in) long for material over 25 mm (1.0in.) thick.
For linear indications, the indications must be separated by a distance greater than the length of an
acceptable indication.
ROUNDED INDICATIONS
a) 8mm (0.3 in) dia long for material up to 13 mm (0.5 in.) thick.
b) 13mm (0.5 in) dia long for material over 13mm (0.5 in.) thick.
C) Four or more rounded indications in a line separated by 1.5mm (0.06in) or less edge to edge are unacceptable.

FORGINGS AND ROLLED or WROUGHT MATERIALS (As per MSS SP 93)
LINEAR INDICATIONS
a) 0.2 in. (5mm) long for materials 0.5 in. (13mm or less) thick.
b) 0.4 in. (10mm) long for materials over 0.5 in. to 1 in. (13mm to 25mm) thick.
indication.
ROUNDED INDICATIONS
b) 0.3 in. (8mm) dia for materials over 0.5 in. (13mm) thick.
c) Four or more rounded indications in a line separated by 1.5mm (0.06in) or less edge to edge are unacceptable.

Castings as per B16.34 Appendix III
Linear Indications
(2) 13-mm (0.5-in.) long for materials 13-mm to 25-mm (0.5-in. to 1.0-in.) thick
(3) 18-mm (0.7-in.) long for materials over 25-mm (1.0-in.) thick
indication. A linear indication is one with length in excess of 3 times the width.
Rounded Indications
(2) 13-mm (0.5-in.) diameter for materials over 13-mm (0.5-in.) thick
Four or more rounded indications in a line separated by 1.5 mm (0.06 in.) or less edge to edge are unacceptable.

Forgings and Rolled or Wrought Material as per B16.34 – Appendix III
Linear Indications
(2) 10-mm (0.4-in.) long for materials over 13-mm (0.5-in.) to 25-mm (1-in.) thick
(3) 15-mm (0.6-in.) long for materials over 25-mm (1.0-in.) thick.
Indication. A linear indication is one with length in excess of 3 times the width.
Rounded Indications
(2) 8-mm (0.3-in.) diameter for materials over 13-mm (0.5-in.) thick.
Four or more rounded indications in a line separated by a 1.5 mm (0.06 in.) or less edge-to-edge are unacceptable.

ULTRASONIC EXAMINATION:
Ultrasonic testing is a form of nondestructive testing. Ultrasonic testing uses special equipment to send high
frequency sound waves to penetrate a material's thickness. Other special equipment is then used to receive these
sound waves. Determinations about material condition and discontinuities can be made based on how the high
frequency sound waves are returned to the recording equipment.
Ultrasonic testing can be used to detect a variety of discontinuities. Material thickness checks can be done to
determine the extent of corrosion a component has undergone. This is especially useful when only one side of the
component is accessible. Ultrasonic testing can also be used to detect flaws that radiographic inspection may not
be able to detect. Discontinuities such as laminations, when observed perpendicular to the plane of the
lamination, are not easily detectable by X-ray; ultrasonic testing is better suited for detecting this flaw.

REF STANDARD:

ASME B16.34 : Valves—Flanged, Threaded, and Welding End
MSS SP-94 : Quality standard for Ferritic and Martensitic Steel Castings for Valves, Flanges, a Fittings
and Other Piping Components – Ultrasonic Examination Method
ASTM A388 : Standard practice for Ultrasonic Examination on Steel Forgings
ASTM A745 : Standard practice for ultrasonic examination of austenitic steel forgings
ASTM A609 : Standard practice for castings, carbon, low-alloy and martensitic stainless steel,
Ultrasonic examination thereof
ANSI/API SPEC 6A : Specification for Wellhead and Christmas Tree Equipment.

REF STANDARD:
Description Raw Material (Before machining)

Test Standard ASTM A388 for forgings / ASTM A609 for castings
ASME B16.34 App – IV & MSS SP-94
Acceptance
API 6A Clause 7.4.2.3.15 for PSL 3/3G
Standard
API 6A Clause 7.4.2.4.11 for PSL 4
ASME B16.34 / API 6A PSL2

• Straight beam examination: Indications equal to or exceed 6.4 mm diameter, flat-bottomed hole in a calibration test piece of thickness equal to the
defect depth are unacceptable.
• Angle beam examination: Indications equal to or exceed 60-deg V-notch, 25 mm long and having a depth not greater than 5% of the nominal wall
Acceptance
thickness in a test piece are unacceptable.
Criteria
API 6A – PSL 3
• No single indication exceeding reference DAC
• No two or more indications each exceeding 50 % of the reference DAC within 13 mm of each other in any direction.
• No continuous cluster of indications on the same plane, regardless of amplitude, shall be found over an area twice the diameter of the search unit
Reference blocks shall be made from similar product form (Cast or Forge) that give an acoustic response similar to the product being examined, Like similar
Reference block
composition and heat treatment as the product it represents.
Area of 100 % of all accessible surfaces.

coverage (In addition to straight beam examination, angle-beam examination shall be performed for rings and hollow forgings)
Stage of test After final heat treatment and prior to final machining operations.
Acceptance Standard ASME B 16.34 – Appendix -IV

Straight Beam Examination
Indications that are equal to or exceed that obtained from a 6.4-mm (0.25-in.) diameter, flat-bottomed hole in a
calibration test piece of thickness equal to the defect depth are unacceptable.
Angle Beam Examination

Indications that are equal to or exceed those obtained from a 60-deg V-notch, 25-mm (1.0-in.) long and having a
depth not greater than 5% of the nominal wall thickness in a test piece are unacceptable.

Manual Valves, Control Valves Inspection and Testing

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Manual Valves, Control Valves Inspection and Testing

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VALVE FUNDAMENTALS & INSPECTION

1. Stopping and starting fluid flow

Manual Valves Control Valves

Rising Stem Gate Valve Non-Rising Stem Gate Valve

Tee Pattern Globe Valve Angle Pattern Globe Valve

Lift Check Valve Ball Check Valve Swing Check Valve

Floating Ball Valve Trunnion Mounted Ball Valve

Flanged End Butterfly Valve Wafer Butterfly Valve

Relief Valve Safety Valve

© Intertek Group Diaphragm Valve 16

Float Steam Traps Thermostatic Steam Traps

Wye Strainer Basket Strainer

Valve Bonnet or Cover

➢ Visual & Dimensional Test

➢ Hydrostatic Seat Leakage Test

➢ Pneumatic Seat Leakage Test

Back Seat Test

Low-Pressure Closure Test

High-Pressure Closure Test

Double Block and Bleed High-Pressure Closure Test

Valve Size Minimum test duration in seconds

Back seat as Closure Check Closure Other

200 to 300 8 to 12 120 60 120 120

≥ 350 ≥ 14 300 60 120 120

Valve Size Minimum test duration in minutes

Back seat as Closure Check Closure Other

20 and larger 500 and larger 30 5 10 10

ASTM A488 Qualification of Procedures for Welding Castings

The opening or closing of automatic control valves is usually done by electrical,

2. Based on the movement profile of the controlling element

3. Based on the functionality

4. Based on the actuating medium

4.Based on the actuating medium

Control valve Standard

ANSI/FCI 70-2 Control Valve Seat Leakage (Formerly ANSI B16.104)

ANSI/ISA 51.1 Process Instrumentation Terminology

Control valve Standard

Valve Sizing & Selection Body & Bonnet assembly

SL Test Procedure Test Procedure Test Procedure

The test medium

Linearity (ISA 75.05.01)

Hysteresis Error (IEC 60534-4)

Dead band (IEC 60534-4)

The Positioner is mounted on valve and as per manufacturer installation procedure,

Valve Closing Time

• Force-balance pneumatic positioner

The next controller (PID) drives the I/P(current-to-pressure) converter as much as

Castings: MSS – SP -55 (II to XII - A & B)

Type I- Hot Tears and Cracks.

Forgings: ASTM A961 Clause 15:

ASME Section V : Non-destructive Examination

2 – 4T for thickness up to and including 19 mm for hole type IQI

Shrink, Type 1 C CA2 CA3 CA3

Shrink, Type 2 C CB3 CB3 CB3

Shrink, Type 3 C CC3 CC3 CC3

Shrink, Type 4 C CD3 -- --

Hot tears and D None None None

Cracks E None None None

Inserts (chills, chaplets) F None None None

ASME Section V : Non-destructive Examination

Description Raw Material (Before machining) Finished components (After Machining)

ASTM E709 for Casting / ASTM A275 for

Acceptance ASME B16.34 App – II, MSS SP-53 & ASME

No relevant rounded indication ≥ 5mm.