BUDGET ITEM NO: 10-00688

UPGRADE SULFUR HANDLING AND EXPORT

FACILITIES - BERRI GAS PLANT

NMR 601

Document #: MRK-USHEF-NMR601-0120 REV.00

SA DUMMY PO# CRIK-F13-04-J123-DA

GATE VALVE

INDUSTRIAL VALVES MANUFACTURER (IVM)

 
  CLIENT:  BI NO:BI‐10‐00688 
  SAUDI ARAMCO 
PLANT LOCATION:  DOC. NO.:MRK‐USHEF‐NMR601‐
M.R. Al-Khathlan BERRI GAS PLANT F‐13  0120 
Company PROJECT:UPGRADE SULFUR HANDLING & EXPORT  SA CONTRACT  REVISION 
  FACILITIES @ BERRI GAS PLANT  NO.  NO. 
  DOCUMENT TITLE:NMR‐601:GATE VALVE  6600036163  00 

 
 
Document Number  : MRK‐USHEF‐NMR601‐0120 REV.00 
Vendor/Manufacturer Doc. No.  : NMR 601 
Reference MRP#  : MRK‐USHEF‐MRP‐0025  REV.00 
Purchase Order#  : MRK/PO/IVM‐937/2018 
SA Dummy PO#  : CRIK‐F13‐04‐J123‐DA 
NMR Form Number  : SA‐7925 
General Material Description:  : GATE VALVE 
 
REVIEW DATES  SUBMITTAL 
Industrial Valves Manufacturer  SIGNATURE 
START  FINISH  DATE 
Prepared by: 
27/05/2018  29/05/2018  30/05/2018  AA 
AA 
Approved by: 
29/05/2018  29/05/2018  30/05/2018  JN 
JN 
REVIEW DATES  SUBMITTAL 
SASEC (Design Contractor)  SIGNATURE 
START  FINISH  DATE 
Lead Engineer:         
 
Project Engineer:         
 
Project Manager:         
 
REVIEW DATES  SUBMITTAL 
M.R. Al Khathlan Co. (Main Contractor)  SIGNATURE 
START  FINISH  DATE 
Position: Discipline Engineer         
Shamnas Koyiloth 
Position: Procurement QC Supervisor         
Ghouse Basha 
Position: QA Manager         
Najeeb Soofi 
Position: Project Manager:         
Yatin K Dambal 
REVIEW DATES  SUBMITTAL 
SAPMT  SIGNATURE 
START  FINISH  DATE 
Position: Project Engineer         
Name: 
Position: Project Lead Engineer         
Name: 
 
 
 
 
  CLIENT:  BI NO:BI‐10‐00688 
  SAUDI ARAMCO 
PLANT LOCATION:  DOC. NO.:MRK‐USHEF‐NMR601‐
M.R. Al-Khathlan BERRI GAS PLANT F‐13  0120 
Company PROJECT:UPGRADE SULFUR HANDLING & EXPORT  SA CONTRACT  REVISION 
  FACILITIES @ BERRI GAS PLANT  NO.  NO. 
  DOCUMENT TITLE:NMR‐601:GATE VALVE  6600036163  00 

 
 
 
REVISION HISTORY
Ite (IVM)  (IVM)  (SASEC) 
Description of   Reason Of 
m  Date  Date  Approved & 
Modification & Rev #  Modification 
No.  Reviewed  Modified  Reviewed By 
1  NMR Revision. 00  30/05/18  30/05/18  First submission   
2           
3           
4           
5           
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
  CLIENT:  BI NO:BI‐10‐00688 
  SAUDI ARAMCO 
PLANT LOCATION:  DOC. NO.:MRK‐USHEF‐NMR601‐
M.R. Al-Khathlan BERRI GAS PLANT F‐13  0120 
Company PROJECT:UPGRADE SULFUR HANDLING & EXPORT  SA CONTRACT  REVISION 
  FACILITIES @ BERRI GAS PLANT  NO.  NO. 
  DOCUMENT TITLE:NMR‐601:GATE VALVE  6600036163  00 

 
 
VENDOR/MANUFACTURER: Industrial Valves Manufacturer 
NMR FORM: NMR 7925 
NMR NO.: 601.1 
 
 
601.1 – GENERAL OUTLINE 
601.2 – DETAILS OF CONSTRUCTION 
601.3 – SEAT DETAILS 
601.4 – BILL OF MATERIALS 
601.5 – WELDING PROCEDURES AND PROCEDURE QUALIFICATIONS (N/A) 
 
 
     
 
 
           APPROVED                             WITH COMMENTS 
 

 
            REVIEWED                              RESUBMIT 
 
 
  THIS APPROVAL OR REVIEW DOES NOT RELIEVE THE VENDOR / SUBVENDOR OF HIS RESPONSIBLITIES 
TO MEET ALL OF THE SPECIFIED REQUIREMENTS OF THE PURCHASE ORDER 
  SASEC (to fill) CHECKED CHECKED APPROVED
  NAME   
 
SIGN   
DATE   
   
 

REV.  DATE  DESCRIPTION  MADE BY  CHECKED BY  APPROVED BY 

00  02/06/2018  For Approval  AA  AA  JN 
           
           
           
           
           
 
 
R913- NPT- F316 F316HFS INDUSTRIAL VALVES MANUFACTURER LTD
GATE OS&Y - BOLTED BONNET SQUARE - GASKET JOINT - CLASS 1500 Customer: M.R. ALKHATHLAN C.O
- STD BORE- NPT ENDS - STD BONNET- STD STEM- STD PACKING PO #: MRK/PO/IVM-937/2018
Item # Size# Qty.
1.1 1/2” 33

General Arrangement Drawing

BILL OF MATERIAL REV

0001 WHEELNUT/LEVERNUT ASTM A582 AISI 303 0
G002 NAMEPLATE ALUMINIUM
0003 HANDWHEEL Carbon steel
0004 YOKE NUT ASTM A473 TYPE 416
0006 GLAND FLANGE ASTM A182 304
0007 GLAND STUD ASTM A193/A320 B8M
0008 GLAND UNS S31600
0009 PACKING GRAPHITE
0010 BOLTS ASTM A193/A320 B8M
0012 STEM ASTM A479 316
0013 BONNET ASTM A182 F316/316L
2014 SPIRAL WOUND GASKET S31600 + GRAPHITE
0015 SEAT ASTM A479 316 + STELLITE GR 6
0017 WEDGE ASTM A182 316
0005 STUD NUT ASTM A194 GR.8M
0018 BODY ASTM A182 F316/316L

STANDARDS
04-SAMSS-035
04-SAMSS-048

PRESSURE TEST (BAR) Shell 388 Seat 285 Back Seat 285

Pneumatic Air

Seat 6 Bar
 Industrial Valves Manufacturer
Date: 04/01/2011 Document No. : OP 024
Revision No. : 00 Page No. : 1

PROCEDURE

FOR PRESSURE TESTING OF VALVES.

Prepared by : ______Jihad______________________

Approved by : ____Ashwani Tickoo___________________________

 Industrial Valves Manufacturer
Date: 04/01/2011 Document No. : OP 024
Revision No. : 00 Page No. : 2

Index: 1. 0 Scope
2. 0 Objectives
3. 0 Applicability
4. 0 References
5. 0 Definitions
6. 0 Modality
7. 0 Responsibility
8. 0 Filing
9. 0 Forms
10.0 Revisions
 Industrial Valves Manufacturer
Date: 04/01/2011 Document No. : OP 024
Revision No. : 00 Page No. : 3

1.0 SCOPE

Scope of this procedure is to give necessary and adequate instructions on how to

perform hydraulic and pneumatic test on IVM Gate, Globe, Ball, and Check valves
up to 2 “N.D.

2.0 PURPOSES

The purpose of this procedure is to assure a correct execution of testing method.

3.0 APPLICABILITY

This procedure applies to Gate, Globe, Ball and Check valves up to 2”N.D. Hand wheel
/ lever and gear operated. This procedure contains the minimum requirements to be
observed during the hydraulic and pneumatic tests.

3.0 REFERENCE
 API 598
 04 – SAMSS – 048

5.0 DEFINITIONS

QC = Personnel of IVM Quality Control Department

DN 0 - A numerical designation of size which is common to all components in a

piping system. It is a convenient round number for reference purposes and it is only
loosely related to manufacturing dimensions.

6.0 MODALITY

Pressure tests are effected using pressure gauges with a valid calibration. Calibration
will be done in accordance with ISO 10012-1 requirements from the external approved
calibrating laboratory. The test pressure shall not be less than 30 % and not greater than
80 % of the full scale range of the pressure gauge. When required and after acceptance
by IVM Q.A. department certified pressure/time recorder shall be used in addition to
produce a permanent record of hydrostatic shell/seat tests

All valves will be vented prior to testing.

All valves are tested in accordance to the following work sequence by personnel of assembling
department. The work sequence is as follows.
a) gate and globe valves:

- body high pressure hydraulic test

- backseat pressure hydraulic test
- seat high pressure hydraulic test
- seat low pressure pneumatic test
 Industrial Valves Manufacturer
Date: 04/01/2011 Document No. : OP 024
Revision No. : 00 Page No. : 4

b) check valves:

- body high pressure hydraulic test

- seat high pressure hydraulic test

Check valves will not have pneumatic test.

c) ball valves:

- body high pressure hydraulic test

- seat high pressure hydraulic test
- seat low pressure pneumatic test

d) ball check valves

- body high pressure hydraulic test

- seat high pressure hydraulic test

Check valves will not have pneumatic seat test.

6.1.0 TEST PRESSURE AND TEST DURATION

6.1.1. Test pressure and test duration for gate, globe and check valves

- Hydraulic test pressures are in accordance with ANSI B 16.34 and reported on “LEAK TEST”
table attached (table n. 009. Pressures stated in the “LEAK TEST” table are the highest working
pressure of various material at 100 F, as stated in the ANSI B16.34, multiplied by 1.5 (for shell test)
and 1.1 times (for seat and backseat test). The pressures has been rounded to the next 25 PSI.

- The pneumatic test shall be carried out by air at a pressure of 6-7 bars and in addition, 0.345 bar
(5psig) for valves with FLARE ISOLATION”. Test duration in accordance to “LEAK TEST”
table.

6.1.2 Hydraulic test pressure and test duration for ball and ball check valves

Test pressures and test durations are reported in the attached tables (tables T-009 Rev.2)

6.2 TEST MEDIUM

* For shell, high-pressure seat and backseat tests, test medium will be clean potable water plus a
water soluble rust inhibitor and wetting agent with chloride content not exceeding 25 ppm.
Water PH shall lie between 6.0 and 8.0 for valves hydro testing.
* For low pressure seat test the fluid shall be clean and oil free air.
 Industrial Valves Manufacturer
Date: 04/01/2011 Document No. : OP 024
Revision No. : 00 Page No. : 5

6.3 TESTING

* Hydrostatic shell test procedure.

Put the valve with both ends closed and in the half open position. Fill the entire body cavity with
Water; apply the test pressure inside the valve body. After stabilization, the pressure shall be
maintained for the specified time. Examine the entire surface of the valve and the body/closures
joint and ascertain that no drops or humidity be visible during the whole duration of the test.

* Hydrostatic backseat test.

Put the valve with the both end closed, in the fully open position and packing gland loose.
Fill the entire body cavity with water; apply the test pressure inside the valve body. After
stabilisation, the pressure shall be maintained for the specified time. Examine packing area and
ascertain that no drops or humidity be visible during the whole duration of the test. Relieve the
pressure leaving the valve body cavity filled with water and turn the valve in the closed position.
Retighten properly glands packing.

* Hydrostatic high pressure seat test procedure. The outer section of the valve, adjacent to the
Upstream seat, shall be pressured at the specified pressure and held for the specified time. The
leakage rate across the tested seat shall be measured after a stabilisation period.

* Pneumatic seat test procedure.

With the valve in the half open position all water shall be removed from the body cavity.
The valve shall be de-pressurised and then closed. The section of the valve adjacent to the up-
stream seat shall be pressured with air pressure of 6-7 bars and in addition, 0.345 bar (5psig) for
valves with FLARE ISOLATION”. After a stabilisation period leakage shall be measured. On
completion of this test, the valve shall be de-pressured and the test conducted on the other seat for
gate valves.

6.4 ACCEPTANCE CRITERIA

* Admitted leakage rate for Gate, Globe and Check valves are reported on “LEAK TEST”
Table attached (table n. 009).
* Admitted leakage rate for Ball and Ball check valves shall be in accordance to BS 6755 part
1 rate B (for Hydrostatic test 0.01 x DN mm3/sec, for Pneumatic test 3,00 X DN mm3/sec).

Closer acceptance criteria shall be as per API 598 & PARA 5.2 OF 04-SAMSS-048.
 Industrial Valves Manufacturer
Date: 04/01/2011 Document No. : OP 024
Revision No. : 00 Page No. : 6

6.5 TEST TEMPERATURE

The test shall be effected at ambient temperature.

The minimum ambient and fluid test temperature shall be 17 C

6.6. TORQUE TEST

6.6.1 Torque test on gate and globe valves

The maximum torque applicable to the valve from either the open or closed position under the
maximum differential pressure recommended shall not exceed 350 N.

6.7 CLEANING

After the hydraulic and pneumatic test, valves shall be properly cleaned and dried by blowing dry
compressed air through the internal parts. An antirust protection will then be applied.

6.8 TEST DOCUMENTATION

After testing, valves, which have passed the tests successfully, end caps will be placed. A test
certificate will be issued by Certification Office of Q.C. department indicating the item no., test
pressures (to be indicated in psi or psi / bar in the test report), references Codes, IVM JOB number
and Purchaser P.O. number.

7.0 RESPONSABILITY

All personnel of assembling area has to test the valves in accordance to this procedure

8.0 FILING

In order to guarantee a correct traceability a copy of IVM certificates is filled in Certification Office
of Q.C. department.
 Industrial Valves Manufacturer
Date: 04/01/2011 Document No. : OP 024
Revision No. : 00 Page No. : 7
Table
TITLE: Leak Test Table
Date Issued by: Approved by: No.009 Rev. 2
25.08 05 Ashwani Ashwan
Leak Test ( According to Normes API 598 & BS 6755 part 1 )
TYPE OF TEST
1 Back Seat Test High Pressure Loose Studs Valve Fully Open
(Water)
2 Body Test High Pressure Tight Studs Valve Half Open
(Water)
3 Seat Test : High Pressure Tight Studs Valve Closed
Left+Right for Gate/Ball Valves (Water)
Unidirectional for Globe & Check V.
4 Seat Test : Low Pressure Tight Studs Valve Closed
Left+Right for Gate/Ball Valves (Air)
Unidirectional only for Globe Valves
TEST PRESSURE
CLASS ASME B 16.34 150 300 600 800 1500 2500 4500
1 Back Seat Test BAR 23 58 116 150 298 483 884
PSI 325 825 1658 2213 4125 6875 12375
2 Body Test BAR 32 79 158 204 395 659 1193
PSI 458 1125 2258 3009 5625 9375 16875
Seat Test :
3 Left+Right for Gate/ Ball Valves BAR 23 58 116 150 298 483 884
Unidirectional for Globe & PSI 325 825 1658 2213 4125 6875 12375
Check Valves
Seat Test :
Left+Right for Gate/Ball Valves BAR 6-7 6-7 6-7 6-7 6-7 6-7 6-7
and Unidirectional Globe Valves PSI 85-100 85-100 85-100 85-100 85-100 85-100 85-100
4
For “FLARE ISOLATION” BAR 0.354 0.345 0.345 0.345 0.345 0.345 0.345
valves PSI 5 5 5 5 5 5 5

TEST TIME TYPE OF REQUIRED TEST Max ALLOWABLE

LEAKAGE
GATE VALVES ½” TO 2” 15 sec 1+2+3+4
0
GLOBE VALVES ½” TO 2” 15 sec 1+2+3+4
BALL VALVES ½” TO 2” 15 sec 2+3+4
2 ½” TO 6” 60 sec 2+3+4
CHECK VALVES ½” TO 2” 60 sec 2 + 3 CC per Minute
1/2” 1.5
3/4” 2.2
1” 3
1 ½” 4.5
2” 6
Note: No Leakage or Seepage is allowed during Body Test.