RESEARCH AND TECHNOLOGY CENTER NUMBER

11211 FM 2920 Tomball, TX 77375

40200
Title: Page Revision

Inspection and Testing Procedures for Plug Valves 1 of 8 F

SPECIFICATION

NAME DATE
Originator Jack Barrington April 11, 1989
Checked Ed Rios April 11, 1989
Design Jack Barrington April 11, 1989
Approved Jerry DeLaat April 11, 1989

Rev ECN # Date Rev ECN # Date

A 3363 8/10/94 D SEE ECN 7/14/03
B 5134 11/5/98 E SEE ECN 9/12/03
C SEE ECN 10/8/2002 F SEE ECN 10/16/03

SPECIFICATION FORM Form #BJT079 Revision 1

 RESEARCH AND TECHNOLOGY CENTER NUMBER
11211 FM 2920 Tomball, TX 77375

40200
Title: Page Revision

Inspection and Testing Procedures for Plug Valves 2 of 8 F

1.0 SCOPE

1.1 This specification covers the minimum recommended practice for inspection, pressure testing and
identification of all plug valves.

2.0 GENERAL

2.1 Plug valves shall be inspected and tested in strict accordance with the procedures described within
this specification at intervals not to exceed twelve (12) months.

2.2 Each district shall be responsible for the performance of required inspections and tests.

2.3 Region personnel, in accordance with Specification No. 40438, will assign each plug valve a unique
serial number.

2.4 Acceptable and unacceptable limits:

2.4.1 Components that are in compliance with this specification will be identified and returned to
service.

2.4.2 Components not in compliance with the requirements of this specification will be identified
and immediately removed from service. Disposition of unacceptable components will be
subject to further inspection to determine if repairable or if replacement is necessary.

2.4.3 Unacceptable components shall be identified by either applying an "X" or other unique
symbol with aerosol spray paint of a color contrasting to the equipment paint color, or
attachment of a device clearly identifying the item as unacceptable. See Inspection Standard
No. 40421 Paragraph 8.0 for additional identification requirements.

3.0 INSPECTION

3.1 Prior to hydrostatic test, all external and internal surfaces shall be visually inspected to ensure such
surfaces are free from signs of erosion, corrosion, and/or surface imperfections.

3.2 Additional items to be inspected shall be in accordance with the following:

(Disassembly may be required).

SPECIFICATION FORM Form #BJT079 Revision 1

 RESEARCH AND TECHNOLOGY CENTER NUMBER
11211 FM 2920 Tomball, TX 77375

40200
Title: Page Revision

Inspection and Testing Procedures for Plug Valves 3 of 8 F

3.2.1 Female Union Sub

Female union sub ACME threads shall be thoroughly cleaned and visually examined to
ensure threads are free of any injurious defects (i.e. cracks, chips, etc.). Sharp edges or
burrs shall be removed with a fine flat file to parent metal only. The union sub will be
inspected using the appropriate gauge kit according to the gauge kit manufacturer’s
instructions.

3.2.2 Union Seals/O-Rings

All union seals/o-rings shall be visually examined and shall be free of cuts, blemishes or
other injurious defects. If defects are found o-rings/seals shall be replaced.

3.2.3 Male Union Sub

Male union sub seal face shall be thoroughly cleaned and visually examined to ensure it is
free of any injurious defects. Burrs or sharp edges shall be removed with a fine flat file to
parent metal only. The union sub will be inspected using the appropriate gauge kit according
to the gauge kit manufacturer’s instructions

3.2.4 Wing Nuts

The wing nut shall be removed, thoroughly cleaned and visually examined to ensure the
threads are free of any injurious defects. Sharp edges or burrs on the body of the wing nut
shall be removed with a fine flat file to parent metal only. Rolled over edges or metal
fragments on hammer lugs shall be ground smooth. Care must be taken not to grind on the
body of the nut. If the nut is found to be gouged or grooved from grinding, it shall be
removed from service and discarded. Wing nut hammer lugs having 1/8” or less across the
flat at the top of the hammer lug shall also be removed from service and discarded. The
retainer segments and retainer ring shall be visually examined to ensure they are free of any
injurious defects. The wing nut will be inspected using the appropriate gauge kit according
to the gauge kit manufacturer’s instructions.

3.2.5 Ultrasonic Testing

SPECIFICATION FORM Form #BJT079 Revision 1

 RESEARCH AND TECHNOLOGY CENTER NUMBER
11211 FM 2920 Tomball, TX 77375

40200
Title: Page Revision

Inspection and Testing Procedures for Plug Valves 4 of 8 F

The male sub neck shall be ultrasonically tested in accordance with BJ Services
Specification 40212. Inspection points are indicated on the plug valve checklist. See
pressure and wall thickness chart for maximum allowable working pressure and minimum
allowable wall thickness. Plug valves with wall thickness less than those shown shall be
removed from service.

3.2.6 Reserved

3.2.7 Plug Valve Body

The plug valve body and all internal components shall be disassembled, thoroughly cleaned,
and inspected in accordance with the manufacturer's recommended procedure if there is
reason to suspect the valve may be leaking or is damaged.

3.2.8 Union Gauge Kit

P/N 861827 - 1-1/2” 1502

P/N 76111 - 2” 1502
P/N 854064 - 3” 1502
P/N 861828 - 4” 602
P/N 861829 - 4” 1002

4.0 RESERVED

5.0 PRESSURE TEST

5.1 All plug valves shall be hydrostatic pressure tested to its maximum allowable working pressure (see
pressure chart) at intervals not to exceed twelve (12) months. Hydrostatic pressure tests shall be
performed in accordance with the following procedure.

5.2 Hydrostatic Test Procedure

Hydrostatic pressure test each plug valve to ensure that all internal parts and surfaces are exposed
to the maximum working pressure. Caution should be exercised that all components used in the
pressure test are the proper size and/or pressure rating , and that the operating temperature is within
the component manufacturer’s recommendation.

SPECIFICATION FORM Form #BJT079 Revision 1

 RESEARCH AND TECHNOLOGY CENTER NUMBER
11211 FM 2920 Tomball, TX 77375

40200
Title: Page Revision

Inspection and Testing Procedures for Plug Valves 5 of 8 F

5.2.1 Caution must be exercised to ensure all air is bled from all systems that may hold
pressure prior to starting the hydrostatic test. Plug off connections and fill plug valve
with water. Apply pressure according to paragraph 5.2.3. After the plug valve has been
fully tested, it is beneficial to pressure test the plug valve in the closed position. Connect test
plug either to male or female end while leaving the opposite end open to atmosphere.
Introduce pressure per paragraph 5.2.3. Repeat this process to the opposite end.

5.2.3 The plug valve shall be pressured up to (1) 500 psi for one (1) minute, (2) increase to
1,000 psi for one (1) minute, (3) to 7,500 psi for one (1) minute, then (4) pressure increase
in increments of 10% of maximum working pressure until maximum working pressure is
reached. Maximum allowable working pressure shall be held for a minimum of three (3)
minutes with no indication of leakage. If leakage occurs, the defective component shall be
removed and further inspected to determine if repairable or if replacement is necessary.

5.2.4 Upon successful completion of hydrostatic pressure test, the equipment being tested and all
systems containing pressure shall be bled to 0 psi prior to being disconnected.

5.2.5 An identification band shall be attached to each component as indicated on the parts
checklist. Each band shall be marked, in letters no less than 1/4" in height, with the
following:

1. Serial Number
2. Date of Inspection

6.0 INSPECTION RECORD

A permanent and progressive record shall be maintained for each plug valve at each district. This record
shall contain such information as necessary to record results of successive inspections and tests (i.e. test log,
chart recording, ultrasonic test results, etc.). The serial number of each plug valve shall be referenced on all
information contained in each individual record.

SPECIFICATION FORM Form #BJT079 Revision 1

 RESEARCH AND TECHNOLOGY CENTER NUMBER
11211 FM 2920 Tomball, TX 77375

40200
Title: Page Revision

Inspection and Testing Procedures for Plug Valves 6 of 8 F

PLUG VALVE MINIMUM WALL THICKNESS AND

MAXIMUM ALLOWABLE WORKING PRESSURE CHART

MINIMUM WALL NEW NOMINAL WALL MAX. ALLOWABLE

THICKNESS THICKNESS WORKING PRESSURE

SIZE MFG. MALE FEMALE MALE FEMALE

1 1/2 –1502 DR150 FMC .350” .439” .540” .975” 15,000 PSI
2”-1502 SP150WU 1” X 2” SPM .300” .250” .570” .580” 15,000 PSI

2”-1502 DR 150 1” X 2” FMC .330” .307” .810” .780” 15,000 PSI

2”-1502 150WU SPM .300” .380” .550” .990” 15,000 PSI

2”-1502 DR-150 FMC .330" .433" .545” .970” 15,000 PSI

2:-2002 DR200 FMC .420” .526” .645” .975” 20,000 PSI

2" 2002 DR100 1” X 2” FMC .420" .526” .670” 1.000” 20,000 PSI
3”-1002 DR 50 FMC .370” .452”* .670” 1.125” 10,000 PSI

SPECIFICATION FORM Form #BJT079 Revision 1

 RESEARCH AND TECHNOLOGY CENTER NUMBER
11211 FM 2920 Tomball, TX 77375

40200
Title: Page Revision

Field Inspection and Testing Procedures for Plug Valves 7 of 8 F

PLUG VALVE MINIMUM WALL THICKNESS AND

MAXIMUM ALLOWABLE WORKING PRESSURE CHART

NEW NOMINAL WALL MAXIMUM ALLOWABLE

MINIMUM WALL THICKNESS WORKING PRESSURE
THICKNESS
SIZE MFG. MALE FEMALE MALE FEMALE
3”-1502 DR-100 FMC .476” .411” .670” 1.065” 10,000 PSI
3”-1502 DR-150 FMC .476” .573” .670” 1.065” 15,000 PSI
3”-1502 ER-150 FMC .476” .625” .670” 1.125” 15,000 PSI
3”-1502 LO-TORC HALLIBURTON .625” .625” .737” .839” 15,000 PSI
2”-1502 MSI .325” .429” .545” .975” 15,000 PSI
3”-1502 MSI .468” .572” .670” 1.125” 15,000 PSI
3”-1502 SP150 WU SPM .480” .460” .670” .880” 15,000 PSI
3”-1502 ULT-150 FMC .476” .573” .670” 1.065” 15,000 PSI
1”-1502 DR-150 FMC .220” .296” .500” .810” 15,000 PSI
3”-1502 DR 50 FMC 476” .588” .670” 1.125” 15,000 PSI
Standard services values are shown only, Contact engineering if plug valve not shown.

SPECIFICATION FORM Form #BJT079 Revision 1