Document No.

SPC-AK-62-016
Applicability BPXA
Date May 9, 2007

Specification for
Ball, Plug, and Other Quarter-Turn Valves –
Common Material

SPC-AK-62-016

Revision History and Approval

Revision Date TA Approval EA Approval Remarks
0 5/9/2007 Thomas O’Grady Corey Herod Initial version.

BPXA
SITE TECHNICAL PRACTICES
May 9, 2007 SPC-AK-62-016
Specification for Ball, Plug, and Other Quarter-Turn Valves – Common Material

Foreword

This is the first issue of Site Technical Practice (STP) BPXA SPC-AK-62-016. This Specification
(SPC) is based on parts of heritage documents from the merged BP companies as follows:

Amoco (ACES)
A PN-VA-GS-E Piping—Valves—General Service—Selection Specification.
A PN-VA-GS-G Piping—Valves—General Service—Selection Guide.

ARCO (APCES)
ES 203-98 Ball Valve Procurement Specification.
ES 206-98 Valve Procurement Specification.

BP Oil US (Refining Practices)

RP 5-3-1 Valve Design and Selection Criteria.
RP 5--3-10 Ball Valves.

British Petroleum (RPSE)

RP 62-1 Guide to Valve Selection.

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Specification for Ball, Plug, and Other Quarter-Turn Valves – Common Material

Table of Contents
Page
Foreword............................................................................................................................................2
1. Scope........................................................................................................................................4
2. Normative References ..............................................................................................................4
3. High-pressure Valves ...............................................................................................................6
4. Large-diameter Flanges............................................................................................................6
5. Alternative Body/Bonnet Joints.................................................................................................7
6. Valve Operation ........................................................................................................................7
7. Weld End Valves ......................................................................................................................8
8. Materials ...................................................................................................................................8
8.1 General..........................................................................................................................8
8.2 Trim ...............................................................................................................................9
8.3 Bolting for body bonnet/shell .......................................................................................10
8.4 Gland packing/seals ....................................................................................................10
8.5 Gearbox Housings.......................................................................................................11
8.6 Valve Stem ..................................................................................................................11
9. Impact (Toughness) Test........................................................................................................11
10. Welding...................................................................................................................................11
11. Repairs ...................................................................................................................................12
12. Functional Testing ..................................................................................................................13
13. Nondestructive Examination (NDE) ........................................................................................13
13.1 General........................................................................................................................13
13.2 Extent of Examination..................................................................................................14
14. Pressure Testing.....................................................................................................................18
15. Storage and Shipping .............................................................................................................18

List of Tables

Table 1 Sizes (DN [NPS]) At and Above Which a Gearbox Is Required ....................................7
Table 2 NDE Requirements......................................................................................................15
Table 3 NDE of Weldments ......................................................................................................16
Table 4 Surface Examination Acceptance Standards ..............................................................16

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Specification for Ball, Plug, and Other Quarter-Turn Valves – Common Material

1. Scope

This SPC provides guidance on industry standards for ball, plug, and other quarter-turn valves that is
common to more than one valve type. Aspects covered include design, materials, fabrication,
inspection, testing, documentation, and preparation for shipment. Clauses of this document are
referenced in the SPC for specific valve types that should be regarded as the primary reference
documents.

2. Normative References

The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. For dated references, subsequent amendments to, or
revisions of, any of these publications do not apply. However, parties to agreements based on this
technical practice are encouraged to investigate the possibility of applying the most recent editions of
the normative documents indicated below. For undated references, the latest edition of the normative
document referred to applies.

American Petroleum Institute (API)

API 6A718 Specification of Nickel Base Alloy (UNS N07718) for Oil and Gas
Drilling and Production Equipment.
API 6A Petroleum and natural gas industries – Drilling and Production
Equipment –Wellhead and Christmas Tree Equipment (ISO 10423).
API 6D Pipeline Valves (ISO 14313)

American Society of Mechanical Engineers (ASME)

ASME B31.1 Power Piping.
ASME B31.3 Process Piping.
ASME B16.34 Valves – Flanged, Threaded, and Welding End.
ASME B16.47 Large Diameter Steel Flanges NPS 26 Through NPS 60.
ASME Sec V Nondestructive Examination.
ASME Sec VIII, Div 1 Pressure Vessels.
ASME Sec IX Welding and Brazing Qualifications.

American Society for Nondestructive Testing (ASNT)

ASNT SNT-TC-1A Recommended Practice.

American Society for Testing and Materials (ASTM)

ASTM A193/A193M Standard Specification for Alloy-Steel and Stainless Steel Bolting
Materials for High-Temperature Service.
ASTM A194/A194M Standard Specification for Carbon and Alloy Steel Nuts for Bolts for
High Pressure or High Temperature Service, or Both.
ASTM A275 Method for Magnetic Particle Examination of Steel Forgings.
ASTM A320/A320M Standard Specification for Alloy-Steel and Stainless Steel Bolting
Materials for Low-Temperature Service.
ASTM E165 Practice for Liquid Penetrant Inspection Method.
ASTM E562 Standard Test Method for Determining Volume Fraction by Systematic
Manual Point Count.
ASTM E709 Practice for Magnetic Particle Examination.

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Specification for Ball, Plug, and Other Quarter-Turn Valves – Common Material

ASTM G48 Standard Test Methods for Pitting and Crevice Corrosion Resistance of
Stainless Steels and Related Alloys by Use of Ferric Chloride Solution.

Manufacturers Standardization Society of the Valve and Fittings Industry, Inc. (MSS)
MSS SP-55 Quality Standard for Steel Castings for Valves, Flanges, Fittings and
Other Piping Components – Visual Method for Evaluation of Surface
Irregularities.
MSS SP-91 Guidelines for Manual Operation of Valves.

NACE International (NACE)

NACE MR0103 Materials Resistant to Sulphide Stress Cracking in Corrosive Petroleum
Refining Environments.
NACE MR0175 Petroleum and natural gas industries—Materials for use in H2S-
containing environments in oil and gas production (ISO 15156).
NACE TM0284 Evaluation of Pipeline and Pressure Vessel Steels for Resistance to
Hydrogen-Induced Cracking.

3. Terms and Definitions

None

4. Symbols and Abbreviations

For the purpose of this SPC, the following symbols and abbreviations apply:

µm micrometers

API American Petroleum Institute

ASME American Society of Mechanical Engineers

BPXA BP Exploration (Alaska) Inc.

CE carbon equivalent

Cr chromium

CRA corrosion-resistant alloy

CRT Criteria

DN nominal diameter

ENP electroless nickel plating

ESD emergency shutdown

HIC hydrogen-induced cracking

ISO International Standards Organization

mm millimeter

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Specification for Ball, Plug, and Other Quarter-Turn Valves – Common Material

MSS Manufacturers Standardization Society of the Valve and Fittings Industry, Inc.

MT magnetic particle inspection

NDE nondestructive examination

NPS nominal pipe size

ppm parts per million

QL Quality Level

SPC Specification

STP Site Technical Practice

UT ultrasonic testing

VPI Vapor Phase Inhibitor

5. High-pressure Valves

For high-pressure valves that are outside the scope of the reference standard, relevant clauses of the
reference standard shall apply, and valves shall be rated and designed in accordance with one of the
following alternatives:

a. ASME B16.34 standard ratings up to and including Class 4500.

b. For weld-end and compact connector valves, an ASME B16.34 intermediate rating up to
Class 4500.
c. API SPEC 6A 10,000 or 15,000 rating (PSL2 minimum) except that for austenitic,
superaustenitic, duplex, and superduplex stainless steels, the allowable stress limit Sm
shall be the lower of 2/3 Sy at design temperature or 1/3 Su at design temperature. If the
piping system is designed in accordance with ASME B31.3, allowable stress limits shall be
as specified in that standard.
The allowable stress limits of API 6A are unconservative in the case of materials
that do not exhibit a yield point and can result in “cold creep” if working or test
stresses are high. The allowable stress values listed in ASME B31.3 are generally
lower than those listed in ASME VIII.
Valves so designed shall be pressure tested in accordance with the applicable SPC and
meet the material traceability requirements and all other relevant requirements of the
applicable SPC. The API 6A monogram shall not be applied unless all requirements of that
standard are also met. Weld-end and compact connector valves may be designed to an
intermediate API 6A pressure rating, but, in this case, the API monogram shall not be
applied.
API 6A makes no provision for intermediate ratings, but this can often provide a
useful weight/cost saving.

6. Large-diameter Flanges

For valves greater than or equal to nominal diameter (DN) 650 (nominal pipe size [NPS] 26), flanges
shall meet ASME B16.47 series A unless otherwise specified.

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Specification for Ball, Plug, and Other Quarter-Turn Valves – Common Material

7. Alternative Body/Bonnet Joints

Clamp-type joints incorporating proprietary metal gaskets of the “Graylok” or “Techlok” type may be
used on pressure ratings greater than Class 600, subject to purchaser approval.

8. Valve Operation

a. Valves shall be operated by handwheel; lever; or pneumatic, hydraulic, or electric motor

power actuators as indicated.
b. Valve actuators shall meet the requirements specified.
c. Valves shall be capable of opening and closing against a differential pressure equal to the
maximum rated pressure of the valve unless otherwise advised.
d. Unless otherwise agreed upon, handwheel operating forces shall not exceed those specified
in MSS SP-91 with a factor of 0.5.
e. The lever length shall not exceed twice the face-to-face dimensions of the valve.
Maximum handwheel diameter shall be 1,000 millimeters (mm) (40 inches). Levers shall
be parallel to the pipe axis with the valve in the open position and incorrect orientation
relative to the position of the ball, plug, or disk, etc. shall be impossible.
f. If a gearbox is necessary, this shall be clearly stated in the bid along with the number of
handwheel turns required for a full stroke of the valve.
g. Valves having sizes equal to or greater than those specified in Table 1 shall be provided
with gearboxes unless otherwise agreed. In the case of reduced bore ball valves, the
nominal sizes may be increased by 50 mm (2 inches).

Table 1 Sizes (DN [NPS]) at and above Which a Gearbox Is Required

Class
Valve Type 150 300 600 900 1500 2500
Ball 200 (8) 200 (8) 150 (6) 150 (6) 150 (6) 50 (2)
Plug 150 (6) 150 (6) 150 (6) 100 (4) 100 (4) 50 (2)
Butterfly 200 (8) 200 (8) - - - -

h. Gear operators shall be fully enclosed in a weatherproof housing, and shall have “lifetime”
lubrication.
i. Power actuators shall comply with the following:
1. Actuators shall be capable of applying a torque/force of at least 1.5 times the
maximum requirement advised by the manufacturer (and recorded during factory
acceptance tests) at all points of the open/close cycle. In the case of emergency
shutdown (ESD) and automatic blowdown ball and plug valves, the minimum safety
factor shall be increased to 2.0.
2. The drivetrain from the actuator to the valve seats shall be capable of withstanding
the maximum output torque/force of the actuator without sustaining permanent
deformation. For electric motor actuators this means at the torque switch setting if the
torque switch is operative throughout the stroke.
3. Valve operators/actuators shall be mounted on the valves by the valve manufacturer
at the factory unless otherwise advised.
4. Valve operating times shall be provided.

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Specification for Ball, Plug, and Other Quarter-Turn Valves – Common Material

9. Weld-end Valves

a. Weld-end valves containing elastomer or polymer seals or seats shall be provided with
extension spools (pipe pups) having a minimum length of 150 mm (6 inches) or the DN
(NPS), whichever is longer with a maximum length of 500 mm (20 inches) unless
otherwise specified.
b. If post-weld heat treatment is required, this shall be performed prior to final valve
assembly.
c. Material requirements relating to the valve body shall apply to the pups.

10. Materials

10.1 General
a. Valve materials shall be suitable for the service conditions identified in this SPC or
otherwise specified including any specified injected chemicals or treatment fluids.
b. If sour service is specified, valve parts in contact with the process fluid and bolting
materials of insulated valves (and other valves if specified, see 8.3e) shall meet NACE
MR0175 or NACE MR0103 as specified.
Where bolting materials cannot be wetted by the process fluid under pressure,
standard grade, high-strength, bolting materials may be used to minimize the weight
and size of bolted joints. If the construction is such that the bolting of the joint may
contact process fluid under pressure (e.g., in the event of gasket leakage), bolting
should be of restricted hardness and meet NACE MR0175, etc.
c. Materials shall be selected such that galvanic corrosion between dissimilar materials is
avoided.
d. Carbon steel materials that are to be field welded shall conform to the following
requirements:
1. Carbon content: 0.25% max. (by weight).
2. Sulfur content: 0.035% max. (by weight).
3. Phosphorous content 0.035% max. (by weight).
4. Carbon equivalent (CE): 0.43% max. (by weight).
Where CE = C + (MN/6) + (Cr + Mo + V)/5 + (Ni + Cu)/15.
e. The carbon content of 5% Cr, ½% Mo steel shall not exceed 0.15% (by weight).
f. Austenitic stainless steel that is to be welded shall have a maximum carbon content of
0.03% by weight.
g. Austenitic stainless steel, including Alloy 20, shall be supplied in the solution annealed
condition.
h. “Free cutting” (resulfurized) steels shall not be used for pressure boundary parts, parts in
contact with the process fluid, or parts that are welded.
i. Forged materials shall be forged close to final shape and incorporate a 20% minimum size
reduction from the billet.
j. The minimum nitrogen content of 22% chromium duplex stainless steel shall be 0.12%.
Duplex stainless-steel forgings and bar shall be subject to a metallographic examination in
accordance with ASTM E562 to demonstrate that the ferrite content of two samples per
heat treatment batch is between 35% and 65%. The microstructure shall exhibit no grain
boundary carbides and shall be free of sigma, chi, and laves phases. Corrosion testing shall
be carried out in accordance with ASTM G48 Method A.

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k. Alloy 718 forgings and bar shall be supplied in accordance with API 6A718.
l. If plate is used for process-wetted and/or pressure-containing parts where sour service is
specified and hydrogen sulfide (H2S) is greater than 1 part per million (ppm), then
resistance to hydrogen-induced cracking (HIC) shall be demonstrated by testing in
accordance with NACE TM0284. Test solution shall be 5%NaCl + 0.5% CH3COOH +
pH2S (100kPa -15 psi) (Test solution A) and acceptance criteria shall be in accordance
with NACE MR0175.

10.2 Trim
a. If trim materials are specified, the supplier may offer a superior alternative having regard
to service conditions and required operating characteristics.
b. If not specified, the base material for balls, plugs, disks, and seats that are not plated,
coated, or overlaid shall be corrosion-resistant. An exception to this is that the plugs of
balanced, lubricated plug valves, for use in oil service or dry gas service – may utilize the
manufacturer’s proprietary surface treatment).
c. Valve stems and shafts shall be corrosion resistant to the specified service, etc. fluids.
d. Hard overlays, coatings, or electroless nickel plating (ENP) shall be used if necessary to
provide wear/erosion resistance and to prevent galling of parts in sliding contact.
Electroless nickel-plated carbon steel base materials shall not be used if water or other
corrosive fluids are present in the process , unless the ENP is applied by a qualified
supplier and has a nominal 0.75µm (0.003 inch) thickness. Chromium plated carbon steel
balls, plugs, and disks shall not be used. The manufacturer shall be able to demonstrate that
coating and plating processes are subject to appropriate controls sufficient to guarantee
quality.
If carbide coating is used base materials usually need to be of high strength.
e. ENP shall be applied by an approved subvendor having a significant record of supply in
similar applications and shall be carried out in accordance with a written procedure
specifying, as a minimum:
1. Surface preparation;
2. Plating thickness (between 0.25 µm and 0.75 µm [0.001 inch to 0.003 inch]);
3. Crack/porosity detection;
4. Adhesion strength;
5. Phosphorous content (8% to 11%);
6. Maximum non-nickel/phosphorous content;
7. Organic bath stabilization;
8. Heat treatment.
f. For carbon steel ball valves greater than DN 100 (NPS 4) in produced water service, water
injection service or product containing a significant proportion of water, or as specified,
flange face ring grooves, seal housings, and contact surfaces, body seat pockets, and other
areas where corrosion of carbon steel is likely to prevent efficient sealing shall be overlaid
with Alloy 625 or austenitic stainless steel Grade 309. If the purchaser has a preference of
alloy, this will be specified. Grade 316 overlay is acceptable only as a secondary layer
where the primary overlay in contact with the carbon steel is Grade 309. If specified, the
seat pockets of valves intended for dry gas service shall be similarly overlaid. Overlay
shall be a minimum of 3 mm (0.12 inch) thick after machining and the weld procedure
qualification report for Alloy 625 shall demonstrate not more than 10% of iron content at
this thickness unless otherwise agreed.

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Specification for Ball, Plug, and Other Quarter-Turn Valves – Common Material

If corrosion occurs on the seal contact faces of valve bodies an efficient seal is not
maintained, so if it is known that such valves will be in contact with water, it is
prudent to overlay the seal contact areas. Valves in dry gas service are vulnerable
to corrosion (before entering service) from residual test water trapped in body seat
pockets, etc. reacting with graphite fire seals, etc. If it is known that such conditions
may exist, seal areas should be overlaid with corrosion-resistant alloy (CRA).
g. If during application of the overlay the base metal critical temperature is exceeded, then
the component should be heat treated such that the base metal is returned to its original
metallurgical state and properties.
h. The disk/seat of butterfly valves and the body/plug of plug valves intended for water
service or service in product containing a significant proportion of water shall be
manufactured from corrosion-resistant alloy or overlaid as required above.

10.3 Bolting for body bonnet/shell

a. Body/bonnet bolting for carbon steel, alloy steel, and duplex stainless-steel valves used in
service temperatures from –29 °C to 454 °C (–20 °F to 850 °F) where valve shell materials
are not subject to impact testing shall be ASTM A193/A193M Grade B7 and nuts shall be
ASTM A194/A194M Grade 2H, unless otherwise specified.
b. Bolting for carbon steel, alloy steel, and duplex stainless-steel valves used in service
temperatures above 454 °C (850 °F) shall be ASTM A193/A193M Grade B16 and nuts
shall be ASTM A194/A194M Grade 16.
c. Bolting for carbon steel, alloy steel, and duplex stainless-steel valves used in service
temperatures from –29 °C to –100 °C (–20 °F to –150 °F) or if valve shell materials are
subject to impact testing shall be ASTM A320/A320M Grade L7 ,and nuts shall be
ASTM A194 Grade 4 or 7.
d. Bolting for austenitic steel and nickel alloy valves shall be ASTM A193/A193M
Grade B8, Class 2 and nuts shall be ASTM A194/A194M Grade 8, Class 2; alternatively,
Grade 660 (UNS 66286) may be used.
e. For sour service, bolting materials for insulated valves or which may otherwise be in direct
contact with the process fluid (e.g., in the event of gasket leakage) or if specified shall
meet NACE MR0103 as applicable.

10.4 Gland Packing/Seals

a. Asbestos packing is not allowed.
b. Graphite packing (excluding end rings), shall be low to medium density (upper limit
1.6 gm/cc (100 lb/ft3), high purity incorporating a nonmetallic, inorganic, phosphorous
based, passivating corrosion inhibitor. The corrosion inhibitor shall be impregnated prior to
die forming.
c. Graphite fire seals, etc. should also conform to Section 10.4b of this SPC.
d. Elastomers, if used in contact with (or able to come into contact with) the hydrocarbon
product, shall be compatible with the operating conditions, the product, the test fluid, and
any specified injected fluids. For gas or unspecified hydrocarbon service, explosive
decompression resistant grades are required. Up to Class 600 rating NBR (nitrile) may be
appropriate, otherwise James Walker FR 58/90, Greene Tweed 926 and Dowty 9730 are
acceptable materials where minimum design temperatures (for sustained exposure under
pressure) are greater than –20 °C (–4 °F). If the minimum design temperature precludes
use of such material, elastomer proposals shall be agreed with the purchaser.
e. O-ring or other elastomer seal section sizes greater than 6 mm (0.25 inch) diameter shall be
avoided if possible in gas or in unspecified hydrocarbon service at Class 600 and higher
ratings. Exceptions shall be brought to the attention of the purchaser.

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Specification for Ball, Plug, and Other Quarter-Turn Valves – Common Material

f. Soft-seated ball, plug, and butterfly valves shall be provided with a polymer or elastomer
seat insert or seal sleeve. Acceptable polymers are polytetrafluoroethylene (Teflon®)
(PTFE) (typically Class 150 and Class 300 only), filled PTFE, nylon, and
polyetheretherketone (PEEK). Nylon shall not be used above 70 °C (158 °F) where there is
exposure to water or methanol.

10.5 Gearbox Housings

Gearbox housings shall be ductile cast iron or steel.

10.6 Valve Stem

a. If stem seals comprise polymer or elastomer materials, surface finish shall be 0.40 µm
(16 µin) or better.
b. The stem surface area in contact with graphite packing shall have a surface finish, Ra of
0.40 to 0.80 µm (16 to 32 µin).

11. Impact (Toughness) Test

a. Materials shall be impact tested to demonstrate adequate toughness at minimum design

temperature if required by any of the following:
1. the material specification;
2. the piping design code;
3. the valve data sheet.
b. Test temperature shall be as required by the material specification or the valve minimum
design temperature, whichever is lower. Testing requirements and impact energies for
carbon and low alloy steels shall be in accordance with the material specification. Impact
energies of duplex stainless steels shall be as follows:
1. Average = 60 Joules (43 ft-lb).
2. Minimum = 50 Joules (36 ft-lb).
c. Impact testing shall form part of welding procedure qualifications under the following
conditions:
1. if impact testing of the material to be joined is required;
2. for ferritic and duplex materials, if the minimum design temperature is below 0 °C
(32 °F).
If impact testing is specified test pieces shall be taken from the weld metal, fusion line, and
heat-affected zone (HAZ). Minimum impact energies for duplex stainless steels are 45J
(32 ft-lb) average and 35J (25 ft-lb) minimum.
d. If required, impact testing shall be conducted on all shell components, bolting, and
drivetrain components made from materials that experience a ductile/brittle transition or
significant reduction in toughness at low temperatures.

12. Welding

a. Welding, weld repairs, cladding, and weld-deposited hard facing shall be performed in
accordance with procedures qualified in accordance with the rules of ASME BPVC,
Section IX. Qualification shall be based upon weld procedure testing. The weld procedures
shall be implemented by welders qualified in accordance with ASME BPVC Section IX.

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b. Welding, weld repairs, cladding, and weld-deposited hard facing procedures shall be
subject to purchaser approval.
c. If fabrication welds are permitted by the purchaser, the welds joining pressure shell
materials forming valve bodies or bonnets shall be joined by full penetration butt-welding.
d. Alignment rings, integral or loose, used as welding aids shall be completely removed
following welding, taking care that the minimum wall thickness is maintained.
e. Heat treatment, following welding, to ensure that the valve body or bonnet materials are
suitable for the full range of service conditions, shall be performed as required by the
material specification.
f. For materials whose specification is not included in the ASME BPVC, Section IX Table of
“P” numbers, qualification tests shall be conducted for each unique material specification.
g. If sour service is specified, the welding procedure qualification test report shall meet the
additional requirements of NACE MR0175 or NACE MR0103 as specified, including
hardness checks. For fillet welds that are qualified by butt welds, the hardness survey shall
be performed on a sample of the fillet weld.
h. The qualification test report for hard facing shall include a hardness survey and finished
surface chemical analysis check.
i. Welded fabrication of pressure-retaining parts, including heat treatment, shall be in
accordance with the requirements of the applicable piping design code (ASME B31.3,
B31.1, etc.). In addition, welding procedures and qualification reports shall include a “weld
map” and specify the maximum allowable fit-up offset and misalignment for butt welds.
j. If duplex stainless-steel materials are to be welded, the procedure qualification shall
include a metallographic examination in accordance with ASTM E562 to demonstrate that
the ferrite content is between 35% and 65%. The microstructure shall exhibit no grain
boundary carbides and shall be free of sigma, chi, and laves phases.
k. Certification and traceability of welding consumables is required.

13. Repairs

a. Repair of structural welds shall be in accordance with the piping design code
(ASME B31.3, B31.1, etc.) including any limitations on imperfections in repairs.
b. For all valves manufactured to order and critical service (Quality Level [QL] 1 and QL2)
valves the following additional requirements apply.
1. Weld repairs are permissible for castings and structural welds provided they do not
extend to more than 25% of the surface area of a casting or 25% of the length of a
weld seam. Minor surface defects may be ground and blended out provided minimum
wall thickness requirements are not affected. Repair gouges shall be examined as
required by Section 15 of this SPC.
2. Repairs shall be pre- and post-weld heat treated as appropriate to the material
specification.
a) Repairs to carbon steel shall be post-weld heat treated except if excavations are
less than 10 mm (0.40 inch) deep or less than 25% of the wall thickness.
b) Repairs to austenitic stainless-steel castings shall be solution annealed and water
quenched.
3. Weld repair procedure qualification records shall include heat treatment,
nondestructive examination (NDE), impact testing, and hardness testing required by
this SPC, the reference standard, and the material specification.

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4. Repair of body castings by peening or impregnation is prohibited.

5. Castings that leak through the body of the casting during hydrostatic or gas testing
shall be rejected and no repairs are allowed.
6. Weld repairs shall be mapped.
7. Weld repair of material manufacturing defects in forgings is not permitted. Weld
repair to correct machining errors, etc. is permissible subject to approval.

14. Functional Testing

a. Critical service hand-operated valves (e.g., QL1, QL2), including those with gear
operators, shall be functionally tested. One valve per size and rating per batch shall be
subject to the following test.
1. The valve shall be cycled close-open-close with rated pressure in the valve.
2. End stops and position indicators/switches shall be shown to function correctly and
give correct alignment of the obturator.
3. The handwheel force necessary to operate the valve (open or closed) against design
differential pressure* shall be measured and shown to be not greater than that
specified in API 6D.
b. Actuated valves shall be tested as follows:
1. The actuator shall be mounted on the valve and the valve cycled close/open/close
twice with rated pressure in the valve.
2. End stops, position switches, and torque switches shall be shown to function correctly
and give correct alignment.
3. One actuated valve per size and rating per batch shall be subject to the following test:
The actuator shall be shown to be capable of opening the valve against design
differential pressure* using minimum pressure or voltage.

* Design differential pressure shall be rated pressure at 38 °C

(100 °F) unless a lower value is specified.

15. Nondestructive Examination (NDE)

15.1 General
a. NDE shall be carried out after completion of heat treatment and shall be conducted in
accordance with written procedures.
b. Magnetic particle inspections (MPIs) and liquid penetrant examinations shall be carried out
on surfaces in their finished form and prior to application of coating on accessible internal
and external surfaces to the extent specified below. The yoke method shall be used if
possible. Permanent magnets shall not be used.
c. Visual examination shall be conducted on the entire, visible internal and external surface
area of the component. For valve bodies, it shall include verification of minimum wall
thickness if practicable.
d. Unless otherwise stated, these requirements apply to all parts of the pressure-retaining
boundary including weldments and welded attachments.
e. NDE operators shall be qualified in accordance with ASNT SNT-TC-1A.

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15.2 Extent of Examination

15.2.1 Quality Level (QL)

a. Minimum requirements are specified below and in Tables 2 and 3 for the three QLs – QL3
(basic), QL2, and QL1 – based on criticality. Additional tests shall be carried out as
necessary to guarantee the quality and fitness for purpose of the product. The QL shall be
as specified. If no QL is specified, QL3 shall be assumed to apply.
Determination of criticality should consider function, size, fluid (gas/liquid),
flammability, toxicity, pressure, temperature, and consequence of failure.
The following guidance on application of the quality levels is suggested where there
are no other criteria. Note that this does not take account of the nature of the fluid
or consequence of failure:
• QL3 – Class 150, less than DN 400 (NPS 16); Class 300, less than DN 250
(NPS 10); Class 600, less than DN 150 (NPS 6); Class 900, 1500, 2500, less
than or equal to DN 50 (NPS 2).
• QL2 – Class 150, greater than or equal to DN 400 (NPS 16); Class 300, greater
than or equal to DN 250 (NPS 10), Class 600, greater than or equal to DN 150
(NPS 6), Class 900, 1500, 2500, greater than DN 50 (NPS 2).
• QL1 – High-integrity pressure protection system (HIPPS), emergency shutdown,
automatic blow-down and other safety critical valves. Valves for highly toxic
service. High-pressure valves manufactured from materials that are difficult to
cast (e.g., duplex stainless steels). Valves for pressures higher than Class 2500,
etc.
Further guidance may be obtained from CRT-AK-42-10 Figure Q1.

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Table 2 Nondestructive Examination (NDE) Requirements

Forgings Bar
Castings Plate
Nondestructive Testing (NDT) of Materials/Components and Tubulars
QL1 QL2 QL3 QL1 QL2 QL3 All
Visual examination Y Y Y Y Y Y Y
Radiography or ultrasonic testing (UT) of critical areas of Y (1)
pressure-containing parts (3)
Radiography or UT of entire pressure-containing parts Y Y
Magnetic particle Inspection (MPI) of machined surfaces of Y Y Y Y Y
pressure containing parts (2)
MPI of entire surface of pressure-containing parts (2) Y Y Y Y (1)
Radiography or UT of weld ends (including 50 mm [2 in.] from the Y Y Y Y Y Y Y
end)
MPI of the surface of weld end (2) Y Y Y Y Y Y Y
Liquid penetrant inspection of weld-deposited overlay Y Y Y Y Y
MPI of the machined surfaces of wetted parts, including seats Y Y Y Y Y
and obturator (2)
MPI of drivetrain components (2) (4) Y Y Y
Notes:
(1) If quantity of any unique item exceeds 5, inspection may be of 20% (rounded up to the next whole number) selected at
random. In the event of any failures, the entire batch shall be examined.
(2) Dye penetrant on nonmagnetic materials.
(3) Critical sections as determined by 100% examination of prototypes. Minimum as defined by ASME B16.34.

Reliance on only the B16.34 defined critical areas is not recommended since
foundries can arrange the process such that these areas are defect free at the
expense of other parts of the casting.
(4) For the purposes of NDE, valve stems shall be considered as part of the drivetrain, not the pressure-containing boundary.

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Table 3 Nondestructive Examination (NDE) of Weldments

Quality Level
NDE of Weldments
QL1 QL2 QL3
Visual examination Y Y Y
Radiography or UT of full-penetration welds Y Y Y
Magnetic particle inspection (MPI) of full-penetration welds Y Y Y
MPI of fillet and attachment welds Y Y

15.2.2 Castings
a. Visual examination in accordance with MSS SP-55.
b. Radiography. Procedure and acceptance standards in accordance with ASME B16.34
Annex B.
c. Magnetic particle testing. Procedure in accordance with ASME B16.34 Annex C.
Acceptance standard in accordance with ASME B16.34 Annex C except that the maximum
size of linear indications shall be as shown in Table 4.
The requirements for QL2 & QL3 are those for forgings in ASME B16.34 Annex C.
d. Liquid penetrant testing (may be substituted for magnetic particle testing in situations
where the latter is inappropriate). Procedure in accordance with ASME B16.34 Annex D.
Acceptance standard in accordance with ASME B16.34 Annex D except that the maximum
size of linear indications shall be as shown in Table 4.

Table 4 Surface Examination Acceptance Standards

Maximum Linear Defect (mm [in.])

Thickness Less Than 13 to 25 mm Greater than
13 mm (0.5 in.) (0.5 to 1 in.) 25 mm (1 in.)
QL1 – Forgings & Castings 5 (0.2) 5 (0.2) 5 (0.2)
Machined Surfaces
QL2 & 3 – Forgings & Castings 5 (0.2) 10 (0.4) 15 (0.6)

15.2.3 Repairs
a. Excavated casting defect areas shall be examined by magnetic particle inspection or liquid
penetrant techniques to confirm removal of the defect to the acceptance standard for QL1
in Section 15.2.2 of this SPC.
b. Excavated welding defect areas shall be examined by magnetic particle or liquid penetrant
techniques to confirm complete removal of the defect.
c. Casting repairs shall be examined as required for the original casting. As a minimum,
repairs shall be subject to surface examination as required for QL1 in Section 15.2.2 of this
SPC.
d. Repaired weldments shall be examined as required for the original weld.

15.2.4 Forgings, Bar, and Tubular Products

a. Visual examination. Acceptance standard – no cracks, laps, tears, or (at weld preparations)
laminar defects.
b. Ultrasonic examination. Procedure in accordance with ASME V Article 5. Acceptance
standard in accordance with ASME VIII Division 1 UF55.
c. Surface examination. Procedure and acceptance standard as for castings in Section 15.2.2
above.

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15.2.5 Plate
a. Ultrasonic examination adjacent to all weld preparations for a distance of 75 mm
(3 inches) back from the edge. Procedure in accordance with ISO 12094 or agreed
alternative. Acceptance standard – no individual indications having a maximum dimension
greater than 6 mm (0.24 inch); no groups of indications having a cumulative area greater
than 1,000 mm2 per m2 (0.15 in2 per ft2) of surface examined.
b. Surface examination of weld prep. Procedure in accordance with ASTM E165, A275,
E709 as appropriate. Acceptance standard – no laminations.

15.2.6 Weldments
a. Full penetration welds (including seams, etc. of pipe extension spools) shall be subjected
to:
1. 100% visual examination. Procedure in accordance with ASME V, Article 9,
acceptance standard in accordance with ASME B31.3, Table 341.3.2 as appropriate to
the service.
2. 100% volumetric examination by radiographic or ultrasonic techniques.
a) Ultrasonics. Procedure in accordance with ASME V Article 5, acceptance
standard in accordance with ASME VIII Appendix 12.
b) Radiography. Procedure in accordance with ASME V Article 2, acceptance
standard in accordance with ASME VIII UW51.
3. 100% surface examination by magnetic particle or liquid penetrant techniques as
follows:
a) Magnetic particle. Procedure in accordance with ASTM E709, acceptance
standard in accordance with ASME VIII Appendix 6.
b) Liquid penetrant. Procedure in accordance with ASTM E165, acceptance
standard in accordance with ASME VIII Appendix 8.
b. Fillet welds shall be subjected to 100% surface examination, as for full penetration welds
above.

15.2.7 Weld Ends

a. Radiographic or ultrasonic examination for a distance of 50 mm (2 inches) back from the
end or bevel. Procedure and acceptance standards as for appropriate product form (i.e.,
casting, forging, etc.) above.
b. Surface examination of weld prep. Procedure in accordance with ASTM E165, A275,
E709 as appropriate. Acceptance standard as required for QL1 in 15.2.2.

15.2.8 Weld Deposited Overlay

a. Visual examination procedure in accordance with ASME V Article 9. No visible defects.
b. Surface examination by liquid penetrant technique. Procedure in accordance with
ASTM E165. Relevant indications are greater than 1 mm (0.04 inch). No relevant linear
indications. No relevant rounded indications greater than 1.5 mm (0.06 inch). No
indications on seat or seal contact areas.
c. Thickness measurement of cladding in finished form. In the case of machined bores, this
shall be at six equidistant points on the circumference.

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15.2.9 Machined Surfaces

a. Magnetic particle examination procedure in accordance with ASME VIII Section V,
Article 25. Acceptance standard as required for QL1 in Section 15.2.2. No indications on
seat or seal contact areas.
b. Liquid penetrant examination procedure in accordance with ASME VIII Section V,
Article 24. Acceptance standard as required for QL1 in 15.2.2. No indications on seat or
seal contact areas.

16. Pressure Testing

a. Valves shall be tested at the factory in the fully assembled condition* and before coating or
painting.

* Includes auxiliary components, fittings, and gland packings.

b. For hydrostatic tests, the test fluid shall be fresh water containing a corrosion inhibitor
unless there is the possibility of damage due to freezing or of adverse effects of water on
the equipment or process. In that case, another nontoxic fluid of equivalent or lower
viscosity may be used. If the liquid is flammable, its flash point shall be at least 49 °C (120
°F) and consideration shall be given to the test environment. For gas tests, the test fluid
shall be air or nitrogen.
Up to 50% glycol (automotive “antifreeze”) may be added to prevent freezing;
alternatively ISO 10 hydraulic oil may be used where this is known to be compatible
with valve seal materials.
c. For testing of austenitic and duplex stainless-steel valves, test water shall have less than
30 ppm chlorides and a pH between 6.0 and 8.5.
d. During the hydrostatic shell test, valve bodies shall be free of external constraints applied
in the direction of the pipe axis.
e. Following pressure testing and draining, the valves shall be dried by blowing with dry air
or dry nitrogen.

17. Storage and Shipping

Austenitic stainless-steel valves shall be protected from chloride attack that can occur from exposure
to salt-water spray or atmosphere during shipment, cleaning, fabrication, testing, and storage.
Protection shall also be provided if shipping by truck in areas where road salt is used. Stainless-steel
valves shall be enclosed or wrapped in a vapor-proof barrier material.

Carbon steel valves which have sealed end caps or are packed in a sealed enclosure shall have Vapor
Phase Inhibitor (VPI) sachets added at 60 g per cubic meter (0.06 oz/ft3), ensuring that VPI is not in
contact with the paint.

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