PROCEDURE MANUAL

Cast Valve
Production

Copyright © 2008 SWI Valve Co., Ltd. All rights reserved. www.swivalve.com
 CAST STEEL VALVES
QA/QC PROCEDURE

DOC No. : SWI-QAC-002

SWI Valve Co., Ltd.

3 2007/02/06 REVISED M.J.KO Y. P. CHO

2 2004/11/12 REVISED T. M. LEE Y. P. CHO

1 2003/09/19 REVISED T. M. LEE Y. P. CHO

0 2002/01/24 ISSUE T. M. LEE Y. P. CHO

REV REVIEWED/
DATE DESCRIPTION PREPARED
NO. APPROVED

SWI VALVE CO.,LTD.

 Doc. No. :SWI-QAC-002
CAST STEEL VALVES Rev. No. : 3
QA/QC PROCEDURE Page : 1 OF 8

1.0 SCOPE.

This procedure covers inspection and pressure test requirements of cast valves produced by
SWI Valve Co. Ltd. (here in after SWI) in accordance with API 598, applicable ASTM, ASME
standards and client specification.

2.0 APPLICABLE STANDARDS.

The following standards shall be applied.

ASME B16.34: STEEL VALVES, FLANGED, THREADED AND WELDING END.

ASME B16.5: PIPE FLANGES AND FLANGED FITTINGS.
ASME B16.10: FACE TO FACE AND END TO END DIMENSIONS OF FERROUS VALVES.
ASME B16.11: FORGED FITTINGS, SOCKET-WELDING AND THREADED.
API 600: STEEL GATE VALVES-FLANGED AND BUTT-WELDS ENDS, BOLTED AND
PRESSURE SEAL BONNETS.
API 6D: SPECIFICATIONS FOR PIPELINE VALVES
(GATE, PLUG, BALL AND CHECK VALVES)
API 603 CORROSION – RESISTANT, BOLTED BONNET GATE VALVES-FLANGED and BUTT-
WELDING ENDS.
API 607: FIRE TEST FOR SOFT-SEATED QUARTER-TURN VALVES.
API 598: VALVE INSPECTION AND TEST.
BS 5351: VALVES-FLANGED, THREADED, AND WELDING END.
MSS SP-55: QUALITY STANDARD FOR STEEL CASTINGS (VISUAL METHOD)
ASTM STANDARD SPECIFICATION A216, A217, A352, A488, A703, E165, E709

3.0 MATERIAL INSPECTION.

3.1 Chemical and physical test shall be performed on charge No. and shall meet the
Requirement specified in the ASTM specification A216 and other applicable ASTM standards
3.2 Material certificate shall be submitted body, bonnet.
3.3 Material to be used shall be identified as the material in approved drawing,
3.4 The charge number stamped on the material shall be identified as the charge No. referred in
Relevant material certificate and the contents of the material certificate shall be in
compliance
With the applicable material standard/code.

SWI VALVE CO.,LTD.

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4.0 ALLOY VERIFICATION (PMI)

Alloy Verification of stainless steel shall be performed on final product with PMI equipment at
100% in accordance with PMI Procedure (SW-PMI-01)

5.0 NDE
NDE shall be performed at body and bonnet of cast steel valves conform to ASME B 16.34. For
Checking casting quality level.

Class 150 ~ 600 All Size

Category 1
Class 900 Sizes up to and including 4”
Class 900 Sizes lager than 4”
Category 2
Class 1500 ~ 2500 All Size
Category 1 Category 2
VISUAL RT MT or PT VISUAL RT MT or PT
100% 0% 10% 100% 10% 100%

6.0 HEAT TREATMENT

6.1 Heat treatment of stainless steel casting shall be done by solution treated at the temperature
of 1070±25oC and carbon steel casting is normalized at 885 ~ 925oC.
6.2 Holding time for the heat treatment at the soaking temperature shall be 1 hour/inch or 1 hour
at minimum.
6.3 The temperature in furnace shall be recorded on a automatic recorder and shall meet the
requirements stated in paragraph 6.1 and 6.2 above.

7.0 REPAIR WELDING CHECK

7.1 If casting has to be repaired for welding, the welders shall be qualified per ASTM A488.
7.2 Casting repair shall be welded in accordance with the approved WPS
7.3. Welded areas shall be subjected to magnetic particle, dye penetrant or radiographic test.
7.4 Such castings shall be stress relieved and re-inspected per applicable ASTM standard

8.0. VISUAL INSPECTION

The following points shall be visually confirmed.

SWI VALVE CO.,LTD.

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8.1 External and internal surfaces of castings shall be free from harmful defects, such as, blow holes,
fins, sand inclusion, and burning.
8.2 Machined surfaces shall be free from harmful defects such as cutting, machining burrs, blow holes,
etc.
8.3 Seat surfaces shall be free from blowholes and other harmful defects.
8.4 Corners and fillets without specified dimensions shall be properly chamfered or rounded.
8.5 Flow path positioned shall be properly finished and cleaned.

9.0 DIMENSION CHECK

The Valves shall be given the following dimensional examined and the dimensions shall be
within tolerance in accordance with ASME B 16.5, ASME B16.11 and ASME B 16.10.
Other dimensions shall be specified in approved drawing.

10.0 MARKING CHECK

The marking shall be performed in accordance with MSS SP-25 and/or purchaser specification.
10.1 Casting-out on Body: Manufacturer’s trade mark. Class, size, material spec., flow direction
and charge No.
10.2 Hand wheel and Lever: Letters symbols and arrow head to indicate “OPEN and SHUT”
10.3 Name Plate, Tag Plate and Material color identification shall be in accordance with
purchase specification.

11.0 WELDING OF BELLOWS CHECK

11.1 10% of welding of bellows shall be performed PT (liquid penetrant examination)

11.2 He test shall be done at 10%

12.0 PRESSURE TEST

The pressure gauge for inspection shall be used within one year after authorized calibration
check.

12.1 The pressure test shall be tested and inspected per API 598 and ASME B 16.34
12.2 Valve type test requirement shall be in accordance with following Table 1, 2

SWI VALVE CO.,LTD.

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Table 1. Valve type test requirement.

(NPS≤ 4” ASME Class ≤1500 or NPS> 4” ASME Class ≤ 600)
Valve Type
Test Description
Gate Globe Check Ball
Shell Test Required Required Required Required
Backseat Test Required Required N/A N/A
Low Pressure Seat Test Required Optional Optional Required
High Pressure Seat Test Optional Required Required Optional
N/A: Not applicable

Table 2. Valve type test requirement

(NPS≤ 4” ASME Class >1500 or NPS> 4” ASME Class > 600)
Valve Type
Test Description
Gate Globe Check Ball
Shell Test Required Required Required Required
Backseat Test Required Required N/A N/A
Low Pressure Seat Test Optional Optional Optional Required
High Pressure Seat Test Required Required Required Optional
N/A: Not applicable
12.3 For shell, backseat and high pressure seat test, the test media shall be water.
12.4 Chloride content of water which is used for pressure test shall be less than 30 PPM
in case of austenitic stainless steel material.
Record of water analysis shall be preserved.
12.5 For low pressure seat test, the test media shall be air.
12.6 The test media temperature shall be not exceed 52℃.
12.7 Valve test pressure requirement shall be in accordance with following Table 3.
12.8 Valve test duration requirement shall be in accordance with following Table 3.

13.0 PRESSURE TEST PROCEDURE

13.1 Shell Test

13.1.1 The shell test shall be done by applying the pressure inside the assembled valve with the
valve ends closed, the valve partially open, and the packing gland sufficiently tight to
maintain the test pressure, thereby testing the stuffing box also. The stuffing box shall not leak
During the shell test.

SWI VALVE CO.,LTD.

13.1.2 Test pressure and duration to be employed shall conform to Table 3 and Table 4.
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Table 3 Test Pressure (API 598 and ASME B 16.34)

Class 150# 300#
Description CWP Shell Seat CWP Shell Seat
Material
psig Kg/cm2 Kg/cm2 psig Kg/cm2 Kg/cm2
A216-WCB 285 32 23 740 79 58
WCC,LCC,WC6,WC9,C5
290 32 23 750 79 58
CD4MCU, CW6MC
CF8,CF8M,CF3,CF3M,CF8C 275 30 23 720 77 56
LCB,LC1,WC1 265 28 21 695 74 54
CN7M,CN3MN 230 25 19.5 600 63.5 47.5

Class 600# 900#

Description CWP Shell Seat CWP Shell Seat
Material
psig Kg/cm2 Kg/cm2 psig Kg/cm2 Kg/cm2
A216-WCB 1480 156 116 2220 236 172
WCC,LCC,WC6,WC9,C5
1500 158 116 2250 237 174
CD4MCU, CW6MC
CF8,CF8M,CF3,CF3M,CF8C 275 30 23 720 77 56
LCB,LC1,WC1 1390 147 109 2085 221 162
CN7M,CN3MN 1200 127 93.5 1800 190 141

Class 1500# 2500#

Description CWP Shell Seat CWP Shell Seat
Material
psig Kg/cm2 Kg/cm2 psig Kg/cm2 Kg/cm2
A216-WCB 3705 392 288 6170 652 478
WCC,LCC,WC6,WC9,C5
3750 395 290 6250 659 483
CD4MCU, CW6MC
CF8,CF8M,CF3,CF3M,CF8C 3600 380 279 6000 633 464
LCB,LC1,WC1 3470 367 269 5785 612 448
CN7M,CN3MN 3000 316.5 232.5 5000 527.5 387
O O
※ CWP : The maximum allowable pressure at –20 F to 100 F(38℃).

SWI VALVE CO.,LTD.

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Table 4 Duration of required Test pressure. (Minimum), unit: sec

Shell Test Seat & Backseat Test

Valve
Backseat
Size Check Other Check Other
V/V V/V V/V V/V

2” and Smaller 60 15 15 60 15

2-1/2 to 6” 60 60 60 60 15

8” to 12” 60 120 60 60 120

14” and Larger 120 300 60 120 120

13.2. Backseat Test.

13.2.1 The backseat test for gate, globe valve shall be done by applying the pressure inside the
assembled valve with the valve end closed. The valve fully open and the packing gland loose.
The backseat test may be made immediately after the shell test. and all packing glands shall
be retightened after the backseat test.
13.2.2 Test pressure and duration shown conform to Table 2 and Table 3.

13.3. Seat leakage test.

13.3.1 Low pressure seat test.

Test fluid used is as shown in Para 11.5 Low pressure seat test method is as shown below.

a.) Apply test pressure to inlet side of closed valve, fill water in outlet side and maintain for
duration shown in Table 4 observe any bubbles thru seating surface, seating, or through
the wedge. Test shall be carried out in both directions.
b.) For the valves having a flow direction specified in the approval drawing, air pressure to
be applied from the flow direction.
c.) Light oil shall thinly be applied to the body and wedge seating surface after cleaning the
surfaces.

13.3.2 High pressure seat test.

Test valve shall be pressurized by water to test pressure shown in Table 3. seat leakage shall
be checked. The duration of the test shall be per Table 4.

SWI VALVE CO.,LTD.

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a.) Test shall be done to check if there is any leakage of water, after filling the valve body
with water, close the valve, open outlet side, keep the body filled with water.
b.) Apply test pressure shown in Table 3 from inlet side and maintain for duration
shown in Table 4.
c.) Light oil shall thinly be applied to the body and disc seating surface after cleaning the
surfaces.

13.4 Acceptable criteria for pressure test.

13.4.1 For shell and backseat tests, no visible leakage is permitted.
13.4.2 For both the low and high pressure seat test shall be in accordance with following Table 5.

Table 5. Maximum Allowable Leakage Rates for Closure Tests.

All Metal Seat
All Metal Seat Valve except Check
Resilient Check Valve
Valve size a
Seated Liquid Test Air Test Liquid Air
(drops per
V/V minute)
(bubbles per minute) Test Test

2” and Smaller 0 0b 0b c N.A

2-1/2 to 6” 0 12 24 c N.A

8” to 12” 0 20 40 c N.A

14” and Larger 0 28 56 c N.A

a. For the liquid test, 1 milliliter is considered equivalent to 16 drops.

b. There shall be no leakage for the minimum specified test duration. (See Table 3).
For liquid test, 0 drop means no visible leakage per minimum specified test duration.
For air test, 0 bubble means less than 1 bubble per minimum specified duration.
c. The maximum permissible leakage rate shall be 0.18 cubic inch (3 cubic centimeters)
per minute per inch of nominal pipe size.
d. For check valves larger than NPS 24, the allowable leakage rate shall be per agreement
between purchaser and manufacturer.

14.0 OPERATION TEST

Assembly function inspection shall be carried out on valve as following.

SWI VALVE CO.,LTD.

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14.1 Gate Valve.

14.1.1 When the valve has been fully closed, the center of seating surface on the wedge shall be
located at the upper part of seating surface on the valve body.
14.1.2 When the valve has been fully opened, the bottom of the wedge shall be not intrude into
the passage of fluid.

14.2 Globe Valve

14.2.1 Disc and valve seat shall place in position respectively, when the valve has been closed.
14.2.2 Valve lift shall be enough obtained.
14.2.3 The valve shall be opened during differential pressure as per the specification acts
upon/from the upper part of the valve disc.

14.3 Ball Valve

Stops shall be provided for both the fully open and fully closed positions of valve.
Angle of fully open and fully closed positions shall be vertical(90°).

15.0 PAINTING.

15.1 Carbon and Low alloy steel

1st : Inorganic Zinc Primer :25um
2nd: Silver Painted.
15.2 Austenitic Stainless steel shall not be applicable.

16.0 TREATMENT AFTER TEST AND INSPECTION.

For the valve which has passed tests and inspection, openings of bore shall be protected so as to
prevent dust, dirt and other foreign material from entering the valve. The serration of flange shall
be protected against damage.

17.0 CERTIFICATES

17.1 Test/Inspection Certificate.

a. Pressure Test b. Dimension. c. Operation. d. Visual
17.2. Material Certificate.
a. Chemical Composition. b. Mechanical Requirement. c. Heat treatment etc.

SWI VALVE CO.,LTD.