TAMIMI Procedure - Field Valve Test (ON-OFF & Control Valve) Rev 01 Tamimi

Doc No: TIS-RE&V-SOP-01
PROCEDURE FOR PRESSURE TESTING OF MANUAL Rev: 01

& INSTRUMENT VALVE (ON-OFF & CONTROL) Date: Jan 10, 2015
Page: 1 of 12
TAMIMI INDUSTRIAL SERVICES
PRESSURE TESTING PROCEDURE

FOR
MANUAL AND INSTRUMENT VALVES
(ON-OFF & CONTROL)
This document is intellectual property of Tamimi Industrial Services. Any unauthorized use, including the modification and
reproduction of the content is strictly prohibited.
Page: 2 of 12
TABLE OF CONTENTS
SECTION DESCRIPTION PAGE

1 OBJECTIVE 3
2 SCOPE 3
3 REFERENCES / STANDARDS 3
4 RESPONSIBILITIES 3
5 ABBREVIATIONS / DEFINITIONS 4
6 GENERAL INSTRUCTIONS 4
7 RECEIVING CHECKS & REGISTRATION 4
8 HYDRO STATIC VALVE TESTING 5
9 PNUMATIC TESTING 6
10 LAYUP PRESERVATION: 6
11 DOCUMENTATION 6
12 SITE ESTABLISHMENT 6
13 SAFETY CHECKLIST 7
14 ATTACHMENTS 7
 Annexure -01  8
 Annexure -02 9
 Annexure -03 10
 Annexure -04 11



Page: 3 of 12
1. OBJECTIVE
To define procedure is to provide to those actually involved in pressure testing carried out on
valves at site valve shop are done effectively, safely and in a controlled manner.
2. SCOPE
This procedure applies to Pressure testing of Manual and Instrument (On-Off & Control) valves of
resilient-seated, as well as metal seated valves, types including but not limited to Gate, Globe,
Plug, Ball, Butterfly and Non-Return valves.
3. REFERENCES/STANDARDS
3.1. INTERNATIONAL STANDARDS
API 598 VALVE INSPECTIONS AND TESTING
API 6D SPECIFICATION FOR PIPELINE VALVES
ANSI FCI 70-2 CONTROL VALVE SEAT LEAKAGE
API 602 COMPACT STEEL GATE VALVES
ASME B16.47 LARGE DIAMETER STEEL FLANGES
ASME B16.34 VALVES FLANGED, THREADED AND WELDING END
ASME B16.5 PIPE FLANGES AND FLANGE FITTING
EN 12266-1 INDUSTRIAL VALVES- TESTING OF VALVES
DIN 3230-3 TECHNICAL DELIVERY CONDITION FOR VALVES
MSS-SP-80 BRONZE GATE, GLOBE, ANGLE AND CHECK VALVES
3.2. SAUDI ARAMCO ENGINEERING / STANDARD/PROCEDURES
SAEP-327 DISPOSAL OF WASTE WATER FROM CLEANING, FLUSHING, HYDROSTATIC
TESTING
SAES-A-004 GENERAL REQUIREMENT OF PRESSURE TESTING
SAES-A-007 HYDROSTATIC TESTING/FLUIDS AND LAY-UP PROCEDURE
SAES-L-108 SELECTION OF VALVES
04‐ SAMSS‐ 048 VALVE INSPECTION AND TESTING REQUIREMENTS
SAES-L-150 PRESSURE TESTING OF PLANT PIPING AND PIPELINES
SATIP-A-004-02 PRESSURE TESTING HYDROSTATIC TEST OF PLANT PIPING
SAIC-L-2042 FIELD HYDROSTATIC TESTING OF ISOLATION VALVES
SATIP-L-108-01 VALVE INSPECTION, TESTING & INSTALLATION PLAN
SAEP‐ 35 VALVE STORAGE AND HANDLING
SATR-A-2001V PRESSURE TEST REPORT (INSPECTION& FIELD TESTING)
GI.0002.102 PRESSURE TESTING SAFETY.
4. RESPONSIBILITIES
4.1. MANAGER - TIS

The Manager- TIS has the responsibility to maintain and make changes to the test
procedure. He is also responsible to identify the hazards & responsibility of each party
involved in the Valve Testing operation and take necessary actions for safe execution of
the job.
4.2. SITE ENGINEER / SUPERVISOR

Prepare the procedure/method statement for client specified standard and reference and
submit for their review and approval. Provide technical support to valve shop Operation
and Site execution jobs. Provide latest revision of procedures, material specification,
standards, and technical specifications. Site engineer/supervisor shall provide his site
valve shop teams with appropriate resources to ensure that works are done in
Page: 4 of 12
accordance with the project quality and HSE requirements and shall be responsible for
the overall site/shop works.
4.3. QA/QC INSPECTOR

QC Inspector shall be responsible for the necessary inspection and test to be carried out
for all the related activities on initial inspection, testing works. He shall monitor all repair
activities and ensure that work execution complies with the related client specification,
codes, and standard and other relevant project documents whenever required. He shall
also prepare quality control records and documents for final inspection and acceptance
by the concerned Client or Company. He shall be fully responsible for preparation of the
valid certificates of testing & repair work.
4.4. SAFETY OFFICER

HSE Manager shall ensure that the working area is in safe working condition and monitor
properly from time to time the implementation of safety procedure, requirements and
ensure that all safety equipment’s and tools are present at working site and in proper or
good condition.
4.5. VALVE TECHNICIAN

The Technician shall be responsible for the direct execution of all valve repair works
including pressure testing and functional test of Manual & control valves, according to the
work plan and directly control or provide instructions to the team. He shall confirm the
proper condition of all maintenance tools and equipment to be used at the valve shop at
site. And He shall ensure that used testing equipment has a valid certificate. He shall also
ensure proper PPEs, good housekeeping, and compliance with Safety Rules and
Regulations.
5. ABBREVIATIONS / DEFINITIONS
TIS Tamimi Industrial Services
TR Tecnicas Reunidas
VRN Valve Registration Number
QC Quality Control Inspector
MTC Material Test Certificate.
6. GENERAL INSTRUCTIONS
6.1. Valve testing and inspection shall be conducted at TIS Valve Shop at client
specified/approved temporary location at site/Ware house area.
6.2. Valves shall be tested, examined and qualified as specified in the industrial Standard
reference or in the client specified testing method/MTC/Design Pressure.
6.3. For Metal Seated Valves, Pressure Tests will generally be in accordance with the
Standard specified in the Data Sheet / Manufacturers specifications or MTC. The
pressure to be applied, Test duration and Allowable Leakages for all the tests as
applicable-shell, Backseat, Pressure Closure Tests will be determined from the same
standard. If not specified in the Standard, API 598 paragraph 5.1.1 of 04‐SAMSS‐048 will
be referred as the standard.
6.4. Leakage rate shall be in accordance with API 598. The pressure to be applied, Test
Duration and Allowable Leakages for all the tests as applicable-shell, Backseat, Pressure
closure tests will be determined from this standard, unless otherwise specified.
6.5. Pressure testing manifold in the actual system pressure test, shall be separately pressure
tested to at least 1.2 times the system test pressure as referred in Aramco Standard
SAES-A-004, Sec 5
Page: 5 of 12
6.6. Test Water Quality shall meet the requirements of Aramco Standard SAES-A-007; Test
water quality shall have a sulfate reducing bacteria (SRB) count of 103 per ml or less as
determined by Rapidchek II method as mentioned in the above mentioned Aramco
standard.
6.7. Test fluid maximum chloride content shall be limited to 50mg/L for hydro test in contact
with stainless steel.
0 0
6.8. Test Water Temperature shall not exceed 125 F (52 C)
6.9. Pressure test relief valve(s) of adequate capacity set to relieve at 5% above the Hydro
test pressure shall be installed. The relief valve shall be tested, dated, and tagged within
one week prior to the hydro test for new Saudi Aramco construction projects.(SAES-A004
Para 5.5.1)
6.10. Pressure gauges are calibrated before the tests. The calibration interval shall not be
exceeding one (1) month. Stickers shall be applied indicating the latest calibration date.
All pressure gauges have a range such that the test pressure is within 30 to 80% of the
full range. And minimum of two pressure gauges shall be available for the test system.
Their accuracy shall be within 5% of one & other. (SAES-A-004 Para 7.1.5)
6.11. Functional Testing of the valves shall consist of minimum on cycle of open and close
positions to check proper functioning of valves.
6.12. Total Log/control sheet of test valve list to be tested shall be maintained and approved by
TR in accordance with Form of Annexure # 4.
7. RECEIVING, CHECKS & REGISTRATION

7.1. Valves Received shall be physically matched with TR List, datasheet and/or drawing as
required.
7.2. Valve shall be checked for their completeness, positions, end connections, packaging
and accessories, etc. Irregularities (if any) shall be noted
7.3. Defective valve shall not be taken for testing unless/otherwise released or approved by
customer.
7.4. TR instructions if any shall be followed.
7.5. Damages shall be recorded in log book or entered in computer, if necessary.
7.6. Ensure that Data sheet , detailed drawings or Product Manual are available (if applicable)
7.7. Valves shall be provided a unique identification number i.e. VRN and registered in TIS-
RE&V FRM-05, the allotted VRN shall be transferred on the Valves either positively
marked by Permanent paint marker at valve, and/or tagged.
7.8. Original crate/special or non-standard pallets shall be preserved for dispatch.
8. HYDROSTATIC VALVE TESTING

8.1. Where practical number of valves shall be connected and bolted/threaded in series (Max.
up to 10 valves depending of size & rating) and blind flanges fitted at either ends only.
8.2. SHELL TEST

8.2.1. Hydrostatic tests are made by filling water to the valve to be tested, making
sure that all air pockets are removed through high point venting, and then
increasing the pressure to the desired predetermined test pressure. This is
usually accomplished via the static workshop test benches or by using a
portable reciprocating pump capable of raising and maintaining the pressure
called for in the various tests.
8.2.2. Shell test shall be done by applying the pressure inside the assembled valve
with the valve ends closed, the valve partially open, and any packing gland or
non-adjustable shaft seals tightened enough to maintain the test pressure.
8.2.3. When the test piece is being filled with liquid. It is necessary to release air and
this is done by opening air valves at the highest level. Once the test pressure
Page: 6 of 12
has been achieved, the valve pressure shall be maintained for a few minutes
or as specified Duration per each test whichever the condition of testing.
8.2.4. The test Pressure
 For material Grade/type, the shell test pressure shall be 1 ½ times the
pressure rating at 100ºF (38ºC), rounded off to the next higher increment
of 25 psig (or 1 bar).
 For valves rated as per DIN standard, the shell test pressure is 1.5 times
the permissible Operating overpressure at 20ºC.
 Shell test Pressure as per (API 598 / ASME B16.34) Annexure -01
(Attached)
 Duration of the shell test as per attached table , Annexure -02 (Attached)
8.3. BACKSEAT TEST.

8.3.1. The backseat test is required for all valves, that have the backseat feature and
shall be performed by applying pressure inside the assembly with the valve
ends closed, the valve fully open, and the packing gland loose.
8.3.2. Valve with the valve ends opened, 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 re-tightened after the
backseat test.
8.3.3. Test pressures shall be at gauge pressure of 1.1 times threating pressure at
100ºF Temp...
8.3.4. Duration of the Backseat test as per attached table , Annexure -02 (Attached)
8.4. VALVE CLOSER TEST (SEAT TEST)

8.4.1. The closure test shall be performed with the seat sealing surface interface
clean and free from oil, grease, and sealant.
8.4.2. Each valve designed for shut-off or isolation service, such as a stop valve,
and each valve designed for limiting flow reversal, such as a check valve,
shall be given a closure test.
8.4.3. Any leakage at the seat sealing surface interface, behind the seat ring, or
through the disk on the open side of the valve shall be detected visually and in
case of a liquid test, leakage shall be measured as drops.
8.4.4. The test Pressure,
 For Manual valves test Pressure shall be as per API 598, ASME 16.34
 For Instrument (On-Off & Control) valves test pressure shall be as per
ANSI FCI 70-2 Table -1
 Test pressure shall not be less than 110% of the 38ºC (100ºF) pressure
rating except:
 That at the manufactures option (Annexure -01 (Attached)
 Duration of the closer test as per attached table, Annexure -02 (Attached),
 Allowable seat leakage table attached Annexure -02
9. PNEUMATIC TESTING
9.1 Pneumatic testing is carried out by pressurizing the valve to be tested with either instrument
quality air nitrogen. Leak detection is undertaken using a proprietary leak detection fluid (e.g.
SNOOP); soapy water or an electronic leak detection device.
9.2 Accepted Criteria for Resilient seated valves (Soft seated) valves: any visible leakage (in
bubble) is not acceptable.
9.3 Accepted Criteria for Metal seated valves: allowable seat leakage table attached (Annexure-
02)
Page: 7 of 12
9.4 A low pressure pneumatic seat test at 35 kpa (5 psi) shall be substitute for the high pressure
hydrostatic test for FLARE system valves.
10. LAYUP PRESERVATION

10.1. Valves shall be thoroughly drained and dried clean of test fluid including from valve
cavities.
10.2. Corrosion prevention, upon completion of drying process, means of corrosion inhibition
and lubrication shall be applied as applicable. The machined surfaces shall be coated
with a light film of high viscosity rust inhibiting oil which will not become fluid and run off
at temperatures below 80°C. Please refer to Aramco Standard(SAES-A-007)
10.3. Valve ends shall be sealed to prevent ingress of foreign matter and protection of threads
or sealing faces, thus protecting the valve against the ingress of foreign matter and shock
vibrations
10.4. Plug or tape all air connections, valves shall be dispatched in a safe manner, whether
palletized or loose to prevent damage during transit.
10.5. Handover or delivery of valve to client as agreed with delivery documents and
certificates.
11. DOCUMENTATION
10.1 Final Test Certificate with complete test details (as applicable) duly signed by TIS QC
Inspector and TR witnessing the test.
12. SITE ESTABLISHMENT

12.1. Site Inductions
12.2. Project in-charge will arrange site inductions and passes for personnel & equipment from
the client, as necessary.
12.3. Risk Assessment
12.4. Job specific risk Assessment will be done in conjunction with the Client for the activities
being carried out at the site.
12.5. Personnel at site shall obtain necessary work permits and/or any approvals which may be
required.
12.6. Site Access
12.7. Client will provide safe access & egress to and from the work area for personnel
(Scaffolding, Ladders, etc.) incl. excavation of the valve (if required)
12.8. Utilities
 Electric Supply (220V, 1Ph and/or 380V, 3Ph) to be specified.
 Compressed air supply (7 bars).
 Water quality shall have a sulfate reducing bacteria (SRB) count of 103 per ml or less
will be provided to the site personnel by TR/TIS as determined in the scope.
12.9. Supply of lifting equipment and qualified personnel as required and agreed.
12.10. Standard PPE’s will be provided to all personnel working at shop/site. Other safety
requirements shall be provided as per agreement.
13. SAFETY CHECK LIST (SITE)

 Toolboxes talk with all personnel, Verify Permits.
 Only authorized personnel shall stay inside the repair area during the repair
operation, Barriers erected.
 Personnel entering Testing facility shall wear minimum approved PPE’s such as
helmet, Safety glass, gloves and safety shoes, irrespective to location and nature of
the work.
 Proper housekeeping shall be maintained in the work area.
Page: 8 of 12
 Ensure all the tools, equipment; nylon belt, slings, shackles etc. are in good
condition.
 Ensure the test flanges, fittings, manifolds, gauges are installed properly and secured
to the required tightness.
 Ensure all the high pressure hoses are clamped.
 Ladder with protection rail shall be used at workplace where working height is more
than 2 Meters.
 Scaffolding if required is verified for usage.
14. ATTACHMENTS
 Annexure -01
 Annexure -02
 Annexure -03
 Annexure -04
Page: 9 of 12
Annexure -01
Valve Test Pressure as per API 598
TABLE # 1
Pressure
Body Material Rating Shall Test Pressure High Pressure Closer
Normal PSI PSI
150 450 325
300 1125 825
A105
A216 WCB 600 2225 1625
A350 LF2 900 3350 2445
A350 LF3
1500 5575 4075
2500 9275 6700
TABLE # 2
Pressure
Normal PSI PSI
A216 WCC 150 450 325
A217 WC6
A217 C5 300 1125 825
A351 CK3MCuN 600 2250 1650
A352 LCC
A182 F22 900 3375 2475
A182 F5 1500 5625 4125
A182 F44
A182 F51 2500 9375 6875
A182 F53
TABLE # 3
Pressure
Normal PSI PSI
150 425 315
300 1100 790

A351 CF8M 600 2175 1585
A182 F316
A351 CF3A 900 3250 2375
1500 5400 3960
2500 9000 6600
This document is intellectual property of Tamimi Industrial Services. Any unauthorized use, including the modification and reproduction of the
content is strictly prohibited.
Page: 10 of 12
Annexure -02
Valve Test Duration as per API 598
Tables #4
Page: 11 of 12
Maximum Allowable Leakage Rate as per API 598

Table #4
Page: 12 of 12
Page: 13 of 12
Page: 14 of 12
WRITTEN BY:
ENGINEER RE&V
APPROVED BY:
MANAGER RE&V

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Doc No: TIS-RE&V-SOP-01

PROCEDURE FOR PRESSURE TESTING OF MANUAL Rev: 01

TAMIMI INDUSTRIAL SERVICES

PRESSURE TESTING PROCEDURE

SECTION DESCRIPTION PAGE

4.1. MANAGER - TIS

4.2. SITE ENGINEER / SUPERVISOR

4.3. QA/QC INSPECTOR

4.4. SAFETY OFFICER

4.5. VALVE TECHNICIAN

7. RECEIVING, CHECKS & REGISTRATION

8. HYDROSTATIC VALVE TESTING

8.2. SHELL TEST

8.3. BACKSEAT TEST.

8.4. VALVE CLOSER TEST (SEAT TEST)

10. LAYUP PRESERVATION

12. SITE ESTABLISHMENT

13. SAFETY CHECK LIST (SITE)

2500 9275 6700

300 1100 790

2500 9000 6600

Maximum Allowable Leakage Rate as per API 598

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