Inspection Procedure

TP 1009

Function Test
Procedure

REVISIONS
Rev Description Date Approved By
1 Updated per Re-Engineering Process 05 March 2019 A. Mahnapoor

Rock Payvand Sanat Arvand

 Rock Payvand Sanat Arvand

Contents
Purpose ........................................................................................................................................... 2
Scope ............................................................................................................................................... 2
Referenced Documents .................................................................................................................. 2
Definitions ....................................................................................................................................... 2
Safety .............................................................................................................................................. 3
Process Flow.................................................................................................................................... 3
Procedure ........................................................................................................................................ 3
Equipment ................................................................................................................................... 3
Test Medium ............................................................................................................................... 4
Test Requirement ....................................................................................................................... 4
Test Procedure ............................................................................................................................ 5
Acceptance Criteria ......................................................................................................................... 5
Stroking Time .............................................................................................................................. 5
Records ............................................................................................................................................ 5

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Purpose
This procedure establishes the definitions, requirements and test procedure for functional testing of
assembled control valves with actuators. Functional testing is done to verify the proper performance of
the control valve. This document describes the method for demonstrating that the actuator has adequate
force to open and close the valve. The procedure shall demonstrate that no mechanical damage or
permanent deformation of valve components will occur and that accessories function properly.

Scope
The testing valve travels from a normal position to a predetermined final position as a fully opened or
closed end position in a certain operating situation. All valves and body subassemblies produced by Rock
Payvand Sanat Arvand are required to be tested to this procedure. By special arrangement with a specific
customer other Functional testing may be performed. These special tests are outside of the scope of this
document.

Referenced Documents
Standard Description Issue
IEC 60534-4 Industrial Process Control Valves - Inspection and Routine Testing Latest Edition
Test Procedure for Control Valve Response Measurement from
ISA 75.25.01 Latest Edition
Step Inputs
DEP 32.36.01.17 Shell manual, Control valves - selection, sizing, and specification April 2003

Definitions
Actuator: A pneumatic, hydraulic, or electrically powered device that supplies force and motion to open
or close a valve.

Bench Set: The calibration procedure of an actuator spring so that it can use a pressure range to fully
stroke a valve to its rated travel (see Inherent Diaphragm Pressure Range).

Fail-Safe: A characteristic of a valve and its actuator, which upon loss of actuating energy supply, will
cause a valve closure member to be fully closed, fully open, or remain in the last position, whichever
position is defined as necessary to protect the process and equipment. action can involve the use of
auxiliary controls connected to the actuator.

I/P: Shorthand for current-to-pressure (I-to-P). Typically applied to input transducer modules.

Positioner: A position controller (servomechanism) that is mechanically connected to a moving part of a

final control element or its actuator and that automatically adjusts its output to the actuator to maintain
a desired position in proportion to the input signal.

Signal: A physical variable, one or more parameters of which carry information about another variable
the signal represents.

Supply Pressure: The pressure at the supply port of a device. Common values of control valve supply
pressure are 20 psig for a 3 to 15 psig range and 35 psig for a 6 to 30 psig range.

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Safety
Any organization performing functional testing under this procedure shall have written safety instructions
detailing how to perform the functional test safely. The information presented in this procedure is an aid
to creating a safe work environment.

Hazard: There are no major or unusual hazards associated with functional testing.

Failures: The credible risks associated functional testing include; loose airlines, pinching (blunt trauma)
and eye injuries.

Risk Mitigation:

Test Conditions: Provide written loading and unloading instructions.

Personal Protective Equipment: Eye protection is mandatory during test.

Equipment: All test equipment should be examined regularly under a preventive maintenance
program and any worn or unsafe equipment must be replaced.

Process Flow

Procedure
Equipment
Accessories: Accessories are included with the actuator to help perform these functions.

Air Instrument: provide clean air pressure to pneumatic controllers, valve positioners, air cylinders and
other equipment.

Loop Calibrator: Loop calibrators are a type of electrical calibrator specifically designed to troubleshoot
4-20 mA current loops. These versatile instruments are capable of measuring current, sourcing current to
unpowered devices in a loop, as well as simulating the operation of loop-powered 4-20 mA transmitters.

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Test Fixtures: The valve shall be fixtured such that the test medium can be applied to the valve inlet. The
valve outlet shall be connected to a low loss flow rate measuring device or open to atmosphere when
graduated cylinders are used.

Positioner: A positioner is a device attached to an actuator that receives an electronic or pneumatic signal
from a controller and compares that signal to the actuator’s position. If the signal and the actuator
position differ, the positioner sends the necessary power to move the actuator until the correct position
is reached.

Pressure Gauges: Gauge accuracy shall be within ±5% at the test pressure. All pressure gauges shall be
verified in accordance with the local operations written gauge quality assurance procedures.

Test Medium
Testing may be performed with any of the following media in accordance as bellow:

 Clean air at 10°-50°C (50°-125°F) Nitrogen gas at 10°-50°C (50°-125°F)

Test Requirement
 The control valve shall be completely assembled and fitted with all accessories such as positioner,
solenoid valve(s), etc.
 During operation, position of open-close should be conform to the indicator.
 The valve positioner shall be checked for correct calibration.
 All required stroking times recommended to check during the functional testing.
 If the control valve is equipped with a hand wheel, it must be possible to fully open and close the
valve using the hand wheel. Operation of valve with handle and actuator should be done smoothly
without irregular torque.
 If the control valve is equipped with limit switches, they shall be checked for functional operation
with a proximity tester.
 The valve stem may be lightly lubricated.
 Hysteresis and Dead Band Test (and stroking test) are available for Valves with E/P Smart
Positioner.
 Hysteresis shall not exceed 2.0% of maximum valve stroke. The dead band test is expressed in
percentage of the input span and shall be measured at approximately 5%, 50% and 95% of the
input span. The maximum dead band found shall not exceed 2% of rated input signal. In case of
special requirement the stroking time shall comply with the time stated in the requisition. Testing
shall be performed under ambient temperature and with the minimum specified air supply
pressure.
 If Hysteresis and Dead Band Test is required for Valves with Non-smart positioner, subject Valve
will be tested with Smart Positioner attached, and then re-assemble with contracted positioner
for shipment.

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Test Procedure
 Check the valve assembled, accessories, instrument air and the Loop Calibrator
 Fixture the valve
 Set the test pressure
 Connect and Set Loop Calibrator to provide current Input signal (4-20mA) to the input terminals
of the valve positioner
 Increase input signal as 4mA, 8mA, 12mA, 16mA, 20mA & record travel
 Decrease input signal as 20mA, 16mA, 12mA, 8mA, 4mA & record travel
 Record the results

Acceptance Criteria
Acceptance criteria should be provided with the test procedures. Less than 5% error is acceptable.
Travel vs Input Signal for Air Fail Open & Close Valve:

Step 0% 25% 50% 75% 100%

SIGNAL (Increase) 4 8 12 16 20
TRAVEL ( % ) 0 25 50 75 100
SIGNAL (Decrease) 20 16 12 8 4
TRAVEL ( % ) 100 75 50 25 0

Stroking Time
Unless specified otherwise, the following stroking times for both directions shall not be exceeded for
throttling control valves under normal operating conditions. Maximum stroking time is recommended as
bellow:

Body size Maximum stroking time

≤ DN 50 (2”) 10 s
DN 80 (3”) 15 s
DN 100 (4”) 15 s
DN 150 (6”) 20 s
DN 200 (8”) 35 s
DN 250 (10”) 50 s
> DN 250 (10”) To be specified by the Principal

Records
A permanent record of the Functional Testing results will be maintained in accordance with local Quality
Assurance Procedures.

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