Inspection of Valves

SBU-Quality Services
Valves
May 5, 2010
Meeting the Challenges of Time & Technology

Inspection of Valves
Valve:
A Valve is a component in a fluid flow or pressure system which regulate
either the flow or the pressure of the fluid, by:
Stopping or starting the flow

Controlling the flow rate
Preventing back flow
Controlling the pressure
Relieving the pressure
Flow or pressure regulation is done by adjusting the position of the closure

member of the valve.
The closure member of the valve is called Disc or Rotor

Inspection Valves
Application:
Valves are used in:
Industrial
Military
Commercial
Residential
Transportation applications

Inspection Valves
Types of Valves:
Valves can be categorized into following design types based on the

design of the closure member:
Gate Butterfly
Globe Plug
Ball Diaphragm
Check Needle

Inspection Valves
Types of Valves: GATE

Inspection Valves
Types of Valves: GLOBE

Inspection Valves
Types of Valves: BALL

Inspection Valves
Types of Valves: CHECK

Inspection Valves
Types of Valves: Butterfly

Inspection Valves
Types of Valves: Based on Function
Valves Operating Manually:
Starting / Stopping the flow

Regulating the Flow
Valves Operating Automatically:
Controlling the Flow

Preventing Back Flow
Relieving Pressure

Inspection Valves
MANUALLY OPERATED VALVES

Inspection Valves
Parts of Valve:

Inspection Valves
Parts of Valve:
Body / Bonnet:
Thickness of the body / bonnet should not be less than
minimum specified.
Disc/Gate:
The movable part of the valve that is positioned in the
flow path to modify the rate of flow through the valve
Seat:
The part of the body which contacts the disc/gate for
making a sealing.
Seat may be integral to the body of the valve or can be
removable. A removable seat is called renewable seat.
Advantage of renewable seat is that it can be removed in
case of any wear and tear without destroying the body.

Inspection Valves
Parts of Valve:
Backseat:
Prevents leakage along the stem
Gland packing can be removed without de-pressurizing
the system
Trim:
Stem, seating surfaces of the body and the disc, internal
keys, pins and small internal components that come in
contact with the contained fluid. Screws and bushes in
contact with the contained fluid are also considered as
trim

Inspection Valves
End Connections of Valve:
Flanged Ends
Welded Ends
Socket Welded Ends (Up to NPS 2)
Butt Welding Ends (> NPS 2)
Threaded Ends (Up to NPA 2)

Inspection Valves
Valve Manufacturing Standard:
ASME/ANSI 16.34: Steel Valves - Flanged & Butt welding Ends
ASME/ANSI B16.10:Face-to-Face Dimensions of Ferrous Valves
API 600: Steel Valves - Flanged & Butt welding Ends
API 602: Compact Steel Gate Valves- Flanged, Threaded, Welding

and Extended-Body Ends
API 603: Class 150, Cast, Corrosion-Resistant, Flanged- End

Gate Valves
API 608: Metal Ball Valves-Flanged and Butt-Welding Ends

Inspection Valves
Valve Manufacturing Standard:
API 609: Butterfly Valves, Lug-Type and Wafer
API 6D: Specification for Pipeline Valves (Gate, Plug, Ball and
Check Valves)
MSS SP-55Quality Standard for Steel Castings for Valves,

Flanges and Fittings and Other Piping Components
API 598Valve Inspection & Testing
BS 6755-1:1986:Testing of Valves - Part 1: Specification for

Production Pressure Testing Requirements

Inspection Valves
Materials (Sample):
Body/Bonnet:
IS 210 (Cast Iron)
ASTM A 216 Gr. WCB, WCC (Cast Steel)
ASTM A 217 Gr. WC6, WC9 (Cast Steel)
ASTM A 352 Gr. LCB, LCC (Cast Steel-Low Temperature Service)
ASTM A 351 Gr. CF8, CF8M, CF3, CF3M (Cast-Austenitic Stainless
Steel)
ASTM A 182 Gr. 304, 304L, 316, 316L (Forged-Austenitic Stainless
Steel)
Stem: ASTM A 479 Gr. 316, ASTM A 182 Gr.316
Seat/Seat Ring: Contact Surface Stellited
Packing: PTFE, Graphite

Inspection Valves
Valve: Size and Rating
Designation: NPS
ASME Pressure Classes: 150, 300, 600, 900, 1500,

2500

Inspection Valves
Inspection & Testing
Material Certification
Visual & Dimensional Inspection
Pressure Test
Calibration (Control Valves)
Functional Test (Automatically operated valves)
Painting Inspection
Final Inspection for Marking/Tagging/Identification
Packing and Preparation for Shipment
Review of Final Documentation
Inspection Release

Inspection Valves
Inspection & Testing: API-598
Applicable for Non-Metallic Seated, Resilient Seated and metal-

to-metal seated valves of the Gate, Globe, Plug, Ball, Check,
Butterfly types.
Applicable Tests:
Visual Examination of Casting
Shell Test
Backseat Test
Low Pressure Closure Test
High Pressure Closure Test
High Pressure Pneumatic Shell Test

Inspection Valves
Inspection & Testing: API-598
Visual Examination Of Casting: MSS SP 55
Pressure Test:
Backseat Test
Shell Test
High Pressure Closure Test (seat test)
Low Pressure Closure Test (Pneumatic)
High Pressure Shell Pneumatic Test (Optional)

Inspection Valves
Pressure Tests as per API-598:
Valves NPS 4and smaller with pressure rating up to and

including ASME Class 1500 and valves larger than NPS 4 having
pressure rating up to and including ASME Class 600, shall be
tested in accordance with Table 1-A
Valves NPS 4and smaller with pressure rating greater than ASME
Class 1500 and valves larger than NPS 4 having pressure rating
greater than ASME Class 600, shall be tested in accordance with
Table 1-B

Inspection Valves
Test Fluid:
Shell, backseat, high pressure closure test: Air, inert gas,

kerosene, water or a non-corrosive liquid with a viscosity not
higher than water. Temperature of test fluid should not exceed
125 Deg. F (52 Deg C)
Low pressure closure test: Air or inert gas.

Inspection Valves
Quality of Water:
Should contain a water soluble oil or a rust inhibitor
For testing austenitic stainless steel valves, the chloride content

should not exceed 100 PPM (water analysis report is required)

Inspection Valves
Test Pressure: In line with Table-2 and Table-3
Test Duration: In line with Table-4
Maximum Allowable Leakage for Closure Test: Table-5

Inspection Valves
Leakages:
For shell and backseat test, no visible leakage is permitted. If the

testing medium is a liquid, there shall be no visible evidence of
drops or wetting of the external surfaces. If the test medium is air
or gas, no leakage will be revealed by established method of
detection.

Inspection Valves

Test Procedure-Backseat Test:
Gland Bolts / Nuts

Loose

Inspection Valves
Test Procedure-Shell Test:

Inspection Valves
Test Procedure-Shell Test:
Closure member
partially open

Inspection Valves
Shell Test: Failure (Example)
Gate,
2” Class
600,
ASTM A
352 Gr.
LCB

Inspection Valves
Test Procedure-High Pressure Closure Test (Gate):

Inspection Valves
Test Procedure-Low Pressure Closure Test:

Inspection Valves
Post Testing Activities:
Valve should be cleaned off the test fluid

Any components dismantled for testing should be re-assembled
and tightened.
Rust preventive should be applied
Protection of ends and closing of the openings with end caps to
be ensured

Inspection Valves
Dimensional Inspection:
Reference:
Customer approved drawings

ASME B 16.10
ASME B16.5/16.47/16.11/1.20.1
ASME B16.25

Inspection Valves
To include but not limited to:
Identification of Valve
Size and Rating of the Valve
Verification of all the parts of the assembled valve with respect to
BOM/Part list (Completeness)
Verification of Name Plates/Tag for Identification / Marking
Verification of Material Grade on different parts
Any special requirements of material (like NACE compliance)
End to end dimension
End Connections
Contd….

Inspection Valves
Flanged Ends: OD/Thickness/No. of holes/PCD/ Staggering of Holes

with respect to axis of the valve/Flange Facing/Finish
RTJ Flanged Ends
Socket Welded Ends: Socket dimension (checking by gauge)
Bevel Welded Ends: Bevel Edge, Bevel Angle
Threaded Ends: Checking of the Threads with GO/NO GO gauges,
extent of threading
Flow direction marker in case of unidirectional valves
Torque to open and close the valve (if required by the specification)

Inspection Valves
SAFETY RELIEF VALVES

Inspection Valves
Safety Relief Valves:
Relief Valves are designed to prevent internal fluid pressure from

rising above a predetermined maximum pressure in a vessel or a
system exposed to emergency or abnormal conditions.
In other words, relief valves provide overpressure protection to a

vessel or a system.

Inspection Valves
Safety Valve:
An automatic pressure relieving device actuated by the static

pressure upstream of the valve and characterized by rapid full
opening or pop action. It is used for gas or vapor service. In the
petroleum industry it is used also for steam and air
Relief Valve:
An automatic pressure-relieving device actuated by the static

pressure upstream of the valve, and which opens in proportion
to the increase in pressure above set pressure. It is used
primarily for liquid service.

Inspection Valves
Safety Relief Valve:
An automatic pressure-relieving device suitable for use as either

a safety or relief valve. It is used in gas or vapor service or for
liquid

Inspection Valves
Safety Relief Valves: Parts

Inspection Valves
Safety Relief Valves: Parts

Inspection Valves
Safety Relief Valves: Types
Conventional Type
The set pressure affected by changes in the superimposed

backpressure

Inspection Valves
Safety Relief Valves: Types
Balanced Type
Incorporates a bellows having effective area equal to that of

the valve seat
Eliminates the effect of backpressure on the set pressure of
the valve, and which effectively prevents the discharging
fluid entering the bonnet space
Inspection Valves
Governing Standard:
ASME Sec-VIII, Div.1

API-526: Flanged Steel Pressure Relief Valves
API-527: Seat Tightness of Pressure Relief Valves
NOTE:
The above description is guide lines only and does not cover IBR
and any other manufacturing standard

Inspection Valves
Safety Relief Valves: Materials (Sample)
Base/Bonnet:
ASTM A 210 (Cast Iron)
ASTM A 216 Gr. WCB, WCC (Cast Steel)
ASTM A 217 Gr. WC6, WC9 (Cast Steel)
ASTM A 352 Gr. LCB, LCC (Cast Steel-Low Temperature Service)
ASTM A 351 Gr. CF8, CF8M, CF3, CF3M (Cast-Austenitic
Stainless Steel)
ASTM A 182 Gr. 316, 316L (Forged-Austenitic Stainless Steel)

Inspection Valves
Safety Relief Valves: Materials
Nozzle:
ASTM A 479 Gr.316, 316L
ASTM A 351 Gr. CF8, CF8M, CF3, CF3M (Cast-Austenitic
Stainless Steel)
ASTM A 182 Gr. 316, 316L (Forged-Austenitic Stainless Steel)
DISC:
ASTM A 565 Gr. 616
ASTM A 479 Gr. 316, 316L
All the parts are to verified with respect to approved drawing /

data sheet

Inspection Valves
Applicable Tests:
Pressure Test (Base and Bonnet)

Set Pressure Test
Seat Tightness Test
Back Pressure Test (Bellow type valves)

Inspection Valves
Test Medium:
Hydrostatic Test: Water having a corrosion inhibitor, temperature

not exceeding 125 Deg. F.
Seat Tightness Test: Air, Steam or Water, the same medium that
has been used for determining the set pressure of the valve.

Inspection Valves
Pressure Test: Base, Bonnet and Nozzle (Hydrostatic)
Nozzle: Primary Side

Base and Bonnet: Secondary Side
Test Pressure:
For set pressure >50PSI: test pressure=0.9Xset
pressure
For set pressure < 50 PSI: test pressure=5
PSI(34.5 KPa)

Inspection Valves
Set Pressure Test:
The pressure at the inlet of the valve at which the Valve is

expected to discharge at the outlet (based on the data sheet)
Cold Differential Set Pressure (CDSP): The pressure at which the

valve is to be tested, taking the service temperature into account.
Temperature correction factor is to be applied for calculating the
CDSP.

Inspection Valves

Set Pressure Test: Gas Service

Inspection Valves
Set Pressure Test: Liquid Service

Inspection Valves
Seat Leakage Test:
90% of set
pressure for
metallic seat
95% of set
pressure for
resilient seat

Inspection Valves
Back Pressure Test:
Applicable for
Balanced Valves
(below type)
Test Pressure:
Super Imposed
Back Pressure

Inspection Valves
Visual & Dimensional Inspection:
Identification of the valve

Size & Rating at Inlet and outlet
Material of parts of valve
Accessories per Data Sheet
Name plate marking

Inspection Valves
CONTROL VALVES

Inspection Valves
Control Valve:

Inspection Valves
Control Valve:

Inspection Valves
Control Valve:

Inspection Valves
Control Valve: Components
Body
Bonnet
Disc
Stem
Yoke
Actuator
Positioner
Limit Switches
Solenoid Valves
Air Filter Regulator
Quick Exhaust Valve
Volume Boosters

Inspection Valves
Control Valve:
Flow Coefficient (Cv):
No. of US Gallons per minute of 60 Deg. F water that will flow

through a valve with one pound per square inch pressure drop.
(A constant, Cv, related to the geometry of a valve, for a given

travel, that can be used to establish flow capacity)

Inspection Valves
Control Valve: Inspection & Tests
Visual Inspection:
Verification of,
assemblies / components as per drawing
Name Plate
Accessories, Sr. No. & Make, with respect to data sheet
Flow Direction Marker
Scale for stroke length
Materials, heat No. etc.
Fasteners for specific application

Inspection Valves
Control Valve: Inspection & Tests
Pressure Test:
Shell Test
Seat Leakage Test (based on leakage class)
Packing Leakage Test
Actuator Leakage Test (pneumatic)
Pneumatic Test of Tubing
Calibration
Functional check for Valve Failure Mode

Inspection Valves
Control Valve: Calibration

Inspection Valves
Control Valve: Calibration

Inspection Valves
Control Valve:
Valve Failure Mode:
Open
Closed
Locked in the Last Position

Inspection Valves
POSITIVE MATERIAL
IDENTIFICATION (PMI)

Positive Material Identification (PMI):
Intended for identification of:

Pressure-retaining alloy material components, flange bolting,
welds, weld overlays and cladding.
It is intended to ensure that the nominal composition of the
alloy components and associated welds have been correctly
supplied and installed as specified


Programme Covers:
Alloy materials
Shop and field-fabricated pressure-retaining components
(base metal, welds and cladding)
Materials used for repair or replacement of pressure-
retaining components

Coverage in Valves:
Body
Bonnet/Base
Trim Materials
Nozzle (Safety Relief Valve)

Equipment:
X-ray Fluorescence type-Unable to detect carbon content

Optical Emission Spectrometer-can detect carbon content

Operator Qualification:
Operator should be qualified to operate the PMI test
equipment.
Equipment Calibration:
Should be done before testing
Calibration should be done with standard calibration
alloy sample, representative of the base material/weld
being tested.

Elements to be verified

Preparation for shipment:
Marking / Labeling
Colour Coding
Tagging
Packing
End Protection

Marking & Labeling

Colour Coding & Flanged End Protection

Packing under Progress

Packing under Progress

Valves Packed

Review of Final Documentation

&
Issue of Inspection Release

Finally :
VISUAL INSPECTION IS
BEST FORM OF INSPECTION


Inspection of Valves

Uploaded by

Copyright:

Available Formats

Inspection of Valves

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Inspection of Valves

Uploaded by

Copyright:

Available Formats

SBU-Quality Services

Meeting the Challenges of Time & Technology

Stopping or starting the flow

Flow or pressure regulation is done by adjusting the position of the closure

The closure member of the valve is called Disc or Rotor

Meeting the Challenges of Time & Technology

Valves are used in:

Meeting the Challenges of Time & Technology

Valves can be categorized into following design types based on the

Meeting the Challenges of Time & Technology

Types of Valves: GATE

Meeting the Challenges of Time & Technology

Types of Valves: GLOBE

Meeting the Challenges of Time & Technology

Types of Valves: BALL

Meeting the Challenges of Time & Technology

Types of Valves: CHECK

Meeting the Challenges of Time & Technology

Types of Valves: Butterfly

Meeting the Challenges of Time & Technology

Types of Valves: Based on Function

Valves Operating Manually:

Starting / Stopping the flow

Valves Operating Automatically:

Controlling the Flow

Meeting the Challenges of Time & Technology

MANUALLY OPERATED VALVES

Meeting the Challenges of Time & Technology

Meeting the Challenges of Time & Technology

Meeting the Challenges of Time & Technology

Meeting the Challenges of Time & Technology

End Connections of Valve:

Meeting the Challenges of Time & Technology

Valve Manufacturing Standard:

ASME/ANSI 16.34: Steel Valves - Flanged & Butt welding Ends

ASME/ANSI B16.10:Face-to-Face Dimensions of Ferrous Valves

API 600: Steel Valves - Flanged & Butt welding Ends

API 602: Compact Steel Gate Valves- Flanged, Threaded, Welding

API 603: Class 150, Cast, Corrosion-Resistant, Flanged- End

API 608: Metal Ball Valves-Flanged and Butt-Welding Ends

Meeting the Challenges of Time & Technology

Valve Manufacturing Standard:

API 609: Butterfly Valves, Lug-Type and Wafer

MSS SP-55Quality Standard for Steel Castings for Valves,

API 598Valve Inspection & Testing

BS 6755-1:1986:Testing of Valves - Part 1: Specification for

Meeting the Challenges of Time & Technology

Meeting the Challenges of Time & Technology

Valve: Size and Rating

ASME Pressure Classes: 150, 300, 600, 900, 1500,

Meeting the Challenges of Time & Technology

Inspection & Testing

Meeting the Challenges of Time & Technology

Inspection & Testing: API-598

Applicable for Non-Metallic Seated, Resilient Seated and metal-

Meeting the Challenges of Time & Technology

Inspection & Testing: API-598

Visual Examination Of Casting: MSS SP 55

Meeting the Challenges of Time & Technology