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TEST AND
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KVT-P07071
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PAGE 1 OF
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FORGED &

CAST STEEL VALVES

99.

07. 07

DESCRIPTION
REV.
DATE

PREPACHEC CHEC APPR
RED KED KED OVED

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1. SCOPE This procedure covers

inspection and pressure test
requirements of forged steel valves and
cast steel valves to be supplied for the
customers. 1. 1. APPLICABLE
STANDARDS The following standards
shall be applied : ANSI B16.34 : STEEL
VALVE, FLANGE AND WELDING ENDS ISA
S75.19 : HYDROSTATIC TESTING OF
CONTROLS VALVES
IEC STD IEC-534-4
: INDUSTRIAL PROCESS CONTROL VALVES,
PART 4 ANSI/FCI-70-2 : AMERICAN NATIONAL
STANDARD FOR CONTROL VALVE SEAT
LEAKAGE API 600 : STEEL GATE VALVES,
FLANG AND BUTT- WELDING API 602 :
COMPACT STEEL GATE VALVE. API 598 :
VALVE INSPECTION AND TEST MSS SP-55 :
QUALITY STANDARD FOR STEEL CASTINGSVISUAL METHOD. 1.2 . TEST AND

INSPECTION ITEMS The following tests

and inspections shall be conducted.
MATERIAL INSPECTION NON-DESTRUCTIVE
EXAMINATION(If performs)
*
RADIOGRAPHIC EXAMINATION(RT)
*
LIQUID PENETRANT EXAMINATION(PT)
VISUAL AND DIMENSIONAL TEST PRESSURE
TEST * SHELL TEST
* BACK SEAT
TEST (For manual globe & gate valve only)
* SEAT TEST(SEAT LEAKAGE TEST PER
ANSI/FCI 70-2 FOR CONTROL VALVES)
* LOW - PRESSURE SEAT TEST (PNEUMATIC
SEAT TEST) FUNCTIONAL(OPERATION) TEST
RUST PREVENTION AND PAINTING
INSPECTION QUANTITY AND IDENTIFICATION
INSPECTION 2. TEST AND INSPECTION 2. 1

Material inspection 2.1.1. Identification

of material to be inspected * (1) BODY *
(2) FLANGE * (3) BONNET * (4) COVER
2.1.2. Material certificates for asterisked
(*) items are to be submitted to the
customer 2.1.3. Material to be used shall
be identified as the materials in approval
drawings. 2.1.4. The charge number put
on the material shall be identified as the
charge number referred to the relative
material certificate and the contents of
with applicable material standard /
code.

FORM P1003-1(0) KEY VALVE TECHNOLOGIES LTD.

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5.0 PRESSURE TESTS 5.1 Tests required

Items The following pressure tests shall
be made on each valves. Shell test - all
valves Backseat test all manual globe
and gate stop valves except swing check
Low pressure seat and seal weld seat all valves except swing check for low
pressure seat test. 5.2 Test fluid For shell
and backseat test, fluid shall be water.
For the low pressure seat test, fluid shall
be air. Water used for any test may
contain a water soluble oil or a rust
inhibitor. Test fluid viscosity is no higher
than that of water. 5.3 Test pressure Test
pressure shall be as per TABLE-3 and
TABLE-2. 5.4 Test duration Test duration
shall be as per TABLE-3 and TABLE-4. 6.0
SHELL AND BACKSEAT TEST PROCEDURE
6.1 Backseat The backseat test is made
by applying the pressure inside the
assembled valve with the valve ends
closed. the valve fully open and the
packing gland loose. 6.2 Shell The shell
test shall be made prior to any painting
of the shell. The shell test is made by
applying pressure to the assembled
valve internal with the valve ends
closed. During shell testing the valve
must be opened. And the packing gland
sufficiently tight to maintain the test
pressure, thereby testing the packing
chamber also. Acceptance standard :
no visible leakage 6.3 Seat Leakage Test
6.3.1 Hydrostatic test The test shall be
made by applying the test pressure
specified in para 5.3 and maintaining the
pressure for a duration specified in para
5.4 to check any sign of leakage from
the seating portion and inside the valve.
When a small amount of leakage is
allowed for the valve, the amount of leak
shall be measured by maintaining the
test pressure for a duration sufficient to
permit the measurement of leak. The
method of applying the test pressure for
each type of valve shall be as follow.

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- For gate valves, the pressure shall be

applied to the inlet side with the gate
closed so that the body and bonnet may
retain the teat pressure. Examination
shall be made to check any sign of
leakage from the outlet side. Valves with
no indication of flow direction shall also
be tested on the seat of the other side,
or both valve seat faced shall be
simultaneously tested under condition of
both flanged ends opened after giving
pressure to inside of valve body and
bonnet / cover and closing valve. - For
globe valves and angle valves, the
pressure shall be applied from upstream
of the seat with the valve closed. - For lift
and swing check valves, the pressure
shall be applied, with back- pressure side
filled with water. - For control valves, the
pressure shall be applied from upstream
of the seat with the valve closed in
according to control valve
specification(data sheet). <Acceptance
criteria > Allowable seat leakage for
gate and globe valves shall be less than
the value in Table 5. Allowable seat
leakage for lift and swing check valve
shall be less than 3 cubic centimeter per
minute per inch of diameter of nominal
pipe size. Allowable seat leakage for
control valves shall be meet the value in
Table 5-1.

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7.0. LOW PRESSURE SEAT AND SEAT

SEAL WELD TEST PROCEDURE 7.1. Gate
Valves The air pressure is applied
successively to each side of the closed
valves with the other side open to the
atmosphere and covered with water to
check leakage of the downstream side of
the seat closure. Air must be blown in so
that it is trapped inside the valve cavity.
Leakage through the seat of the valve
shall be detected by observation of
bubbles when the seat is covered with
water. Later cover with water seat seal
weld area to check for leakage.
Permissible leakage through the seat
shall be following Table 5 and no leakage
is allowed through the seal weld. 7.2.
Globe Valves The pressure is applied
from below the closed disc through the
valve end clamped to the air test fixture
with the other side open to the
atmosphere to check leakage of the
downstream side of the closure including
the seat seal weld. Any leakage at the
seat on the open end of the valve shall
be detected by observation of bubbles
when the seat and weld is covered with
water. Acceptance standard for seat shall
be following Table 5, and leakage
through seal welds not permitted. 7.3.
Check Valves Air Pressure Seat Seal Weld
Test Procedure. The pressure (5.6barG
air) is applied from below the closed disc
through The valve and clamped to the
air test fixture with the other side open
to the atmosphere to check the seal
weld. Any leakage shall be detected by
observation of bubbles when the weld is
covered with water. A device that
holding clapper in closed position can be
used on seat. Leakage through seal
welds not permitted. 8. 0
FUNCTIONAL(OPERATION) TEST
Assembly functional inspection shall be
carried out of valve as follows. 8.1.
General requirements 8.1.1. Serial
number of each part, material, outside
appearance, clean shall be in accordance
with the instructions. 8.1.2. Sealing
agent, lubricant, seize inhibitor shall be
FORM P1003-1(0) KEY VALVE TECHNOLOGIES LTD.
applied as per the Instructions. 8.1.3.
Outside appearance, dimensions and
position of assembled valves shall be as
per the instructions. 8.1.4. Easy

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8.1.6. Nameplate and markings shall be

as per the instructions. 8.1.7. Valve
indicator shall be kept to indicate correct
position of valve travel. 8.1.8. Gland
packing shall be equally fastened, not to
be fastened one side. 8.2. Gate valve
8.2.1. when the valve has been fully
closed, the center of seating surface of
the wedge shall be located at the upper
position for the center of seating surface
of the valve body. 8.2.2. When the valve
has been fully opened, the bottom of the
wedge shall be not intrude into the
passage of fluid. 8.3. Globe valve 8.3.1.
Disc and seat are on the same
concentric circle and disc shall perfectly
fit on seat when valve has been fully
closed. 8.3.2. Valve lift shall be enoughly
obtained and disc shall smoothly lotate.
8.4. Lift and Swing check valve 8.4.1.
Check by manually operation that
function for opening and closing disc up
to the stopper positioned on valve body
or cover shall be smoothly obtained.
8.4.2. Open and close of disc shall be
easily obtained with its weight. 8.5.
Electric Motor Operated Valves 8.5.1.
Test items and time of test. All of the
electric motor operated valves shall be
tested upon assembling. 8.5.2. Test
method and acceptance standards.
8.5.2.1. All wiring of the motor and other
equipment shall be checked to assure
conformance to the drawing. 8.5.2.2.
Limit switches and torque switches shall
function properly and correctly in the full
open closed positions. 8.5.2.3. It shall be
verified that the change from manual
operation to motor operation, and vice
versa, may be accomplished smoothly.
8.5.2.4. No-load operation (with no
pressure applied in the valve) Operate
the valve from the full open position to
closed position over three times to verify
that the maximum current, operating
current, starting current are within the
specified values. The starting current
shall be the design current of motor.

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8.5.2.5. Loaded operation. (operation

under the design pressure applied
toward the inlet of the disc) Opening /
closing shall be motor operated more
than three times, and make sure that
start up current, in-operation current are
respectively within specification.
However, start up current shall be under
motor design current value. 8.5.2.7.
Make sure opening / closing times
conforms with the specification .
Acceptance criteria shall be as follows.
Acceptance criteria : To be within 110%
of planned. But, to be maintained for
three seconds if duration is specified
within three seconds and below. 8.5.2.8.
Make sure that valve lift conforms with
the specification. Acceptance criteria
shall be as per TABLE-6. 8.5.2.9. The full
open bad closed positions of valves shall
conform respectively, to those indicated
by the position indicator of motor
actuator. 8.5.2.10 Seat leakage Test
Manual operation To be the same
procedure as clause 7 and seat seal weld
test shall be done in accordance with
clause 8. Motor operation Pressurize
closing-off differential pressure
(hydraulic pressure) specified in the
specification after disc has been fully
closed. And when test pressure is higher
than the closing differential pressure,
after clamped additionally by hand and
test shall be performed. ( C) Acceptance
criteria : To be as per TABLE-5.
Performance test of equipment as
electrical components. Insulation
resistance shall be tested by 500
voltmegger to assure it least 30 Megaohms. The dielectric strength tests at
specified voltages shall be made by
equipment manufacturer and it shall be
verified on the test report that no
abnormality exists in pressure retaining
parts. Records Results of inspections and
tests specified in paragraphs 3 to 9 shall
be recorded on test reports, which shall
be submitted. DIMENSIONAL INSPECTION
The main dimensions such as face - to
-face, end flanges and drilling shall be
measured in comparison with applicable
drawings. Allowable dimension is to be
shown in TABLE-7 to TABLE-9.

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Allowable valve for internal diameter D

of socket for socket welded area shall be
defined as an extent from minimum
dimension to maximum dimension
specified as per ANSI B16.11 (as shown
in approval drawings.) The dimension
shall be taken on the completed valve
each type and size by 20% sampling or 5
sets max. But the purchaser keeps the
right to require to increase a percentage
of the check if necessary. The surface
finish of end flange shall be checked in
comparison with applicable drawings.
RUST PREVENTION AND PAINTING
INSPECTION The procedure for Paint shall
be as per the manufacturers standard.
The procedure for Rust Prevention shall
be as per the manufactures standard.
QUANTITY AND IDENTIFICATION TEST
Quantity shall be visually confirmed
according to the specification in
accordance with the supply list.
CONFIRMATION FOR PACKING AND
MARKING. For Packing and Marking, the
following points shall be visually
checked. Shipping Marks Identification
Marks Plant Marks Care Marks Volume,
style And Type of Package Fixation of
Goods Material of Package Condition of
Package

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TABLE-1 Test Pressure (Gate & Globe Valve)
UNIT : BarG TABLE-2 Test Pressure (swing &
Check Valve )
UNIT : BarG TABLE-3
Test duration
(Gate and Globe valve ) SHELL TEST
PRESSURE HIGH PRESSURE SEAT & BACK
SEAT TEST CLASS WCB A105 WC6 F11 CF8
CF3 F304 LOW PRESSUR E SEAT WCB A105
WC6 F11 CF8 CF3 F304 150 31.1 31.1 29.4
5.6 21.8 22.1 21.1 300 77.6 77.6 75.9 5.6
56.2 56.9 54.9 600 153.5 155.2 150.0 5.6
112.4 113.8 109.3 800 207.0 207.0 206.9 5.6
152.O 152.O 145.9 1500 384.4 387.9 372.4
5.6 281.4 284.5 273.1 SHELL TEST
PRESSURE HIGH PRESSURE SEAT CLASS WCB
A105 WC6 F11 CF8 CF3 F304 WCB A105 WC6
F11 CF8 CF3 F304 150 31.1 31.1 29.4 21.8
22.1 21.1 300 77.6 77.6 75.9 56.2 56.9 54.9
600 153.5 155.2 150.0 112.4 113.8 109.3
800 207.0 207.0 206.9 152.0 152.0 145.9
VALVE SIZE SHELL (SEC.) BACKSEAT(SEC.)
SEAT (SEC.) 2 & SMALLER 15 15 15 2-1/2
TO 6 60 60 60 8 TO 12 120 60 120 14 &
GERATER 300 60 120

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TABLE- Test Duration (Check valves )
4
Maximum allowable leakage rates
TABLE- for closure tests. * 1 milliliter is
5
considered equivalent to 16 drops.
TABLE- Warning : Air must pass through
6
filter to prevent the deposit of foreign
particles on seating faces. Tolerance
For Motor Operated Valve Lift Note
(a) For gate valve, the bottom of a
disc shall not be at flow passage
when a disc has been fully opened.
(b) To be as 2mm, when tolerance of
15% is shown as below 2mm.
VALVE SIZE SHELL (SEC.) SEAT
(SEC.) 2 & SMALLER 15 15 2-1/2
TO 6 60 60 8 TO 12 120 120 14
& GERATER 300 120 VALVE SIZE
(NPS) SHELL (SEC.) SEAT (SEC.) 2 &
SMALLER 0 ( * drop ) 0 ( bubble ) 21/2 TO 6 12 ( * drop ) 72
( bubble ) 8 TO 12 20 ( * drop ) 120
( bubble ) 14 & GERATER 28 ( * drop
) 168 ( bubble ) SPECIFIED LIFT
(mm) TOLERANCE GATE VALVE
GLOBE VALVE up to 20 15 % over
20 up to 40 10% 10 % over 40
up to 100 5 % 5 % over 100 up
to 200 3 % 3 % over 200 up to
350 2.5% over 350 2 %

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-7

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Dimensional Tolerances of Flange
Unit : mm Designation of Dimension
Surface Condition Dimensional
Divisions Tolerance Black Skin up to
300 +4 -2 over 300 up to 600 +5 -2
over 600 up to 1000 +6 -2 over 1000
+8 -3 Finished up to 300 1 over
300 up to 600 1.5 over 600 up to
1000 2 Outside Dia. D over 1000
2.5 Black Skin up to 100 2.0 over
100 up to 250 2.5 over 250 up to
450 3.0 over 450 up to 500 4.0
Inside Dia. d over 500 5.0 C
1.6Bolt Hole P Drilled
0.5 up to 20 0.8 g Finished over 2
0.5Gasket Facing f Finished
0.5 up to 20 +1.5 0 over 20 up to
40 +3.0 0 Finished, One Face over 40
up to 100 +4.8 0 up to 20 +1 0 over
20 up to 50 +1.5 0 Thick. Of Flange t
Finished, Both Faces over 50 up to
100 +2 0

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TABLE-8 Dimensional Tolerance for Butt
Welding End TABLE-9
Tolerances for Face
to Face Dimension, Parallelness and
Squareness of Valve Unit : mm Face to Face
Dimension Parallelness Nominal size Globe,
Gate and Check Valves Angle Valves and
Squareness up to 4B 30 5B to 10B 1.5
0.8 20 12B and over 3.0 1.5 15