Lal " Doc No :PS.ELMS-05 i "Repair, Overhauling & Testing fer Too = : Bate 0ut19, 2015 Page fal 1, OBJECTIVE: This document describes Repair, overhauling and testing of Safety/Relief, Pilot Operated Safety/Relief & Pressure/Vacuum Safety/Relief Valves, Control Valves, Ball Valves, Gate Valves, Plug Valves & Check Valves on shutdowns/turnaround. SCOPE: This document describes the Scope of Work for Repair and Testing of Safety/Relief, Pilot Operated Safety/Relief & Pressure/Vacuum Safety/Relief Valves, Control Valves, Ball Valves, Gate Valves, Plug Valves & Check Valves, TERMINOLOGY: Pressure Relief Valve A Pressure relief vaive is @ spring-loaded pressure relief device, which is designed to open to relieve excess pressure and to reclose and prevent the further flow of fiuid after normal conditions have been restored. It is characterized by rapid ‘opening pop action or by opening generally proportional to the increase in pressure over the opening pressure. Itis primarily used for liquid service Safety Valve A Safety valve is a pressure relief valve actuated by inlet static pressure and characterized by rapid opening or pop action. It is normally used for steam and air services, Relief Valve A Relief Vaive is a pressure relief device actuated by inlet static pressure having 2 gradual lift generally proportional to the increase in pressure over opening pressure t' may be provided with enclosed spring housing suitable for closed discharge system application and is primarily used for liquid service. Safety Relief Valve A Safety Relief Valve is a pressure Relief Valve characterized by rapid opening or pop action, or by opening in proportion to the increase in pressure over the opening pressure, depending on the application and may be used either for liquid or compressible fluid Pilot-Operated Pressure Relief Valve AA Pilot-Operated Pressure Relief Valve is a pressure relief valve in which the major relieving device is combined with and is controlled by @ self-actuated auxiliary pressure relief device. Vacuum Relief Valve A Vacuum relief valve is a pressure relief device designed to admit fluid to prevent aan excessive internal vacuum; it is designed to reclose and prevent further flow of fluid after normal conditions have been restored Set Pressure This documents the intelectual Property of Descon Engineering Limited Any uneuthonzed use. eluding the moditcation and “eproduevon of te coments snc ‘ronbed © Copyrante Gromance 2002 Fights ReservedESCON yd Method Statement for CV, PSV's Doc No Repair, Overhauling & Testing Reel an Page : 20f 15 The value of increasing inlet static pressure at which a Pressure Relief Valve will relieve at incorporating the system temperature and back pressure when fitted to the process, Cold Set Pressure Itis the inlet static pressure at which a pressure relief valve is adjusted to open on the test stand. This test pressure includes corrections for service conditions of Superimposed back pressure andlor temperature, Back Pressure Back pressure is the pressure existing at the outlet of a pressure relief valve due to pressure in the discharge system or as a result of flashing in the valve body. Control! Valve A power operated device which modifies the fluid flow rate in a process control system. It consists of a valve connected to an actuator mechanism that is capable of changing the position of a flow controlling element in the valve in response to a signal from the controlling system Actuator ‘An actuator is a fluid powered or electrically powered device which supplies force and motion to a valve closure member. Positioner A position controller is mechanically connected to a moving part of a final control element or its actuator and automatically adjusts its output pressure to the actuator in order to maintain a desired position that bears a predetermined relationship to the input signal. The positioner can be used to modify the action of the vaive (reversing positioner), extend the stroke/controller signal (split range positioner), increase the pressure to the valve actuator (amplifying positioner) or modify the control valve flow characteristic (characterized positioner). Valve Trim ‘The internal parts of a valve such as the plug, seat ring, cage, stem and parts used to attach the stem to the plug that are in flowing contact with the service medium. ‘Stem ‘The part usually a rod, shaft or spindle which connects the valve actuator with the closure member. Packing A sealing system consisting of deformable material of one or more mating and deformable elements contained in a packing box which may have an adjustable compression means to obtain or maintain an effective pressure seal. ‘Stem Seals Opt Tepraaucion ofthe Conn stncypromaved © Coprnghts Ordinance 2002 Ai Rights ReservedMethod Statement for CV, PSV's DocNo -PS-EHMS-O8 Repair, Overhauling & Testing Reed ae Page: 30f 15. The part or parts needed to effect a pressure-tight seal around the stem while allowing movement of the stem. Back Seat A seating surface in the bonnet area that mates with the closure member or valve stem in the extreme open position to provide pressure isolation of the stem seal Yoke The structure which rigidly connects the actuator power unit to the valve Cage A part in a globe valve surrounding the closure member to provide alignment and facilitate assembly of other parts of the valve trim. The cage may also provide flow characterization and/or a seating surface for globe valves and flow characterization for some plug valves. Globe Valve A valve with a linear motion closure member, one or more ports and a body distinguished by a globular shaped cavity around the port region Gate Valve A valve with a linear motion closure member that is a flat or wedge shaped gate which may be moved in or out of the flow stream. It has a straight fiow path. Diaphragm Valve ‘A valve with a flexible linear motion closure member that is forced into the internal flow passageway of the body by the actuator. Ball Valve A valve which modifies flow rates with rotary motion of the closure member, which is either a sphere with an internal passage or a segment of a spherical surface. Butterfly Valve A valve with a circular body and a rotary motion disk closure member, pivotally supported by its stem, Plug Valve A valve with a closure member that may be cylindrical, conical or a spherical ‘Segment in shape. It is positioned, open to closed, with rotary motion ‘Check Valve Valves designed to close against pressure from one direction only. Control Valve Seat Leakage This documents the lnelectual Propo of| con Engineering Limted Any uneuthonzed us. including the meat’ ty erohated. © Copynghis Ordnance 2002 Al Rights Reserved Teproducton ofthe conten i= oESCON Method Statement for CV, PSV's Seen PSEHIS-6 verhaulins estin ev Repair Cvesbaulind ehecuns) Date Oct 19, 2015 Page: 40f18 5. The quantity of test fluid passing through an assembled valve in the closed position Under the test conditions as specified for the leakage class. Fail-Close A condition wherein the valve closure member moves to a closed position when the actuating energy source fails Fail-Open A condition wherein the valve closure member moves to an open position when the actuating energy source fails. Fail-Safe ‘A characteristic of a particular valve and its actuator, which upon loss of actuating energy supply, will cause a valve closure member to fully close, fully open or remain in fixed position, Fail-safe action may involve the use of auxiliary controls connected to the actuator. ABBREVIATIONS / DEFINITIONS: sm Site Manager me Inspection and Test Plan Fal Electrical & Instrumentation aagac Quality Assurance & Quality control PPE Personal Protective Equipment HSE Health, Safety & Environment RIT Request for Inspection and testing PROCEDURE: A, OVERHAULING, CALIBRATING, & TESTING OF SAFETY | RELIEF, PRESSURE | VACUUM & PILOT OPERATED SAFETY / RELIEF VALVES. \ Upon receipt of the valve from service, record all valve details on the worksheet, > Blow out the test stand to remove any loose particles from the system, Clean the valve inlet and Clamp the valve securely on the test stand. Select suitable pressure gauge by ensuring that the Set Pressure of the valve falls in the middle third of the gauge > Carry out an as received Lift tes/Pre-pop test as applicable and record the lift pressure. If the vaive fails to lift at a pressure of up to 110% max of its cold set pressure then no more pressure shall be applied and record the fact that the valve failed to lif. Where a LifvPre-pop test may raise a hazardous situation, the test may be waived and recorded as such on the report > A bellows test shall be carried out to check their integrity for all valves that have bellows feature. A test pressure of 15 PSIG or 50% of CSP, whichever is less, shall be applied through the valve outlet test flange and monitored for a peri Ths documents the lnelectual Property of Descon Engineering Lined Any unauthonzed use ding the mecfication ts Reserved reproduction ofthe contents stetyprohised © Corynghts Ordinance 2002 Al FigLd Method Statement for CV, PSV's Doc No :PS-EL-MS-06 DESCON ‘ i p Re 00 Repair, Over! ov ‘epair, Overhauling & Testing Beek LO EEG Page Sof 15 of 2 minutes. Leakage across the bellows shall be detected at the bonnet vent using a bubble pot. Any leakage shall be cause for rejection. Release the pressure and remove the valve from the test stand. DISASSEMBLY OF SAFETY/RELIEF VALVES ‘Remove the cap and cap gasket or the lifting lever device for valves that have this feature ‘Record the position of the control rings for the purpose of reassembling anci remove the control ring set screws and set screw gaskets ‘Loosen the adjusting bolt locknut and record the depth of the adjusting bolt in the: bonnet and count the number of turns required fo remove the spring load for the purpose of easy reassemble e ‘Release the entire spring load by rotating the adjustment bolt and remove the: bolts holding the bonnet to the valve body ‘rLift the bonnet up to clear the spindle & valve spring. Remove the spring with spring-washers fitted together. '-Remove the spindle, guide, disc holder, disc insert and the bellows subassembly: for valves that have this feature {Remove the disc holder from the spindle, lift the guide off the disc holder, remove: the disc insert from the disc holder and the nozzle ring from the nozzle. ‘rin most cases the nozzle can be reconditioned without removal from the valve body, but may be removed if necessary, due to severe damages to the nozzle seat Clean the internal parts and the valve body using cleaning solvents and wire: brush, provided the brushes shall not damage or contaminate the base metals. Only stainless stee! wire brushes shall be used on stainless steel components, Check and record all valve parts for wear and corrosion. The valve seats on both the nozzle and disc insert shall be examined for damages and if necessitates remaining, shall consult the original equipment manufacturers, specifications for critical machining dimensions or replacement of parts, ‘The valve springbellows shall be inspected for evidence of cracking, piting or | @ deformation ‘The bearing surfaces on the guide and disc holder should be checked for residual product build up and any evidence of scoring The disassembled valve shall be adequately boxed/palletized and stored in a secure area to prevent loss or damage to the components. fi, DISASSEMBLY OF PILOT OPERATED SAFETY/RELIEF VALVES Ensure any residual pressure is removed from the valve by venting the field test connection where applicable. Remove the sense tube and remove the pilot valve from the main valve, Remove the pilot cap and measure the adjusting bolt and blow down setting bolt height from the top of the lock nuts to the top of the adjusting bolts, where applicable. ‘Release the adjusting bolt locknut and remove the adjusting bolt and lock Unscrew and remove pilot bonnet. This documents the Inelectusl Propet of Descon Engineening Led. Any reproduction ofthe content sicty rombled © Copynants Grd zed use. including the modicaton|= Doct PS-EHS.08 DESCON Wettiod) Siatement Rae, Pev's ae fa yd par, Overhauling & Testing See Seg 208 Remove and disassemble the pilot internals and store in @ secure area to prevent loss or damage to the components Release the blowdown setting bolt locknut and remove the blowdown setting bolt and locknut ‘Remove the main valve bonnet stud nuts, lift off the bonnet, and remove the bonnet seal Remove the aise, diaphragm or bellows as applicable Remove guide, lif out the nozzle and seal where necessary iii, DISASSEMBLY OF PRESSURE/VACUUM SAFETY RELIEF VALVES Spring loaded style pressurelvacuum safetylrelief valves Loosen and remove the cap, lifting cap and cap screw where applicable. ‘Measure the adjusting bolt height from the top of the locknut to the top of the adjusting bolt. Release the adjusting bolt locknut, loosen, and remove the adjusting bolt and ocknut Loosen and remove the pressure grub screw and the top screw cap where applicable, The top screw cap shall be removed with caution as this may be retaining the spring under tension Remove the bonnet where applicable Remove the pressure spring assembly. Remove the compression from the vacuum spring Remove the vacuum discipoppet, the vacuum spring, and all O-rings DEADWEIGHT STYLE PRESSUE/VACUUM SAFETY/RELIEF VALVES Remove coversiplates and hinge mechanisms, as applicable Lift off pressurelvacuum pallet weight and lift off pressure/vacuum pallet where applicable, Loosen and remove the retaining screws and the retaining plate Remove the diaphragm, the back-up disc and spacer. v, RECONDITIONING OF SEATS © Reconditioning of the valve seats shall be carried out by lapping the seating surfaces of the nozzle and disc separately against suitable cast iron lapping blocks. All lapping blocks shall have two perfectly flat working sides and essentially retain a high degree of flatness to produce a truly flat seating surface. Except where severe sconng of the valve seat necessitates machining, lapping of the valve seats sequentially in order or as required with Medium Coarse (Gr.400), Medium (Gr 600), Fine (Gr.800), Polish (Gr.1200) and Microfinish (3 1) lapping compounds resp. would satisfactorily recondition the seats. The lapping compounds shall be clean and free from dirticontamination to obtain a truly flat seating surface. > Check the lapping blocks periodically to ensure the flatness of the blocks F If severe damages to the seats necessitate machining, the seats shall/é machined as per OEM recommendations. This document isthe lnolectual Property of Dascon Engineering Limted Any unauthorized use ncvsing he modification a Teproavcton ofthe coments sey promod © Copyrghte Oramance 2002 Ai Rights Reserved=, tee Decne -FS-INs.00 Bw Repair, Overhauling & Testing Date Oct 19, 2015 | vi. REASSEMBLING vill, Reassemble with clean components in the reverse order of the disassembly technique, applying lubricanvantisieze on threads and at other specific locations as necessary or as recommended in the OEM maintenance manual The adjustment screw shall be set to the measurement as noted during disassembly. The nozzle and guide rings, where applicable, shall be set as per the applicable OEM repair manuals or where OEM repair manuals are not available; the rings | shall be set to the original settings as noted during disassembly TEST MEDIUM Test medium for safety/relief valves on gas/vapor service shall be clean & dry | compressed air or nitrogen. For valves on liquid service, the test medium shall be hydraulic oll or fresh water containing a corrosion inhibitor. | TESTING Setting up to required Cold Set Pressure (CSP) Blow out the test stand to remove any loose particles from the system. Mount the valve vertically and clamp securely on the test stand Raise the inlet pressure gradually at a slow & steady rate to avoid damage to the internals when the valve lifts. Adjust the valve until the required cold set pressure is obtained. Ensure the locknut is tightened after each adjustment The valve lifipop may be repeated once again to check for reliability and accuracy of the cold set pressure and recorded on the report form Unless otherwise specified by the OEM, the general cold set pressure tolerances for acceptance shall be as follows a) 2 psig (+ 0.13 barg) for pressures up to and including 70 psig (4.8 barg) b) £ 3% of set pressure for pressures above 70 psig (4.8 barg) Seat Tightness Following the cold set pressure setting, the valve seat tightness test shall be performed on the test bench with an appropriate bubble flange and bubble pot built to API Std 527 and fited to the valve outlet Test Pressure For valves whose set pressure is greater than 50 psig (3.4 barg), the leakage rate in bubbles per minute shall be determined with the test pressure at the valve inlet held at 90% of the set pressure. For valves set at 50 psig (3.4 barg) or less, the test pressure shall be held at § psig less than the set pressure. Leakage test Testing with airinitrogen (closed bonnets) - Before the bubble count, the of pressure shall be applied for at least 1 minute for a valve whose nominal pine size is 2° (50 mm) or smaller. 2 minutes for a valve whose nominal pipe size Kec} This documents the netectual Property of Descon Engineering Limited. Any unauthorized use. including the modification and reproduction othe content ssc pronibted © Copynghts Oromance 2002 A Rigs ReservedMethod Statement for CV, PSV's Doc No sPS-ETMS-06 Repair, Overhauling & Testing Rev a Page 8 of 15 2%, 3° or 4” (65 mm, 80 mm or 100 mm), and § minutes for a valve whose ‘nominal pipe size is 6” (160 mm) or larger. The valve shal then be observed for leakage for at least 1 minute. Testing with airinitrogen (open bonnets) ~ The valve outlet shall be partially sealed with water to about %" (12.7 mm) above the nozzle's seating surface. ‘The inlet pressure shall then be increased gradually to the test pressure and held at this pressure for 1 minute before the bubble count. The valve shall then be observed for leakage for at least 1 minute. Testing with water ~ Following the set pressure lift, the valve outlet body bow! shall be filled with water and allowed to stabilize with no visible flow from the valve outlet. The inlet pressure shall then be increased to the test pressure. The valve shall then be observed for 1 minute at the test pressure. xii, Acceptance Criteria Testing with airfnitrogen (closed bonnets) ~ For valves with metal seat, the leakage rate in bubbles per minute shall not exceed the appropriate value in Table ‘A’. For soft-seated valves, there shall be no leakage for 1 minute (0 bubbles per minute) Testing with airinitrogen (open bonnets) ~ For valves with metal seat, the leakage rate in bubbles per minute shall not exceed 50% of the appropriate value in Table ‘A’. For soft-seated valves, there shall be no leakage for 1 minute (0 bubbles per minute) Testing with water ~ For metal-seated valves whose inlet have a nominal pipe size of 1” of larger, the leakage rate shall not exceed 10 Cu. Cms. per hour per inch of nominal inlet size. For metal-seated valves whose inlet has a nominal pipe size of less than 1”, the leakage rate shall not exceed 10 Cu, Cms, per hour. For soft-seated valves, there shall be no leakage for 1 minute. xill, Back pressure test 1» Following seat tightness test, a back pressure shall be carried out by applying pneumatic test pressure through the valve outlet, All gasket areas shall be sprayed with soap solution and monitored for 2 minutes for signs of leakage There shall be no leakage during this test > For valves with balanced bellows feature, a pneumatic test pressure is applied through the vaive outiet and the bellows integrity may be checked at the casing vent hole. > Back pressure tests shall be carried in accordance with OEM specified test pressures or as per the customer requirements for the applicable service conditions, xiv. Lead sealing & Tagging Upon satisfactory completion of all tests, the valve openings shall be covereditaped to prevent ingress of dirt > Tag the valve and lead seal the cap and set screws as applicable, to prevent interference. TABLE-A Maximum Seat Leakage Rates for Metal-Seated Pressure Relic! Valves é This documents the Inotlectusl Property of Descon Engineering Limited Ary unauihonzed use_iniuting te moditeaton an Treproaucion of he coments sincyprohded © Copyrights Ordmance 2002 Ai Rigs Reservea= - Doc Ne ELMS nzzer| og sitenatorcuireve |g Tgesoe oad 0 ‘9 Date Oct 19, 2015 |. OVERHAULING & TESTING OF BALL, GATE, PLUG, GLOBE, CHECK & BUTTTERFLY VALVES e@ \ Upon receipt of the vaive from service, record all valve details on the worksheet. Disassemble the valve using proper tools as necessary. Label / mark every component for identification Carry out inspection and check for any damage, wear, pitting and corrosion to the intemal parts and document. (Refer OEM instruction manuals or data sheets if available for special details) Clean, grit blast and paint Renew all gaskets and packing Replace necessary spares. Reassemble and check function \ \ i. TEST MEDIUM Mixture of soluble oil and water Clean air TEST EQUIPMENT e Calder pressure test unit > Haskel Sat Rig pressure test unit Resato pressure test unit \Ventil high pressure test unit Suitable rated Pressure Gauges Y \ \ Y y All the above equipment shail have valid calibration and test records. ii, HYDROSTATIC TESTING Shell Test Shell tests shall be performed by applying the specified pressure inside the assembled valve with valve ends closed, the valve partially open and any packing gland tight enough to maintain the test pressure; thereby, also testing the stuffing box. No visible leakage is permitted for shell tests. Closure Test ‘This document isthe ineslectuel Property of Descon Engineenng Limited. Any uneuthoried use ntact aateato NS Tepocucion of he coments set prahtes © Copyrghts Grance 2002 Ai Rights ReseedMethod Statement for CV, PSV's Doc No :PS-ELMS.06 Repair, Overhauling & Testing ee pon 49,2015 Page 100f 15 For valves designed to close against pressure from both directions, the pressure shall be applied successively to each side of the closed valve with the other side ‘open to atmosphere to check for leakage. The seat test may be repeated each side, if required, to demonstrate satisfactory mechanical operation and continued tightness, For valves designed to close against pressure from one direction only and so marked, the pressure shall be applied on the downstream side, Low-pressure closure tests may be performed at 60 — 00 psig or 4 ~ 7 barg for a minimum of 2 minutes, Backseat Test Backseat tests are recommended only for valves that have the Backseat feature and shall be performed by applying pressure inside the assembled valve with the valve ends closed, the valve fully open and the packing gland loose, The Backseat tests may be combined with the Shell test or can be performed immediately after the Shell test and all packing glands shall be retightened after the Back seat test TEST PRESSURES Hydrostatic Shell Test Pressure Unless otherwise specified, the Shell Test Pressure shall be 1.5 times the pressure rating at 38°C (100°F) rounded off to the next higher increment of 25, Psig or 1 Barg for the applicable material group in accordance with ASME B 16.34. Test duration shall be in accordance with Table — D. Hydrostatic Seat Test Pressure The Seat test pressure shall not be less than 1.1 times (110%) of the pressure rating at 38°C (00°F) for the applicable material group as per ASME B 16.34 VALVE PE Gass [SHELL TEST PRESSURE Whnimand—] Pig Barg__— | Dasa ron 50 0 = 300 ws % Cason a TST] Tot a TPS 14 75 0 Castor 2 WSZT| we a WPS 12:24 525 F Seal Flanged TB 2500, Butwed 150-4800 Threaded" & Sodewald 300 x 150-4800] Ibe in accordance with Table ~ D. Nores: * RSME B16 uns THREO=D EN VALNES TCLASS 25008 LOHER *PeRASNE B16. This document isthe netectual Property of Descon Engineering Lintod, Any unauthoned use, neusng the modicaer Teprodueton ote contents sine proheited © Copynghts Ordinance 2002 A Fights Reserved so77m7ca 7He4oo, 1 Method Statement for CV, PSV’s Doc No -PS-EL4S-06 a Repair, Overhauling & Testing oa Oe Page “110118 Fo CSS B00 VALVES, I SHEL EST PRESSURE SHALE 1-1/2 THES THE PRESSURE RATING A TOD 38°C, ROUNDED OFF TO THE NEXT HER NREENT OF 5°91 (8 BAR) TABLE-C: MAXIMUM ALLOWABLE LEAKAGE RATES FOR CLOSURE TESTS. ‘ALL METAL SEATED VALVES EXCEPT CHECK | METAL SEATED CHECK VALVES VALVESIZE | ALLRESILIENT (wes) | seateovatvest| Liquid Test Gas Test Uauates | Gastes (rops per minute) | (Bubbles per minute) 7 e e o y v @ 28 u T Ea 0 o 3 o * 7 7 Notes: "For the liquid test, 1 mm is considered equivalent to 16 drops. ® There shall be no leakage for the minimum specified test duration (see Table 4). For iquid test, 0 drops means no visible leakage per minimum specified test duration. For gas test O bubbles means less than 1 bubble pet ‘minimum spected test duration “The maximum permssible leakage rate shall be 0.18 cu in, (3.cu cm) per minute per in. of nominal pipe size “The maximum permissible leakage rate shall be 1.5 standard cubic (0.042 cu mt) of gas per hour per inch of ominal pipe size * For valves greater than or equal to NPS 14, the maxamum permissible leakage rate shall be 2 drops per min per in. NPS. "For valves greater than or equal to NPS 14, the maximum permissible leakage rate shal be 4 bubbles per minute per in. NPS: iv. TEST DURATION ‘TABLE ~ D | MINIMUM TEST DURATION (SECONDS, VALVE SIZE ‘SHELL, BACKSEAT CLOSURE Al valves with tues cnches) | Cheek vaies | ber Valves | AONE | check Vales | Other Valves e =z @ 5 15 @ 7% Papen) 0 0 o 0 3-2 0 72 @ 0 20 S14 12 200 0 2 72 Note The test curation isthe period of inspection after the valve i fully prepared & is under full pressure ‘TABLE ~ C: OTHER TEST PRESSURES Tins document's the inte Prop Teprodueton of the 2 of Descon Engineering Limited Any uneutherited use including the moc ‘ranted © Comynghs Onsnence 2002 A Rights Reseneary ESCON y Method Statement for CV, PSV's Doc No :PS-El-MS-06 Repair, Overhauling & Testing er po potente Page: 120f15 vi TEST TEST PRESSURE” Psig | Barg Valves Bxcopt Butterfly & Check High-pressure cosure & backseat” Low-pressure closure & backseat” 0-100 Buttery Vave [High sessure cosure [Cow-pressure closure 3100 a7 Check Va [High-pressure cosure (lass 125 (cast ron) Nesta] 200 if NPS 14-48] 150 i (lass 250 (cast ron) NPS2- 12] 500 3% NPS 14-24] 300 2 Class 150 (duce ron} 250 7 ‘has 300 (ductile ion} 0 a Carbon, alloy, stainsess steel & spon aloys [Low pressure closure if eootiable) 60-100 a CONTROL VALVE SEAT LEAKAGE Leakage Classes Class | — A modification of any Class lI, Ill or IV valve where design intent is the same as the basic class, but by agreement between user and supplier. no test is required, Class Il - This class establishes the maximum permissible leakage generally associated with commercial double-port, double-seat control valves or balanced single-port control valves with a piston ring seal and metal-to-metal seats Class Ill - This class establishes the maximum permissible leakage generally associated with Class II but with a higher degree of seat and seal tightness. Class IV - This class establishes the maximum permissible leakage generally associated with commercial unbalanced single-port, single-seat control valves and balanced single-port control valves with extra tight piston rings or other sealing means and metal-to-metal seats Class V ~ This class is usually specified for critical applications where the control valve may be required to be closed, without a blocking valve, for long periods of time with high differential pressure across the seating surfaces. It requires special manufacturing assemble and testing techniques. This class is generally associated with metal seat, unbalanced single-port, single-seat control valves or balanced single port designs with exceptional seat and seat tightness. Class VI - This class establishes the maximum permissible seat leakage generally associated with resilient seating control vaives either unbalanced or balanced single port with ‘O’ rings or similar gapless seals. ‘This documents the Inolecual Property of Descan Engineering Lmtd Any urauthorzed us, ding the moafcation a Teprosueion of he coten! is sinely prone © Copyrights Oninance 2002 Al Rights ReservedRepair, Overhauling & Testing beam Ln Rotenral Page 13 of 15 a, aa es TaBLe 1: CONTROL VALVE SEAT LEAKAGE CLASSIFICATIONS, (IN ACCORDANCE WITH ANSUFCI 70-2) [estage] warm Seat Leakage sag] HN SLO Tesuetin] esse Testor abn Rang 7 z Toei porn ner no ose Mrwama] Anne 4S-S0Pan ms. ced 2 es M9 "] ceastcmny | 2:32 | ma se wen wt | I srt ery a ht be art 1 otros rene i om As above As abowe As above coy Tae " mace ‘sion ‘eae ett iy The test lifeenal pessye | Pressue sped lowe tater Ry ene toy Shak be ‘Re max, seroe | canta comet ng wn wae a akg vale presse op 2505 ah pl, | phy coed wih ee actor agus to mea the rt exceedeg tre masmum | epuaing cardons speced, The pel aco Ast erat pescre_at_ fom | shal bo bo spoated ra, Nat cuts be he ‘enperaue a6 caersead by | spe0sod nat eal #0 be ved. Ver leakage How ANS! B15, 155, 1634 | slabi2ed, he ualy cl be obeened ne 2 pre af 510 oper mre ot water per oes Gamat per ps | Wotrat v | aera) (x 10° m | r0-seec er seen of water oa P 0-125°F) im of aee sete par Ieseepescue by agreement. | ine suc a ta aveatrg 10% aoaniny ‘Shalt exceed te Prssue spl 10 the wave inet and the tet leakage vies mavionet Jair/Necoen | 35 bag 60 Ps cr maxed | comecte To a sutable measieng deuce. WIN the vi | in tase 2 exressd in [a 0-82°C | ererrtl pease acces wove | ecisr atited to meet the cperang condtons rl pe inte versus got f60-125°F) | pug wncever slower ‘ected, al nama ced thst ren be oles sacle Allow er estan on fo stbize belo mesg Table 2: CLASS VI - MAXIMUM ALLOWABLE SEAT LEAKAGE Tianna Por Danae Tee Ra i a Tae Bao pa T B O15, T i a 0 Z 7 aI bas Hl Ey a 050 a zi Te 00, = a 102 170 i = 182 7007 zr = 2 B75 e 7 Bubtes per rate as buted a sugges alervoive Based ona Suse cltated measur dence, His case 8 W (6 A) (00 «0.032 (08 mm) wa tbe submerged wate oa det ef Fam 1/8 to LA (3 to 6 mn). The ube end shal be cit squere Bnd semaot with no ches oF Guns an6 ne tute aes SMa De perpedcule Yo the suface of the water. ther apparatus may be Carsruced andthe numberof busbles per mine may’ fer Frm those shown ae fng asthe comer incete the Row in pet Not: Provsons shoul be made t avo oveoressunng of measuring devices resting for advertent opening ofthe va ob 6. PRECAUTIONS > Using of standard tools. > _No.using homemade tools, This document iste ntoectual Property af Descon Engineering Lisied Aay unauthoried use. including the moda Toprosveton of te contents sty gronbied © Copyrights Ordnance 2002 alt Rights ReservedHS rm I DocNo :PS-EL-MS-06 aes Memo automat inev.rave | Bes ae i 9 & Testing bse“ Oert9.2015 | > Wearing gloves during working > During work, the area should be totally Barricades > No outside person comes inside during work > Only related person inside barricaded area > Material shifting very carefully Housekeeping is most important for completion of work, 7. HSE INSTRUCTIONS The following measures shall be approved forall the personnel involved in the project activities. > Adequate PPE include hard hat, safety glasses, Face shield, coverall with long sleeves, steel toed safety shoes, rubber gloves, dust mask(if required), and ear plugs (other PPE to be won as per job requirement) > Before starling the job motors isolation should be confirm from Client site representative Size of roling shaft shall be according to the drum capacity. > Property insulated and non-conductive tools shall be used for cable termination job. > The workers will be made aware of safety requirements related to this activity through daily toolbox and safety talks > Recess and good housekeeping should be maintained at site. > Fire extinguisher should be available in working area, > All waste material should be segregated and ensure proper housekeeping at all times of the activities and avoid any tripping hazards! blocking of emergency access points. 8. RELATED DOCUMENT: QABQCIFRM08 Corrective Action Request (CAR) form. QA&QCIFRM-21 Quality Inspection plan QA&QC/FRM-314 SAFETY RELIEF VALVE TEST REPORT QA&QC/FRM-318 CONTROL VALVE PRE-INSTSLLATION CALIBRATION e a Date BOOS, —[ 30-06-15 Name Wiemoona Gul ‘Ahmad Abbas Wirea Positio BD Coordinator & Head PC&S BA a Planning Engineer Role Written By [Reviewed By |_Approved By Tis document isthe Inectual Pr Toprodvcton ofthe contents snty promod © Canynghts Oa of Dascon Engineering Limited fny ynoulhonzed use eluding he mesktealicn arc c0 2052 i Fights Reserved