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PROCEDURE MANUAL

Forged Valve
Production

Copyright © 2008 SWI Valve Co., Ltd. All rights reserved. www.swivalve.com
FORGED STEEL VALVES
QA/QC PROCEDURE

DOC No. : SWI-QAC-001

SWI Valve Co.,Ltd.


6 2005/07/19 Dow COMMENTS T. M. LEE Y. P. CHO

5 2005/05/04 COMMENTS T. M. LEE Y. P. CHO

4 2004/11/21 SAMPLING PLAN COMMENTS T. M. LEE Y. P. CHO


ADD TO BAR STOCK &
3 2004/11/13 SAMPLING PLAN T. M. LEE Y. P. CHO

2 2003/10/08 ADD TO COMMENTS M.J.KO T. M. LEE

1 2003/03/10 ADD TO COMMENTS K.J.PARK T. M. LEE

0 2002/11/10 FIRST ISUED K.J.PARK T. M. LEE


REV REVIEWED/
DATE DESCRIPTION PREPARED
NO. APPROVED

SWI VALVE CO.,LTD.


Doc. No. :SWI-QAC-01
QA/QC PROCEDURE Rev. No. : 6
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1.0 SCOPE.

This procedure covers manufacturing, inspection and pressure test requirements of valves
manufactured by SWI Valve Co., Ltd. (here in after SWI) in accordance with API 602, API 598, etc.,
ASME B16.34, ASTM A105, A182, A193, A216, A217, A370, A961 etc. and MSS SP25⑤

2.0 APPLICABLE STANDARDS.

The following standards shall be applied.


ASME B16.34 : STEEL VALVES, FLANGED, THREADED AND WELDING END.
ASME B16.5 : PIPE FLANGES AND FLANGED FITTINGS.
ASME B16.10 : FACE TO FACE AND END TO END DIMENSIONS OF FERROUS VALVES.
ASME B 1.20.1 PIPE THREADS, GENERAL PURPOSE.
API 602 - 1998 COMPACT STEEL GATE VALVES.
API 598 : VALVE INSPECTION AND TEST.
API 591 : USER ACCEPTANCE OF REFINERY VALVES.
BS 5351 : VALVES-FLANGED, THREADED, AND WELDING END.
MSS SP-25: STANDARD MARKING SYSTEM OF VALVES, FITTINGS, FLANGES AND
UNIONS(VISUAL METHOD).
ASTM STANDARD SPECIFICATIONS.- A105, A182, A193, A 216, A217,A961, A370, & A962 etc.

3.0 MATERIAL INSPECTION.

3.1 Chemical and physical test shall be performed on charge/lot number. and shall meet the
requirements specified in the applicable ASTM specification. ⑤
3.2 All cut bar stock will be controlled by heat number of original bar stock MTR and transferred to
any cut bar stock material by heat number stamping or the heat resistant sticker.③ Responsibility
of transferring these heat numbers shall rest with the supplier of the bar stock. SWI inspector,
while conducting 100% PMI test on cut round bars and alloy steel stocks will check the heat
number stamps on the materials.⑤
3.3 Material certificate shall be submitted for body, bonnet, seat ring, stem, and disc/wedge.
3.4 Material to be used shall be identified as the material in approved drawing,
3.5 The heat number, stamped on the material shall be identified as the heat number referred in the
corresponding material certificate and the contents of the material certificate shall be in
compliance with the applicable material standard/code.
3.6 PMI is performed 100% of lot for alloy steel round bar, cut bar of any grade and 10% of lot for
forging.

SWI VALVE CO.,LTD.


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4.0. VISUAL INSPECTION


The following points shall be visually confirmed.

4.1 External and internal surfaces of forgings shall be free from harmful defects, such as blow holes,
fins, sand inclusion , and burning.
4.2 Machined surfaces shall be free from harmful defects such as cutting, machining burrs, blow holes,
etc.
4.3 Seat surfaces shall be free from blow holes and other harmful defects, such as, burrs,.
4.4 Corners and fillets without specified dimensions shall be properly chamfered or rounded.
4.5 Flow path positioned shall be properly finished, and cleaned.

5.0 HEAT TREATMENT

5.1 Heat treatment shall be performed by the employees, qualified by SWI’s QA Manager per applicable
ASTM code A105, A182, and A350 .
5.2 Hardness test shall be performed with 10% per lot after heat treatment.
5.4 All wedge with 13CR and other applicable grades will be heat treated and hardness test performed
with 10% per lot after heat treatment, with results recorded on MTR. ④

6.0 Valve Design, Construction and Fabrication.

6.1 Body and Bonnet Wall Thickness

The minimum thickness for the body and bonnet wall shall not be less than the values in Table 1.
6.2 Standard for Face to Face Dimension
The face to face dimension of flanged-end valves shall be in compliance with ASME B16.10.
The serration of flange shall be plastic caped against damage. ⑥
6.3 Standard for Valve End Connection
6.3.1 Threaded-end valves, as well as the female threaded ends of extended-body valves, shall be
internally taper-threaded as specified in ASME B1.20.1.
6.3.2 Socket-welding-end preparation, including the female ends of extended valves, shall conform to
of ASME B16.11. The minimum wall thickness of female socket-welding ends shall be in Table 4 of
ASME B16.34.

SWI VALVE CO.,LTD.


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Table 1. Body and Bonnet Wall Thickness


Minimum Wall Thickness
Size Class 150#,300#,600#,800# Class 1500#
Inches Millimeters Inches Millimeters
1/4 0.12 3.1 0.15 3.8
3/8 0.13 3.3 0.17 4.3
1/2 0.16 4.1 0.19 4.8
3/4 0.19 4.8 0.24 6.1
1 0.22 5.6 0.28 7.1
1-1/4 0.23 5.8 0.33 8.4
1-1/2 0.24 6.1 0.38 9.7
2 0.28 7.1 0.47 11.9

6.3.3 Socket-welding-end is checked 10 % per lot with limit gauge.


6.3.4 Threaded-end is checked 10 % per lot with thread gauge that is calibrated once in every 12
months. ⑤

6.4 Surface Finish.

6.4.1 Valve End Flange

a) The facing finish of end flanges shall be in accordance with the requirements of ASME B16.5
b) Flange face finish for raised-face and flat-face flange shall have serrated finish with 3.2 to 6.3
Ra (125 to 250 AARH) to ASME B46.1-1978, obtained by machining with a round nosed
cutting tool having a shared 1.6 mm radius at a feed rate between 0.35 and 0.45mm per
revolution.
c) The serration of flange is checked with Table number 10% per lot with ASME B46.1 and the
applicable drawing for the raised-face. ④

6.4.2 Stem and Stuffing Box


a) The stem shall have a surface finish RA of 32 micro inches (0.80 micrometers) or smoother in
the area of contact with the packing.
b) The stuffing box finish Ra shall be 125 micro inches (3.2 micrometers) or smoother unless
otherwise specified in the purchase order.
c) The stem diameter shall be subject to the figures shown in Table 2.
d) Stem machined surfaces shall be protected against damage. ⑥

SWI VALVE CO.,LTD.


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Table 2. Stem Diameter of Class Gate Valve


Millimeters(minimum)
Valve Type Size, NPS
800# 1500#
1/2 9.0 11.2
3/4 10.0 11.2
Gate 1 11.5 14.6
1-1/2 15.0 16.0
2 16.5 17.0

d) Receiving Inspection for stem surface shall be performed with 10% per lot with roughness
gauge.(Mitutoyo Model : SJ-301). ④
e) Stuffing box depth shall be checked with 10% per lot by stuffing box limit gauge, ④
f) Stuffing box surface shall be checked with Table 7 sample size per lot with roughness
gauge.(Mitutoyo Model : SJ-301). ④

7.0 WELDING

4.1 Welding shall be performed by the personnel qualified by QA manager per ASME SECTION IX.
4.2 Welding shall be performed in accordance with the established WPS/PQR.

8.0 MARKING CHECK

The marking shall be performed in accordance with API 602, ASME B16.34 and MSS SP-25.

8.1 Forging-out on Body : Manufacturer’s trade mark. Class, size, material spec., flow direction
and Heat No.
8.2 Hand wheel : Letters symbols and arrowhead to indicate “ OPEN and SHUT or Close”
8.3 Name Plate : API 602/ASME B16.34, Manufacturer’s trade mark. Model, Class, size,
Applicable pressure rating, Body material, Trim material.
8.4 Stem: Color coding
8.5 Wedge: Material grade and Heat No.
8.6 Bolt : According to Para. 19 of ASTM A193, the manufacturer’s trade mark, Material grade, are
required for only 3/8”(10mm) in diameter and larger②

SWI VALVE CO.,LTD.


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9.0 DIMENSION CHECK

The Valves shall be examined for the dimensions per tolerance in accordance with ASME B 16.5,
ASME B 16.10. and ASME B1.20.1.
Other dimensions shall be specified in approved drawing.

Check Point Applicable Standard


Face to face, end to end ASME B 16.10
Flange ASME B 16.5
Socket Welding ASME B 16.11
Thread Ends ASME B 1.20.1

10.0 PRESSURE TEST

10.1 The pressure test, including inspection shall be conducted per API 598 and ASME B 16.34
10.2 Valve type test requirement shall be in accordance with following Table 3.

Table 3. Valve type test requirement


Valve Type
Test Description
Gate Globe Check Ball
Shell Test Required Required Required Required
Backseat Test Required Required N/A N/A
High Pressure Seat Test Optional Required Required Optional
Low Pressure Seat Test Required Optional N/A Required
N/A : Not applicable

10.3 For shell, backseat and high pressure seat test, the test media shall be water.
10.4 Chloride content of water which is used for pressure test shall be less than 30 PPM in case
of stainless steel material. The record of analysis of water shall be preserved.
10.5 For low pressure seat test, the test media shall be air.
10.6 The test media temperature shall be not exceed 52℃.
10.7 Valve test pressure requirement shall be in accordance with following Table 5.
10.8 Valve test duration requirement shall be in accordance with following Table 4.

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Table 4 Duration of required Test pressure.(Minimum) , unit : sec

Shell Test Seat & Backseat Test


Valve Back
Size Check Other seat Check Other
V/V V/V V/V V/V
≤ 2 60 15 15 60 15

11.0 PRESSURE TEST PROCEDURE

11.1 Shell Test

11.1.1 The shell test shall be conducted by applying the pressure inside the assembled valve with the
valve ends closed, the valve partially open, and the packing gland sufficiently tight to
maintain the test pressure, thereby testing the stuffing box as well. The stuffing box shall not
leak during the shell test.

11.1.2 Test pressure and duration of testing shall conform to Table 4 and 5.

11.2. Backseat Test.

11.2.1 The backseat test for gate valve shall be performed by applying the pressure inside the
assembled valve with the valve end closed, the valve fully open, and the packing gland loose.
The backseat test may be made immediately after the shell test and all packing glands shall
be retightened after the backseat test.

11.2.2 Test pressure and duration shown conform to Table 4 and 5.

11.3. Seat leakage test.

11.3.1 Low pressure test.

In accordance with Table 3, the test is applicable for the gate as well as ball valve.
Test fluid used is as shown in the paragraph 10.5. Low pressure test method is as shown
below.

SWI VALVE CO.,LTD.


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Table 5 Test Pressure (API 598 and ASME B 16.34) kg/cm2

Class 150# 300#

Description CWP Shell Seat CWP Shell Seat


Material
psig Kg/cm2 Kg/cm2 psig Kg/cm2 Kg/cm2

A105, A350-LF2 285 32 23 740 80 59

A182-F5,F9,F11,F22 290 32 23 750 80 59

A182-F304,F316 275 30 23 720 78 57

A182-F304L, F316L 265 25 19.5 600 64 48

Class 600# 800#

Description CWP Shell Seat CWP Shell Seat


Material
psig Kg/cm2 Kg/cm2 psig Kg/cm2 Kg/cm2

A105, A350-LF2 1480 157 117 1975 210 153

A182-F5,F9,F11,F22 1500 159 117 2000 211 155

A182-F304,F316 1440 153 113 1920 204 150

A182-F304L, F316L 1200 127 94 1600 169 125

Class 1500# 2500#

Description CWP Shell Seat CWP Shell Seat


Material
psig Kg/cm2 Kg/cm2 psig Kg/cm2 Kg/cm2

A105, A350-LF2 3705 392 289 6170 653 478

A182-F5,F9,F11,F22 3750 396 291 6250 660 484

A182-F304,F316 3600 380 280 6000 633 465

A182-F304L, F316L 3000 317 233 5000 528 387

※ CWP means the maximum allowable pressure at –20 OF to 100 OF(38℃).

SWI VALVE CO.,LTD.


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11.3.1.1 Gate valve

a.) Apply test pressure to the inlet side of closed valve, fill water in the outlet side and maintain the
pressure of water for the duration shown in Table 4. Observe any bubbles through seating
surface, seat ring, or through the wedge. Test shall be carried out in both directions.
b.) For the valves having a flow direction specified in the approval drawing, air pressure to
be applied in the same direction as of flow direction.
c.) Light oil shall thinly be applied to the body and wedge seating surface after cleaning the
surfaces.

11.4 Acceptable criteria for pressure test.

11.4.1 For shell and backseat tests, no visible leakage is permitted.

11.4.2 For both the low and high closure test, acceptance criteria shall be in accordance with the
following Table 6.

Table 6. Maximum Allowable Leakage Rates for Closure Tests.


All Metal Seat
All Metal Seat Valve except Check
Resilient Check Valve
Valve size a
Seated Liquid Test Air Test Liquid Air
(drops per
V/V minute)
(bubbles per minute) Test Test

2” and Smaller 0 0b 0b c N.A

a. For the liquid test, 1 milliliter is considered equivalent to 16 drops.


b. There shall be no leakage for the minimum specified test duration.(see Table 4).
For liquid test, 0 drop means no visible leakage per minimum specified test duration.
For air test, 0 bubble means less than 1 bubble per minimum specified duration.
c. The maximum permissible leakage rate shall be 0.18 cubic inch (3 cubic centimeters)
per minute per inch of nominal pipe size.

12.0 OPERATION TEST

Assembly function inspection shall be carried out on valve as furnished below.

SWI VALVE CO.,LTD.


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12.1 Gate Valve.


12.1.1 When the valve has been fully closed, the center of seating surface on the wedge shall be
located at the upper part of seating surface on the valve body.
12.1.2 When the valve has been fully opened, the bottom of the wedge shall be not intrude into
the passage of fluid.
12.2 The inspector should check whether the gland flange press the gland properly using jigs. And the
Inspector should check parallel of the gland flange visually.
12.3 In the case the leakage occurs at pressure testing, it is allowed for the inspector to make an
maximum 1/4 additional adjustment turn. ⑥

13.0 Record.
QA/QC records shall be retained for a minimum of 5 years , not exceeding 10 years.

14.0 Receiving Inspection Sample size.( ASTM F 1470 Table 3 Sample size A) ④
Table 7 Sample Size
Lot Size Sample Size
1 to 2 2
3 to 15 3
16 to 25 4
26 to 50 5
51 to 90 6
91 to 150 7
151 to 280 10
281 to 500 11
501 to 1200 15
1201 to 3200 18
3201 to 10000 22
10001 to 35000 29
35001 to 150000 29
* The acceptance number in all cases is zero defects.
* Zero defects – zero defects applies only to the random sample.
It gives a 95% confidence level that the shipping
lot is free from defects.

SWI VALVE CO.,LTD.


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15.0 Parts receiving inspection and sample size ④

Table 8. Receiving inspection and sample size


Parts Receiving Inspection Sample Size Record
Round Bar / Cut PMI 100 % Yes.
Bar of any grade
Forging Visual (Marking) 10 % Yes.
PMI (Alloy Steel) 10 % Yes.
Hardness 10 % Yes.
Dimension Table 7 Yes
Body Machining Visual Table 7 Yes
Dimension Table 7 Yes.
Thread 10 % Yes
Socket Welding 10 % Yes
Flange Visual Table 7 Yes
Dimension Table 7 Yes.
Serration 10 % Yes
Bonnet Machining Visual Table 7 Yes
Dimension Table 7 Yes.
Stuffing Box Surface Table 7 Yes
Stuffing Box Depth 10 % Yes
Wedge / Disc Hardness 10 % Yes
Dimension Table 7 No.
Stem Visual Table 7 Yes
Dimension Table 7 Yes.
Surface 10 % Yes
Hardness 10 % Yes
Bolt & Nut Marking Table 7 Yes.
Hardness Table 7 Yes.
Others Parts Visual Table 7 No.
Dimension Table 7 No.
If a non-conformity is observed in the sample size 100% of the lot shall checked.

SWI VALVE CO.,LTD.