VES-5097 Inspection and Testing of Valves

TS-ENC-STD-0056
‘Helping me do my job better’ VICO Indonesia

VES-5097 Inspection and Testing of Valves

Author A.R. Thanura(Discipline Engineering Section Head)

Reviewer A.Rastiarsa (E&C Manager)

P.Stegers (Technical Support Vice

Approver President) / Vania De Stefani
(Engineering Authority)

VMS Primary VMS Secondary

11.3
Element Reference Element Reference
Date of Issue 31-Jul-2013 Next Review Date 31-Jul-2016
Revision Number B.01 Document Level 2 - Standard
NOT CONTROLLED WHEN PRINTED OR DOWNLOADED
 VES-5097 Inspection and Testing of Valves
TS-ENC-STD-0056
‘Helping me do my job better’ VICO Indonesia

Revision History
Amendment Date Revision Amender Amendment
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Title

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 ──────────

VICO INDONESIA

──────────

DOCUMENT : VICO ENGINEERING STANDARD

NUMBER : VES-5097

TITLE : INSPECTION AND TESTING OF VALVES

5 11/02 Changed Virginia Indonesia Company Isdiarso K. Sukiswanto

to Virginia Indonesia Company LLC
and changed BPPKA/PERTAMINA to
BP MIGAS
4 4/93 Converted from Word Processor No. Djarot S.S. Lukman M.
WPD-105 to Word Perfect 51

3 4/90 Changed HES to VES D.I. Jenie D.S. Newson

2 11/89 Section 8.3, Delete Appendix A D.I. Jenie D.S. Newson

1 8/86 Section 2.0, 4.0, 5.2, 8.0, Appendix A T.W. Bartlett G.E. West

0 6/85 Original Issue J. Carlson G.E. West

NO. DATE REVISION ENGINEER APPROVED BY

VES - 5097

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 INSPECTION AND TESTING OF VALVES

TABLE OF CONTENTS

PAGE

1.0 SCOPE 3

2.0 REFERENCE SPECIFICATIONS, CODES AND STANDARDS 3

3.0 DEFINITIONS 4

4.0 INSPECTION 4

5.0 VALVE TESTING 6

5.1 Test Medium 6

5.2 Test Pressures 6
5.3 Duration of Tests 6
5.4 Shell Test 6
5.5 Backseat Test 7
5.6 Seat and Closure Member Test 7
5.7 Performance Testing 9
5.8 Low Pressure Seat Test 9
5.9 Retesting 9

6.0 PREPARATION FOR SHIPMENT 9

7.0 REQUIRED TESTING FOR VARIOUS VALVES 10

TABLE 7.1 - MINIMUM TESTING REQUIREMENTS FOR VALVES 10

8.0 DOCUMENTATION 11

8.1 Material Certificate 11

8.2 Test Certificate 11
8.3 Test Report 11
8.4 Record Charts 12
8.5 Test Equipment 12
8.6 Ownership 12

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1.0 SCOPE

This specification defines the minimum inspection and testing requirements for all sizes and ratings of
the following valves:

a) Gate Valves
b) Ball Valves
c) Plug Valves
d) Globe Valves
e) Check Valves

2.0 REFERENCE SPECIFICATIONS, CODES AND STANDARDS

The latest edition of the following documents shall form a part of this specification when referenced
herein:

American Petroleum Institute (API)

API Spec 6A - Specification for Wellhead Equipment

API Spec 6D - Specification for Pipeline Valves

American National Standards Institute (ANSI)

B 16.5 - Steel Pipe Flanges and Flanged Fittings

Company Specifications

VES-1000 - General Technical Conditions for Tender and Purchase of Equipment and Materials.
VES-5091 - Standard Design Instructions for In-Plant Piping
VES-5094 - Standard Specification for Fabricated Piping
VES-5095 - Ball valves for Pipeline Service
VES-5096 - General Valve Standard

Manufacturers Standardization Society of the Valve and Fittings Industry (MSS)

MSS-SP 25 - Standard Marking System for Valves, Fittings, Flanges and Unions
MSS-SP 55 - Quality Standard for Steel Castings
MSS-SP 82 - Valve Testing Methods

In the event of conflict among these various specifications, Vendor shall immediately notify Purchaser
in writing with a complete description of the conflict. In general, the more stringent requirement shall
prevail.

3.0 DEFINITIONS

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 The following definitions shall be applicable throughout this specification:

Company - Virginia Indonesia Company LLC.

Purchaser - Company or a third party representing Company which has place a purchase
order for valves to be used in Company's facilities.

Vendor - The organization named on the purchase order for valves to be used in
Company's facilities.

Manufacturer - The company responsible for final assembly and testing of valves intended for
Company's use.

Inspector - Company personnel or third party personnel authorized by Company to perform

all inspection and witness any testing of valves covered under this specification.

No Visible Leakage -
Liquids - The term "no visible leakage" applied to a hydrostatic test liquid is defined as a
leak rate which will produce no visible weeping or formation of drops at the
pressure and for the duration of test.

No Visible Leakage -
Gas - The term "no visible leakage" applied to air or gas testing is defined as a
leak rate which will produce no visible formation of bubbles in a water
immersion test or after the application of leak detection fluid at the pressure
and for the duration of test.

4.0 INSPECTION

4.1 Purchaser or his designated representative shall inspect and witness testing of all valves.

4.2 Prior to any test procedure being performed, Vendor shall demonstrate his capability to
perform the procedures to Purchaser's satisfaction. This demonstration shall include
preparation of detailed test procedures which Purchaser must approve prior to
commencement of testing.

4.3 Vendor shall provide to Purchaser a detailed test procedure which complies with all
standards and specifications relating to "Valve Testing".

4.4 Vendor shall provide the following as a minimum requirement:

a) A suitable designated safe area for the specific purpose of testing valves.

b) Suitable designed and certified equipment for the testing of valves.

c) Equipment required for recalibration of gauges and instrumentation.

4.5 A detailed schedule shall be provided by Vendor at the time the purchase order is placed,
showing dates and location where the testing procedure shall be performed. Purchaser
requires a minimum of fifteen working days to review schedule and notify Vendor of his

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 acceptance. Vendor shall notify Purchaser immediately, should any adverse conditions arise
preventing inspection and testing deadlines being achieved.

4.6 For new valves, testing shall be performed prior to painting. Where prepainted valves are
offered from stock, the paint coat need not be removed, except where specific paint types do
not satisfy the specific requirement set out in the purchase order and specification.

4.7 Final inspection for valves ordered with operators or additional control equipment shall be at
that location where tests for proper functioning of the complete assembled unit can be
made. Vendor shall designate this location in his proposal documents.

4.8 All documents required for verification of metallurgy, heat treatment, welding and any other
documents required by the purchase order shall be present at the location where the valves
are to be inspected for Purchaser's review at the scheduled time for final testing.

4.9 All valves shall be inspected to verify that the end connections are of the proper size and
rating and that the actual dimensions comply with those specified in the purchase order.

4.10 All valves shall be visually inspected to verify that the nameplates contain the information
required by MSS-SP 25 and API 6A or 6D, if applicable, as well as Purchaser's tag and
purchase order numbers.

4.11 All valves shall be visually inspected to ensure that packing of the correct type has been
properly installed.

4.12 All valve castings shall be visually inspected to ensure that no gas holes, pockets or other
objectionable defects are present, in accordance with MSS-SP-55.

4.13 All required pressure testing of valves shall be witnessed by Purchaser.

4.14 All required functional testing of valves and/or valve operators shall be witnessed by
Purchaser.

4.15 Under no circumstance shall Vendor offer for testing, second hand, reclaimed or refurbished
valves for testing. IT IS STRICTLY FORBIDDEN. In the event that such valves are offered
they shall be immediately rejected. All claims made as a result of late delivery, non
compliance with purchase order and specifications, shall be levied against Vendor.

4.16 Vendor shall be totally responsible for health and safety of all personnel during test periods.
Signs should be posted around the perimeter of the test area prohibiting the entry of
personnel. The test area should also be taped off, clearly marking the area.

4.17 Vendor shall produce a procedural document itemizing the safeguard procedures to be
implemented, contingency plans and procedures that may be necessary in the event of any
foreseeable problems arising.

5.0 VALVE TESTING

5.1 Test Medium

Pressure tests shall be carried out with air, water or kerosene. Water shall contain a

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 corrosion inhibitor. Other liquids may be acceptable provided that the viscosity is not greater
than that of water and prior Company approval has been obtained.

5.2 Test Pressure

The minimum test pressure shall be as defines in the following for standard flanged end or
weld end valves:

ANSI Valve Class Test Pressure (PSIG)

Shell Test Seat Test

150 425 300

300 1100 800
400 1450 1060
600 2175 1600
900 3250 2400
1500 5400 4000
2500 9000 6600

For valves which do not have standard flanged or weld ends, the minimum test pressure
shall be 1.5 times the 100oF rating of the valve rounded to the next highest 25 PSI
increment.

When specified on the purchase order, pressure testing at higher pressures will be required.

5.3 Duration of Tests

The duration of pressure testing for each valve shall be as defined in the following:

Valve Size (Inches) Shell Test Duration Seat Test

Duration

Smaller than 2 2 minutes 2 minutes

2 through 4 2 minutes 2 minutes
6 through 10 5 minutes 5 minutes
12 through 18 15 minutes 5 minutes
20 and larger 30 minutes 5 minutes

When specified on the purchase order, pressure tests of longer duration will be required.

5.4 Shell Test

The shell test is an internal pressure test of the valve's pressure containing envelope. When
a shell test is required by this specification or by the purchase order, it shall be performed in
the following manner, using water or kerosene as the test medium:

a) The valve shall be placed on a test rack or jig which has been designed to permit free
expansion of the valve shell.

b) The valve gate, wedge, disc, ball or plug shall be in the partly open position.

c) The valve ends shall be closed and the valve shell shall be freed of air.

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 d) The valve shall be filled with the hydrostatic test medium and pressured to the specified
test pressure and held at this test pressure for the specified test duration.

e) No visible leakage, wetting of external surfaces or permanent distortion of the valve

shell is permitted.

5.5 Backseat Test

All valves which are provided with a backseat to permit repacking of the valve in service
shall be subjected to a backseat test. This test may be made consecutively with the shell
test. The backseat test shall be performed in the following manner:

a) The valve shall be placed in a test rack or jig which has been designed to permit free
expansion of the valve shell.

b) The valve shall be in the fully open position.

c) The valve ends shall be closed and the valve shell shall be freed of air.

d) The valve shall be filled with the hydrostatic test medium and pressured to the specified
seat test pressure.

e) The stem packing gland shall be loosened. No visible leakage or wetting of the external
surfaces is permitted for the specified duration of the test.

5.6 Seat and Closure Member Test

The seat and closure member test is an internal pressure test of flow regulating elements
including seats, seals, gates, disc, balls and plugs. When a seat and closure member test is
required by this Specification or by the purchase order, it shall be performed in accordance
with one of the following procedures, at the specified seat test pressure for the specified
duration. Unless otherwise specified, seat and closure member tests shall be conducted
using air or water as the test medium.

5.6.1 Valves with Non-Resilient Seats

Non-resilient seats include metallic, ceramic, carbon graphite and other similar
hard seating materials.

During this test the valve shall be filled with test medium, including the body
cavity; and any leakage shall be detected by the observation of drops
overflowing from the side of the valve which is open to the atmosphere. As an
alternative, a displacement measuring device may be used to detect leakage.

For non-resilient seated gate, plug, ball, and other than block-and-bleed valves,
the pressure shall be applied successively to each side of the closed valve with
the other side open to the atmosphere. For globe valves, the pressure shall be
applied under the disc. For check valves, the seat test pressure shall be applied
at the downstream side of the disc. In each case, the test pressure shall be held
for the specified duration. No evident leakage exceeding the maximum
allowable leakage rate shall be permitted during the closure test.

5.6.2 Valves with Resilient Seats and Block-and-Bleed Valves

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 Resilient seats include rubber, polymers, PTFE and other similar flexible seating
materials. During this test the valve shall be filled with test medium, including
the body cavity, up to a vent opening so that any leakage will overflow from the
opening. As an alternative, a displacement measuring device connected to the
body cavity may be used to detect leakage.

For resilient seated and block-and-bleed (double sealing) valves, the pressure
shall be applied successively or simultaneously to both sides of the gate, plug or
ball in the closed position with the body cavity open to the atmosphere. In each
case, the test pressure shall be held for the specified duration.

Valves with resilient seats shall show no visible leakage for the duration of the
pressure test.

5.6.3 Maximum Leakage during Seat and Closure Member Test

For valves with non-resilient seats, the following table defines the maximum
acceptable leakage during seat testing, using air or water as the test medium.

Nominal Port Diameter Bubbles per mL per Minute

Minute
Inch mm

1 25 1 0.15
1 1/2 38 2 0.30
2 51 3 0.45
2 1/2 64 4 0.60
3 76 6 0.90

4 102 11 1.70
6 152 27 4.00
8 203 45 6.75

5.7 Performance Testing

Performance testing requires operation of the valve with a differential pressure applied across the
valve closure. When required by this Specification or by the purchase order, the performance
test shall be applied after the shell test and seat and closure tests have been carried out. The
valve shall be operated a number of times from closed to fully open position and vice versa to
demonstrate satisfactory operation.

In case of power operators, the performance test shall be made on the complete unit using the
operator that will be shipped with the valve. The torque required to open a ball, gate or plug valve
shall be measured by the Manufacturer in accordance with API Specification 6D. Not less than
ten (10) complete strokes shall be made on all valves equipped with a power operator. Not less

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 than two (2) complete strokes shall be made on all other direct lever, handwheel and gear-
operated valves. Subsequent to the valve operation, the seat and closure member test shall be
repeated. After each test, the valve shall be opened by the power operator, if supplied, while the
differential pressure specified in the Purchase Order is being applied to the valve.

5.8 Low Pressure Seat Test

When required by this Specification or by the purchase order, a low pressure seat test shall be
performed. The low-pressure seat test procedure shall be the same as for the high-pressure
closure test. The test medium may be either liquid or air, unless air has been specified in the
Purchase Order.

The low-pressure seat test shall be made with the seats clean and free of oil heavier than
kerosene, except for valves in which a lubricant provides the primary seal. Valves shall be
subjected to a seat test at 80 psig, except the resilient seated valves of ANSI B 16.5, Class 150
or lower pressure rating, which shall be tested at 10 psig. The leakage of air shall be checked by
submergence in water or by means of soap suds. In the case of seated valves, the body cavity
shall be provided with a connection ending under water. If the test medium is liquid, the low
pressure test may be made consecutively with the high pressure test; however, the valves shall
be partially opened and closed before applying each low-pressure seat test. The same leakage
criteria specified for the seat and closure member test shall apply to the Low Pressure Seat Test.

5.9 Retesting

If a valve fails a required test as defined in this Specification, it shall be either repaired or
replaced with a new valve. In either case, the valve shall be retested until such time that all
specified testing has been successfully completed.

6.0 PREPARATION FOR SHIPMENT

After testing is completed, all valves shall be dried both externally and internally, painted and prepared
for shipment in accordance with applicable specifications. Valves shall not be disassembled in order to
dry internal parts or for any other reason.

7.0 REQUIRED TESTING FOR VARIOUS VALVES

Table 7.1 defines the minimum testing requirements for typical valves used in Company's facilities. If
additional testing is specified on the purchase order, then the requirements defined on the purchase order
shall govern.

TABLE 7.1 - MINIMUM TESTING REQUIREMENTS FOR VALVES

Nominal Valve ANSI Class MINIMUM TESTING REQUIREMENT FREQUENCY

Size (Inches)
SHELL SEAT & CLOSURE LOW PERFORMANC
TEST PRESSURE E
SEAT

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2" – 10" 150 Testing required only when specified
on Purchase Order.

2" - 6" 300 x x x Random selection of 1 out of every 10

valves, minimum 1 valve per order or
one per manufacturer, whichever
greater.

2" - 4" 600 x x x Random selection of 1 out of every 7

valves, minimum 1 valve per order or
one per manufacturer, whichever
greater.

2" and Larger 900 and Higher x x x x All Valves

8" – 10" 300 x x x x Random selection of 1 out of every 5

valves, minimum 1 valve per order or
one per manufacturer, whichever
greater.

6" – 10" 600 x x x x Random selection of 1 out of every 3

valves, minimum 1 valve per order or
one per manufacturer, whichever
greater.

12" and Larger 150 and Higher x x x x All Valves

1. All valves rated ANSI Class 1500 and higher shall be subjected to all testing defined in this Specification.
2. All actuated valves larger than 8" shall be subjected to all testing defined in this Specification.
3. All valves provided with a backseat shall be backseat tested regardless of valve size or class.

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8.0 DOCUMENTATION

Vendor shall furnish Purchaser with the following list of documents and certificates. All this
documentation must be available at time of final inspection at Vendor's facility where the
valves are physically present. This documentation shall be considered as the a minimum
requirement:

8.1 Material Certificate

Each valve shall have a material certificate prepared by Vendor which includes the
following information:

a) Valve manufacturer
b) Valve type
c) Valve serial number
d) Purchase order number
e) Company tag number (per VES-5096)
f) Valve size (end connections) and Class
g) Trim size
h) Pressure/Temperature rating of all pressure containing parts
i) Trim material chemical composition (including seats)
j) Body and pressure containing part chemical composition
k) Brinell hardness for pressure containing parts and hard surfaced trim materials
l) Mill test certificates for all pressure containing parts

8.2 Test Certificate

Each valve shall have a test certificate prepared by Vendor which includes the
following information:

a) Valve manufacturer
b) Valve type
c) Valve class
d) Valve serial number
e) Size (end connections)
f) Trim size
g) Valve number per Company Specification VES-5096
h) Type of test performed on valve.
i) Date of test
j) Place of test
k) Name of Supplier
l) Name of Purchaser
m) Type of repairs, if any
n) Date of repairs
o) Date of retest

8.3 Test Report

A test report is required and equipment subject to test procedure will not be accepted
by Company until all relevant information has been included and duly signed and
accepted by Purchaser.

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 8.4 Record Charts

The original copy of the pressure, temperature & time chart signed and witness by all
parties involved in the test procedures shall be securely attached to the test report. If
this part of the documentation is missing Company reserves the right to request a
retest on the valve at Vendors expense.

8.5 Test Equipment Certification

Vendor shall supply the original calibration certificates signed and witnessed by all
parties. The following shall be considered as a minimum requirement;

a) Manufacturer
b) Type
c) Model
d) Serial number
e) Date of test & calibration
f) % of accuracy
g) Calibration person
h) Calibration person signature
i) Vendor's name
j) Vendor's signature
k) Inspectors name
l) Inspectors signature
m) Description of calibration procedure
n) Equipment used for calibration procedure
o) Manufacturer
p) Type
q) Model
r) Serial number
s) Certified by
t) Date of certification

8.6 Ownership

All documentation pertaining to the purchase and testing of valves shall become and
remain the property of Company.

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