PROCEDURE FOR AN INDEPENDENT

ASSESSMENT OF PROCESS VALVES FOR

USE ON LIQUID CHLORINE, PRIOR TO
CONSIDERATION FOR EURO CHLOR
APPROVAL

GEST 86/129
8th Edition
May 2011

EURO CHLOR PUBLICATION

This document can be obtained from:

EURO CHLOR - Avenue E. Van Nieuwenhuyse 4, Box 2 - B-1160 BRUSSELS

Telephone: 32-(0)2-676 72 65 - Telefax: 32-(0)2-676 72 41
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Euro Chlor

Euro Chlor is the European federation which represents the producers of chlorine
and its primary derivatives.

Euro Chlor is working to:

 improve awareness and understanding of the contribution that chlorine

chemistry has made to the thousands of products, which have improved
our health, nutrition, standard of living and quality of life;

 maintain open and timely dialogue with regulators, politicians, scientists,

the media and other interested stakeholders in the debate on chlorine;

 ensure our industry contributes actively to any public, regulatory or

scientific debate and provides balanced and objective science-based
information to help answer questions about chlorine and its derivatives;

 promote the best safety, health and environmental practices in the

manufacture, handling and use of chlor-alkali products in order to assist
our members in achieving continuous improvements (Responsible Care).

***********

This document has been produced by the members of Euro Chlor and should not be reproduced in
whole or in part without the prior written consent of Euro Chlor.

It is intended to give only guidelines and recommendations. The information is provided in good
faith and was based on the best information available at the time of publication. The information is
to be relied upon at the user’s own risk. Euro Chlor and its members make no guarantee and
assume no liability whatsoever for the use and the interpretation of or the reliance on any of the
information provided.

This document was originally prepared in English by our technical experts. For our members’
convenience, it may have been translated into other EU languages by translators / Euro Chlor
members. Although every effort was made to ensure that the translations were accurate, Euro
Chlor shall not be liable for any losses of accuracy or information due to the translation process.

Prior to 1990, Euro Chlor’s technical activities took place under the name BITC (Bureau
International Technique du Chlore). References to BITC documents may be assumed to be to Euro
Chlor documents.

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RESPONSIBLE CARE IN ACTION

Chlorine is essential in the chemical industry and consequently there is a need for
chlorine to be produced, stored, transported and used. The chlorine industry has
co-operated over many years to ensure that its activities cause the minimum harm
to the well-being of its employees, local communities and the wider environment.
This document is one in a series which the European producers, acting through
Euro Chlor, have drawn up to promote continuous improvement in the general
standards of health, safety and the environment associated with chlorine
manufacture in the spirit of Responsible Care.

The voluntary recommendations, techniques and standards presented in these

documents are based on the experiences and best practices adopted by member
companies of Euro Chlor at their date of issue. They can be taken into account in
full or partly, whenever companies decide it individually, in the operation of existing
processes and in the design of new installations. They are in no way intended as
a substitute for the relevant national or international regulations which should be
fully complied with.

It has been assumed in the preparation of these publications that the users will
ensure that the contents are relevant to the application selected and are correctly
applied by appropriately qualified and experienced people for whose guidance
they have been prepared. The contents are based on the most authoritative
information available at the time of writing and on good engineering, medical or
technical practice but it is essential to take account of appropriate subsequent
developments or legislation. As a result, the text may be modified in the future to
incorporate evolution of these and other factors.

This edition of the document has been drawn up by the Equipment Working Group
to whom all suggestions concerning possible revision should be addressed
through the offices of Euro Chlor.

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Summary of the Main Modifications in this version

Section Nature
Improvement for the periodic re-approval procedure

TABLE OF CONTENTS
FOREWORD 6

1. SCOPE 6

2. APPROVAL 6

3. APPLICATION FOR APPROVAL 7

4. QUALITY ASSURANCE 7

4.1. General 7

4.2. Manufacturer’s Quality Policy 7

4.3. Quality Assurance System 7

4.4. Inspection and Testing Personnel 7

4.5. Design Control 8

4.6. Document Control 8

4.7. Control of Purchase Materials/Services 8

4.8. Manufacture 8

4.9. Material Identification and Traceability 8

4.10. Inspection and Testing 8

4.11. Inspection and Test Equipment 9

5. TECHNICAL SPECIFICATION EVALUATION 9

5.1. General 9

5.2. Euro Chlor GEST Specifications for Valves 9

5.3. Assessment of Design 9

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5.4. Materials 9

5.5. Inspection Procedures/Methods and Acceptance Criteria 10

5.6. Production Testing 10

5.7. Marking 11

5.8. Preparation for Despatch 11

5.9. Certificates 11

5.10. Records 11

6. PRODUCTION VALVE EXAMINATION 12

6.1. Drawings 12

6.2. Inspection and Tests by the Independent Inspection Body 12

6.3. Number of Valves to be Examined 12

6.4. Pressure Testing 12

6.5. Compliance with Manufacturer’s Drawings 13

6.6. Welding 15

6.7. Marking 15

6.8. Preparation for Despatch 15

7. PROTOTYPE TESTING 15

7.1. General 15

7.2. Valve to be Tested 15

7.3. Mechanical Strength Test 16

8. INDEPENDENT INSPECTON BODY REPORT 16

9. DOCUMENTS FOR EURO CHLOR MASTER FILE 17

10. REFERENCES 17

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FOREWORD

This document relates to a procedure to be followed in order to establish the

adequacy of design, manufacture, quality, testing and performance of valves for
use on liquid chlorine.

Euro Chlor has published a specification covering different types of valves for use
on liquid chlorine (GEST 06/318 – Globe Valves for Use on Liquid Chlorine).
The present document complements this guideline and defines the procedure
which an independent inspection body, acceptable to Euro Chlor, carries out at the
valve manufacturer’s workshop prior to consideration for Euro Chlor approval.

The procedure for Euro Chlor approval of valves for use on liquid chlorine is given
in GEST 98/128 - Procedure for Approval of Process Valves for Use on Liquid
Chlorine.

1. SCOPE

This document gives the procedure to be used by an independent inspection body

when carrying out an assessment to establish the adequacy of the quality
assurance system, design, manufacture, inspection and testing of valves for use
on liquid chlorine. The assessment is carried out prior to consideration for Euro
Chlor approval.

2. APPROVAL

Prior to the GEST Equipment Group giving consideration to a valve manufacturer’s

request for approval an independent inspection body (proposed by the valve
manufacturer and acceptable to Euro Chlor) shall carry out an assessment of the
valve manufacturer’s capability to consistently provide valves that meet the
requirements of the relevant part of the Euro Chlor GEST 06/318 – Globe Valves
for Use on Liquid Chlorine.

The assessment shall comply with this procedure.

When the assessment has been successfully completed and the assessment
report and manufacturing documents are available, the Euro Chlor GEST
Equipment Group shall carry out the approval in accordance with GEST 98/128 -
Procedure for Approval of Process Valves for Use on Liquid Chlorine.

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3. APPLICATION FOR APPROVAL

Application for Euro Chlor approval shall be made, by the valve manufacturer, in
accordance with GEST 98/128 - Procedure for Approval of Process Valves for
Use on Liquid Chlorine. This requires that the valve manufacturer states the
specific valve type(s) for which approval is requested.

4. QUALITY ASSURANCE

4.1. General

The independent inspection body shall establish that the valve manufacturer has a
quality system that satisfies the requirements of ISO 9000 (or equivalent). Checks
shall be made to ensure that the quality system is properly established,
documented, implemented and maintained and that both internal and external
audits are properly carried out.

In particular the checks shall include that documentation relating to the

requirements of sections 4.2 to 4.11 here below is available and meets the
requirements of this procedure.

4.2. Manufacturer’s Quality Policy

The valve manufacturer’s quality policy shall be understood, implemented and

maintained throughout the valve manufacturer’s organisation.

4.3. Quality Assurance System

The documents relating to the quality assurance system organisation,

responsibilities, authority etc. shall be up-to-date.

The quality manager shall have the authority to initiate actions to correct any
quality problem, even if this requires stopping the production process.

4.4. Inspection and Testing Personnel

Personnel used for carrying out inspection and testing shall have technical
competence and experience commensurate with the needs of the specified
methods of inspection and testing. In particular the level and category of personnel
carrying out non-destructive examination/testing shall be in accordance with an
appropriate national certification scheme.

The availability of personnel competency certificates shall be confirmed.

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4.5. Design Control

The control of design shall ensure that the design of the valve(s) satisfies the
requirements of the relevant part of the Euro Chlor GEST specification and that
the basis of the design is properly documented and references made to
calculations and associated standards. Design changes and modifications shall be
properly controlled and documented.

4.6. Document Control

The control of documents shall ensure that both external and internal documents
relevant to the quality system are authorised and the current revision status
identified. Withdrawn and obsolete documents shall be secured against
unintentional use. Changes to documents shall be authorised and appropriate
records of the changes shall be kept.

4.7. Control of Purchase Materials/Services

The suppliers of materials/services shall have a quality system consistent with that
of the valve manufacturer. The valve manufacturer’s quality system shall cover
verification of purchased products against the relevant specifications, supplier’s
provision of documentation (material/test certificates) and the valve manufacturer’s
control of supplier’s non-conformances.

4.8. Manufacture

Any process that directly affects quality of the valve shall be identified and the
valve manufacturer shall ensure that all such processes are fully documented and
carried out under controlled conditions which may include the work, for example
welding, being carried out by qualified personnel using qualified procedures.

Records shall be kept and maintained of qualified personnel and qualified

procedures.

4.9. Material Identification and Traceability

The valve manufacturer shall maintain a positive system of identification and

traceability for the materials used during manufacture.

4.10. Inspection and Testing

Inspection and testing shall be carried out in order to verify that materials,
components, assemblies and completed valves conform to the specified
requirements. Test methods and acceptance criteria shall be specified and shall
relate where appropriate to incoming materials, in-process materials and the final

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product. The valve manufacturer shall maintain records as evidence that the
relevant inspection and testing has been carried out.

4.11. Inspection and Test Equipment

The inspection and test equipment used shall be suitable for the inspection
method or test to be applied and of the appropriate range and accuracy.
Inspection and test equipment shall be uniquely identified, properly maintained
and calibrated at prescribed intervals.

5. TECHNICAL SPECIFICATION EVALUATION

5.1. General

The independent inspection body shall verify that the valve manufacturer’s quality
assurance activities, implemented within the quality system, ensure that the valves
produced conform to the requirements of the relevant part of the Euro Chlor GEST
specification and any additional requirements of purchase orders. The activities
shall be fully documented (quality procedures/work instructions) and the
documents readily available to those carrying out quality control.

5.2. Euro Chlor GEST Specifications for Valves

The independent inspection body shall ensure that the assessment is carried out
relative to the current edition of the relevant part of the Euro Chlor GEST 06/318 –
Globe Valves for Use on Liquid Chlorine.

5.3. Assessment of Design

The valve manufacturer shall make available documentation relevant to the design
of the valves. The documentation shall include the calculations, general
arrangement drawings, detailed drawings and parts lists giving the
material/material specification and grade of each part (including seats, gaskets,
packing and fasteners).

5.4. Materials

The valve manufacturer shall make available the current sources from which
materials (specific to the nominated valves) including raw, semi-finished or
finished components are obtained. In those cases where a supplier has more than
one source, each shall be given. The valve manufacturer shall, when requested by
the independent inspection body, provide access to supplier’s premises for
inspection or audit of the facilities, quality control, records etc. Checks at the valve

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manufacturer’s premises and where necessary at a supplier’s premises shall

include those relating to:

a) Material specifications

b) Purchase documents

c) Method of manufacture and treatment

d) Material identification and traceability

e) Identification of batches, heat numbers etc

f) Quality control

g) Documents (materials certificates, test certificates etc.)

h) Records of inspections/tests

i) Provision of temporary corrosion protection

j) Restrictions on chemical analysis and physical properties of carbon and

carbon manganese steel forgings and castings

k) Repairs to forgings and castings

5.5. Inspection Procedures/Methods and Acceptance Criteria

The valve manufacturer shall inform the independent inspection body of all
relevant inspection procedures/methods and acceptance criteria. Additionally,
information shall be provided of all relevant inspection equipment and the
competence of inspection personnel. The inspection shall cover incoming
materials, in-process inspection, final inspection and control of non-conforming
materials. The independent inspection body shall verify that all the ‘Examination’
requirements given in the relevant part of the Euro Chlor GEST specification are
covered by the valve manufacturer’s quality assurance documentation.

5.6. Production Testing

The independent inspection body shall verify that the “Production Testing”
requirements given in the relevant part of the Euro Chlor GEST specification are
covered by the valve manufacturer’s quality assurance documentation. The
hydrostatic and pneumatic pressure testing facilities shall be verified and test
personnel confirmed as having the appropriate training and expertise to carry out
the work. Hydrostatic pressure testing of valve bodies, bonnet/cover and bellows
and the pneumatic pressure testing of assembled valves shall be witnessed.

Calibration and test records shall be examined.

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5.7. Marking

The independent inspection body shall verify that the “marking” requirements
given in the relevant part of the Euro Chlor GEST specification are covered by the
valve manufacturer’s quality assurance documentation. The valve manufacturer’s
system of valve serial numbers (the unique number that identifies the valve in all
aspects) shall be examined.

5.8. Preparation for Despatch

5.8.1. General

The independent inspection body shall verify that the “Preparation for Despatch”
requirements given in the relevant part of the Euro Chlor GEST 06/318 – Globe
Valves for Use on Liquid Chlorine are covered by the manufacturer’s quality
assurance documentation.

5.8.2. Painting

The equipment and procedures for degreasing, mechanical or chemical cleaning

and priming/painting shall be examined.

5.8.3. Lubrication

The system for ensuring that only chlorine-compatible chloro-fluorinated grease is

used, for those parts requiring lubrication, shall be examined.

5.8.4. Drying and Blanking

The equipment and procedures for drying, use of desiccants and blanking shall be
examined and the operation witnessed.

5.9. Certificates

The manufacturer’s system for ensuring the accuracy of information on the

certificate provided with each order for valves shall be examined. It shall be
confirmed that material certificates of materials used in the manufacture of a valve
are retained for at least ten years from the date of despatch of that valve.

5.10. Records

A review shall be carried out of the system for indexing, filing and retrieving
records.

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6. PRODUCTION VALVE EXAMINATION

6.1. Drawings

The valve manufacturer shall supply documentation relating to the valve(s) to be

assessed. The documents shall include a general arrangement drawing, detailed
component drawings and parts lists identifying the material/material
specification(s) and grade(s). The documents shall provide full manufacturing
details including dimensions, tolerances, surface finishes, thread type, welding
procedure reference, weld preparations, heat treatment, hardness limits, material
identification and traceability.

6.2. Inspection and Tests by the Independent Inspection Body

The independent inspection body shall carry out or witness the inspections and
tests required by Sections 6.4 and 6.5. Physical tests, chemical analysis and some
non-destructive examinations may have to be performed by an external
organisation which shall be acceptable to the independent inspection body.

6.3. Number of Valves to be Examined

The valve manufacturer shall make available six valves including two different
nominal sizes (three small valves, usually forged, and three larger valves, usually
cast) for each specification type, pattern, pressure designation and material for
which the valve manufacturer has requested approval. Where a forged valve and a
cast valve are manufactured in the same nominal size, three forged valves and
three cast valves shall be made available.

In the case of an already existing valve type, the independent inspection body
shall verify that the valves offered are representative of normal production valves
and have not been produced specifically for the assessment.

The independent inspection body shall select one valve from each set of three and
apply an appropriate and unique identification mark to the body and bonnet/cover
prior to testing. When, during the inspection and tests by the independent
authority, a material or component does not comply with the specified
requirements this shall be brought immediately to the attention of the valve
manufacturer and a further valve selected from the original set of three. When a
material or component of the second valve does not comply the assessment shall
be discontinued.

6.4. Pressure Testing

The valve manufacturer’s records, for the specific valve, of the production testing,
i.e. hydrostatic pressure testing of individual components, pneumatic shell test and
pneumatic seat test shall be examined to verify conformance to the requirements

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of the relevant part of the Euro Chlor GEST 06/318 – Globe Valves for Use on
Liquid Chlorine.

This shall be followed by a hydrostatic pressure test of the valve to 1.5 times the
maximum allowable working pressure of the valve and a pneumatic pressure test
of the shell and seat.

6.5. Compliance with Manufacturer’s Drawings

6.5.1. General

Following satisfactory pressure testing, the valve shall be examined and the
appropriate data recorded and compared with the specified requirements. Checks
shall include, where appropriate, those listed in sections 6.5.2 to 6.5.5. Hardness
(6.5.2b)11) and chemical composition shall preferably be determined non-
destructively. However, where considered necessary by the independent
inspection body, test samples may be cut from the valve components. See
sections 6.5.5c) and 6.5.5e).

6.5.2. Dimensions, etc…

a) Assembled valve

1. Face to face dimension

2. Flange dimensions and position of flange bolt holes

3. Centre to top dimension

4. Handwheel diameter/wrench length

5. Projection of studs/studbolts etc. through their nuts

6. Mass

7. Operability: fully closed to fully open

check indicator positions

8. General appearance

b) Individual components of dismantled valve

1. Body and bonnet/cover thicknesses

2. Stuffing box and gland follower dimensions

3. Stem diameter, length, circularity and straightness

4. Packing: type, dimensions, number of rings

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5. Gaskets: type and dimensions

6. Bellows: dimensions and number of convolutions

7. Method of attaching and locking the stem to disc

8. Clearance between obturator (disc) and body

9. Presence for lubricator and lubricant

10. Attachment of seat(s) to body

11. Hardness of metal seat and disc seating.

6.5.3. Surface Finish

a) Stem

b) End flange gasket contact facing

c) Body to bonnet/cover joint gasket contact facing

d) Cast surfaces of body, bonnet/cover, after removal of any paint.

Compare with the specified surface requirements.

6.5.4. Bolting and Threads

a) Type of thread

b) Type, number, diameter, length of body to bonnet/cover fasteners

c) Type and diameter of gland fasteners

d) Dimensions and straightness of pillars.

6.5.5. Materials

a) Material identification

b) Material certificate giving chemical, mechanical and impact

properties

c) Chemical composition of body, bonnet/cover, stem, seating, bellows,

yoke nut

d) Material of packing and gaskets

e) Welding consumables used for welding, including repairs by welding

and weld deposition.

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6.6. Welding

The welding procedure specifications and welder qualification for all welding,
including repairs by welding, shall be examined. Radiographs shall be checked.
The extent of any repairs shall be recorded. Records including photographs
relating to magnetic particle or liquid penetrant inspection shall be examined. The
possible weld repairs will be done according to the GEST 96/220 – Specification
for Weld Repairs during Manufacturing of Cast Valves for Liquid and Dry
Gaseous Chlorine.

Any post-weld heat treatment procedures and furnace records shall be examined.

6.7. Marking

The body and bonnet/cover marking and identification plate marking shall be
checked for clarity and conformance with the requirements of the relevant Euro
Chlor GEST specification.

6.8. Preparation for Despatch

Records shall be checked to confirm that the valve had been properly dried, the
body and bonnet/cover mechanically or chemically cleaned, primed, painted and
blank flanges fitted.

7. PROTOTYPE TESTING

7.1. General

Valves shall be prototype tested unless the requirement for testing is waived by
the GEST Equipment Group on evidence that:

a) Similar valves have achieved the criteria for “satisfactory operating

experience” (see GEST 98/128 - Procedure for Approval of
Process Valves for Use on Liquid Chlorine)

or

b) Similar valves have been satisfactorily subjected to a strength test

equivalent to Appendix A prior to the assessment and the results
are fully documented.

7.2. Valve to be Tested

The valve used for the production valve examination (see clause 6) and the record
of the dimensions, straightness, freedom from damage etc. may be used for the

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mechanical strength test. Alternatively a valve shall be selected from those

remaining from the original set of three.

7.3. Mechanical Strength Test

Prototype valves shall undergo a mechanical strength test unless the conditions of
Sections 7.1a) or 7.1b) are satisfied.

The mechanical strength tests for globe valves shall comply with the procedures
given in Appendix A. The preparation and testing shall be witnessed by the
independent inspection body. The test results shall be recorded and certified as
correct by the valve manufacturer and the independent inspection body.

8. INDEPENDENT INSPECTON BODY REPORT

The independent inspection body shall provide a fully detailed report of the
assessment carried out in accordance with the requirements of this procedure.
The report shall include:

a) Quality assurance

Detailed comments relating to each of the individual sub-clauses 4.1 to

4.11 inclusive. A statement as to whether or not the valve
manufacturer’s and supplier’s quality assurance systems fulfil the Euro
Chlor quality requirements.

b) Technical specification evaluation

Detailed comments relating to each of the individual sub-clauses 5.1

and 5.3 to5.10 inclusive.

A statement as to whether or not the valve manufacturer has the ability

to comply fully with the Euro Chlor technical requirements.

c) Production valve examination

Detailed comments relating to each of the individual sub-clauses 6.1 to

6.8 inclusive. A statement as to whether or not the valve manufacture
can consistently provide valves that conform to the requirements of the
relevant part of the Euro Chlor GEST specification.

d) Prototype testing

A statement as to whether or not the valve can withstand the

mechanical strength test procedure given in Appendix A. In the case of
a satisfactory test, the certification and test data.

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The report shall be in English, French or German and sent to the Euro
Chlor Secretariat within 90 days of the completion of the assessment.

9. DOCUMENTS FOR EURO CHLOR MASTER FILE

The manufacturer shall provide to the independent inspection body all documents
required for the production valve examination to be carried out (see Clause 6).

The independent inspection body shall review the file and confirm that the
documentation is consistent with the examination and send it to the Euro Chlor
Secretariat within 90 days of the completion of the assessment.

10. REFERENCES

GEST 86/128 - Procedure for Approval of Process Valves for Use on Liquid
Chlorine

GEST 96/220 – Specification for Weld Repairs during Manufacturing of Cast

Valves for Liquid and Dry Gaseous Chlorine

GEST 06/318 – Globe valves for Use on Liquid Chlorine

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Appendix A

Appendix A – Prototype Mechanical Strength Test

Procedure for Globe Valves

10.1. Definition: “Seating Torque”

“Seating Torque” is given in the GEST 06/318 – Globe Valves for Use on Liquid
Chlorine

Procedure
Step 1 Check dimensions of all valve components and record

Step 2 Assemble valve, including the gland packing

Step 3 Prepare valve for hydrostatic pressure test, fitting appropriate blank flanges,
gaskets and bolting

Step 4 With the disk partially open hydrostatically pressure test the valve at a
pressure appropriate to the pressure rating and the materials of the body and
bonnet/cover. Maintain the test pressure for at least five minutes. Check for
visible leakage and make good any leaks.

Step 5 Release pressure and drain test liquid

Step 6 Prepare valve for a pneumatic pressure test of the seat in compliance with the
relevant part of the Euro Chlor GEST specification, ensuring that the seats are
dry and free from oil and grease.

Step 7 Measure and record the torque necessary to achieve a bubble tight shut-off at
a pressure appropriate to the pressure rating and the materials of the body and
bonnet/cover.

Step 8 Release test pressure

Step 9 Fully close the valve and apply the “Seating Torque”. Then fully open

the valve and apply the “Seating Torque”. Do this ten times.

Step 10 Repeat Steps 7 and 8

Step 11 Fully close the valve and apply a torque of (900 x d) Nm. Then fully open the
valve and apply a torque of (900 x d) Nm. Do this ten times.

Step 12 Repeat Steps 7 and 8

Step 13 Dismantle valve

Step 14 Dimensionally check and visually examine all valve components. Record
dimensions and compare with those recorded in Step 1. Note any pertinent
changes and any damage.

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Appendix A

Step 15 Repeat Step 2. New stem packing and a new body to bonnet/cover gasket
may be used.

Step 16 Repeat Steps 3, 4, 5, 6, 7 and 8.

Step 17 Fully close the valve and apply a torque sufficient to cause a component
failure. Record the torque at which failure occurs.

Step 18 Apply a hydrostatic pressure test, as Steps 3 and 4, until evidence of leakage
or the pressure given in Step 4 is achieved.

Step 19 Dismantle valve and inspect the valve components.

Step 20 Prepare test report.

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Industrial consumers of chlorine, engineering and equipment supply companies

worldwide and chlorine producers outside Europe may establish a permanent
relationship with Euro Chlor by becoming Associate Members or Technical
Correspondents.

Details of membership categories and fees are available from:

Euro Chlor

Avenue E Van Nieuwenhuyse 4

Box 2

B-1160 Brussels

Belgium

Tel: +32 2 676 7211

Fax: +32 2 676 7241

e-mail: eurochlor@cefic.be

Internet: http://www.eurochlor.org

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