w ETHYLENE MALAYSIA SDN. BHD. w on POLYETHYLENE MALAYSIA SDN. BHD. wat INSPECTION INSTRUCTION ‘TITLE: VALVE TESTING PROCEDURE INSTRUCTION NO. INSP-011 REVISION ° DATE AUGUST, 2010 TABLE OF CONTENTS — INDEX PAGE NO. TABLE OF CONTENTS 4 RECORD OF CHANGE 2 1, OBJECTIVE 3 2. SCOPE 3 3. REFERENCES 3 4. PROCEDURE 4 5. REPORT KEEPING 5 6. VALIDITY PERIOD 5 7, EXEMPTION FROM TESTING 5 TABLE 1: PRESSURE TEST REQUIREMENT 6 AUTHOR = REVIEWED BY : APPROVED BY : Designation | Executive Designation | Manager [Designation | — Senior Manager (inspection) (inspgction) (Technical) Signature Signature Signature Name JHASNUL RADZIB. |Name | RARIM sé JBADRUL HIGHAM B YAHAYA Gin IBRAHIM Date (S=B—de10 [Pate 22- effete a 2¥fafo ae T= Exec. Inspection Vale Testa “Grea t Technical Deparment EPEMSB< “ w ETHYLENE MALAYSIA SDN. BHD. 4 oe meee POLYETHYLENE MALAYSIA SDN. BHD. chest INSPECTION INSTRUCTION TITLE: VALVE TESTING PROCEDURE INSTRUCTION NO. INSP-O1T REVISION z DATE AUGUST, 2010 Valve Testing“ ETHYLENE MALAYSIA SDN. BHD. we POLYETHYLENE MALAYSIA SDN. BHD. é INSPECTION INSTRUCTION TITLE: VALVE TESTING PROCEDURE INSTRUCTION NO, INSP-077 REVISION 0 DATE AUGUST, 2010 [ H. OBJECTIVE The objective of this guideline is to ensure that purchased block valves listed in section 2 below are received without damage and in full compliance with purchase order specifications and good to be used at site, SCOPE The following valves that are delivered to EPEMSB warehouse and/or sourced through vendor are subjected to testing as defined in this procedure guide: a) Manual Gate valve (size 2 2" & rating 2 300# & service steam or HC) b) Manual Globe valve (size 2 2° & rating 2 300# & service steam or HC) ©) Manual Ball valve (size 2 2” & rating 2 300# & service steam or HC) d) Manual Check valve (size 2 2” & rating 2 300# & service steam or HC) €) Manual Plug valve (size 2 2°8 rating 2 300# & service steam or HC) f) Above valves with size < 2°, or rating <300#, or non-steanvHIC service but required by P.O REFERENCES 3.0 PTS 31.36,00.30: Pipeline Valves 3.1 ASME B16.34 3.2. API Std, 598: Valve Inspection & Testing 3.3. Positive Material Identification (PMI) Inspection Instruction, INSP-007 3.4 Purchase Order (P.O) Valve Tasting awe ETHYLENE MALAYSIA SDN. BHD. . POLYETHYLENE MALAYSIA SDN. BHD. ws INSPECTION INSTRUCTION TITLE: VALVE TESTING PROCEDURE INSTRUCTION NO, INSP-077 REVISION 0 DATE ___: AUGUST, 2010 PROCEDURES 4.1. Requests for Inspection All incoming valves (as listed in section 2) to EPEMSB warehouse shall be subjected to testing before acceptance. Prior to testing, the valves shall be inspected as per Inspection Instruction No: INSP-006. Testing may be done at EPEMSB workshop or at vendor's yard, For testing carried out at vendor's yard, Mechanical shall include the requirement for vendor to perform the test in the Purchase Order. For testing done at EPEMSB workshop, Ware- house shall notify Workshop to perform valve testing and shall raise an inspection request to Inspection section as per Attachment 4 4.2. Review of Valve Datasheet & Material Certificate The inspector shall determine whether the datasheet and certificate meets the specification / requirement mentioned in P.O. and pipe specifications. 4.3. Traceability & Markings ‘The inspector shall confirm the traceability of materials, i.e. to check that the heat/batch number stated on the certificate tally with the marking on the valve parts. Marking on each valve parts shall be in accordance with the referenced standard. 44 Valve Testing Valve shall be tested via hydrostatic test method only. For stainless steel valve, demineralized water shall be used as test medium. Prior to testing, inspector shall ensure internal of valve is free from any contaminant (oil, debris, grease, leftovers) that can affect test result. Inspector shall also ensure external of valve is free from any coating or masking that can mask any leaking Workshop or valve vendor shall perform required test as stated in valve certification or as tabulated in Table 1. Workshop shall ensure all arrangement has been made prior to valve test to ensure that itis safe to perform the test. Pressure gauge shall be calibrated and the gauge range shall fall within 2-4 times the test pressure. Only full-ated blind plate shall be used for the testing. Valve Tasting aETHYLENE MALAYSIA SDN. BHD. POLYETHYLENE MALAYSIA SDN. BHD. INSPECTION INSTRUCTION TITLE: VALVE TESTING PROCEDURE INSTRUCTION NO, _: INSP-077 REVISION 20 DATE : AUGUST, 2010 ‘The valve shall be gradually pressurized and depressurized (in stages) before and after the test pressure. Throughout the testing, inspector shall ensure no external force being applied on the valve. Once reaches the test pressure, the valve shall be isolated from the pressure source and put on hold for specified period of time. During holding time, inspector shall check the valve body, flanges, and seat for any leaking. No leaking is allowed for the valve to be accepted. 4.5. Inspection Reporting Inspector shall fil-up the request form and inform verbally and in written whether the tested valve is accepted or rejected. If accepted, Inspector shall also fill up EPEMSB hydrotest form as per Attachment 2. Both forms shall be returned to EPEMSB Warehouse within two (2) ‘working days duration. Inspection personnel wil clearly state the reason for any rejected valve for further action ‘The forms shall be approved by Inspection Executive or Inspection Manager. RECORD KEEPING EPEMSB warehouse shall keep the record for accepted valve, as per Inspection Instruction No: INSP-006, VALIDITY PERIOD Valve that has been tested shall be installed within 1 year from the test date. Over this, period, the valve shall be retested to confirm its integrity. EXEMPTION FROM TESTING ‘Any exemption or deviation from this procedure, requestor shall follow Inspection Instruction INSP-012. Valve Testing — 5bs ETHYLENE MALAYSIA SDN. BHD. % POLYETHYLENE MALAYSIA SDN. BHD. wate INSPECTION INSTRUCTION TITLE: VALVE TESTING PROCEDURE INSTRUCTION NO, + INSP-O77 REVISION 0 DATE :AUGUST, 2010 Table 1: Test Requirement for Metallic Valves Valve type Gate Globe | Ball | Plug | Check shot | +8X pressure rating @ 38degC (refer Table 2 in ASME 816.34) Testing type a Seat ‘7° 1.1 X pressure rating @ 38degC (refer Table 2 in Backseat‘ | ASME B16.34) NA NA NA 1) For bidirectional vaive, seat test shall be done on both side (except for double block-bleed valve & globe valve). For unidirectional valve, seat test shall be done on the pressure side only. 2) Seat test for check valve shall be done on the downstream side, 3) Seat test for globe valve shall be done in one direction and pressure applied under the disk. 4) Applicable for vaives with backseat feature, Valve Testing=e ae eC TSuREN, SUFEN OWEN Aq panorddy Aq pasodsuy i Aq pasonboa ed BORIS | FOOTER (Gaeisoat yy) WANMO AG CATIA aa OL Peg ATA Bea TON Od FON PU (oad) NTLAE (lo6z) aswad (101z) aswa (Zo1z) wou) meld “ayep Azaarrep axp wo SREP TURIN wmowy apeur aq ssn synsay “suian Hayaor[oy amp Uo UoN}oadsur ue 109 aBuELE AIPUTY, LSANOTN NOLLOAdSNI ANILAOW wud gers Eisavavin EEAq panoiddy Gunsar jo area —_ aunsseid Aq passeuyim ‘fq payonpuoo Gunso, unser wor ‘wnpow yon Beg aanssaia 1501 (uu) owt | 0 — ov | | 0z ¢ 8s $ 8 (61eg) ainsseig 2 B 2 & — (Gieg) aunssaid (uw) ouny Wuo4 1s3LONGAH