ICM-PU-5316.2 CV Quality Assurance Inspec Test

ICM-PU-5316.
2
Control Valve Quality Assurance, Inspection, and Test Plan
Requirements
Operating Environment: Onshore, Topsides
This document is the confidential property of Chevron U.S.A. Inc. and its affiliates. When made available
to any contractor providing services to Chevron U.S.A. Inc. or its affiliates, the contractor’s use of this
document shall be governed by the confidentiality provisions of the applicable contract or bid package.
Without limiting the foregoing, neither the whole nor any part of this document may be disclosed by the
contractor to any third party, other than an affiliate of the contractor that requires this information for
purposes of the contract with the Chevron entity, without the prior written consent of the Chevron entity
that has disclosed this document to the contractor. When requested by Chevron U.S.A. Inc. or its
disclosing affiliate, the contractor must return all copies of this document to the Chevron entity
requesting such return and delete any electronic copies from the contractor’s systems.
Any and all modifications (changes, amendments, etc.) to this document must follow approved
Chevron Engineering Standards governance processes.
Rev. Date Description Author Technology Leader

— 02/15 Initial release. R. Dye P. Gomez
.1 04/17 Technical modification: replaced references to O. Nava n/a
ICM-DG-5130 and ICM-DS-5130 with ICM-DU-5152.
.2 12/18 Technical modification: Updated Section 5.4, and C. Chang R. Dye
Tables 2, 4, 6, 7, and 8.
February 2015 © 2015–2018 Chevron U.S.A. Inc. All rights reserved. Confidential – Restricted Access 1 of 52
Control Valve Quality Assurance, Inspection, and Test Plan Requirements ICM-PU-5316.2
Summary of Changes
1. Revised technical content is indicated by change bars in the right margin.
2. Added, deleted, moved, and combined items are listed below.
Previous Current Description Type of Change

Rev. Rev.
Initial release—n/a.
Contents
1.0 Scope............................................................................................................................................... 5
2.0 References ...................................................................................................................................... 6
2.1 Owner Documents .............................................................................................................. 6
2.2 Industry Codes and Standards ........................................................................................... 6
2.3 Conflict Resolution .............................................................................................................. 8
3.0 Acronyms ........................................................................................................................................ 8
4.0 Quality Management and Quality Control ................................................................................. 10
4.1 General ............................................................................................................................. 10
4.2 Non-Conforming Products ................................................................................................ 11
5.0 Fisher Manufacturing Procedures – Pre-Accepted .................................................................. 13
5.1 General ............................................................................................................................. 13
5.2 Welding Procedures .......................................................................................................... 14
5.3 Testing Procedures ........................................................................................................... 15
5.4 Painting Procedures .......................................................................................................... 15
5.5 Packaging Procedures ...................................................................................................... 15
6.0 Inspection Requirements ............................................................................................................ 15
6.1 General ............................................................................................................................. 15
6.2 Inspections ........................................................................................................................ 17
6.3 Visual ................................................................................................................................ 17
6.4 Dimensional ...................................................................................................................... 18
6.5 Material ............................................................................................................................. 18
6.6 Final Inspection ................................................................................................................. 19
6.7 Rust Prevention and Painting Inspection .......................................................................... 19
7.0 Testing Requirements ................................................................................................................. 19
7.1 General ............................................................................................................................. 19
7.2 Nondestructive Examination ............................................................................................. 20
7.3 Pressure Tests .................................................................................................................. 22
7.4 Functional (Operational) Test ........................................................................................... 23
8.0 Witness Test Points ..................................................................................................................... 25
9.0 Control Valve QC/ITP Requirements Tables ............................................................................. 26
9.1 General ............................................................................................................................. 26
9.2 QC/ITP Requirements Table Details................................................................................. 27
9.3 Item Number ..................................................................................................................... 27
9.4 Activity Selected, Type, and Description........................................................................... 27
9.5 Reference Documents ...................................................................................................... 28
9.6 Acceptance Criteria and Reference of Certification/Documentation ................................ 29
9.7 Responsibility and Inspection Record ............................................................................... 29
10.0 ANSI Class ≥ 900 QC/ITP Additional Requirements ................................................................. 30

10.1 General ............................................................................................................................. 30
10.2 Weld Control and NDE Requirements .............................................................................. 30
11.0 Quality Assurance, Inspection, and Testing ............................................................................. 33
11.1 General ............................................................................................................................. 33
11.2 Operational Tests .............................................................................................................. 34
11.3 Welding and Repair........................................................................................................... 34
12.0 Documentation Requirements .................................................................................................... 35
12.1 General ............................................................................................................................. 35
12.2 Documentation Examination ............................................................................................. 35
13.0 Painting and Coating Requirements .......................................................................................... 36
14.0 Packaging ..................................................................................................................................... 37
14.1 Preparation for Shipment .................................................................................................. 37
14.2 Shipping ............................................................................................................................ 37
15.0 Purchasing Guarantee ................................................................................................................. 37
Appendix A Manufacturing Procedures ............................................................................................ 39
Appendix B ANSI Class < 900 QC/ITP Criteria .................................................................................. 41
Appendix C ANSI Class ≥ 900 QC/ITP Criteria .................................................................................. 47
List of Tables
Table 1: Control Valve Metallurgy for Test Selection ..................................................................... 31
Table 2: Fisher Manufacturing Pre-Accepted Procedures ............................................................. 39
Table 3: ANSI Class < 900 Control Valve QC/ITP Tag Summary ................................................. 41
Table 4: ANSI Class < 900 Control Valve QC/ITP Requirements ................................................ 42
Table 5: ANSI Class ≥ 900 Control Valve QC/ITP Tag Summary ................................................. 47
Table 6: ANSI Class ≥ 900 Control Valve QC/ITP Requirements ................................................ 48
1.0 Scope
1. This specification addresses the following requirements for control valve assemblies
(control valve, actuator, and accessories):
a. Quality Management (QM)
b. Quality Assurance (QA)
c. Quality Control (QC)
d. Inspection and Testing
e. Factory Acceptance Testing (FAT)
2. This specification addresses the requirements as related to engineering, procurement,
manufacturing, fabrication, assembly, inspection, testing, and documentation activities that
are met by the following:
a. Supplier providing goods and services directly to Purchaser.
b. Sub-Suppliers providing goods and services on behalf of the main Supplier.
3. The scope of this specification covers the following control valves and control valve
assemblies:
a. Globe, angle, ball, butterfly, and disc control valves, whether or not the control valve
has an actuator.
b. Air-operated diaphragm actuators and piston actuators that are either spring-return or
double-acting.
c. Control valve positioning devices.
d. Cast and forged control valves.
4. The following control valves, valves, and valve applications are not within the scope of this
document:
a. Hand-operated valves.
b. Gate valves.
c. Direct-operated or self-contained regulators.
d. Electric-motor operated control valves.
e. Automated on-off valves.
5. This specification does not address the verification and testing of the control valve
assembly once receipt of the control valve assembly is on site.
a. Project technical requirements should identify and address the verification and testing
requirements once the control valve assembly has arrived on site.
b. Activities and tasks should be performed once the control valve assembly has arrived
on site to verify functionality, hook-ups, and integration with the control system.
2.0 References
1. The following documents are referenced herein and are considered part of this
specification.
2. Unless otherwise specified in Sections 2.1 or 2.2, use the latest edition of the referenced
documents in effect at the time of placement of the initial purchase order.
Note: Some references appear only in ICM-IT-5316.
2.1 Owner Documents

CPM-PU-5074 Material Verification Program
ICM-SU-5102 Selection and Fabrication of Control Valves
ICM-DU-5152 SmartPlant Instrumentation Design
ICM-IT-5316 Inspection and Testing Requirements Forms for Control Valves
2.2 Industry Codes and Standards

American Petroleum Institute (API)
Spec 6D Specification for Pipeline and Piping Valves (same as ISO 14313)
Std 598 Valve Inspection and Testing
Std 607 Fire Test for Quarter-turn Valves and Valves Equipped with
Nonmetallic Seats
American Society of Mechanical Engineers (ASME)

Boiler and Pressure Vessel Code
Section VIII, Rules for Construction of Pressure Vessels, Division 1
B16.5 Pipe Flanges and Flanged Fittings – NPS 1/2 Through NPS 24
Metric/Inch Standard
B16.34 Valves – Flanged, Threaded, and Welding End
B31.3 Process Piping
International Organization for Standardization (ISO)

14313 Petroleum and natural gas industries – Pipeline transportation
systems – Pipeline valves (same as API 6D)
Spanish Association for Standardisation and Certification

(Asociación Espaῆola de Normalización y Certificación) (AENOR)
UNE-EN 10204 Metallic products – Types of inspection documents
ASTM International (ASTM)

A216/A216M Standard Specification for Steel Castings, Carbon, Suitable for Fusion
Welding, for High-Temperature Service
A217/A217M Standard Specification for Steel Castings, Martensitic Stainless and
Alloy, for Pressure-Containing Parts, Suitable for High-Temperature
Service
A351/A351M Standard Specification for Castings, Austenitic, for Pressure-
Containing Parts
E10 Standard Test Method for Brinell Hardness of Metallic Materials
E18 Standard Test Methods for Rockwell Hardness of Metallic Materials
E186 Standard Reference Radiographs for Heavy-Walled (2 to 4½-in.
(50.8 to 114-mm)) Steel Castings
E280 Standard Reference Radiographs for Heavy-Walled (4½ to 12-in.
(114 to 305-mm)) Steel Castings
E446 Standard Reference Radiographs for Steel Castings Up to
2 in. (50.8 mm) in Thickness
Fluid Controls Institute (FCI)
70-2 Control Valve Seat Leakage
International Organization for Standardization (ISO)

8501-1 Preparation of Steel Substrates Before Application of Paints and
Related Products ‒ Visual Assessment of Surface Cleanliness ‒
Part 1: Rust Grades and Preparation Grades of Uncoated Steel
Substrates and of Steel Substrates After Overall Removal of Previous
Coatings
9000 Quality Management Systems ‒ Fundamentals and Vocabulary
9001 Quality Management Systems ‒ Requirements
International Society of Automation (ISA)

7.0.01 Quality Standard for Instrument Air
75.19.01 Hydrostatic Testing of Control Valves
Manufacturers Standardization Society of the Valve and Fittings Industry (MSS)
SP-53 Quality Standard for Steel Castings and Forgings for Valves, Flanges,
Fittings, and Other Piping Components
SP-55 Quality Standard for Steel Castings for Valves, Flanges, Fittings, and
Other Piping Components ‒ Visual Method for Evaluation of Surface
Irregularities
SP-61 Pressure Testing of Valves
NACE International (NACE)

MR0103 Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum
Refining Environments
MR0175/ISO 15156 Petroleum and natural gas industries – Materials for use in H2S-
containing environments in oil and gas production
2.3 Conflict Resolution

1. If there are any conflicts between this specification and other standards or specifications,
Supplier shall bring these inconsistencies, in writing, to the attention of Purchaser for
review and resolution with acceptance by Owner.
2. Any deviation from these codes and standards shall be reviewed by Purchaser prior to the
manufacture and/or assembly of the end product.
3.0 Acronyms
Note: Some acronyms appear only in ICM-IT-5316.
A Accept
AM Amendment
BDV Blowdown/Depressurization Valve
CMTR Certified Material Test Report
CR Criticality Rating
CSP Customer Special
CVPP Control Valve Procurement Procedures
D Data (activity type)
DFT Dry Film Thickness
DVC Digital Valve Controller
EPC Engineering, Procurement, and Construction
ESD Emergency Shutdown
FAT Factory Acceptance Testing
FSH Fisher
H Hold
HT Hardness Testing
I Inspection; also Information (activity types)
ITP Inspection and Test Plan
KPI Key Performance Indicator

LBP Local Business Partner
LPT Liquid Penetrant Test
MCP Major Capital Project
MPT Magnetic Particle Test
NA Not Applicable
NDE Nondestructive Examination
PAK Packing Procedure
PK Packaging (activity type)
PMI Positive Material Identification
PNT Painting Procedure
PQR Procedure Qualification Record
PT Penetrant Test or Exam; also Painting (activity type)
QA Quality Assurance
QC Quality Control
QCP Quality Control Point
QM Quality Management
QMS Quality Management System
R Review
RT Radiographic Test
Rz Roughness
S Surveillance
SIF Safety Instrumented Function
SIS Safety Instrumented Systems
SST Stainless Steel
T Testing
TST Testing Procedure
UT Ultrasonic Test
VDD Vital Data and Documentation
W Welding; also Witness (activity types)
WLD Welding Procedure

WPS Welding Procedure Specification
4.0 Quality Management and Quality Control

4.1 General
1. Supplier/Sub-Supplier shall be responsible for identifying and implementing quality
assurance (QA) and quality control (QC) procedures and programs.
2. Supplier shall have an overall quality management system (QMS) that covers the following
services as described in the project specification:
a. Equipment.
b. Components and parts.
c. Material.
d. Systems.
3. QMS shall accomplish the following objectives (as a minimum):
a. Identify processes and controls to be implemented by Supplier and/or Sub-Suppliers.
b. Ensure that the items within the project specification and scope of work meet specified
requirements.
4. Supplier’s proposed QM system shall satisfy the requirements of referenced Owner
documents and industry codes and standards at any stage of project execution, and shall be
fully auditable.
5. Supplier shall ensure that the QM program provides for fabrication, manufacturing,
inspection, and testing processes that are sufficient to implement QA and QC for activities
performed by Supplier.
6. QMS shall include procedures for the following:
a. Criticality evaluation and developing inspection and test plans (ITPs), including format
and requirements, to be submitted for Owner acceptance.
b. Control, stores, and calibration of inspection, measuring, and test equipment.
c. Tracking inspection and test status of material and equipment.
d. Qualification, process control, and documentation of project activities to meet specified
technical and quality requirements.
e. How, what, and where an activity will be performed, identifying responsible persons
and verifying documentation produced.
f. Inspection and testing of material and equipment at the fabrication, manufacturing,
storage, and installation sites.
g. Reporting performance, tracking of key performance indicators (KPIs), and lessons
learned during project execution.
h. Handling, storage, and preservation of material, equipment, and packing plan. Supplier
shall provide lifting certifications and lift diagrams with the center of gravity notation
as part of the shipping documentation.
i. Control, storage, and handover of spare parts and associated documentation.
j. Identification, reporting, tracking, and resolution of non-conformances at
Supplier’s/Sub-Supplier’s shop, and at involved manufacturing, assembly, and test
locations and installation sites.
k. Documenting, controlling, and ensuring effectiveness of corrective and preventative
action.
l. Performing internal audits of quality-related activities and external audits of Sub-
Suppliers.
m. Controlling process activities, from issuance of design documents through fabrication
to final testing, certification, close-out documentation, and shipment.
n. Controlling and managing the engineering design review process as an incorporation of
previous lessons learned and design reviews.
7. QA/QC activities and status records shall be compiled in the database referencing the
appropriate ITP, procedure, and certification, so that the QA/QC status can be continually
monitored as the work progresses.
4.2 Non-Conforming Products

1. For non-conforming products, Supplier shall determine by review, inspection, test, or
objective evidence the non-conforming status of product it produces, purchases or
transforms, and incorporates into the final product for delivery to Purchaser.
2. Supplier shall be responsible for controlling non-conforming product, including its
identification, segregation, evaluation, position, and re-verification. Supplier shall be
responsible for the following:
a. Clearly marking or tagging non-conforming product to identify status.
b. Segregating non-conforming product to prevent it from proceeding to the next process
stage, and to prevent its unintended use or delivery in the supply chain.
c. Evaluating the need and extent of the investigation required to determine the cause of
the non-conformity, in order to eliminate both the non-conformity and its cause.
1) Personnel performing evaluations shall be competent to evaluate the total effects of
the non-conformity.
2) Investigation shall include the same or similar product—both in production and
after delivery—to determine if trends or patterns of occurrence require attention.
d. Determining the disposition necessary to deal with the non-conformity.
1) Personnel determining dispositions shall have the authority, technical knowledge,
and resources necessary to define appropriate corrective action.
2) Planned disposition shall use only the following terms:
i. Rework (correction).
ii. Repair (amend).
iii. Use as is (concession).

iv. Scrap.
3) “Return to Supplier” or a similar term shall not be an acceptable disposition. The
disposition shall be designated as Rework, Repair, Use As Is, or Scrap.
4) Suppliers and/or Sub-Suppliers that the Purchaser has the right to validate shall
determine and verify by review, inspection and evaluation, test, and objective
evidence that the requirements are met for the following:
i. Disposition is complete and satisfactory.
ii. Non-conforming product is corrected by rework or repair demonstrating
conformity.
3. Supplier shall determine and implement the action necessary to eliminate the causes of
undetected non-conformity or other undesirable situations in order to prevent recurrence.
4. The required corrective action shall be identified and agreed upon by Supplier and
Purchaser QA/QC representative within 30 days of identification of non-conformity.
Time extensions shall be reviewed and accepted by Purchaser.
5. At the discretion of Purchaser, agreed-upon corrective action shall be reviewed during
subsequent inspection visit to check implementation and to evaluate effectiveness.
6. In conjunction with potential concession, Supplier shall comply with limits imposed by
relevant authorities and Purchaser, with acceptance by Owner.
7. Supplier shall maintain records describing the nature of non-conformity and actions taken
to correct non-conformities. The records shall include the following (as a minimum):
a. Unique report number.
b. Name, location, and job number of Supplier organization controlling the non-
conformity.
c. Name and location of Sub-Supplier organizations connected to the non-conformity.
d. Name, project, and agreement number of Purchaser organization.
e. Reference by document number and revision to the unfulfilled requirements.
f. Comprehensive description of the non-conformity (including type, extent, location,
quantity, batch, heat, lot number, details of requirements, and details of non-
conformity) traceable to the product by tag number, serial number, or other
distinguishing identification.
g. Name, title, and dated signature of Supplier’s representative reporting the non-
conformity.
h. Description of the planned disposition of the non-conformity, including any supporting
data and attachments such as sketches, drawings, calculations, or correspondence.
i. Name, title, and dated signature of the Supplier representative who determined the
planned disposition.
j. Name, title, and dated signature of the Purchaser representative who accepted the
planned disposition.
k. Description of the re-verification action and results.
l. Name, title, and dated signature of the Supplier representative who determined and re-
verified by review, inspection, test, or objective evidence that non-conforming product
corrected by rework or repair demonstrates conformity to the requirements.
5.0 Fisher Manufacturing Procedures – Pre-Accepted

5.1 General
1. The manufacturing procedures, figures, and tables that are referenced within this
specification are aligned with Fisher control valves and are in accordance with the
requirements of ICM-SU-5102 and ICM-DU-5152.
2. If Fisher control valves are not selected, the following (as a minimum) shall occur:
a. Equivalent manufacturing procedures for the selected control valve manufacturer
shall be developed and accepted by Owner.
b. Additional manufacturing procedures shall be developed and accepted by Owner to
ensure that all aspects of the manufacturing process are addressed for the different
selected control valve manufacturer(s).
c. Some of the additional manufacturing procedures (not all inclusive) to be developed
shall be as follows:
1) Casting and/or forging.
2) Machining.
3) Fabrication.
4) Assembly.
5) Inspection.
6) Painting.
7) Testing.
8) Documentation.
9) Crating.
10) Shipping.
Note: If non-Fisher control valves are selected, the project team should expect delivery of
the control valves to take much longer, and months of schedule delays will be
incurred in accepting the control valve manufacturing procedures. These delays
would be similar for each additional control valve manufacturer used on the
project.
3. The core group of Fisher manufacturing procedures has been pre-accepted by Owner and
shall require concurrence from the project team only with the acceptance of each
manufacturing procedure.
Note: The pre-acceptance of this core group of Fisher internal manufacturing procedures
ensures consistency. It saves project hours and reduces the schedule to procure the
project control valves.
The “Purchaser” of the control valves is not the Owner but rather the Engineering,
Procurement, and Construction (EPC) Supplier. Since many Owner projects may
be ongoing at any time, with different EPC Suppliers being utilized for each Major
Capital Project (MCP), Fisher is required to re-review and re-submit these
manufacturing procedures for review and acceptance on each MCP.
This process causes significant delays in procurement of the control valve order
execution. To minimize or eliminate this delay and improve lead times, Owner
subject matter experts and Fisher’s subject matter experts have developed Owner-
wide acceptance of these Internal Fisher Manufacturing Procedures.
4. The core group of pre-accepted internal Fisher manufacturing procedures as specified in
Table 2 of Appendix A have been categorized as follows:
a. Welding fabrication and welding repair.
b. Testing.
c. Painting.
d. Packaging.
5.2 Welding Procedures

1. The welding procedures shall include both fabrication and repair procedures for the
following metallurgies:
a. Carbon steel.
b. 316L stainless steel.
c. Duplex stainless steel.
d. Super duplex stainless steel.
2. If additional manufacturing procedures are required for non-identified metallurgies that are
not part of the core group for the project, the project team shall develop both the fabrication
and repair procedures for the additional metallurgical requirements.
3. Owner shall be consulted for pre-acceptance of additional manufacturing procedures.
4. When post-weld heat treatment is required per industry and/or project requirements, the
pre-accepted post-weld heat treat procedure shall be followed.
5. When nondestructive examination (NDE) testing is required, the pre-accepted
manufacturing procedure tests shall be as follows:
a. RT.
b. RT at maximum feasible level 2 acceptance.
c. UT.
d. MPT.
e. LPT.
f. HT.
5.3 Testing Procedures

1. The pre-accepted manufacturing testing procedures shall include the following:
a. Hydro test.
b. Seat leak test.
c. Functional/operational test.
d. PMI.
2. Additional testing procedures shall be as follows:
a. Valve signature series test.
b. Final visual and dimensional checks.
5.4 Painting Procedures

1. The pre-accepted manufacturing painting procedures shall include the following:
a. Three-coat offshore environment.
b. Four-coat offshore environment.
2. The three-coat offshore environment paint procedure shall be used for all onshore and near-
shore facilities.
3. The four-coat offshore environment paint procedure shall be used for offshore, topsides and
the bottom of topsides down to the splash zone..
5.5 Packaging Procedures

1. The pre-accepted manufacturing packaging procedures shall include the following:
a. Apply preservatives for either domestic or export, depending on project technical
requirements.
b. Apply oil or water-based rust preventative/inhibitor on machined surfaces, depending
on project technical requirements.
Note: This is not applied to stainless steel control valves.
2. Flange coverings shall meet the requirements of Section 14.0.
6.0 Inspection Requirements

6.1 General
1. The inspection and testing activities shall include the following minimum accepted
documentation for each control valve:
a. Data sheet per ICM-DU-5152.
b. Drawings.
c. Purchase order.
d. Specifications referenced.
2. The inspector shall examine the components as described herein, the documentation,
certificates, etc., for each control valve to ensure compliance with project documentation.
The following shall be checked:
a. Surface finish.
b. Heat or cast number.
c. Mechanical properties.
d. Heat treat condition.
e. NDE utilized and results.
f. Certificate number(s).
3. All control valves equal to or greater than ANSI Class 900 shall be inspected.
4. Supplier shall develop an internal system and an external system for a technical compliance
audit program that complies with ISO 9001. The system shall be specified by contract,
purchase order, and statutory requirements.
5. Inspection of control valves shall be performed by Supplier in accordance with API 598,
API 6D, ASME B16.5, and ASME B16.34, as applicable.
6. Supplier, as a minimum, shall make provisions for inspecting levels 1 and 2, unless
specifically waived in writing by Purchaser, with acceptance by Owner.
7. Deviations from the following specified inspection points shall be obtained in writing from
Purchaser:
a. Level 1 Inspection – Resident inspection (manufacturing inspection), including daily
inspections to ensure that the shop is manufacturing equipment for the referenced
order.
b. Level 2 Inspection – Pre-inspection meeting with regular in-process inspection visits.
8. Inspection provisions shall be in accordance with the project technical requirements and
this specification.
9. Supplier shall use the inspection points in item 7 above to accomplish the following:
a. Ensure that incoming materials and equipment are properly identified.
b. Conform to the requirements of purchase documents.
c. Determine that the materials have not been damaged during transport.
10. Purchaser and Owner, per ICM-IT-5316, shall reserve the right to inspect the control
valve/actuator assemblies at any time during fabrication to ensure that the materials and
workmanship are in accordance with specifications and applicable standards and codes.
The applicable manufacturing “hold, accept, review, witness, and inspection points” shall
be implemented in the schedule to accommodate this requirement.
11. Refer to the appropriate sections of project or facility governing contracts and purchase
documents for control valve assembly warranty terms.
6.2 Inspections
1. Supplier shall conduct in-process inspection for items during manufacturing, fabrication,
assembly, and testing in accordance with Owner-accepted quality plan, ITPs, and
procedures.
2. Inspections shall include the following (not all inclusive):
a. Identification.
b. Quantity.
c. Visual.
d. Dimensional.
e. Material.
f. Rust prevention.
g. Painting.
6.3 Visual
1. Control valves shall have permanent identification on the valve bodies, including the
following information:
a. Size.
b. ANSI class rating.
c. Flow direction.
d. Material.
e. Manufacturer’s name.
2. Forgings shall be void of the following:
a. Scars.
b. Cracks.
c. Fullering.
d. Laps.
3. Visual inspection of castings shall be in accordance with MSS SP-55.
4. Castings shall be free of harmful defects such as sand inclusion burning and cracks, fins,
and blow holes for the following:
a. External surfaces.
b. Internal surfaces.
c. Machined surfaces.
d. Seat surfaces.
5. Flow paths shall be properly finished and cleaned.
6. Corners and fillets without specific dimensions shall be properly rounded and chamfered.
7. Each control valve shall be checked for the following, to verify that it conforms to the
instrument data sheets:
a. Manufacturer.
b. Model.
c. Material.
d. Range.
e. Accessories.
f. Flow direction.
8. Control valves shall be checked to verify that digital controller positioner is installed.
9. The following shall be confirmed:
a. Control valve packing conforms to the data sheet.
b. If specified, the lubricator on each control valve contains the correct lubricant.
c. One pressure regulator is provided per instrument air user (such as a pneumatic
instrument or control valve assembly).
d. Each valve positioner has a visible sign cautioning the use of magnets at or around the
valve components.
10. Locations of control valves and other components, as shown on the P&IDs with respect to
vessels, piping, valves, and equipment, shall be verified.
6.4 Dimensional
The control valve body and assembly shall be verified with the accepted assembly drawings
and purchase order.
6.5 Material
1. Material certifications shall be submitted for the following:
a. Body.
b. Bonnet.
c. Flange.
d. Volume tanks.
2. Materials that are used for the components shall be stated and identified on the accepted
drawings and/or other appropriate documentation.
3. The reference number (if any) of the material shall be identified on the drawings and other
applicable documents.
4. The materials for the covered components (not all inclusive) shall be as follows:
a. Body.
b. Bonnet.
c. Stem.
d. Trim.
e. Closure member.
f. Flanges.
g. Volume tanks.
6.6 Final Inspection

1. The inspector shall verify the following:
a. Cleanliness and dryness.
b. Flanges.
c. All components.
2. The inspector shall record the information accordingly.
6.7 Rust Prevention and Painting Inspection

1. The following shall be verified:
a. Cleaning method per the specifications.
b. No blow holes, weld spatter, or other defects.
c. No pin holes or run damage or other discontinuity to the surface.
2. Covers for all openings shall be verified as included and secured.
7.0 Testing Requirements

7.1 General
1. For the valve/actuator assembly, Supplier shall test the operations of the valve, actuator,
and accessories that are installed and connected to the control valve assembly.
a. Valve, actuator, and associated components in the pneumatic system shall be tested in
the complete assembled state.
b. Test shall be designed to prove operability of the valve and actuator assembly under
static assembly bench test.
c. Purchaser shall specify if a simulated test of operating conditions is required, as defined
by the control valve data sheet. Simulated test and its procedures shall require Owner
review and acceptance.
d. Instrument air used during the testing shall comply with ISA 7.0.01 requirements.
2. Testing of valves shall be performed by Supplier in accordance with API 598, API 6D,
ASME B16.5, and ASME B16.34, as applicable.
3. Testing provisions shall be in accordance with the project technical requirements.
4. Supplier shall have accessible current certification for testing equipment used during testing
and functional testing with a national or international standard.
5. If control valve assembly does not pass testing requirements due to quality of work as
defined by ICM-IT-5316, Purchaser shall have the right to require retesting with Owner
review and acceptance.
6. Butterfly and disc-type valves shall be tested by the valve Supplier in accordance with
ASME B16.34 or MSS SP-61, as applicable.
7. Testing of other control valve types shall be performed by Supplier in accordance with the
following industry standards for testing of control valves:
a. ISA 75.19.01 for hydro test.
b. FCI 70-2 for seat leak test.
8. Test pressure for valve bodies shall be in accordance with the rating defined in
ASME B16.5.
9. Control valves shall be properly drained and dried after testing.
10. Tests shall include the following (not all inclusive):
a. NDE (if required).
1) RT.
2) LPT.
b. Pressure test.
1) Shell.
2) Back seat test (if bi-directional shut-off required).
3) Seat leakage.
4) Low-pressure seat test (pneumatic seat test).
c. Functional (operational test).
7.2 Nondestructive Examination
7.2.1 General
1. NDE requirements shall be covered in project specifications and shall be subject to further
development by Supplier.
2. To ensure quality, the following minimum requirements shall be applied where not
included in these specifications. Manufacturing procedures for Fisher Control Valves
addressing NDE requirements shall have been pre-accepted as defined in Table 2 of
Appendix A.
a. Prior to the start of NDE for materials and welds, Supplier shall establish detailed
procedures to cover NDE requirements.
b. Non-accepted NDE procedures shall be submitted for Purchaser and Owner acceptance
for all proposed NDE methods and techniques prior to the start of work.
c. As a minimum, procedures shall contain NDE map or drawing(s). In the case of simple
components such as piping, an NDE procedure summary shall be acceptable.
d. Supplier shall use only accredited companies and testing laboratories for NDE and
testing services. Selection of companies shall be subject to Purchaser and Owner
acceptance.
7.2.2 Radiographic Test

1. The RT of the surface to be radiographed shall be free from surface irregularities on both
the inside and outside.
2. The irregularities shall be removed prior to radiography so as not to mask the image of any
discontinuity.
3. Single-wall radiographic technique shall be preferred instead of a double-wall testing
technique.
4. If a double-wall radiographic technique is used with acceptance by Owner, a sufficient
number of exposures shall be made to demonstrate that the required coverage has been
obtained.
5. Radiographic testing identification shall be employed to produce permanent identification
(not obstructing the area of interest) to the radiographic traceability of the following:
a. Contract.
b. Welds.
c. Components.
d. Welds and/or weld seams.
e. Part numbers.
6. Any repairs shall be per the pre-accepted manufacturing procedures as defined in Table 2.
7.2.3 Liquid Penetrant Test

1. Parts or areas of the valve body shall have LPT as follows:
a. Welded area of the valve body to the end of the flange.
b. If the valve is a butt weld end valve, all butt weld ends of the valve body.
2. The LPT shall be conducted and reviewed for acceptance as follows:
a. On the raw material or after the rough-machining process per ASME B16.34,
Annex D.
b. On the finished-machined surface after the finish machining process per
ASME B16.34, Annex D.
3. The information shall be recorded as follows:
a. Date of inspection and examination.
b. Manufacturer’s/Supplier’s project number.
c. Date and time of inspection and examination.
d. Name of inspector.
e. Conclusion/recommendation.
7.3 Pressure Tests
7.3.1 General
1. The pressure tests shall be performed as follows:
a. Shell.
b. Back seat test (if bi-directional flow required).
c. Seat leakage.
d. Low-pressure seat test (pneumatic seat test).
2. The pressure test shall be as follows:
a. Test fluid viscosity shall be less than water.
b. Water shall be treated via a reverse osmosis process containing a low chloride rust
inhibitor.
c. Shell and back seat test shall use a test fluid of water.
d. Low pressure seat test shall use air as the test fluid.
7.3.2 Shell and Back Seat Test

1. The shell pressure test shall be conducted prior to painting and shall be as follows:
a. Both the upstream and downstream connections are sealed.
b. Valve closure member is open (100 percent).
c. Packing gland is tight.
d. Pressure is applied to the valve internal.
2. The back seat pressure test shall be conducted as follows:
a. Both the upstream and downstream connections are sealed.
b. Valve closure member is open (100 percent).
c. Packing gland is loose.
d. Pressure is applied to the valve internal.
3. No visible signs of leakage shall be observed.
7.3.3 Seat Leakage Tests

1. The seat leakage tests shall be per FCI 70-2.
2. The seat leakage requirement shall be as specified on the control valve data sheet.
3. The test pressure shall be in accordance with the design pressure and temperature for the
specific ANSI class of the control valve.
4. If a small amount of leakage is permissible, the duration of the test shall be sufficient to
permit the measurement of the leak at the required test pressure.
5. The test shall be conducted with the valve member in the closed position.
6. Pressure shall be applied on the upstream side of the valve end connection, which is
upstream of the seat.
7. The downstream side shall be observed for leakage and the leakage shall be measured.
8. If the valve application requires bi-directional flow and/or shut-off requirements in the
reverse flow direction, the test shall be conducted in both directions.
9. The test requirement shall be as specified on the data sheet.
10. The following parameters shall be recorded:
a. Water temperature (only if facility is not environmentally controlled).
b. Body temperature (only if facility is not environmentally controlled).
c. Test pressures.
d. Water quality.
11. After the hydrostatic leakage test is complete, the following actions shall be performed on
the control valve:
a. Depressurized.
b. Drained.
c. Dried.
d. Desiccant/preservative applied.
7.4 Functional (Operational) Test

1. The control valve shall be fully assembled.
2. The following details of the functional test shall be recorded:
a. Serial numbers.
b. Appearance of the control valve.
c. Components per accepted drawings and data sheet.
d. Name plate and tagging.
e. Signature test.
f. Packing gland.
3. Plug/disc and seat shall be verified to be on the same concentric circle in the fully closed
position.
4. Operational tests shall consist of measuring valve stem position for increasing and
decreasing input signals.
a. Inputs shall be simulated for all accessories (e.g., positioners, controllers).
b. Supplier shall provide test reports and certificates.
5. Control valves shall meet the requirements of Supplier’s published specifications, Owner’s
specifications, and Purchaser’s project-related documentation.
6. The valve body and bonnets shall pass a hydrostatic test at Supplier’s facility. Hydro test
and inspection shall be in accordance with either ISA 75.19.01 or API 598.
7. All functions of the control valve and control valve assembly shall be verified and
recorded, such as the following (list not all inclusive):
a. Record baseline data during operational and functional tests (signature prior to
packaging, shipping, and delivery):
1) Signature (verify digital storage of baseline data).
2) Analog input signals.
3) Hysteresis.
4) Linearity.
5) Deadband.
6) Instrument control signal to pneumatic conversion.
7) Friction.
8) Step response.
9) Dynamic test (scan).
10) Drive signal.
11) Travel.
12) Valve position.
13) Non-volatile memory verification.
b. Fail action on loss of motive forces:
1) Instrument air to the control valve assembly.
2) Control signal to the digital valve positioner.
3) Control signal to the solenoid valve.
c. Control valve internals (written documentation verification):
1) Packing.
2) Seat and plug.
d. Actuator and yoke assembly:
1) Packing follower.
2) Fasteners.
3) Bolts.
4) Nuts.
e. Accessories:
1) Regulator (airsets).
2) Volume boosters.
3) Quick exhausts (if accepted).
4) Insect screens.
5) Tubing metallurgy.
f. Open and close functionality (not to exceed data sheet requirements):
1) Open/closing times.
2) Travel deviation.
3) Travel cutoff high and low.
4) Travel setpoint.
g. Pressure:
1) Supply.
2) Output to the actuator.
3) Fall-back.
4) Sensor fail.
5) Supply pressure verification above upper bench set.
6) Verify relays.
h. Alerts:
1) Cycle counter.
2) Deadband.
3) Pressure.
i. Deviation.
ii. Supply.
iii. Output to actuator.
iv. Sensor failure.
4) Travel deviation.
5) High and low travel alerts.
6) Notifications full.
8.0 Witness Test Points

The following shall be witnessed and confirmed as specified in the control valve data sheet and
purchase order:
1. Hydrostatic seat and body test.
2. Valve dimensions to conform to drawings and specifications.
3. Body and bonnet melt numbers for alloy steel and cold service applications.
4. Name plate tag information per the purchase order and data sheet.
5. Manufacturer’s test certificates.
9.0 Control Valve QC/ITP Requirements Tables

9.1 General
1. The QC/ITP requirements and procedures shall comply with the following Owner
documents:
a. ICM-SU-5102.
b. ICM-DU-5152.
c. ICM-IT-5316.
2. ICM-IT-5316 shall be completed for each control valve. All tables and/or forms referenced
in this specification are included as part of ICM-IT-5316.
3. Control valves shall be typically grouped by “tag numbers” according to specific
requirements and/or activities that are required. Two summary tables have been provided
as follows:
a. ANSI Class < 900 – Control Valve QC/ITP Tag Summary Requirements in Table 3 of
Appendix A.
b. ANSI Class ≥ 900 – Control Valve QC/ITP Tag Summary Requirements in Table 5 of
Appendix C.
4. The control valve QC/ITP standard requirements—identified with a check mark ()—and
standard required activities shall meet Owner specifications as follows:
a. QC/ITP requirements for control valves ANSI Class < 900 shall be as specified in
Table 4 of Appendix A.
b. QC/ITP requirements for control valves ANSI Class ≥ 900 shall be as specified in
Section 10.0 and Table 6 of Appendix C.
5. Non-standard QC/ITP options—shown without a check mark— are available when
standard options are not sufficient for specific control valve application. The control valve
QC/ITP optional requirements and optional activities shall meet Owner specifications as
follows:
a. Non-standard QC/ITP requirements for control valves ANSI Class < 900 shall be as
specified in Table 4 in Appendix A.
b. Non-standard QC/ITP requirements for control valves ANSI Class ≥ 900 shall be as
specified in Section 10.0 and Table 6 in Appendix C.
Note: Some control valve applications require additional technical options to ensure that
the control valve meets the requirements of the design intent. The non-standard
technical options that are available for each ITP may have an impact on cost and
schedule, which should not be a deterrent to the inclusion of the additional options
and resulting activities, as technically required.
9.2 QC/ITP Requirements Table Details

1. The QC/ITP tables in Appendix B and Appendix C, are designed to capture the QC and ITP
requirements for control valves, and shall be used by the following:
a. Engineering, Procurement, and Construction (EPC) Supplier.
b. Engineering and procurement:
1) EPC.
2) Owner project team.
c. Inspectors.
d. Manufacturer of control valves.
2. The QC/ITP tables shall contain the following categories:
a. Item number.
b. Activity selected.
c. Activity type.
d. Activity description.
e. Reference documents.
f. Acceptance criteria.
g. Reference of certification/documentation.
h. Inspection responsibility, including QC points and criticality rating (CR).
i. Inspection record remarks/sign-off.
9.3 Item Number

1. The item number shall specify a unique requirement for the QC/ITP.
2. Additional item numbers shall be added for other requirements to supplement the core
group, which may be necessary for a given control valve application.
9.4 Activity Selected, Type, and Description
9.4.1 Activity Selected

1. The column titled Activity Selected defines the activities that are standard and optional.
2. The Activity Selected column shall be one of the following:
a. Standard activity, identified with a check mark ().
b. Optional activity, identified with a blank field ( ).
Note: The standard and optional activities have been defined based on information from
QC/ITPs of previous Major Capital Projects (MCPs).
9.4.2 Activity Type

1. The Activity Type specified for each activity shall be one of the following:
a. Data – D
b. Inspection – I
c. Packaging – PK
d. Painting – PT
e. Testing – T
f. Welding – W
2. The activity type shall be correlated with the requirements identified in Table 2 in
Appendix A to provide the type of Fisher manufacturing procedure to be used for the
activity.
9.4.3 Activity Description

1. The column titled Activity Description shall contain the requirements for the specific task
or activity to be completed for the QC/ITP.
2. Only one of the activities that are part of the Preservation and Packaging section,
items 50 through 53, shall be selected for the control valve application.
3. The activities that are part of Review and Acceptance, items 6 through 12, include
manufacturing procedures that shall be selected for the specific control valve application.
These are as follows:
a. Assembly drawings.
b. Weld and weld repair procedures.
c. Paint procedures.
d. Packaging procedures.
e. PMI procedures.
4. The proper Fisher manufacturing procedures, as identified in Table 2 in Appendix A, shall
be selected for each of the line items that require review and acceptance.
9.5 Reference Documents

1. The column titled Reference Document shall be used to provide the required documents
and/or standards to be used for the activity. It shall be one of the following:
a. Control valve data sheet.
b. Purchase order.
c. Fisher manufacturing procedure.
d. Industry standard.
e. Owner and/or project documents.
2. This column shall also identify additional procedures and standards as required to meet the
requirements of the control valve application.
3. Additional manufacturing procedures shall be developed by the EPC and project team as
required to meet the control valve application. These procedures shall require Owner
acceptance.
9.6 Acceptance Criteria and Reference of Certification/Documentation

1. The columns titled Acceptance Criteria and Reference of Certification/Documentation shall
identify the successful completion of the Activity.
2. The successful completion shall be identified as follows:
a. Industry standard requirements.
b. Data sheet requirement.
c. Purchase order requirement.
d. Manufacturing procedure result(s).
e. Report.
f. Completed.
g. Drawings.
h. Documentation.
9.7 Responsibility and Inspection Record
9.7.1 Responsibility
1. The column titled Responsibility shall consist of the following three types of information:
a. Entity responsible for activity and/or action.
b. Quality control points (QCPs).
c. Criticality rating (CR) of the control valve.
2. The columns titled Inspection Responsibility in the QC/ITP table shall specify one of the
following entities to perform the QCP based on the CR as follows:
a. Fisher Sub-Supplier.
b. The control valve manufacturer ‒ Fisher Controls/Local Business Partner (LBP).
c. Contractor.
d. Owner.
3. The QC/ITP QCP shall be as follows:
a. H (Hold) ‒ Work stops until a formal release or inspection release has been received or
the hold has been waived.
b. R (Review) ‒ Document sent for review only, work does NOT stop.
c. W (Witness) ‒ Witness invitation is issued for a specific date; if responsible individual
does not attend and/or respond, work continues.
d. A (Accept) ‒ Document must be accepted before work continues.
e. I (Information) ‒ Informational only, work does NOT stop.

f. S (Surveillance) ‒ Verification spot inspection, work does not stop.
4. The control valve CR shall be defined as follows:
a. (1) ‒ High Criticality: Provide full-time quality representative.
b. (2) ‒ Medium Criticality: Provide regular quality representative.
c. (3) ‒ Low Criticality: Provide random quality representative visits and witness tests.
d. (4) ‒ Non-Critical: Provide quality representative for visits on an exception basis only.
5. Inspection responsibilities for a specific activity not required shall be defined as (-).
9.7.2 Inspection Record

The party responsible for the inspection of the activity shall provide the following:
1. Date the activity was verified as complete and acceptable.
2. Initials of the inspector.
3. Status of the activity indicating “Acceptance” with a “Y” or “N,” including any concerns
and feedback as comments.
10.0 ANSI Class ≥ 900 QC/ITP Additional Requirements

10.1 General
1. This section contains QC/ITP requirements for control valves in ANSI Class ≥ 900
applications in addition to the requirements detailed in Section 9.0.
2. ASME Class 900, 1500, and 2500 control valve bodies, including flanges, shall be
inspected in accordance with this section and the requirements in Table 6 of Appendix C.
10.2 Weld Control and NDE Requirements

1. The weld control and NDE requirements shall be defined in addition to the details and
requirements in Section 9.0.
2. The activities that are part of the Test Selected Based on Metallurgy section—items 18‒26
in Table 6 of Appendix C—include several manufacturing procedures that shall be selected
for the specific control valve application as follows:
a. Determine and specify the weld documentation requirements, with Owner acceptance.
b. Determine test selection based on control valve metallurgy as shown in Table 1.
Table 1: Control Valve Metallurgy for Test Selection

Control Valve Metallurgy
Test
Carbon Steel Low Alloy Steel Stainless Steel
Radiographic Test (RT)   
Ultrasonic Test (UT)   
Magnetic Particle Test (MPT)   
Liquid Penetrant Test (LPT)   
3. The proper Fisher manufacturing procedure (as identified in Table 6) shall be selected for
the Test Selected Based on Metallurgy section.
4. Table 6 shall be completed with these items by defining the following:
a. Selected item ‒ a check mark ( ).
b. Items not selected ‒ a blank field ( ).
10.2.1 Carbon Steel and Low Alloy Control Valve Castings

1. Table 6 of Appendix C shall be referenced for this section.
2. Suppliers shall certify that the inspections in items 3‒7 below are included.
3. Castings and test bars shall be heat treated together.
4. Critical body and bonnet casting sections, typically defined by ASME B16.34, shall be
radiographed and shall meet the requirements of ASTM E446 (up to 2 inches [50 mm]
thick) as follows:
a. Category A, B, & CA = Level 2.
b. Category CB, CC, & CD = Level 3.
c. Category D, E, F, & G = Level 0.
5. End test and magnetic particle inspection of the entire surface area of body and bonnet
castings that is accessible shall be in accordance with ASTM A216 for CS and
ASTM A217 for low alloy steel, with supplemental requirements S3 and S4.
Note: Some areas on smaller control valves are not accessible.
6. Evaluation of magnetic particle inspection shall be in accordance with MSS SP-53, except
that no lineal discontinuities shall be allowed.
7. Brinnel hardness of heat-treated castings shall not exceed 225.
8. Repairs to defective castings shall be outlined in writing to Purchaser and Owner before
repair commences.
9. Repair methods shall be reviewed and accepted by Purchaser and Owner prior to welding.
10. Inspections and repairs shall be witnessed by Purchaser inspectors as defined in
ICM-IT-5316.
11. Inspection and hold points shall be as defined in ICM-IT-5316 prior to time of order
entry/purchase order.
12. Castings shall be preheated to a minimum 400°F (204°C) prior to welding, unless the
mandated code or standard requires a higher preheat temperature, in which case the code or
standard shall be followed (e.g., ASME Section IX qualified weld procedure) with Owner
review and agreement.
13. Chromium-molybdenum alloys shall be post-weld heat treated after welding is complete.
10.2.2 Stainless Steel Control Valve Castings

1. Supplier’s certification of the inspections in this section shall be required.
2. Castings and test bars shall be heat treated together.
3. Castings shall be in the solution heat treated and pickled condition.
Note: Pickling is a soaking of the casting in an acid bath to remove hardened scale that
develops during the manufacturing process. If the casting is stainless steel,
commercial blast cleaning alone is not acceptable. Supplier must be made aware
of this requirement early so that appropriate and realistic quotes, including
delivery and cost, can be provided.
4. Critical body and bonnet castings sections, typically defined by ASME B16.34, shall be
radiographed and shall meet the requirements of ASTM E446 (up to 2 inches [50 mm]
thick) as follows:
a. Category A, B, & CA = Level 2.
b. Category CB, CC, & CD = Level 3.
c. Category D, E, F, & G = Level 0.
5. The entire accessible surface area of castings shall be liquid penetrant inspected after
pickling.
Note: Some areas on smaller control valves are not accessible. The LPT
(a nondestructive test) and inspection are required for these pressure classes to
identify surface cracks and imperfections that may have occurred as a result of the
manufacturing process.
6. Interpretation shall be in accordance with Appendix 8 of the ASME Boiler and Pressure
Vessel Code, Section VIII, Division 1.
a. Relevant indications shall be removed.
b. Indications 1/16 inch (3 mm) and greater shall be rejected.
c. Bright red indications (regardless of size) and clusters of pink indications (potential
porosity) shall be cause for removal of metal.
7. Additional dye examination shall be performed until all indications have been removed.
8. Repairing methods shall be reviewed and accepted by Purchaser and Owner prior to
welding.
Note: If a repair is required, the repair is potentially a hold point during the fabrication
process. Therefore, it is suggested that weld repair methods and procedures be
submitted in advance for review, to minimize the potential and duration of hold
points.
Fabrication buttwelds during the control valve fabrication are required to

be 100 percent radiographed and evaluated in accordance with paragraph 344.5
of ASME B31.3, with a minimum casting quality factor of 0.95.
Repair welds such as any fillet or attachment welds require LPT/inspection

and MPT/inspection. 100 percent radiographing can potentially add
1 to 3 hours per valve where this is applicable.
Supplier should be made aware of this requirement early so that appropriate and
realistic quotes, including delivery and cost, can be provided.
9. Inspections and repairs shall be witnessed by Purchaser’s inspectors per ICM-IT-5316.
Note: Inspection and hold points need to be specified prior to time of order
entry/purchase order.
10. If fire test for external leakage valves is specified, API 607 performance requirements
shall be met.
11. Compliance for internal leakage across the seat shall not be required, unless the control
valve is used as part of safety instrumented systems (SIS), safety instrumented function
(SIF), emergency shutdown (ESD), blowdown/depressurization valve (BDV), electric
ball valve, etc.
11.0 Quality Assurance, Inspection, and Testing

11.1 General
Note: Inspection and testing for control valves should be similar to that required for process
piping and equipment. The process piping and equipment requirements should be
reviewed on a valve-by-valve basis. Inspection requirements should be specified on
ICM-DU-5152. Complex inspection details, when defined in the piping class
specification sheets, should be attached to ICM-DU-5152.
The most frequently required inspections apply to ASME Class 900, 1500, and 2500
valve bodies. Inspection requirements for CS and SST bodies in classes are
documented in Section 7.2 and 7.3, respectively, in ICM-SU-5102. Inspections may
also be required for alloy body valves (e.g., Hastelloy, Carpenter 20, etc.). These
inspections should be defined in comparable detail and attached to the specification
sheets.
1. For the valve/actuator assembly, Supplier shall test the operation of the valve, actuator, and
accessories that are installed and connected to the control valve assembly.
a. Valve, actuator, associated components, and pneumatic system shall be tested in the
complete assembled state.
b. Tests shall be designed to prove operability of the valve and actuator assembly under
static assembly bench tests. Purchaser shall specify if a simulated test of operating
conditions is required. Simulated test and its procedures shall require Owner review
and acceptance.
2. Inspections and testing of valves shall be performed by Supplier in accordance with
API 598, API 6D, ASME B16.5, and ASME B16.34, as applicable.
3. Purchaser and Owner, per ICM-IT-5316, shall reserve the right to inspect the valve/actuator
assemblies at any time during fabrication to ensure that the materials and workmanship are
in accordance with specifications and applicable standards and codes. The applicable
manufacturing “hold and review points” shall be implemented in the schedule to
accommodate this requirement.
4. Butterfly valves shall be tested by the valve Supplier in accordance with ASME B16.34 and
MSS SP 61 prior to being shipped to valve/actuator assembly Supplier. Inspections and
testing of other control valve types shall be performed by Supplier in accordance with
industry standards for testing of control valves that are ANSI/ISA 75.19.01 for hydro test
and ANSI/FCI 70-2 for seat leak test.
5. Test pressure for steel valve bodies shall be in accordance with the rating defined in
ASME B16.5.
6. Test pressure for bronze bodies shall be equal to two times the primary pressure rating.
7. Control valve shall be properly drained and dried after testing.
11.2 Operational Tests

1. Operational tests shall consist of measuring valve stem position for increasing and
decreasing input signals.
a. Inputs shall be simulated for all accessories (i.e., positioners, controllers).
b. Supplier shall provide test reports and certificates.
2. Valves shall meet the requirements of Supplier’s published specifications, Owner’s
specifications, and Purchaser’s project-related documentation.
3. The valve body and bonnet shall pass a hydrostatic test at Supplier’s facility. Hydro test
and inspection shall be in accordance with either ISA 75.19.01 or API 598.
11.3 Welding and Repair

1. Welding procedures and performance of welders and welding operators shall meet the
requirements of ASME B31.3.
2. Repair of valves, if required, shall conform to the applicable ASTM (e.g., ASTM A217
and ASTM A351) and ASME codes.
3. At a minimum, control valves shall be re-hydro tested after repair. Supplier non-pre-
accepted weld procedures and non-pre-accepted weld repair procedures shall be reviewed
and accepted by Purchaser and Owner per ICM-IT-5316.
12.0 Documentation Requirements

12.1 General
1. The inspector shall be provided with the following (not all inclusive) documentation:
a. Data sheet.
b. Accepted drawings.
c. Purchase order.
d. Manufacture QC plan.
e. ITP.
f. Calibration certificates for test equipment.
g. Welding procedure specification (WPS) and procedure qualification records (PQRs).
h. Welder qualification reports.
i. NDE procedures.
j. NDE personnel qualification reports.
k. Material test reports.
l. Heat treatment procedure.
m. Hydrostatic testing procedure and water quality document.
n. Preparation and painting procedure.
o. Preservation, packing, and shipping procedure.
p. Packing list.
12.2 Documentation Examination

1. The inspector shall sign off on the following documents:
a. As-built drawings conforming to the project documentation.
b. Dimensional drawings.
c. Material certificates or certified mill test reports for pressure boundary parts.
d. NDE records.
e. Pneumatic test records.
f. Hydrostatic test records.
g. Final assembly.
h. Shipping records.
i. Spare parts list.
j. ITP.
2. The inspector shall verify that all electronic documentation has been obtained for each
control valve.
13.0 Painting and Coating Requirements

1. Supplier shall organize the inspection and shall record data on weather conditions, surface
preparation, and paint preparation prior to starting blasting and painting work.
2. Supplier shall organize the supervision and quality inspection of blasting and painting
work.
3. The following shall be inspected and recorded:
a. Environmental conditions.
b. Surface blasting.
c. Visual inspection for each application.
d. Dry film thickness (DFT).
e. Paint adhesion testing.
4. Supplier shall determine subsequent steps on the basis of inspection results.
5. Surface preparation shall be as follows:
a. Abrasives used for surface blasting shall be visually inspected according to project
technical requirements and Supplier’s mill certificate prior to use.
b. QA/QC representative shall identify steel surface roughness (Rz) with a special
instrument at Purchaser’s request. Steel surface Rz measurement shall conform to
project technical requirements.
c. Surface cleanliness shall conform to project specifications and surface shall be visually
inspected and compared with the relevant standard samples in ISO 8501-1.
6. Coating inspection shall meet the following requirements:
a. Coating inspection equipment shall be calibrated prior to inspection.
b. Coating shall be visually inspected to assess the general quality of work and to detect
technical defects such as remains, runs, swelling, and air bubbles. Special attention
shall be paid to corners, edges, and welds.
c. The DFT of each application shall be measured with an Elcometer® 345 or another
acceptable measuring instrument.
d. At least 20 points, uniformly distributed over a 108 ft2 (10 m2) area, shall be measured.
e. DFT measurement results shall not be less than 10 percent of the specified thickness.
f. Test shall be conducted on test panels with an Elcometer 106 or other acceptable
measuring instrument. Adhesion tests shall not be allowed on the product.
7. The following records for coating work shall be maintained by Supplier and Sub-Suppliers:
a. Paint adhesion testing report.
b. Daily blasting and painting inspection report.
c. Coating quality records (with project as-built records).
14.0 Packaging
14.1 Preparation for Shipment
1. Prior to packing, the control valve shall be verified for the following:
a. Cleanliness and dryness.
b. Rust prevention for all machined surfaces.
c. Covers for all openings.
d. Packing per specifications.
2. Type of shipping and transportation—such as barge, air freight, and overseas—shall be
verified to ensure that proper preparation and shipping is completed.
14.2 Shipping
1. Packing and shipping criteria and methods shall be as follows:
a. Flange faces shall comply with the following:
1) Painted with Rustban® or equal.
Note: Rust preventative Cortec® VpCl-369D and sealing ends with
Cortec VpCl-126 moisture barrier are not equivalent to Rustban.
2) Protected by solid covers securely fastened to flanges.
3) Provided with a shipping gasket and a solid cover attached with low-grade bolts
and nuts. Stainless steel bolts and nuts shall not be required.
4) Provided with a cover that is of a low-grade metal material (preferred) or masonite
that is bolted onto the control valve flange.
Note: Masonite covers can be provided. The masonite cover thickness may vary,
depending on the control valve flange size. Supplier needs to confirm
masonite flange cover thickness. If the manufacturer is not able to bolt the
masonite cover onto the flange, the manufacture must provide a low-grade
metal material as a barrier that is to be bolted onto the control valve
flange.
b. Flange covering, bolting, and nuts shall be resistant to corrosion.
c. All other openings shall be covered to prevent dirt and foreign matter from entering.
2. Threaded connections shall have thread protectors to exclude dirt and other foreign matter.
3. Control valve body, actuator, mounting brackets, etc., shall be painted with the Supplier’s
standard paint and color, unless specified otherwise. The paint and color requirements shall
be reviewed and accepted by Owner.
4. Rust inhibitor shall be applied on the inside of each control valve.
15.0 Purchasing Guarantee

1. Requirements for equipment purchasing guarantee are covered by the terms and conditions
of purchase in force at the time of order.
2. Purchasing Guarantee shall be specified for all control valve orders.

3. The purchaser shall include purchasing guarantee in the control valve purchase order.
Appendix A Manufacturing Procedures

Table 2: Fisher Manufacturing Pre-Accepted Procedures
Item Group CVPP Fisher Fisher Short Description
Document Procedure Document Amendment
Number Number Number
(CVX-FSH-CVPP-) (CSP-CHEVRON-AM-)
1 Welding WLD-009 FWPS P1-TSP-JS1 N/A Carbon steel (CS)

fabrication
2 Welding WLD-008 FWPS P1-TSP-RS1 N/A Carbon steel (CS) repair
3 Welding WLD-007 FWPS P8-TSN-JS1 N/A 316L SS fabrication
4 Welding WLD-006 FWPS P8-TSN-RS1 N/A 316L SS repair
5 Welding WLD-002 FWPSP 10H-TSN-JS1 N/A Duplex fabrication
6 Welding WLD-003 FWPSP 10H-TSN-RS1 N/A Duplex casting repair
7 Welding WLD-004 FWPSP 10H-TSN-JS2 N/A Super Duplex fabrication
8 Welding WLD-005 FWPSP 10H-TSN-RS2 N/A Super Duplex casting
repair
9 Welding WLD-001 FMP 6A1 N/A Post-weld heat treat
procedure
10 Testing TST-001 FMP 2G17 6 Radiographic test
(RT)/ultrasonic test (UT)/
magnetic particle test
(MPT)/liquid penetrant test
(LPT) per ASME B16.34
(PL4 and PL5)
11 Testing TST-002 FMP 2G20 5 RT, maximum feasible,
level 2 acceptance
(Pl5, Opt B5, and D1)
12 Testing TST-003 FMP 2G10 N/A Hardness testing (HT)
13 Testing TST-004 FGS 4L1 8 Hydro procedure
14 Testing TST-005 FGS 4L5 9 Seat leak procedure
15 Testing TST-006 FMP 2C6 10 Functional test procedure
16 Testing TST-007 FMP 2G19.3 N/A Positive material
identification (PMI)
procedure
17 Painting PNT-002 WMP 8X17 3 Special paint ‒ four-coat
offshore environment
18 Painting PNT-003 WMP 8X22 1 Special paint ‒ three-coat
offshore environment
19 Packaging PAK-001 WMP 10L1 7 Tape and seal ends ‒ oil
based
20 Packaging PAK-002 WMP 10L3 N/A Tape and seal ends ‒
water based
21 Packaging PAK-003 WMP 11A1 N/A Domestic packaging ‒
immediate use
Item Group CVPP Fisher Fisher Short Description

Document Procedure Document Amendment
Number Number Number
(CVX-FSH-CVPP-) (CSP-CHEVRON-AM-)
22 Packaging PAK-004 WMP 11A3 N/A Export packaging ‒

immediate use
23 Packaging PAK-005 WMP 11A8 11 Extended storage
packaging
Appendix B ANSI Class < 900 QC/ITP Criteria

Table 3: ANSI Class < 900 Control Valve QC/ITP Tag Summary
ANSI Class < 900 – Control Valve QC/ITP Tag Summary
Project Information
Document No.: Date:
Document Name: Rev. No.:

Project Name: Location:
Order IMA No.:
Contractor Information
Contractor Name:
Contact Name: Contact Phone No.: Contact E-Mail:
Supplier Information
QC/ITP No.: Manufacturer:

Rev. No. Date Item No. Tag No. P&ID No. Service Description Remarks
Table 4: ANSI Class < 900 Control Valve QC/ITP Requirements
Appendix C ANSI Class ≥ 900 QC/ITP Criteria

Table 5: ANSI Class ≥ 900 Control Valve QC/ITP Tag Summary
ANSI Class ≥ 900 – Control Valve QC/ITP Tag Summary
Project Information
Document No.: Date:
Document Name: Rev. No.:
Project Name: Location:
Order IMA No.:
Contractor Information
Contractor Name:
Supplier Information
QC/ITP No.: Manufacturer:
Rev. No. Date Item No. Tag No. P&ID No. Service Description Remarks
Table 6: ANSI Class ≥ 900 Control Valve QC/ITP Requirements

ICM-PU-5316.2 CV Quality Assurance Inspec Test

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ICM-PU-5316.

Operating Environment: Onshore, Topsides

Rev. Date Description Author Technology Leader

Previous Current Description Type of Change

10.0 ANSI Class ≥ 900 QC/ITP Additional Requirements ................................................................. 30

Note: Some references appear only in ICM-IT-5316.

2.1 Owner Documents

2.2 Industry Codes and Standards

American Society of Mechanical Engineers (ASME)

International Organization for Standardization (ISO)

Spanish Association for Standardisation and Certification

ASTM International (ASTM)

International Organization for Standardization (ISO)

International Society of Automation (ISA)

NACE International (NACE)

2.3 Conflict Resolution

KPI Key Performance Indicator

WLD Welding Procedure

4.0 Quality Management and Quality Control

4.2 Non-Conforming Products

iii. Use as is (concession).

5.0 Fisher Manufacturing Procedures – Pre-Accepted

5.2 Welding Procedures

5.3 Testing Procedures

5.4 Painting Procedures

5.5 Packaging Procedures

6.0 Inspection Requirements

6.6 Final Inspection

6.7 Rust Prevention and Painting Inspection

7.0 Testing Requirements

7.2 Nondestructive Examination

7.2.2 Radiographic Test

7.2.3 Liquid Penetrant Test

7.3 Pressure Tests

7.3.2 Shell and Back Seat Test

7.3.3 Seat Leakage Tests

7.4 Functional (Operational) Test

8.0 Witness Test Points

9.0 Control Valve QC/ITP Requirements Tables

9.2 QC/ITP Requirements Table Details

9.3 Item Number

9.4 Activity Selected, Type, and Description

9.4.1 Activity Selected

9.4.2 Activity Type

9.4.3 Activity Description

9.5 Reference Documents

9.6 Acceptance Criteria and Reference of Certification/Documentation

9.7 Responsibility and Inspection Record

e. I (Information) ‒ Informational only, work does NOT stop.

9.7.2 Inspection Record

10.0 ANSI Class ≥ 900 QC/ITP Additional Requirements

10.2 Weld Control and NDE Requirements

Table 1: Control Valve Metallurgy for Test Selection

10.2.1 Carbon Steel and Low Alloy Control Valve Castings

10.2.2 Stainless Steel Control Valve Castings

Fabrication buttwelds during the control valve fabrication are required to

Repair welds such as any fillet or attachment welds require LPT/inspection

11.0 Quality Assurance, Inspection, and Testing

11.2 Operational Tests

11.3 Welding and Repair

12.0 Documentation Requirements

12.2 Documentation Examination

13.0 Painting and Coating Requirements

15.0 Purchasing Guarantee