V7: PART 2

TECHNICAL SPECIFICATION FOR

DISTRIBUTION VALVES
PART 2 - PLASTICS BODIED VALVES OF SIZES UP
TO 63 mm SUITABLE FOR OPERATION AT
PRESSURES NOT EXCEEDING 5.5 bar

SEPTEMBER 1995

J287 ( Rev 01/98 )

.
 V7: PART 2

CONTENTS

Page

FOREWORD iii

BRIEF HISTORY iv

1. SCOPE 1

2. REFERENCES 1

3. DEFINITIONS 1

3.1 General 1

3.2 Miscellaneous 1

3.3 Mandatory and non-mandatory requirements 1

4. MATERIALS 2

5. PRESSURE CLASSIFICATION 2

6. DESIGN 2

7. TESTING 3

7.1 General 3

7.2 Production testing 4

7.3 Phase 1 and Phase 2 approval testing (type testing) 5

8. CONTROL OF TEST CONDITIONS 6

8.1 Test conditions 6

8.2 Specimen conditioning 6

8.3 Pneumatic pressure testing 6

9. MARKING 6

10. PROTECTION AND STORAGE OF VALVES 7

11. CERTIFICATION 7

12. COMPLIANCE 7

13. VARIANTS 7

TABLES

1 Spigot connection dimensions 3

2 Production testing schedule 4

3 Phase 1 and Phase 2 approval schedule 5

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V7: PART 2

APPENDICES

A LIST OF REFERENCES 9

B DIMENSIONS 10

C THERMAL STABILITY TEST 11

D SHORT TERM PRESSURE TEST 13

E SPIGOT END REVERSION TEST 14

F STRESS CRACK RESISTANCE AT ELEVATED TEMPERATURE 15

G LONG TERM STRENGTH AND OPERATION 16

H IMPACT 17

I RESISTANCE TO TENSILE LOAD 18

J RESISTANCE TO BENDING MOMENT APPLIED

VIA THE OPERATING CAP 19

K RESISTANCE TO BENDING MOMENT APPLIED

VIA THE ADJACENT PIPEWORK 20

L EROSION RESISTANCE 21

M PRESSURE LOSS 22

N CORROSION RESISTANCE 24

O STRENGTH OF STOPS 25

P EASE OF OPERATION 26

Q LEAKAGE TO ATMOSPHERE 27

R INTERNAL LEAKAGE (SEAT LEAKAGE) 28

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 V7: PART 2

FOREWORD

This specification has been adopted by Transco and is an editorial revision of the former British Gas TransCo
specification V7: Part 2. It reflects the identity and organizational structure of Transco - a part of BG plc.

This Transco specification has been approved for use throughout Transco.

Comments and queries regarding the technical content of this Transco specification should be directed to:

Lead Role Engineer

Transco
West Area Office
Glevum House
Bristol Road
Gloucester
GL2 6YA

Further copies of this Transco specification can be obtained from Dataform Print Management using the print
requisition form G004 quoting the Form Number of this Transco specification (not the designation) and your
cost code.

Transco specifications are revised, when necessary, by the issue of amendments or new editions. Users should
ensure that they are in possession of the latest versions by referring to the Transco Register of Engineering
Documents available on the Transco Information Library.

Contractors and other users external to Transco should direct their requests for further copies of Transco
specifications to the department or group responsible for the initial issue of their contract documentation.

Compliance with this specification does not confer immunity from prosecution for breach of statutory or other
legal obligations.

DISCLAIMER

This specification is provided for use by Transco and such of its contractors as are obliged by the terms of
their contracts to comply with this specification. Where this specification is used by any other party it is the
responsibility of that party to ensure that the specification is correctly applied.

J287 ( Rev 01/98 ) - iii -

V7: PART 2

BRIEF HISTORY

First published as BGC/PS/V7: Part 2 June 1986

Revision published as V7: Part 2 September 1995

© BG plc 1995

This Transco specification is copyright and must not be reproduced in whole or in part by any means without
the approval in writing of BG plc.

- iv - J287 ( Rev 01/98 )

 V7: PART 2

TECHNICAL SPECIFICATION FOR

DISTRIBUTION VALVES
PART 2 - PLASTICS BODIED VALVES OF SIZES UP
TO 63 mm SUITABLE FOR OPERATION AT
PRESSURES NOT EXCEEDING 5.5 bar

1. SCOPE
1.1 This Transco Technical Specification* specifies the requirements for plastics bodied valves of sizes
up to 63 mm manufactured from polyethylene (PE) for use at operating pressures not exceeding 5.5 bar and
operating temperatures in the range -20 0 C to 40 0 C .
* Hereinafter referred to as 'this specification'.

1.2 The valves shall be suitable for use in systems conveying natural gas, of a composition within the
ranges specified in DAT 33.

1.3 This specification is applicable to valves which are to be buried.

1.4 This specification includes requirements for materials, dimensions, design, performance, testing,
labelling and packaging of plastics bodied valves.

2. REFERENCES
This specification makes reference to the documents listed in Appendix A. Unless otherwise specified, the
latest editions of these documents apply, including all addenda and revisions.

3. DEFINITIONS
3.1 General
For the purposes of this specification, the definitions given in 3.2 and 3.3 apply.

3.2 Miscellaneous
Contractor: the person, firm or company with whom Transco enters into a contract to which this
specification applies, including the Contractor's personal representatives, successors and permitted assigns.

no leakage: the absence of any bubble of the test gas breaking loose from the valve during the test period
specified.

spigot length: the length of spigot, measured from the spigot end towards the valve, having the same outside
diameter as the spigot end itself.

standard dimension ratio (SDR): the 'specified minimum pipe outside diameter' divided by the 'specified
minimum pipe wall thickness'.

Transco: Transco - a part of BG plc.

3.3 Mandatory and non-mandatory requirements

can: indicates a physical possibility.

may: indicates an option which is not mandatory.

must: indicates a requirement in law and in matters of health and safety.

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V7: PART 2

shall: indicates a Transco requirement.

should: indicates a strong preference, but allows deviations exceptionally.

will: indicates an intention by Transco to do something.

4. MATERIALS
4.1 All materials used for the components of the valve shall be suitable for use with natural gas as
defined in 1.2 and shall not be adversely affected by any of its constituents or additives.

4.2 PE shall be used for end connections and shall be material which complies with the requirements of
PL2: Part 6 and shall be compatible with PE pipe produced to PL2: Part 1. Compatibility shall be
demonstrated by the Contractor in accordance with requirements of PL2: Part 4.

4.3 Where PE is used, it shall be of material which complies with the requirements of PL2: Part 6.
Other non-metallic materials may be proposed for consideration by Transco provided compliance with
regression tests to 50 years at 8.3 MN/m 2 can be shown together with resistance to other mechanisms of
failure (e.g. environmental stress cracking).

4.4 Elastomeric materials used for components of the valve (e.g. seals) shall comply with the
requirements of BS 2494 Type G. Other materials (e.g. filled or unfilled polytetrafluorethylene (PTFE) or
nylon may be proposed for consideration by Transco provided that they can be shown to meet the
requirements of this specification.

4.5 Internal or external metallic components shall be of stabilized stainless steel complying with
BS 970: Part 1, Grades 316 - S13, 316 - S11 or 320 - S31 or copper alloy complying with BS 1400, LG2 or
LG4. Other equivalent metallic materials may be proposed for consideration by Transco, but free machining
grades shall not be used for the closure member.

4.6 The colour of the valve body and spigots shall be yellow to BS 5252, 10 E 50, 10 E 53 or 10 E 55.

5. PRESSURE CLASSIFICATION
Operating pressures are given in the Transco Engineering Procedures (formerly British Gas Code of Practice
for Distribution).

6. DESIGN
6.1 Valves shall be quarter-turn and clockwise to close. They shall not be of the rising spindle type.

6.2 The pressure rating of the body and the maximum operating pressure of the valve shall be 5.5 bar.

6.3 The end connections of the valve provided for fusion to the PE system shall be of the spigot type
unless otherwise agreed with Transco.

6.4 Adequate clearance for the valve operating tool shall be ensured by maintaining a clear area
100 mm in diameter measured from the centre line of the top cap. The electrofusion coupler shall not infringe
on this clear area nor on the minimum spigot length specified in Table 1. The valve shall not be adversely
affected by the heat generated during the jointing process.

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 V7: PART 2

TABLE 1 - Spigot connection dimensions

6.5 The design and construction of valves shall be such that no maintenance is required.

6.6 Valves shall be suitable for installation and operation below ground.

6.7 All parts of the valve, including those parts which are not normally subject to line pressure, shall be
sealed against the ingress of water, dirt, soil, etc.

6.8 Valves shall not be bolted or screwed and shall be so designed that they cannot be dismantled. Any
mechanism that puts a loading on any seal shall be permanently locked. Line pressure shall not be relied upon
as the sole source of seat loading.

6.9 The valve shall carry an operating member which can be turned by a 50 mm square socket 40 mm
deep. This operating member shall not be damaged by the metal socket during normal valve operation and
shall bear clear indication of the position of the valve port.

6.10 Stops shall be provided at the fully open and fully closed positions either on the body of the valve or
on an associated part such as a mounting cradle or box.

6.11 Valves shall be capable of operation and sealing against gas flowing from either direction.

6.12 End connections and valve bodies manufactured as separate items shall be permanently fused
together during manufacture using a procedure approved by Transco.

6.13 Where any dissimilar metallic materials are used which may be in contact with moisture, the
possibility of galvanic corrosion shall be avoided.

6.14 Once a valve has received approval, any changes in design, materials or method of manufacture
shall be proposed as a variant for consideration by Transco whose approval in writing shall be obtained
before the modified valve is tendered or supplied.

7. TESTING
7.1 General
The tests specified in Appendices B to R inclusive have been devised to provide an assessment of the integrity
and dimensions of the valve. The test methods outlined are reference methods; other techniques may be
proposed as a variant for consideration by Transco

In the type test, spigotted ends shall be joined by electrofusion. In the production test, other methods may be
proposed as a variant for consideration by Transco.

Valves shall be dried and cleaned after testing.

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V7: PART 2

A strength of stops test, at 40 0 C only, as given in Appendix N, shall be applied prior to all other test
schedules.

7.2 Production testing

7.2.1 All production made valves shall be tested by the Contractor in accordance with the details set out
in Table 2.

Failure to meet the requirements of any one of the tests shall be cause for rejection of the batch. When a
failure occurs in a test where only a sample has been taken, the whole of the batch will be quarantined. A
system of back checking shall be carried out before any of the batch can be released. The cost of retrieval of
any valves released before the completion of the tests and any other expenses incurred as a result of additional
tests shall be borne by the Contractor.

TABLE 2 - Production testing schedule

7.2.2 Samples of valves from production runs shall be required by Transco for validation testing. The
cost of testing these samples shall be borne by the Contractor.

The number of samples shall be specified by Transco and shall depend on the range of valves offered and on
previous manufacturing history, but shall not exceed 10% of the Contractor's test level.

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 V7: PART 2

7.3 Phase 1 and Phase 2 approval testing (type testing)

7.3.1 Approval testing shall be undertaken in two parts, Phase 1 and Phase 2. It shall be carried out by
the Contractor or by an independent laboratory acting on his behalf.

Phase 1 approval is divided into two parts, enabling Contractors to supply to Transco, valves for restricted
use, after 2500 h of the long term strength and operation test (see Appendix G), provided that all other
Phase 1 tests have been successfully completed. Samples for long term strength and operation test should also
be ongoing simultaneously for full Phase 1 approval.

7.3.2 Phase approval testing shall be carried out in accordance with Table 3. Failure to meet the
requirements of the tests shall be cause for rejection.

TABLE 3 - Phase 1 and Phase 2 approval schedule

7.3.3 Satisfactory approval testing of each size and design of valve that the Contractor offers as
complying with this specification is necessary before it may be supplied to Transco.

7.3.4 Before commencement of Phase 1 testing, the Contractor shall compile a proposed test schedule in
accordance with Table 3 and a set of drawings showing all critical dimensions and production techniques.
Changes shall not be made unless they are proposed as variants for consideration by Transco. Further testing
may be required.

After completion of Phase 1 testing, a detailed data folder shall be submitted containing all relevant
information and test results to Transco.

7.3.5 No valve shall be supplied to Transco until the above procedures have been carried out and either
full or partial Phase 1 approval has been granted. No Contractor shall claim compliance with this

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V7: PART 2

specification or include the designation of this specification on the valve or packaging marking until all
approval tests have been completed and Phase 2 approval granted.

7.3.6 Failure of the long term strength and operation test between 2500 h and 5000 h may result in the
partial approval on the basis of successful 2500 h testing being withdrawn.

7.3.7 Valves which have been successfully tested to 2500 h will have their use restricted. Completion of
full Phase 1 testing will remove this restriction.

7.3.8 Where a Contractor does not have a valve in production, Phase 1 or partial Phase 1 approval may
be given on pre-production valves. Thereafter, and within 18 months of receipt of Phase 1 approval, Phase 2
approval shall be obtained on valves representing at least three months production or Phase 1 approval may
be withdrawn.

7.3.9 Transco will require to witness some or all of the tests to a programme as laid down in this
specification. Transco reserve the right to select valves for Phase 2 testing.

7.3.10 Where a Contractor has production made valves, representative of at least three months production,
a joint Phase 1 and Phase 2 programme may be proposed as a variant for consideration by Transco and, in this
case, partial Phase 1 and full Phase 1 approval will be granted as the testing proceeds successfully.

8. CONTROL OF TEST CONDITIONS

8.1 Test conditions
The tests and measurements shall be conducted in a standard laboratory atmosphere of 23 ± 2 0 C unless
otherwise specified.

8.2 Specimen conditioning

During type testing specimens shall be conditioned prior to test by being kept at 23 ± 2 0 C for not less
than 12 h, unless otherwise specified. In the case of hydrostatic tests involving liquid immersion, the
specimens shall be conditioned prior to test for 1 h at the specified temperature.

8.3 Pneumatic pressure testing

Adequate safety precautions shall be taken during any pneumatic pressure testing.

9. MARKING
9.1 All valves supplied in accordance with this specification shall be suitably and individually marked.

9.2 The information to be given to identify the item shall be as follows:

1) The Contractor's identity.

2) Base polymer.
3) The size of valve in mm.
4) SDR rating.
5) Individual component identification code.
6) The letters V7, if Phase 2 approval has been achieved.

9.3 All marking shall remain legible under normal handling, storage and installation procedures. The
method of marking shall not prevent the valve from meeting the requirements of this specification. There shall
be no marking on the minimum spigot length.

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 V7: PART 2

10. PROTECTION AND STORAGE OF VALVES

10.1 The valves shall be individually bagged by the Contractor to protect the product during storage.

10.2 The valve shall be stored in such a manner as to avoid damage. Particular attention shall be given to
the prevention of damage to spigot ends and to protection from the effects of sunlight.

11. CERTIFICATION
Certified records appertaining to the materials used, inspection and testing of all manufactured valves shall be
kept by the Contractor. Such records shall be available for inspection by Transco at the Contractor's or Sub-
contractor's premises.

12. COMPLIANCE
Dispatch by the Contractor of valves shall signify to Transco that such fittings have been manufactured,
inspected, tested and stored in compliance with the requirements of this specification.

13. VARIANTS
A contractor shall only propose variants to this specification where the text indicates that variants would be
considered by Transco.

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V7: PART 2

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APPENDIX A
LIST OF REFERENCES
This specification makes reference to the documents listed below (see clause 2).

British Standards

BS 970 - Specification for wrought steels for mechanical and allied engineering
purposes:
Part 1 - General inspection and testing procedures and specific
requirements for carbon, carbon manganese alloy and stainless steels

BS 1400 - Specification for copper alloy ingots and copper alloy and high
conductivity copper castings

BS 2494 - Specification for elastomeric seals for joints in pipework and pipelines

BS 2782 - Methods of testing plastics:

Part 11 - Thermoplastics pipes, fittings and valves: Method 1101A -
Measurement of dimensions of pipes

BS 5252 - Framework for colour co-ordination for building purposes

Transco specifications

DAT 33 - Range of composition of natural gas

PL2 - Specification for polyethylene (PE) pipes and fittings for natural gas
and suitable manufactured gas:
Part 1 - Pipes for use at pressures up to 5.5 bar
Part 4 - Fusion fittings with integral heating element(s)
Part 6 - Spigot end fittings for electrofusion and/or butt fusion
purposes.

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V7: PART 2

APPENDIX B
DIMENSIONS
B.1 GENERAL
All measurements shall be carried out using the procedures specified in BS 2782: Part 11, Method 1101A,
unless qualified by the requirements of this Appendix B.

The valve shall be free from visible cracks, voids, blisters, distortion, dents, injurious inclusions or other
defects.

B.2 MEAN OUTSIDE DIAMETER

B.2.1 For valves sizes of 25 mm or less, BS 2782: Part 11, Method 1101 A, clause 4 refers, except that
four equally-spaced measurements shall be taken around the circumference at a distance of one diameter from
the end of the pipe.

The result shall be the arithmetic mean of the four readings, rounded off to the nearest 0.05 mm.

B.2.2 For valve sizes greater than 25 mm, BS 2782: Part 11, Method 1101A, clause 3 refers, but the
measurements shall be taken at least one diameter from the end of the valve.

B.3 MAXIMUM AND MINIMUM WALL THICKNESS OF SPIGOTS

For all valve sizes, BS 2782: Method 1101A, clause 2 refers, except that:

1) valve ends shall be free of cutting burrs;

2) measure both ends of the valve not less than 15 mm from the cut ends;
3) rotate the valve or move the measuring instrument as convenient until a maximum and
minimum wall thickness have been found.

B.4 OUT-OF-ROUNDNESS OF VALVE ENDS

For all valve sizes, BS 2782: Method 1101A, clauses 4.1 and 4.2 refer. The result shall be expressed as the
maximum diameter minus the minimum diameter and the value rounded off to the nearest 0.1 mm.

The spigot shall not exhibit out-of-roundness in excess of 1 mm + 0.008d, where d is the mean outside
diameter of the spigot.

B.5 WALL THICKNESS OF TENSILE TEST SPECIMEN

For all pipe sizes, BS 2782: Part 11, Method 1101A, clause 2 refers subject to the measurement being
contained within the zone bounded by the two reference lines (gauge marks).

B.6 OUT-OF-SQUARE TOLERANCE

The maximum out-of-square tolerance of the spigot end shall be 1 mm.

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 V7: PART 2

APPENDIX C
THERMAL STABILITY TEST
C.1 APPARATUS
The apparatus shall consist of a differential scanning calorimeter (DSC) used to determine the induction time
of the material. The appropriate temperature scale of the equipment shall be calibrated using pure indium and
pure tin to lie within 156.6 ± 0.5 0 C and 231.9 ± 0.5 0 C respectively. The operating instructions of the
instrument manufacturer shall be followed except when in conflict with this Appendix C.

C.2 SPECIMENS
A sample shall be taken by use of a core drill directed radially through the valve or spigot wall. The diameter
of the core shall be just less than the inner diameter of the sample pan of the thermal analyser and care should
be taken not to overheat the sample during the coring operation. Using a scalpel, discs shall be cut from the
core sample each weighing 15 ± 0.5 mg, selecting the inner surface, outer surface and mid-wall, as the
minimum sample points, which shall each be tested individually.

C.3 PROCEDURE
A nitrogen flow of 50 ml min −1 . through the DSC shall be established. A check shall be made when the
switchover to oxygen is made to ensure the gas flow continues at that rate and then may be reverted back to a
nitrogen flow of 50 ml min −1 .

A 15 ± 0.5 mg circular polyethylene sample shall be introduced into an open aluminium pan and placed with
an empty aluminium reference pan in the cell. The instrument shall be set to run isothermally at 200 ± 0.1 0 C
and the temperature raised at a rate of 20 0 C min −1 , until the temperature has stabilized. Corrections to the
heater voltage to bring the specimen temperature to 200 ± 0.1 0 C shall be made. The thermogram, which is a
plot of the temperature differential against time, shall be recorded.

After 5 min and when steady conditions exist under nitrogen, the switchover to oxygen shall be made and this
point marked on the thermogram. The cell shall be purged within 1 min of atmosphere changeover. The
thermogram shall be recorded until the oxidation exotherm has occurred, and has reached its maximum.

C.4 INTERPRETATION OF RESULTS

The thermal stability of the specimen shall be the time taken in minutes from the introduction of oxygen to the
intercept of the extended baseline and the extended tangent drawn to the exotherm at the point of maximum
slope (see Figure C.l).

C.5 REQUIREMENTS
The valve body, and end connections when manufactured from PE, shall be thermally stable. The oxidation
induction time shall be at least 20 min when tested in accordance with this Appendix C.

Alternative methods may be proposed as a variant for consideration by Transco, provided the results can be
equated to induction time.

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V7: PART 2

FIGURE C.1 - Example of DSC trace

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 V7: PART 2

APPENDIX D
SHORT TERM PRESSURE TEST
D.1 GENERAL
When tested in accordance with this Appendix D, the valve assembly shall meet the performance
requirements specified in D.4. Any part of the valve which may be subjected to line pressure under normal
operation or under fault conditions within the valve shall be exposed to the test pressure. Failure shall be
deemed to have occurred when any part of the valve or spigot does not contain the applied pressure.

D.2 APPARATUS
The apparatus shall consist of a temperature-controlled water bath or air space maintained for the duration of
the test at the temperature specified to ± 1 0 C . The equipment shall allow the internal water pressure to be
steadily increased until the pipe yields. At yield the internal pressure shall be measured to an accuracy
of ± 2%.

D.3 SPECIMENS
More than one valve may be tested simultaneously, provided that the connecting pipe has been validated in
accordance with PL2: Part 1 and that the free length of pipe between valves of any type is not less than three
times the outside diameter of the pipe.

The specimen shall be closed with pressure-tight, end-load bearing end-caps or plugs which shall be provided
with connections for the entry of water and the release of air.

Joint assemblies for approval testing shall be made up using electrofusion fittings to PL2: Part 4.

D.4 PROCEDURE AND REQUIREMENTS

The specimen shall be maintained at a temperature of 20 ± 1 0 C and shall be pressurized internally to a
pressure of 24 bar at a steady rate over a period of between 30 s and 40 s. The specimen shall withstand this
pressure which shall be held for a period of not less than 1 h.

The internal pressure shall then be raised to above 32 bar, within a period of 15 s, and maintained for a
minimum period of 5 s. The failure pressure shall be greater than 32 bar.

Where materials other than PE are used different pressures and periods of time may be applied to this test.

J287 ( Rev 01/98 ) - 13 -

V7: PART 2

APPENDIX E
SPIGOT END REVERSION TEST
E.1 GENERAL
The valve spigot ends shall be within their specified diameter tolerance at standard laboratory conditions,
(see clause 8), after a relaxation period at the specified temperature.

This test may be carried out on the same sample of valves as the stress crack resistance test.

E.2 APPARATUS
The apparatus shall consist of a bath containing water or other suitable liquid heat transfer medium, the whole
of which is thermostatically controlled to a temperature of 80 ± 2 0 C . A device which keeps the specimens
submerged in the bath and prevents the test section being constrained by the apparatus shall be used.

E.3 SPECIMENS
Each specimen shall be a valve and include the finished length of spigot. A circumferential line shall be
marked at 0.5D from both spigot ends and square to the spigot itself.

E.4 PROCEDURE AND REQUIREMENTS

The specimen shall be immersed in the bath for a period of 30 min. After immersion the valve shall be
removed and allowed to cool naturally to 23 ± 2 0 C when the pipe diameters at the marks shall be measured
with a circumferential vernier (Pi tape) placed so that the tape is on the spigot end side of the mark, with the
measuring edge at the marks. The readings shall be measured and rounded to the nearest 0.05 mm on
diameter. The result shall be the average of the readings from each end of the valve.

The spigot end shall be within its specified diameter tolerance (see Table 1).

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 V7: PART 2

APPENDIX F
STRESS CRACK RESISTANCE AT ELEVATED TEMPERATURE
F.1 GENERAL
The test pressure shall be applied to all parts of the valve which may be subjected to line pressure under
normal operation or under fault conditions.

F.2 APPARATUS
The apparatus shall consist of a temperature-controlled water bath or air space maintained at the specified
temperature ± l 0 C and equipment capable of subjecting the specimen to a constant internal water pressure to
an accuracy of ± 2%. An anti-surge valve shall be incorporated into the supply line of the valve under test.

F.3 SPECIMENS
More than one valve may be tested simultaneously providing that the connecting pipe has been validated in
accordance with PL2: Part 1 and that the free length of pipe between valves of any type is not less than three
times the outside diameter of the pipe.

The specimen shall be closed with pressure-tight, end-load bearing end-caps or plugs which shall be provided
with connections for the entry of water and the release of air.

Joint assemblies for testing shall be made up using electrofusion fittings to PL2: Part 4.

F.4 PROCEDURE AND REQUIREMENTS

The specimens shall be conditioned at a temperature of 80 ± l 0 C for a minimum period of 1 h immediately
prior to testing and shall be maintained at that temperature throughout the test.

The specimens shall then be tested as follows:

1) For the phase approval tests, the specimens shall be pressurized to a pressure of 8 bar
± 2% at a steady rate over a period of between 30 s and 40 s. This pressure shall be
maintained for a period of 1000 h without any failure of the valve.
2) For the production tests, the specimens shall be pressurized to pressure of 9.2 bar ± 2%
at a steady rate over a period of between 30 s and 40 s. This pressure shall be maintained
for a period of 170 h without any failure of the valve.

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V7: PART 2

APPENDIX G
LONG TERM STRENGTH AND OPERATION
G.1 GENERAL
The test pressure shall be applied to all parts of the valve which may be subjected to line pressure under
normal operation or under fault conditions.

G.2 APPARATUS
The apparatus shall consist of a temperature-controlled water bath or air space maintained at the specified
temperature ± 1 0 C and equipment capable of subjecting the specimen to a constant internal water pressure to
an accuracy of ± 2%. An anti-surge valve shall be incorporated into the supply line of the valve under test.

G.3 SPECIMENS
Half the specimens shall be tested in the closed position. The remainder shall be tested in the open position.

More than one valve may be tested simultaneously providing that the connecting pipe has been validated in
accordance with PL2: Part 1 and that the free length of pipe between valves of any type is not less than three
times the outside diameter of the pipe with connections for the entry of water and the release of air.

The specimen shall be closed with pressure-tight, end-load bearing end-caps or plugs which shall be provided
with connections for the entry of water and the release of air.

Joint assemblies for testing shall be made up using electrofusion fittings to PL2: Part 4.

G.4 PROCEDURE AND REQUIREMENTS

The specimens shall be maintained at a temperature of 20 ± 1 0 C and shall be pressurized internally to a
pressure of 18 bar ± 2% at a steady rate over a period of between 30 s and 40 s. The pressure shall be
maintained within ± 2% for the period of 10 000 h for Phase 2 approval, 5000 h for Phase 1 approval and
2500 h for restricted use Phase 1 approval.

Within 1 h of being depressurized and removed from the rig, the specimens shall be tested, in the order
specified, as required by:

1) Appendix H - Impact.
2) Appendix O - Strength of stops.
3) Appendix P - Ease of operation.
4) Appendix Q - Leakage to atmosphere.
5) Appendix R - Internal leakage.

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 V7: PART 2

APPENDIX H
IMPACT
H.1 GENERAL
The operating cap shall be struck once at a selected point on the top of the cap.

H.2 APPARATUS
The apparatus shall consist of a controlled environment maintained at the specified temperature ± l 0 C , with a
means of rigidly clamping the valve within the minimum spigot length on both spigot outlets and a means of
allowing the tup to fall freely and strike the valve cap.

H.3 PROCEDURE
The valve shall be conditioned for 2 h at a temperature of -20 0 ± l 0 C . It shall be tested within 30 s of
removal from the environment by allowing a 3 kg, 25 mm diameter, spherical tup to fall freely from a height
of 1 m on to the cap. A single impact shall be made.

H.4 REQUIREMENT
The most critical point on the cap shall be selected and used as the drop point. No part of the specimen shall
be visibly cracked by the impact.

Following the impact test above the specimen shall still meet the phase approval test requirements of
Appendix O - Strength of Stops, and Appendix P - Ease of Operation.

J287 ( Rev 01/98 ) - 17 -

V7: PART 2

APPENDIX I
RESISTANCE TO TENSILE LOAD
I.1 GENERAL
The tensile load shall be applied to a valve and pipe assembly which has a minimum of one pipe diameter
between the coupler and any adaptor which allows the tensile load to be applied.

I.2 APPARATUS
The apparatus shall consist of a tensile testing machine capable of applying a tensile axial load to the valve
under test with suitable fittings to allow application of the load.

I.3 PROCEDURE
The tensile axial load specified in Table I.1 shall be applied to the valve assembly under test at an extension
rate of 25 ± l mm/min, until either a distinct localized reduction to 75% of the diameter of the PE pipe occurs
or 5 min has elapsed, without damage to the valve.

Following the resistance to tensile load test above, the specimen shall still meet the test requirements of
Appendices P, Q and R, ease of operation, leakage to atmosphere and seat leakage all for phase testing.

TABLE I.1 - Tensile load on valves

- 18 - J287 ( Rev 01/98 )

 V7: PART 2

APPENDIX J
RESISTANCE TO BENDING MOMENT APPLIED VIA THE OPERATING CAP
J.1 GENERAL
The valve shall not leak to atmosphere when in the half-open position* when tested in accordance with
Appendix P - Ease of Operation, and whilst the operating cap is subjected to the specified bending moment.
Also, once the moment has been removed the valve shall meet the requirements for Appendix Q - Leakage to
Atmosphere requirements and Appendix R - Internal Leakage. The mechanical failure of any component of
the valve at any stage shall constitute failure of the test.
* Provision shall be made to pressurize any bonnet or body cavity which is not pressurized by the valve being in the half open position. Such
provision shall be temporarily sealed after completion of the test.

J.2 APPARATUS
The apparatus shall consist of a temperature-controlled water bath maintained at the specified temperature of
20 0 C ± l 0 C , equipment which is capable of applying the specified bending moment to the valve stem in the
most demanding plane, and equipment which is capable of subjecting the valve to a constant internal air
pressure to an accuracy of ± 2%. The test fixture shall be designed such that the potential leakage source
shall not be more than 250 mm below the water surface.

J.3 PROCEDURE AND REQUIREMENTS

With the valve in the half-open position*, it shall be pressurized pneumatically to 25 mbar over and above the
hydrostatic head produced by the water. Whilst the pressure is still applied, the operating cap shall be
subjected to a bending moment in excess of 55 Nm for a minimum period of 1 h, during which time the valve
shall not leak to atmosphere.
* Provision shall be made to pressurize any bonnet or body cavity which is not pressurized by the valve being in the half open position. Such
provision shall be temporarily sealed after completion of the test.

With the specimen still pressurized and the bending moment still applied, the valve shall be tested in
accordance with Appendix P - Ease of Operation. During this test the specimen shall not leak to atmosphere.

The bending moment shall then be removed and for 1 h from the removal of the moment, and with the valve
still pressurized, the valve shall not leak to atmosphere.

Subsequently, with the valve fully closed, the 25 mbar pressure leak test in Appendix R - Internal Leakage,
shall be applied for a minimum period of 1 h, during which time the manometer shall not gain more than 5 mm
of water gauge or the valve shall be considered to have failed. The test for internal leakage shall be repeated
on the other end of the valve.

The above test procedure shall then be repeated at the pressures of 8.25 bar for leakage to atmosphere and
5.5 bar for internal leakage.

J287 ( Rev 01/98 ) - 19 -

V7: PART 2

APPENDIX K
RESISTANCE TO BENDING MOMENT APPLIED VIA THE ADJACENT PIPEWORK
K.1 GENERAL
The specimen shall be conditioned by exposure to the specified temperature cycle whilst being subjected to
the bending moments specified. With the bending moments still applied, the valve shall comply with the
requirements for internal and external leakage tests and ease-of-operation test.

K.2 APPARATUS
The apparatus shall consist of a temperature-controlled air space, environmental chamber or alternative
capable of maintaining the specimen at the specified temperature ± 2 0 C , together with a framework capable
of subjecting the specimen to the specified bend radius under a four-point bending load (see Figure K.1). The
equipment shall be capable of subjecting the specimen to an internal air pressure to an accuracy of ± 2%.

FIGURE K.1 - Rig for bending moment test

K.3 PROCEDURE
The specimens shall be fitted to the framework producing the specific constant bend radius of 25 − 1 + 0 D
using a four-point bending load (see Figure K.1). Half of the sample valves shall be fully closed with the
valve spindle in the plane of bending. The rest of the sample shall be fully open and have the valve spindle
perpendicular to the plane of bending. The assembly shall be thermally cycled between 40 0 C and -20 0 C for
50 cycles. The temperature shall be measured within the valve and held at the high and low temperature for a
period of 10 h during each cycle.

- 20 - J287 ( Rev 01/98 )

 V7: PART 2

APPENDIX L
EROSION RESISTANCE
L.1 GENERAL
The valve shall be subjected to erosion by dust-laden air at the velocity specified and for the length of time
specified. Following this part of the test, the valve shall comply with the requirements for ease of operation,
leakage to atmosphere and internal leakage.

L.2 APPARATUS
The apparatus shall consist of a means of injecting dust into the gas upstream of the valve, pressure regulation
and flow control. The 'dust' used shall be fine aggregate (sand) capable of passing through a 600 µm sieve but
not through a 300 µm sieve.

L.3 PROCEDURE
The pressure regulator shall be set to maintain a 150 mbar pressure into the test rig. The flow control valve
shall be set to give a 25 m/s gas velocity in the pipe when the valve is in the fully open position and the dust
injection rate is 10 g/min.

The valve shall be subjected to dust laden gas under the above conditions for a period of 30 min. At the end of
this, the valve shall be left for a period of 24 h in the open position.

After completion of the erosion test, including the 24 h period in the open position, the valve shall be tested
for ease of operation to Appendix P, leakage to atmosphere to Appendix Q and internal leakage to
Appendix R.

The valve shall not be operated prior to subjecting it to the ease of operation tests.

J287 ( Rev 01/98 ) - 21 -

V7: PART 2

APPENDIX M
PRESSURE LOSS
M.1 GENERAL
The valve and its associated joints, including 20 diameters of pipe, shall be subjected to pressure drop tests.

M.2 APPARATUS
A typical layout of the test rig shall be as shown in Figure M.1 with the approximate positions of the pressure
tappings indicated in terms of the diameter of the pipe (e.g. 15D).

The apparatus shall consist of a gas (air, nitrogen, methane or other) source, a pressure regulator (A) to
provide the specified steady pressure, a flowmeter (B) and a length of pipe containing the fitting under test.
The pipe size used in this test shall be that of the size of the fitting under test.

Pressure tapping points upstream and downstream of the fitting under test shall be flush with the pipe bore and
free from burrs.

At the downstream end of the pipe a valve (C) is located for control of the flow rate.

If a diaphragm flow meter is used, a reservoir shall be used downstream of it to reduce variations in gas flow.

The pressure regulator (A) shall be capable of maintaining the specified output pressure ± 1 mbar.

Pressure measurement shall be accurate to within 1 mbar of true value.

Differential pressure measurement equipment shall be selected such that realistic pressure drop measurements
may be obtained (e.g. a pressure drop of approximately 0.1 mbar may be expected through 6 m of 32 mm
PE pipe at a velocity of 1.5 m/s).

Flow measurement shall be accurate to within 2% of true value.

M.3 TEST SPECIMENS

The specimen valve shall comprise a valve assembled with electrofusion couplers and shall be incorporated in
the test rig layout as shown in Figure M.1. For pressure loss calculations, the valve shall be considered to
include all parts to the end of the spigot.

M.4 PROCEDURE
The flow control valve (C) shall be partially opened and then the gas inlet valve opened so that gas flows from
the flow control valve. Using the pressure regulator (A), the line pressure shall be regulated to 25 mbar and
the gas flow rate (B) and differential pressure (G) recorded.

Readings of differential pressure (G) shall be taken for increasing gas flows, evenly spaced between 1.5 m/s
and 7.5 m/s, by opening the flow control valve (C) and re-adjusting the line pressure at the pressure
regulator (A).

The velocity head loss (K m ) shall be calculated for each velocity and an average taken.

The following calculations shall be used to obtain the valve velocity head loss:

V = Q A
where V = velocity in the pipe, in m/s.

Q = measured volume flow rate, in m 3 /s.

- 22 - J287 ( Rev 01/98 )

 V7: PART 2

A = bore area of the pipe, in m 2 .

200∆P
Km =
ρV 2

Where K m = velocity head loss specific to the system at each

velocity

∆P = measured pressure drop at a velocity, in mbar.

ρ = test fluid density, in kg/m 3

∑ Km
KF =
n

where K F = average velocity head loss due to the valve.

M.5 REQUIREMENT
The average velocity head loss (K F ) shall be equal to or less than the maximum figure shown in Table 1.

KEY

A - Pressure regulator
B - Flow meter
C - Flow control valve
E - Reservoir
F - Valve under test
G - Differential manometer

NOTES

1. D is the internal diameter of the pipe.

2. The differential pressure is P 1 minus P 2 .

FIGURE M.1 - Typical pressure loss test rig

J287 ( Rev 01/98 ) - 23 -

V7: PART 2

APPENDIX N
CORROSION RESISTANCE
N.1 GENERAL
Where any part of the valve is made of dissimilar metals or where exposed metal components are used, the
complete valve shall be immersed in a sodium chloride solution as specified. Following this immersion, the
valve shall comply with the requirements for ease of operation, leakage to atmosphere and internal leakage.

Corrosion data may be acceptable to Transco in lieu of this test.

N.2 APPARATUS
The apparatus shall consist of a temperature-controlled bath containing the specified solution at the specified
temperature to ± 1 0 C .

A dry air environment at standard conditions (see clause 8) shall be maintained.

N.3 SPECIMENS
The valve shall have pipe pups each of clear length four times the outside diameter of the pipe. Pressure-tight,
load bearing end connections shall be fitted which shall not unduly restrict the pipe bore or flow of test gas
and shall be capable of accepting a closure which has a pressurization/air release tapping.

The material used for the pipe pups shall conform to PL2: Part 1 and the electrofusion joints between pipe and
valve shall be made using fittings to PL2: Part 4.

N.4 PROCEDURE
The complete valve, fitted with end-caps, shall be immersed in the 3 ± 1% sodium chloride solution bath for
15 months at 50 0 C in such a manner that the solution has access to all external parts of the valve. This
requirement includes those parts which may, for example, be shrouded, though not sealed, by the top cap.
After 1 h the internal pressure due to temperature shall be vented to atmosphere. With the vent open, the valve
shall be operated once to ensure venting of any body cavity. During the venting operation the valve shall
remain immersed in the bath. The valve shall then be left in the closed position.

When the valve is removed from immersion it shall be air dried for two weeks at 20 0 C in dry air.

After being dried, the valve shall be tested for ease of operation to Appendix P, leakage to atmosphere to
Appendix Q and internal leakage to Appendix R.

The valve shall not be operated prior to subjecting it to the ease of operation tests.

- 24 - J287 ( Rev 01/98 )

 V7: PART 2

APPENDIX O
STRENGTH OF STOPS
O.1 GENERAL
The stops that prevent the valve member from rotating past its fully-open or fully-closed position shall resist
the specified rotational torque applied to the operating cap when tested at the specified temperature.

O.2 APPARATUS
The apparatus shall consist of that shown in Figure O.1. The valve and the mounting frame are to be housed in
an environmental chamber maintained to ± l 0 C of the specified temperature as shown. The mounting frame
shall support the valve at each spigot end or electrofusion coupler covering the spigot and at no other point.

FIGURE O.1 - Stop strength test rig

O.3 PROCEDURE
The valve, in the closed position, shall be connected into the apparatus with the external arm in such a
position that it relieves the weight being applied to the torque arm. The weight being applied to the torque arm
shall be such as to develop a torque of 150 Nm applied through the 50 mm square socket to the operating cap.
A temperature of -20 ± 1 0 C shall be maintained for 25 h. The operating arm shall be moved to a position so
that the weights are applied to the torque arm. After 15 s the weights shall be relieved from the torque arm.

The test may be carried out in the environmental chamber but, if removed, shall be completed within 30 s of
removal.

The test shall be repeated at a temperature of 40 0 C

O.4 REQUIREMENT
The stops shall be capable of resisting the torque applied, for the time specified, without failure or damage.

J287 ( Rev 01/98 ) - 25 -

V7: PART 2

APPENDIX P
EASE OF OPERATION
P.1 GENERAL
When measured at the specified temperature, the torque to initiate movement of the closure member (the
initiating torque), in either direction, and the running torque shall meet the values specified.

P.2 APPARATUS
The apparatus shall consist of a temperature-controlled air space, environmental chamber or alternative
capable of maintaining the specified temperature to ± 2 0 C . A hand-operated torque wrench shall be used.

P.3 PROCEDURE
P.3.1 Phase approval
The valve shall be conditioned for 24 h, in the closed position, at a temperature of 40 ± 1 0 C before
commencing the test, and shall remain at that temperature throughout the test.

The test shall commence with the valve still in the closed position and with a supply of air connected to one
side of the closure member to pressurize that side to 5.5 bar. The valve shall then be cycled, with a steady
movement, ten times from closed-to-open-to-closed. The time between each cycle shall not exceed 60 min. At
each operation the torque to initiate movement in both the opening and the closing directions shall be
measured and the running torque shall be monitored continuously in both the opening and closing directions.

The test shall be repeated at a temperature of -20 ± 1 0 C .

P.3.2 Production test

The valve shall be operated at ambient factory temperatures through the full opening and closing cycle.
During this time the operating torque required shall be measured.

P.4 REQUIREMENTS
Neither the torque to initiate movement nor the running torque shall exceed 30 Nm in either the opening or
closing directions. The torque to initiate movement shall not be less than 10 Nm.

- 26 - J287 ( Rev 01/98 )

 V7: PART 2

APPENDIX Q
LEAKAGE TO ATMOSPHERE
Q.1 GENERAL
The valve shall not leak when tested pneumatically under clear water at the specified pressures and times.

Q.2 APPARATUS
The apparatus shall consist of a temperature-controlled water bath maintained at the specified temperature
± 1 0 C and equipment which is capable of subjecting the specimen to a constant internal air pressure to an
accuracy of ± 2%. The test fixture shall be designed such that the potential leakage source shall not be more
than 250 mm below the water surface.

Q.3 SPECIMENS
More than one valve may be tested simultaneously, provided that the connecting pipe has been validated in
accordance with PL2: Part 1 and that the free length of pipe between valves of any type is not less than three
times the outside diameter of the pipe.

The specimen shall be closed with pressure-tight, end-load bearing end-caps or plugs which shall be provided
with connections for the entry of air.

Joint assemblies for approval testing shall be made up using electrofusion fittings to PL2: Part 4.

Q.4 PROCEDURES AND REQUIREMENTS

Q.4.1 Phase approval test
The valve shall be conditioned for 24 h, in the half-open position*, at a temperature of 23 ± 1 0 C before
commencing the test, and shall remain at that temperature throughout the test.
* Provision should be made to pressurize any bonnet or body cavity which is not pressurized by the valve being in the half-open position. Such
provision should be temporarily sealed after completion of the test.

With the valve still in the half-open position, the valve shall be pressurized under clear water to a pressure
of 25 mbar over and above the hydrostatic head produced by the water. This pressure shall be maintained for
24 h. The valve shall then be pressured to 8.25 bar and this pressure maintained for 24 h.

The valve shall be observed for the first hour and the last hour of each test period, during which times there
shall be no leakage.

Q.4.2 Production test

With the valve half-open and at ambient factory temperature, the valve shall be pressurized under clear water
to a pressure of 25 mbar over and above the hydrostatic head produced by the water. This pressure shall be
maintained for 30 s. The valve shall then be pressurized to 8.25 bar and this pressure maintained for 30 s.

There shall be no leakage at any time during this test.

J287 ( Rev 01/98 ) - 27 -

V7: PART 2

APPENDIX R
INTERNAL LEAKAGE (SEAT LEAKAGE)
R.1 GENERAL
The valve shall not leak when tested pneumatically in the fully closed position, at the lower specified pressure
and time and then at the higher specified pressure and time.

R.2 APPARATUS
A temperature-controlled air space maintained at the specified temperature ± 1 0 C and equipment which is
capable of subjecting the specimen to a constant internal air pressure of ± 2% and a 'U' tube manometer.

R.3 PROCEDURE AND REQUIREMENTS

The valves shall be maintained at a temperature of 23 0 ± 1 0 C throughout the phase approval test and at
ambient factory temperatures throughout the production test.

Both ends of the valve shall be sealed with pressure-tight end fittings. If the specimens are fused into a test
configuration, no more than 15 pipe diameters shall be allowed at either end.

Subsequently, a connection between the manometer and the specimen valve shall be made, the link pipe being
no greater than 6 mm diameter and 1 m in length. The manometer side of the specimen shall be pressurized to
50 mm water gauge. The other side of the specimen shall be pressurized to 25 mbar and the system allowed to
condition for 1 h. The manometer shall be readjusted to read 50 mm water gauge if necessary.

Pressures shall then be applied to the non-manometer side as follows:

1) For the phase approval test, the pressure of 25 mbar shall be maintained for 24 h and then
increased to 5.5 bar and maintained for 24 h.
2) For the production test, the pressure of 25 mbar shall be maintained for 30 s and then
increased to 5.5 bar and maintained for 30 s.

After application of the above pressures, the manometer shall not gain more than 5 mm of water gauge,
allowing for correction due to any changes in barometric pressure, or the valve shall be considered to have
failed.

- 28 - J287 ( Rev 01/98 )