WELCOME

Thursday, February 04, 2021

 VALVES

VALVES INSPECTION
AND TESTING
PRESENTED BY
B. RAJASEKAR
TÜV RHEINLAND ( I ) PVT LTD

Thursday, February 04, 2021

 VE S
VAL
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INTRODUCTION

1. Valves are mechanical devices, specifically designed to direct, start, stop, and mix or regulate the flow, pressure and temperature of process fluid.
2. In 1681 the first safety valve was invented by Denis Papin.
3. In 1840 the first valve patent granted in the United States went to James Robinson for his gate valve.
4. In 1846 the globe valve design is developed and patented by Walworth.
5. The first Mercedes car built around 1901 introduced a butterfly valve in the fuel intake linked to the accelerator pedal.

VALVES FUNCTIONS

1. Stopping and starting a fluid flow. Depending on whether a valve is open or closed, it let pass the process fluid or halt the fluid.
2. Throttling the fluid flow. Some of the valves let you throttle the fluid depending open % of total opening. Lesser the opening higher the throttling and otherwise.
3. Controlling the direction of a fluid flow. Multiport valve lets you decide the way fluid will go.
4. Regulating a flow or pressure within the piping system. Some of the automatic control valves maintain the flow and pressure within the system by adjusting opening and closing.
5. Relieve pressure or vacuum from the piping system and equipment. Pressure and vacuum relief valve safeguard the process system from over pressure and during vacuum condition.

Thursday, February 04, 2021

BASIC CONSTRUCTION OF VALVE

 Body

The main pressure containing

structure of the valve and contains
the valves internal part that comes
in contact with the working fluid.

 Bonnet

Provide a leak proof closure for the valve

body.

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 BASIC CONSTRUCTION OF VALVE Contd….

 Seat ring

Provide uniform leak proof tightness.

Usually beveled to allow guiding during
the final stage of closing.

 Disk

Are closure member of the valve rests on

the seat ring, connected to the stem which slide or screwed up or down
to throttle the flow using a handle.

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 BASIC CONSTRUCTION OF VALVE Contd….

 Stem

Connects actuator / handle to the inside of the valve (disc) and transmits the
actuation force. Stems are either smooth for actuator-controlled valves or threaded for
manual valves.

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CLASSIFICATION OF VALVES BASED ON END CONNECTIONS.
Based on the end connection, valve ends can be

1. Screwed or threaded that connects with matching thread on the pipe. Small bore valve used in instruments connection or as a sample point has a threaded end.
2. Majority valve used in piping has a Flanged type ends.
3. Butt welded valves are used in very high pressure and temperature services.
4. Socket welded valves are used in low pressure.
5. Check valve and butterfly valves are available in wafer and lug end construction. These types of ends are used when space is constrained.
 
CLASSIFICATION OF VALVES.

1. Function 4. Design
2. Application 5. Method of control
3. Port type 6. Actuation
 
VALVES CATEGORIZED BY FUNCTION

1. On-off / Isolation valve: Function of blocking the flow or allowing it to pass.

2. On-return valve: Function of allowing flow to travel in one direction only.
3. Throttling / Regulation valve: Function of allowing flow at any point between fully open to fully closed

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 Based on Functions

Isolation Regulation Safety Relief Valve Non Return Special Purpose

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VALVE TYPES

Valves used in the oil and gas industry and for piping applications can be classified in
multiple ways.

VALVES CATEGORIZED BY DISC TYPE

1. Linear motion

I. Gate valve is the most used in piping and pipeline application.

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II. Globe valve is used to throttle (regulate) the fluid flow.

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 III. Check valve is used to avoid backflow in the piping system or the
pipeline that could damage downstream apparatus as pumps,
compressors, etc.

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 IV. Pinch valve is a linear motion valve that can be used for
throttling and shut-off application in piping application that handle solid
materials, slurries and dense fluids.

V. Diaphragm valve

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2. Rotary motion

I. Butterfly valve is a versatile, cost-effective valve to modulate or

open / close the flow of the fluid.

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 II. Ball valve is a quarter turn valve used for shut-off application. The
valve opens and closes the flow of the fluid via a built in ball, which
rotates inside the valve body.

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 Rotary motion Contd…
III. Plug valve is classified as a quarter-turn valve for shut-off
applications.

IV. Eccentric valve

V. Swing check valve

3. Quarter Turn

Device that require approximately a quarter turn motion from 0 to 90° of the stem
to move from fully close to a fully open position or vice versa.

VALVES CATEGORIZED BY DESIGN

1. Piston valve 3. Needle valve

2. Relief & Safety valve 4. Special valve
 
VALVES CATEGORIZED BY APPLICATION

1. General Service valve 3. Special Service valve

2. Severe Service valve
 
VALVES CATEGORIZED BY METHOD AND CONTROL

1. Linear Motion valve 2. Rotary valve

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VALVES CATEGORIZED BY PORT SIZE

1. Full Port valve 2. Reduced Port valve

CLASSIFICATION OF VALVES BASED ON TYPES OF ACTUATORS

1. Manual

The valve is operated manually via levers, wheels and or gears.

2. Automatic

The valve is auctioned via electromechanical devices called actuator, that

may be electric, pneumatic, hydraulic and gas over oil.

Based on Operation

Manual Power Automatic

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INSPECTION
AND
TESTING
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INSPECTION AT THE VALVE MANUFACTURER’S PLANT

The purchaser will specify in the purchase order his intention to inspect valves and
witness tests and examinations at the valve manufacturer’s plant. The purchaser’s inspector
shall have free access to any part of the plant concerned with manufacture of the valves
whenever work on the order is under way.
 
INSPECTION OUTSIDE THE VALVE MANUFACTURER’S PLANT

When the purchaser specifies that the inspection will include shell components
manufactured at locations other than the valve manufacturer’s plant, these components shall
be subject to the purchaser’s inspection at the location where they are manufactured.

EXTENT OF INSPECTION

The extent of inspection may be specified in the purchase order and, unless otherwise
indicated, will be limited to the following

a. Inspection of the valve during assembly to ensure compliance with the

specifications of the purchase order. Inspection may include the use of
specified nondestructive methods.
b. Witnessing of the required and specified optional pressure tests and
examinations.
c. Witnessing of any supplementary examinations.
d. Review of mill records and nondestructive examination records (including
specified radiographs).

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EXAMINATION

I. A visual examination shall be performed by the valve manufacturer of all

castings of bodies, bonnets, covers, and closure elements to assure conformance
with MSS SP-55.
II. The valve manufacturer shall examine each valve to assure compliance
with this standard and the referenced purchase specification (e.g., API Std
599).
III. All examinations shall be performed in accordance with written
procedures that comply with the applicable standards.

TEST EQUIPMENT

If an end-clamping fixture is used, the valve manufacturer shall be able to demonstrate

that the test fixture does not affect the seat sealing capability of the valve being tested. End
clamping is allowed for valves designed to function between mating flanges, such as wafer
check and wafer butterfly valves.

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PRESSURE TESTS

TESTS REQUIRED
TABLE 1-A PRESSURE TESTS

Valves: NPS ≤4 & ASME Class ≤ 1500

NPS >4 & ASME Class ≤ 600
Valve Type
Butterfly &
Test
Trunnion
Description Gate Globe Plug Check Floating Ball
Mounted
Ball
Shell Required Required Required Required Required Required
Backseata Required Required NA NA NA NA
Low
Pressure Required Optionalc Requiredb Optionalc Required Required
Closure
High
Pressure Optionalc,f Requiredc Optionalb,c,f Required Optionalc,f Optionalc,f
Closured
Notes: NA = Not applicable.
a
The backseat test is required for all valves, except for bellows seal valves, that have the
backseat feature.
b
For lubricated plug valves, the high-pressure closure test is mandatory and the low-pressure
closure test is optional.
c
When the purchaser specifies an “optional” test, the test shall be performed in addition to the
required tests. Thursday, February 04, 2021
 TESTS REQUIRED Contd….

d
The high-pressure closure test of resilient-seated valves may degrade subsequent sealing
performance in low-pressure service.
e
For power-operated and manually operated gear actuated globe valves, including non-return
type globe valves, the high-pressure closure test shall be performed at 110% of the design

differential pressure used for sizing of the operator.

f
A high-pressure closure test is required for all valves specified to be double block and bleed
valves.

TABLE 1-B PRESSURE TESTS

Valves: NPS ≤4 & ASME Class > 1500

NPS >4 & ASME Class > 600
Valve Type
Butterfly &
Test
Floating Trunnion
Description Gate Globe Plug Check
Ball Mounted
Ball
Shell Required Required Required Required Required Required
Backseata Required Required NA NA NA NA
Low
Pressure Optionalb Optionalb Optionalb Optionalb Required Optionalb
Closure
High
Pressure Optionalc,f Requiredd Required Required Optionalc,e Required
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Closurec
 TESTS REQUIRED Contd….

Notes: NA = Not applicable.

a
The backseat test is required for all valves, except for bellows seal valves, that have the
backseat feature.
b
When an “optional” test is specified by the purchaser, the test shall be performed in
addition to the required tests.
c
The high-pressure closure test of resilient-seated valves may degrade subsequent sealing
performance in low-pressure service.
d
For power-operated and manually operated gear actuated globe valves, including non-
return type globe valves, the high-pressure closure test shall be performed at 110% of the
design differential pressure used for sizing of the operator.
e
A high-pressure closure test is required for all valves specified to be double block and bleed
valves.

HIGH-PRESSURE PNEUMATIC SHELL TEST

When specified by the purchase order, a high-pressure pneumatic shell test shall be
performed. This test shall be performed after the hydrostatic shell test, using appropriate
safety precautions. The pneumatic shell test pressure shall be 110% of the maximum
allowable pressure at 100°F (38°C) or as specified in the purchase order. Visible leakage is
not allowed.

TEST FLUID

1. For shell, high-pressure backseat, and high-pressure closure tests, the test fluid shall
be air, inert gas, kerosene, water, or a non-corrosive liquid with a viscosity not higher than
that of water. Unless otherwise specified in the purchase requisition, the test fluid
temperature shall be within the range 41°F (5°C) to 122°F (50°C). Thursday, February 04, 2021
2. For the low-pressure closure and low-pressure back-seat tests, the test fluid shall be air
or inert gas.
3. When air or gas is used for closure, shell, or backseat tests, the valve manufacturer
shall be capable of demonstrating the adequacy of the method of leakage detection.
4. Water used for any test may contain water-soluble oil or rust inhibitor. When
specified by the purchaser, a wetting agent shall be included in the water. For testing of
austenitic stainless steel valves, water with chloride content not exceeding 100 parts per
million shall be used. The valve manufacturer shall be able to document the chloride
content.

TEST PRESSURES

TABLE 2 – SHELL TEST PRESSURE

Shell Test Pressure (Min)

Valve Type Class Pounds per Square
Bar
Inch Gauge
150 400 26
Ductile Iron
300 975 66
Cast Iron
NPS 2 -12 125 350 25
NPS 14 – 48 265 19
Cast Iron
NPS 2 – 12 875 61
250
NPS 12 – 24 525 37
Steel
Flanged 150 – 2500 b
Buttweld 150 – 4500 b
Threadeda and Socket weld 800 c
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150 - 4500 b
 TEST PRESSURES Contd….

Notes:
a
ASME B16.34 limits threaded-end valves to Class 2500 and lower.
b
Per ASME B16.34.
c
For Class 800 valves, the shell test pressure shall be 1 1/2 times the pressure rating at
100°F (38°C), rounded off to the next higher increment of 25 pounds per square in. gauge
(or 1 bar) (see Table 2 of API Std 602).

TABLE 3 – OTHER TEST PRESSURES

Test Pressured
Test Pounds per Square Inch
Bar
Gauge
Valves Except Butterfly and Check
High pressure closure and backseata b

Low pressure closure and backseata 60 - 100 4-7

Butterfly Valve
High pressure closure c

Low pressure closure 60 - 100 4-7

Check Valve
High pressure closure
Class 125 (cast iron)
NPS 2 – 12 200 14
NPS 14 – 48 150 11
Class 250 (cast iron)
NPS 2 – 12 500 35
NPS 14 – 24 300 21
Class 150 (ductile iron) 250 17
Class 300 (ductile iron) 640 Thursday, February 04,
442021
Carbon, alloy, stainless steel, and special alloys b
 TEST PRESSURES Contd….

Notes:
a
The backseat test is required for all valves that have this feature.
b
110% of maximum allowable pressure at 100°F (38°C) in accordance with the
applicable purchase specification.
c
110% of design differential pressure at 100°F (38°C) in accordance with the appli-cable
purchase specification.
d
Single values shown are minimum test pressures. A range of values indicates both
minimum and maximum test pressures.

TEST DURATION

For each type of test, the required test pressure shall be maintained for at least the
minimum time specified as below

TABLE 4 - DURATION OF REQUIRED TEST PRESSURE

Minimum Test Duration (Seconds)a
Shell Backseat Closure
Valve Size (NPS) All Valves with
Check Valve Check Valve
Other Valves Backseat Other Valves
(API std 594) (API std 594)
Feature
≤2 60 15 15 60 15
2 1/2 - 6 60 60 60 60 60
8 – 12 60 120 60 60 120
≥14 120 300 60 120 120
Note: a The test duration is the period of inspection after the valve is fully prepared and is under
full pressure. Thursday, February 04, 2021
TEST LEAKAGE

I. Shell, Stem Seals, and Backseat

i. For shell tests, visually detectable leakage through the pressure boundary
walls and any fixed body joint is not permitted.
ii. For backseat tests, visually detectable leakage is not permitted.
iii. For valves with adjustable stem seals, leakage through the stem seals
during the shell test shall not be cause for rejection. However, the
manufacturer shall demonstrate that the stem seals are capable of retaining
pressure at least equal to the 100°F (38°C) valve rating without visible leakage.
iv. For valves with non-adjustable stem seals (o-rings, fixed single rings, and
the like), visually detectable leakage during the shell test is not permitted.
v. Where no visual detectable leakage is permitted, the following definitions
apply:
a) If the test fluid is a liquid, there shall be no visible
evidence of drops or wetting of the external surfaces of the test valve.
b) If the test fluid is air or inert gas, no leakage will be
revealed by the established detection method.
II. For both the low-pressure closure test and the high-pressure closure test, visual
evidence of leakage through the disk, behind the seat rings, or past the shaft seals (of
valves that have this feature) is not permitted and structural damage is not
permitted. The allowable rate for leakage of test fluid at the seat-sealing surface
interface, for the duration of the tests, is listed in Table 5.
III. The allowable leakage rate for closure tests of valves with nonmetallic (e.g.,
ceramic) seat materials shall be equal to that specified in Table 5 for a metal-seated
valve of equivalent size and type.
Thursday, February 04, 2021
 TABLE 5 – MAXIMUM ALLOWABLE LEAKAGE RATES FOR CLOSURE TESTS

All Metal seated Valves Except

Metal seated Check Valves
All Resilient Check
Valve Size
Seated Liquid Testa Gas Test
(NPS)
Valvesb (Drops Per (Bubbles Per Liquid Test Gas Test
Minute) Minute)
≤2 0 0b 0b c d

2 1/2 - 6 0 12 24 c d

8 – 12 0 20 40 c d

≥14 0 e f c d

Notes:
a
For the liquid test, 1 milliliter is considered equivalent to 16 drops.
b
There shall be no leakage for the minimum specified test duration (see Table 4). For liquid
test, 0 drops means no visible leakage per minimum specified test duration. For gas test, 0
bubbles means less than 1 bubble per minimum specified test duration.
c
The maximum permissible leakage rate shall be 0.18 cubic in. (3 cubic centimeters) per
minute per in. of nominal pipe size.
d
The maximum permissible leakage rate shall be 1.5 standard cubic ft (0.042 cubic meter) of
gas per hour per in. of nominal pipe size.
e
For valves greater than or equal to NPS 14, the maximum permissible leakage rate shall be
2 drops per minute per in. NPS.
f
For valves greater than or equal to NPS 14, the maximum permissible leakage rate shall be 4
bubbles per minute per in. NPS.

Thursday, February 04, 2021

PRESSURE TEST PROCEDURES

I. Valves designed to permit emergency or supplemental introduction of an injectable

sealant to the seat area shall be tested with the injection system empty and not in use,
except for lubricated plug valves.
II. When a liquid is used as the test fluid, the valve shall be essentially free from trapped
air during the test.
III. Required protective coatings, such as paint, which may mask surface defects, shall
not be applied to any surface before inspection or pressure testing. (Phosphatizing and
similar chemical conversion processes used to protect valve surfaces are acceptable even if
applied before the tests, provided that they will not seal off porosity.)
IV. When closure testing valves, the valve manufacturer’s test procedure shall ensure
that excessive force is not used to close the valve. The applied force may be determined
from the appropriate, but in any case shall not exceed the values published by the valve
manufacturer.
V. The valve shall be visually examined for leakage after it has been fully prepared and
is under full test pressure.

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BACKSEAT TEST

I. The backseat test is required for all

valves, except for bellows seal
valves, that have the backseat
feature and shall be performed by
applying pressure inside the
assembled valve with the valve
ends closed, the valve fully open,
and the packing gland loose or
packing not installed. If the backseat
test is performed after the shell test,
the packing shall be installed and/or
packing glands re-tightened after the
backseat test. The successful
completion of the backseat test shall
not be construed as a
recommendation by the valve manufacturer
that, while the valve is pressurized, the valve
stuffing box may be repacked or the packing
may be replaced.

II. For valves 4 in. NPS and smaller, the backseat test may be combined with the shell test
when volumetric devices are used to monitor leakage from the shell and back-seat.
When tested by this method, the packing shall be loose. The manufacturer shall be
responsible for demonstrating that the packing will not leak at the valve’s rated pressure
at 100°F (38°C).
Thursday, February 04, 2021
SHELL TEST

The shell test shall be made by applying the pressure inside the assembled valve with
the valve ends closed, the valve partially open, and any packing gland tight enough to
maintain the test pressure, thereby, except for bellows seal valves, testing the stuffing box.

SEAT TEST ( AIR)

Valves shall be subjected to an air seat test at any pressure between 5’5 to 6’9
bar gauge. In case pressure rating is less than 5.5 bar, air seat test pressure, if
specified in purchase order, shall be equal to pressure rating. There shall be no
leakage during the test. Thursday, February 04, 2021
On valves intended for low differential pressure service or vacuum service, a low
pressure air seat test shall be carried out by the manufacturer, if so specified in the
purchase order. The test pressure, then shall be specified by the purchaser and
witnessed by purchaser’s representative, if so desired. The pressure shall be applied as
given below:

a) Globe valve - Under the disc

b) Check valves - This test is not required
c) Gate, plug and ball-valves - Successively to each side of the
closed valves. For Valves designed for flow in one direction only and so marked on
the valve the pressure shall be applied on the upstream side of the valve only.

Thursday, February 04, 2021

 SEAT TEST ( AIR) Contd…

In all cases the valve shall be in the closed position with the side not under
pressure open to atmosphere for detection of leakage.

For valves in double block and bleed application and for valves with independent
double seating, the pressure shall be applied inside the bonnet or body with the
discs closed and both sides open’ for inspection.

Plug and ball-valves shall be operated from filly closed to fully open position
three times to demonstrate satisfactory mechanical operation and continued tightness
after operation. it is permitted to charge sealant before testing on valves relying on
sealing compound to effect seal.

HYDROSTATIC SEAT TEST

The seat test shall be made with seat clean and free of oil. However, if
necessary to prevent galling, the seats may be coated with a film of oil of viscosity
not greater than that of kerosene. This requirement does not apply to a valve in
which a lubricant provides the primary seal. The seat test shall be carried out by
closing the valve in the normal manner.

Valve shall be subjected to hydrostatic seat tests at a gauge pressure not less
than 110 percent (the hydrostatic seat test pressure shall not exceed the body rating
or seat rating whichever is lower) of the rated pressure at 38’C rounded off to the
next higher 1 bar increment, This shall be applied as specified in the seat test (air).
There shall be no visible leakage during the test.

Thursday, February 04, 2021

 HYDROSTATIC SEAT TEST Contd…

For check valves the hydrostatic seat

pressure shall be applied on the down
stream side. In addition to this, check
valves shall also be tested on the down
stream side to 25 percent of the
hydrostatic seat test pressure.

No leakage is permissible during

these tests.

LOW-PRESSURE CLOSURE TEST

 HIGH-PRESSURE CLOSURE TEST
 
SPECIAL TESTS

1. FIRE SAFE TESTS

When required, and specified in the relevant Indian Standard, these
tests shall be carried out to an agreed procedure and requirement between the
manufacturer and the purchaser.

2. ANTISTATIC DEVICE TESTING

When required and specified in the relevant Indian Standard, these

tests shall be carried out to an agreed procedure and requirement between the
manufacturer and the purchaser.
Thursday, February 04, 2021
 TEST GAUGES

The gauges used for pressure testing shall be calibrated at intervals

not exceeding three months by an independent competent authority if the
manufacturer does not have such facilities. The results shall be recorded and shall be
liable to inspection and verification by the purchaser’s representative for acceptance as
and when required.

In all the pressure tests, test pressure shall be measured for the
stated duration without continuous use of-any input to pressure build up by
mechanical or any other means.

REFERENCE STANDARD

1. API 598 – 2004

2. IS 6157 – 1981
3. GOOGLE ASSISTANT

Thursday, February 04, 2021

THANK YOU

Thursday, February 04, 2021