SBU-Quality Services

Valves

May 5, 2010
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Inspection of Valves

Valve:
A Valve is a component in a fluid flow or pressure system which regulate either the flow or the pressure of the fluid, by: Stopping or starting the flow Controlling the flow rate Preventing back flow Controlling the pressure Relieving the pressure Flow or pressure regulation is done by adjusting the position of the closure member of the valve. The closure member of the valve is called Disc or Rotor

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Inspection Valves Application:

Valves are used in:

Industrial Military Commercial Residential Transportation applications

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Inspection Valves Types of Valves:

Valves can be categorized into following design types based on the design of the closure member: Gate Globe Ball Check Butterfly Plug Diaphragm Needle

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Inspection Valves

Types of Valves: GATE

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Types of Valves: GLOBE

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Types of Valves: BALL

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Types of Valves: CHECK

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Inspection Valves

Types of Valves: Butterfly

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Inspection Valves Types of Valves: Based on Function

Valves Operating Manually: Starting / Stopping the flow Regulating the Flow Valves Operating Automatically: Controlling the Flow Preventing Back Flow Relieving Pressure

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Inspection Valves

MANUALLY OPERATED VALVES

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Inspection Valves

Parts of Valve:

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Inspection Valves Parts of Valve:

Body / Bonnet: Thickness of the body / bonnet should not be less than minimum specified. Disc/Gate: The movable part of the valve that is positioned in the flow path to modify the rate of flow through the valve Seat: The part of the body which contacts the disc/gate for making a sealing. Seat may be integral to the body of the valve or can be removable. A removable seat is called renewable seat. Advantage of renewable seat is that it can be removed in case of any wear and tear without destroying the body. Meeting the Challenges of Time & Technology

Inspection Valves Parts of Valve:

Backseat: Prevents leakage along the stem Gland packing can be removed without de-pressurizing the system Trim:

Stem, seating surfaces of the body and the disc, internal keys, pins and small internal components that come in contact with the contained fluid. Screws and bushes in contact with the contained fluid are also considered as trim

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Inspection Valves End Connections of Valve:

Flanged Ends Welded Ends Socket Welded Ends (Up to NPS 2) Butt Welding Ends (> NPS 2) Threaded Ends (Up to NPA 2)

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Inspection Valves Valve Manufacturing Standard:

ASME/ANSI 16.34: Steel Valves - Flanged &

Butt welding Ends

ASME/ANSI B16.10:Face-to-Face Dimensions of Ferrous Valves API 600: Steel Valves - Flanged & Butt welding Ends API 602: Compact Steel Gate Valves- Flanged, Threaded, Welding and Extended-Body Ends API 603: Class 150, Cast, Corrosion-Resistant, Flanged- End Gate Valves API 608: Metal Ball Valves-Flanged and Butt-Welding Ends

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Inspection Valves Valve Manufacturing Standard:

API 609: Butterfly Valves, Lug-Type and Wafer API 6D: Specification for Pipeline Valves (Gate, Plug, Ball and Check Valves) MSS SP-55Quality Standard for Steel Castings for Valves, Flanges and Fittings and Other Piping Components API 598Valve Inspection & Testing BS 6755-1:1986:Testing of Valves - Part 1: Specification for Production Pressure Testing Requirements

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Inspection Valves Materials (Sample):

Body/Bonnet: IS 210 (Cast Iron) ASTM A 216 Gr. WCB, WCC (Cast Steel) ASTM A 217 Gr. WC6, WC9 (Cast Steel) ASTM A 352 Gr. LCB, LCC (Cast Steel-Low Temperature Service) ASTM A 351 Gr. CF8, CF8M, CF3, CF3M (Cast-Austenitic Stainless Steel) ASTM A 182 Gr. 304, 304L, 316, 316L (Forged-Austenitic Stainless Steel) Stem: ASTM A 479 Gr. 316, ASTM A 182 Gr.316 Seat/Seat Ring: Contact Surface Stellited Packing: PTFE, Graphite Meeting the Challenges of Time & Technology

Inspection Valves Valve: Size and Rating

Designation: NPS ASME Pressure Classes: 150, 300, 600, 900, 1500, 2500

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Inspection Valves

Inspection & Testing

Material Certification Visual & Dimensional Inspection Pressure Test Calibration (Control Valves) Functional Test (Automatically operated valves) Painting Inspection Final Inspection for Marking/Tagging/Identification Packing and Preparation for Shipment Review of Final Documentation Inspection Release

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Inspection Valves

Inspection & Testing: API-598

Applicable for Non-Metallic Seated, Resilient Seated and metalto-metal seated valves of the Gate, Globe, Plug, Ball, Check, Butterfly types. Applicable Tests: Visual Examination of Casting Shell Test Backseat Test Low Pressure Closure Test High Pressure Closure Test High Pressure Pneumatic Shell Test

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Inspection Valves

Inspection & Testing: API-598

Visual Examination Of Casting: MSS SP 55 Pressure Test: Backseat Test Shell Test High Pressure Closure Test (seat test) Low Pressure Closure Test (Pneumatic) High Pressure Shell Pneumatic Test (Optional)

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Pressure Tests as per API-598:

Valves NPS 4and smaller with pressure rating up to and including ASME Class 1500 and valves larger than NPS 4 having pressure rating up to and including ASME Class 600, shall be tested in accordance with Table 1-A Valves NPS 4and smaller with pressure rating greater than ASME Class 1500 and valves larger than NPS 4 having pressure rating greater than ASME Class 600, shall be tested in accordance with Table 1-B

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Inspection Valves

Pressure Tests as per API-598:

Test Fluid: Shell, backseat, high pressure closure test: Air, inert gas, kerosene, water or a non-corrosive liquid with a viscosity not higher than water. Temperature of test fluid should not exceed 125 Deg. F (52 Deg C) Low pressure closure test: Air or inert gas.

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Inspection Valves

Pressure Tests as per API-598:

Quality of Water: Should contain a water soluble oil or a rust inhibitor For testing austenitic stainless steel valves, the chloride content should not exceed 100 PPM (water analysis report is required)

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Inspection Valves

Pressure Tests as per API-598:

Test Pressure: In line with Table-2 and Table-3 Test Duration: In line with Table-4 Maximum Allowable Leakage for Closure Test: Table-5

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Inspection Valves

Pressure Tests as per API-598:

Leakages: For shell and backseat test, no visible leakage is permitted. If the testing medium is a liquid, there shall be no visible evidence of drops or wetting of the external surfaces. If the test medium is air or gas, no leakage will be revealed by established method of detection.

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Inspection Valves Pressure Tests as per API-598:

Test Procedure-Backseat Test:

Gland Bolts / Nuts Loose

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Inspection Valves

Pressure Tests as per API-598:

Test Procedure-Shell Test:

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Inspection Valves

Pressure Tests as per API-598:

Test Procedure-Shell Test:

Closure member partially open

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Inspection Valves

Pressure Tests as per API-598:

Shell Test: Failure (Example)

Gate,
2 Class 600, ASTM A 352 Gr. LCB

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Inspection Valves

Pressure Tests as per API-598:

Test Procedure-High Pressure Closure Test (Gate):

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Inspection Valves

Pressure Tests as per API-598:

Test Procedure-Low Pressure Closure Test:

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Inspection Valves

Pressure Tests as per API-598:

Post Testing Activities: Valve should be cleaned off the test fluid Any components dismantled for testing should be re-assembled and tightened. Rust preventive should be applied Protection of ends and closing of the openings with end caps to be ensured

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Inspection Valves

Dimensional Inspection:

Reference: Customer approved drawings ASME B 16.10 ASME B16.5/16.47/16.11/1.20.1 ASME B16.25

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Inspection Valves

Dimensional Inspection:

To include but not limited to: Identification of Valve Size and Rating of the Valve Verification of all the parts of the assembled valve with respect to BOM/Part list (Completeness) Verification of Name Plates/Tag for Identification / Marking Verification of Material Grade on different parts Any special requirements of material (like NACE compliance) End to end dimension End Connections
Contd.

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Inspection Valves Dimensional Inspection:

Flanged Ends: OD/Thickness/No. of holes/PCD/ Staggering of Holes with respect to axis of the valve/Flange Facing/Finish RTJ Flanged Ends Socket Welded Ends: Socket dimension (checking by gauge) Bevel Welded Ends: Bevel Edge, Bevel Angle Threaded Ends: Checking of the Threads with GO/NO GO gauges, extent of threading Flow direction marker in case of unidirectional valves Torque to open and close the valve (if required by the specification)

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Inspection Valves

SAFETY RELIEF VALVES

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Inspection Valves

Safety Relief Valves:

Relief Valves are designed to prevent internal fluid pressure from rising above a predetermined maximum pressure in a vessel or a system exposed to emergency or abnormal conditions.
In other words, relief valves provide overpressure protection to a vessel or a system.

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Inspection Valves

Safety Relief Valves:

Safety Valve: An automatic pressure relieving device actuated by the static pressure upstream of the valve and characterized by rapid full opening or pop action. It is used for gas or vapor service. In the petroleum industry it is used also for steam and air Relief Valve: An automatic pressure-relieving device actuated by the static pressure upstream of the valve, and which opens in proportion to the increase in pressure above set pressure. It is used primarily for liquid service.

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Inspection Valves

Safety Relief Valves:

Safety Relief Valve: An automatic pressure-relieving device suitable for use as either a safety or relief valve. It is used in gas or vapor service or for liquid

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Inspection Valves

Safety Relief Valves: Parts

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Inspection Valves

Safety Relief Valves: Parts

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Inspection Valves

Safety Relief Valves: Types

Conventional Type

The set pressure affected by changes in the superimposed backpressure

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Inspection Valves Safety Relief Valves: Types

Balanced Type

Incorporates a bellows having effective area equal to that of the valve seat Eliminates the effect of backpressure on the set pressure of the valve, and which effectively prevents the discharging fluid entering the bonnet space Meeting the Challenges of Time & Technology

Inspection Valves

Safety Relief Valves:

Governing Standard: ASME Sec-VIII, Div.1 API-526: Flanged Steel Pressure Relief Valves API-527: Seat Tightness of Pressure Relief Valves NOTE: The above description is guide lines only and does not cover IBR and any other manufacturing standard

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Inspection Valves

Safety Relief Valves: Materials (Sample)

Base/Bonnet: ASTM A 210 (Cast Iron) ASTM A 216 Gr. WCB, WCC (Cast Steel) ASTM A 217 Gr. WC6, WC9 (Cast Steel) ASTM A 352 Gr. LCB, LCC (Cast Steel-Low Temperature Service) ASTM A 351 Gr. CF8, CF8M, CF3, CF3M (Cast-Austenitic Stainless Steel) ASTM A 182 Gr. 316, 316L (Forged-Austenitic Stainless Steel)

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Inspection Valves

Safety Relief Valves: Materials

Nozzle: ASTM A 479 Gr.316, 316L ASTM A 351 Gr. CF8, CF8M, CF3, CF3M (Cast-Austenitic Stainless Steel) ASTM A 182 Gr. 316, 316L (Forged-Austenitic Stainless Steel)

DISC: ASTM A 565 Gr. 616 ASTM A 479 Gr. 316, 316L All the parts are to verified with respect to approved drawing / data sheet

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Inspection Valves

Safety Relief Valves:

Applicable Tests: Pressure Test (Base and Bonnet) Set Pressure Test Seat Tightness Test Back Pressure Test (Bellow type valves)

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Inspection Valves

Safety Relief Valves:

Test Medium: Hydrostatic Test: Water having a corrosion inhibitor, temperature not exceeding 125 Deg. F. Seat Tightness Test: Air, Steam or Water, the same medium that has been used for determining the set pressure of the valve.

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Inspection Valves

Safety Relief Valves:

Pressure Test: Base, Bonnet and Nozzle (Hydrostatic) Nozzle: Primary Side Base and Bonnet: Secondary Side Test Pressure: For set pressure >50PSI: test pressure=0.9Xset pressure For set pressure < 50 PSI: test pressure=5 PSI(34.5 KPa)

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Inspection Valves

Safety Relief Valves:

Set Pressure Test: The pressure at the inlet of the valve at which the Valve is expected to discharge at the outlet (based on the data sheet) Cold Differential Set Pressure (CDSP): The pressure at which the valve is to be tested, taking the service temperature into account. Temperature correction factor is to be applied for calculating the CDSP.

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Inspection Valves

Safety Relief Valves:

Set Pressure Test: Gas Service

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Inspection Valves

Safety Relief Valves:

Set Pressure Test: Liquid Service

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Inspection Valves

Safety Relief Valves:

Seat Leakage Test:

90% of set pressure for metallic seat 95% of set pressure for resilient seat

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Inspection Valves

Safety Relief Valves:

Back Pressure Test:

Applicable for Balanced Valves (below type) Test Pressure: Super Imposed Back Pressure

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Inspection Valves

Safety Relief Valves:

Visual & Dimensional Inspection:

Identification of the valve Size & Rating at Inlet and outlet Material of parts of valve Accessories per Data Sheet Name plate marking

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Inspection Valves

CONTROL VALVES

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Inspection Valves

Control Valve:

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Inspection Valves

Control Valve:

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Inspection Valves

Control Valve:

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Inspection Valves

Control Valve: Components

Body Bonnet Disc Stem Yoke Actuator Positioner Limit Switches Solenoid Valves Air Filter Regulator Quick Exhaust Valve Volume Boosters

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Inspection Valves Control Valve:

Flow Coefficient (Cv): No. of US Gallons per minute of 60 Deg. F water that will flow through a valve with one pound per square inch pressure drop.

(A constant, Cv, related to the geometry of a valve, for a given travel, that can be used to establish flow capacity)

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Inspection Valves Control Valve: Inspection & Tests

Visual Inspection: Verification of, assemblies / components as per drawing Name Plate Accessories, Sr. No. & Make, with respect to data sheet Flow Direction Marker Scale for stroke length Materials, heat No. etc. Fasteners for specific application

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Inspection Valves

Control Valve: Inspection & Tests

Pressure Test: Shell Test Seat Leakage Test (based on leakage class) Packing Leakage Test Actuator Leakage Test (pneumatic) Pneumatic Test of Tubing Calibration Functional check for Valve Failure Mode

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Inspection Valves

Control Valve: Calibration

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Inspection Valves

Control Valve: Calibration

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Inspection Valves

Control Valve:

Valve Failure Mode: Open Closed Locked in the Last Position

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Inspection Valves

POSITIVE MATERIAL IDENTIFICATION (PMI)

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Inspection of Valves Positive Material Identification (PMI):

Intended for identification of:

Pressure-retaining alloy material components, flange bolting, welds, weld overlays and cladding.
It is intended to ensure that the nominal composition of the alloy components and associated welds have been correctly supplied and installed as specified

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Inspection of Valves Positive Material Identification (PMI):

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Inspection of Valves Positive Material Identification (PMI):

Programme Covers: Alloy materials Shop and field-fabricated pressure-retaining components (base metal, welds and cladding) Materials used for repair or replacement of pressureretaining components

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Inspection of Valves Positive Material Identification (PMI):

Coverage in Valves: Body Bonnet/Base Trim Materials Nozzle (Safety Relief Valve)

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Inspection of Valves Positive Material Identification (PMI):

Equipment:

X-ray Fluorescence type-Unable to detect carbon content Optical Emission Spectrometer-can detect carbon content

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Inspection of Valves Positive Material Identification (PMI):

Operator Qualification:

Operator should be qualified to operate the PMI test equipment.

Equipment Calibration: Should be done before testing Calibration should be done with standard calibration alloy sample, representative of the base material/weld being tested.

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Inspection of Valves Positive Material Identification (PMI):

Elements to be verified

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Inspection of Valves Preparation for shipment:

Marking / Labeling Colour Coding Tagging Packing End Protection

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Inspection of Valves Preparation for shipment:

Marking & Labeling Meeting the Challenges of Time & Technology

Inspection of Valves Preparation for shipment:

Colour Coding & Flanged End Protection Meeting the Challenges of Time & Technology

Inspection of Valves Preparation for shipment:

Packing under Progress Meeting the Challenges of Time & Technology

Inspection of Valves Preparation for shipment:

Packing under Progress Meeting the Challenges of Time & Technology

Inspection of Valves Preparation for shipment:

Valves Packed Meeting the Challenges of Time & Technology

Inspection of Valves

Review of Final Documentation & Issue of Inspection Release

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Inspection of Valves

Finally :

VISUAL INSPECTION IS BEST FORM OF INSPECTION

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Inspection of Valves

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