Valve Testing QUALITY PROCEDURE阀门测试质量程序

QUALITY PROCEDURE VALVE TESTING
CONTENTS
1.0 SCOPE
2.0 PURPOSE
3.0 DEFINITION
4.0 RESPONSIBILITIES
5.0 REFERENCES
6.0 TESTING PROCEDURE
7.0 QUALITY CONTROL
8.0 APPENDIX 1
9.0 APPENDIX 2
10.0 APPENDIX 3
11.0 APPENDIX 4
12.0APPENDIX 5
13.0APPENDIX 6
1.0 SCOPE
The procedure applies to the inspection and testing of valve testing.
2.0 PURPOSE
The Quality Procedure has been developed in order to highlight the main
works of operation a nd performance in accordance with the Quality Control
activities during doing valve testing.
3.0 DEFINITIONS
None
4.0 RESPONSIBILITIES
Construction Manager shall be responsible for the overall implementation of the Work Procedure, coordination with the Planning and Scheduling Department, to ensure efficient execution of works in accordance with the project relative specification, requirement and procedure.
Project Engineers or Site Engineers shall be responsible for the efficient use of resources to execute the works in accordance with the construction drawings and project specification.
The Quality Control Department shall be responsible for compiling various technique documents and quality procedure, conducting surveillance and inspection duties at the various stages of works, efficient recording and reporting of the results as required.
The Quality Manager shall receive all requests for inspection form from various Project Engineers or Site Engineers and inform the TR Representative, as and when their presence is required to witness the inspections.
The Piping Quality Control Inspector shall accompany the TR Representative to carry out routine inspections and release hold points by signing and obtaining TR Representative approval signatures on the various quality records as proof of an inspection conforming to specifications. The Piping Quality Control Inspector shall coordinate with other discipline Quality Control Inspectors for ensuring that all other discipline activities that require inspection within the piping construction works have been inspected and approved.
The Operators shall be responsible for carrying out valve testing according to required procedure.
5.0 REFERENCES
API598-1996
API602-1993
ASME B16.34a-1998
6.0 TESTING PROCEDURE
6.1 Testing range and rate
Hydrostatic test for all valves before installation will be required only for valves bigger than 2”.Performing only for 10% of valves bigger than 2”
and smaller than 4” is required.100% of valve testing for items bigger than
4” shall be required.
The testing shall involve the shell test and closure test.
6.2 Preparation work
A. To prepare special area for valve testing.
B. To prepare special equipment for all kinds of valve testing.
C. To prepare pressure gauges for test, the accuracy level of the
pressure gauges should not be less then 1.5 grade and the gauges
should not be out of calibration deadline.
D. To prepare testing medium, in this testing, potable water will be
used as medium for general valves; the demin-water (the content of
chloride no more than 30ppm) will be used as medium for austenitic
stainless steel valves. The temperature of inspection medium shall
not exceed 52℃
E. To prepare the tag material or tools for qualified and unqualified
valves.
6.3 Valves shell testing
A. Testing method
Close the entry and exit of valves, and keep the valves in on
position, filling the valves with medium, discharge the air inside the
valves from high point, then increase the pressure to testing
pressure gradually (check valves shell be pressurized from the
entry).
B. Valves shell test pressure (minimum)(See APPENDIX 1)
C. Pressure sustaining time (minimum)(see APPENDIX 2)
D. Approval standard
In pressure sustaining time, outside surface of valve shell shall not
have drip and dampness phenomena. Valve body, valve lining,
connection of valve body and valve cover shall not have leakage.
Accepted by TR’s inspection department as pressure un-drop and
un-leakage, then sign the approval tag.
6.4 Valve closure test
A. The valve closure test includes upper closure test, high pressure
closure test and low pressure closure test. The valve closure test
shall be carried out immediately after valve shell test approved.
B. The choice of test
a. When nominal diameter is bigger than 2” and smaller than 4”,
nominal pressure is less than or equal to 25Mpa(1500LB), and
nominal diameter is more than 4”, nominal pressure is less than
or equal to 10Mpa (600LB), shall choose ways according to
APPENDIX 3.
b. When nominal diameter is bigger than 2”and smaller than 4”,
nominal pressure is more than 25Mpa(1500LB), and nominal
diameter is more than 4”, nominal pressure is more than 10Mpa
(600LB), shall choose ways according to APPENDIX 4.
C. Test method
a. The method of upper sealing test: block valve outlet and inlet,
loosen the stuffing box; open valve and close upper seal; fill
interior with test medium, and discharge the air inside from
high point; increase pressure to test pressure gradually. After
reaching pressure required, then sustaining required time.
b. The method of high pressure closure test: install the valve on
the test-bed, close one side of inspected seals and filling it
with test medium; increase the pressure to testing pressure
gradually.
The medium’s importing and the direction of pressurization
shall meet the following requirements:
●The valve with medium flowing direction (i.e. check
valve), which shall be filled the medium and pressurized
according to the medium flowing direction.
●The valve without medium flowing direction (i.e. gate
valve, ball valve etc.), which shall be filled the medium
and pressurized from the each end side.
●The valve with two seals, which shall be filled the
medium and pressurized between two seals.
c. Method of low pressure closure test shall be same as the high
pressure closure test.
D. Closure test pressure (minimum)(see APPENDIX 5)
E. Pressure sustaining time (minimum) (see APPENDIX 2)
F. Approval standard
When the closure test pressure reaching the pressure required and
pressure sustaining time reaching the time required, visually inspect
the leakage of seal surface. If no leakage, the test shall be
approved. Max allowable leakage of metal seat (see APPENDIX 6) 6.5 The marking of valve accepted
After the valve test, it shall be marked with marker. Write “OK” in valve body with red oily waterproof pen and hang a eligible tag for approval valve; Write “×”in valve body with red oily waterproof pen for unapproved valve.
6.6 Disposal method of unapproved valve
As 10% inspection rate, nominal diameter and grade, the inspection rate shall be increased to 20%; as 100% inspection rate, unapproved valve shall return to TR’s warehouse and inform relative personnel.
6.7 The management after the valve passing testing
A. After the valve passing testing, clean up the interior and close the
inlet and outlet.
B. After the valve passing testing, store the valves according to spec,
type, and materials. All valves shall be separated with rubber and
wooden board.
C. If inspection eligible valve is left unused over half year, shall be
rechecked before use.
D. Register and return to the warehouse in time for approval valves.
E. For unapproved valves, it shall be return to TR’s warehouse and
inform TR’s inspector.
6.8 Report and record
After testing, for approval and unapproved valve, the inspector shall fill the test information in table. The test result shall be confirmed by TR’s quality inspector.
7.0 QUALITY CONTROL
7.1 The testing medium shall be in accordance with use requirement,
especially for austenitic stainless steel valves, the content of chloride is
no more than 30ppm. Generally, the gas medium shall be used a little
because there are hazards involved when gas is used as the fluid for
testing. Appropriate precautions are required when a gas is used.
7.2 Strictly implement test procedure and choose correct test way.
7.3 Ensure that test pressure and sustaining time meet requirement.
7.4 The tested valve shall be avoided to damage, especially, seal surface
and flange surface.
7.5 For approval and unapproved valve, shall be marked, recorded and
dividually stored.
8.0 APPENDIX 1
Note:
①As per ASME B16.34
②It shall be not less than1.5 times of rating pressure at 38℃, rounded off to the
next higher increment of 25 pounds per square inch gauge (see Table 2 of API
Standard 602)
9.0 APPENDIX 2
10.0 APPENDIX 3
Note:
①Have upper closure test for all valves except bellows sealed valve with upper seal
features.
②After high pressure test of elastic valve, use high pressure will reduce the seal up
when in low pressure conditions.
③For motor operation of globe valve, high pressure closure test shall be carried out
according to 1.1 times differential pressure designed when confirm the motor
specifications of motor operated valve.
④For lubricating plug valve, high pressure closure test is compelling while low
pressure closure test is optional.
⑤If buyer agrees, it can be used low pressure closure test for instead of high
pressure closure test.
11.0 APPENDIX 4
Note:
①Have upper closure test for all valves except bellows sealed valve with upper seal
features.
②After high pressure test of elastic valve, use high pressure will reduce the seal up
when in low pressure conditions.
③For motor operation of globe valve, high pressure closure test shall be carried out
according to 1.1 times differential pressure designed when confirm the motor
specifications of motor operated valve.
④If buyer agrees, it can be used low pressure closure test for instead of high
pressure closure test.
12.0 APPENDIX 5
Note:
①the test pressure is 1.1 times of design differential pressure at 38℃.
②the test pressure is 1.1 times of maximum allowable pressure at 38℃.
13.0 APPENDIX 6
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