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IDENTIFICATION AND CLEANING OF VALVE:
Before taking up testing the valves are identified and their size, type, pressure rating are
verified with respect to valve drawing. Depending on the pressure rating of the valve the test
pressure is obtained from Manufacture drawing or ASME standards.
THEN THE FOLLOWING STEPS ARE TAKEN.
Clean the Valve internally and externally – manually and using compressed air.
Use calibrated pressure gauges having measuring range within 20% ‐ 80% of the pressure
gauge full scale reading.
Valve test will be performed in the presence of Client representative/Third party
Inspector.
Valve will be brought to test facility; the test facility shall be barricaded with suitable
safety sign board reading “Danger ‐ Pressure Test in Progress Keep Off”.
Persons associated with Valve pressure testing should be wearing appropriate Personnel
Protective Equipment’s.
All the connecting hoses, fittings and adaptors used for making test connections should
be visually examined to ensure their integrity and it should be ensured their pressure
rating is suitable for the highest test pressure that is going to be applied.
The test medium for hydro test shall be DM/Potable water with rust inhibitor according
to the service requirement of the valves and client’s specification requirement.
SEAT LEAK TEST:
Valve testing will be carried out by bolting the test flange on both sides of the valve.
Flange bolt tightening torque requirements shall be as per vendor requirements.
After fixing the blind flange, valve will be kept in horizontal position.
Fix a calibrated pressure gauge on pressurizing side of the flange.
Close the valve and apply the test pressure on upstream side of the valve and measure
the seat leakage from downstream side of the valve or drain / vent point.
For low pressure seat test, test medium is ambient air @ 6.0 Bar.
For hydro static seat test, keep the valve in half open condition.
Fill the test fluid in the valve from downstream flange side for avoid the air entrap.
Test fluid shall be water containing corrosion inhibiter and surface tension depressant
and fluid shall contain less than 30 PPM Chloride.
Test fluid temperature shall not exceed 30ºC and below lower than 10ºC.
Close the valve and apply the seat test pressure (Rated pressure) for the valve from
downstream side of the flange and upstream side keep to atmospheric pressure.
For Ball Valve valves repeat the above stems on other side also.
Valve seat test holding time and acceptance as per manufacturer Testing standard
mentioned in manufacturer drawing.
SHELL TEST:
The valves are subjected to pressure with the valve in the half open position.
Gradually increase the pressure up to 50% of test pressure, then pressure is raised in
increment of 1/10th of test pressure, till the required test pressure is reached.
Test pressure shall be maintained for the specified time and the examination for any
leak is carried out.
Test pressure should be rated pressure at ambient temperature.
Test holding time as per manufacturer Testing standard mentioned in manufacturer
drawing.
No leak is permitted in shell test.
After the completion of the examination, the test pressure is reduced to atmospheric
pressure.
Draining of water is done onto a tray kept underneath the Valve and the collected water
is transferred to the designated tank.
The valve is removed from the bench & dried with hot air (maximum 40o C).
TEST COMPLETION:
After the completion of test, the acceptance tag is applied on the tested valve.
The pressure test report is prepared by the Quality Control Engineer and subsequently signed
by Client / TPI Representative.