Aviation valve inspection – Italy

Supplier must note that stage wise inspection for complete fabrication, testing including the raw
material inspection to be carried out
Material test certificates (physical property, chemical composition, make, heat treatment report, etc.) as
applicable for

6 Inspection and Testing

1. Every valve shall be subjected to all the mandatory tests and checks called in the
respective codes / data sheet.
2. Every valve, its components and auxiliaries, must be subjected to all the mandatory
tests and checks called in the respective codes, data sheets etc. ,by the manufacturer.
3. The extent of third party (TPI) / owner inspection shall be as follows.
4. FORGED VALVES:
a. Visual and dimensional inspection
b. Review of material test certificates
c. Any mandatory or supplementary test review of records.
d. Witness hydrostatic test on 10% valves (or minimum 5 numbers for each size
and spec ) selected on random basis. Review records for balance.
e. Strip check is required for 1% of total ordered quantity of valves (min 1 no.)
for Stainless Steel, Alloy Steel or valves meant for special service (like
Sulphuric acid service) or as mentioned in the individual data sheet.
f. 10% of ordered quantity of gate valves ( minimum 5 nos of each size and
spec ) to be checked for satisfactory operation. Gate opening should be
100%.
5. CAST STEEL VALVES:
a. Visual and dimensional inspection
b. Review of Material test certificates
c. Review of Radiographs / Radiographic reports or any other NDT tests
wherever applicable as per data sheet.
d. Any mandatory or supplementary test - witness/review of records
e. Hydrostatic test-Witness 100% for body, 10% other tests (minimum 5 nos for
each size and spec) . Review records for balance
f. Strip check is required for 1% of total ordered quantity of valves (min 1 no.)
for Stainless Steel, Alloy Steel or valves meant for special service (like
Sulphuric acid service) or as mentioned in the individual data sheet. Samples
for strip check shall be selected at random and shall generally be in the
highest size in the lot.
g. 10% of ordered quantity of gate valves ( minimum 5 nos of each size and
spec ) to be checked for satisfactory operation. Gate opening should be
100%.
6. In case of motor operated or actuator operated valves, functional / operational checks
as per the requirements of the specifications shall be made on each valve.
7. Positive Metal Identification shall be in the scope of the vendor, when applicable.
8. Vendor shall be supplying flame proof / PESO,India approved electrical actuators
along with the valves where ever specified.
9. Valves under critical, very highly critical, lethal and toxic services shall be
radiographed as specified in respective data sheets. When specifically not mentioned
in individual data sheets, valve castings shall undergo radiographic examination as
specified hereunder(irrespective of material of construction)
Standard inspection of gate valves includes the following:
a) Check overall dimensions, including face-to-face dimensions, with the Vendor's
approved drawing, weld ends, size and flange ratings and bolt materials against the
Client's data sheets and approved documentation.
b) Carry out a visual inspection of body, bonnet etc. for imperfections. (Especially
Castings)
c) Check nameplate data against the instrument data sheet and ensure that trim
material is recorded.
d) Witness body pressure tests, shut-off and seat leakage tests - recording results for
each valve for the final inspection report
e) Check seat and gland materials and obtain copies of Mill Test Certificates. Check that
Code Stamp is applied when required by the Purchase Order or Specifications.
f) Witness operation of the actuator after assembly on the valve. (If Applicable)
g) Check and record the actuator power supply rating and ensure that nameplate
details correspond. (If Applicable)
h) Check orientation of actuator operation. (If Applicable)
i) Check that valves are properly tagged with correct tag numbers. Tags should be of
Stainless Steel
j) Cross check heat numbers marked on valve components with relevant certification.

INSPECTION AND TEST PROCEDURES of Ball valves

Bodies
Valve bodies must be inspected as required by applicable Specifications and the Client’s
Purchase Order requirements. Note that for below ground installation, valves may require
coating and wrapping at site. Care must be taken to ensure that welded or cast bodies are
dressed smoothly to accept the wrapping. Any dressing required must be carried out before
pressure testing. Certificates of mechanical test and analysis must be obtained and checked
against Specification for all pressure containing parts and for the ball drive shaft.

Dimensional Check
Check overall dimensions, wall thickness (by Vendor's physical or ultrasonic system) and
welding ends or the flange dimensions and bolt holes.
Check that in fully open position bore the ball matches correctly with the valve body bore.
Note: the required bore through the valve will vary according to the wall thickness of the pipe
into which it will be installed e.g. 36” x 1/2“w.t. = 35” bore:36” x . “wall = 34 .” bore.
Hydrostatic Testing
Valve bodies must by hydrostatically tested to Standards or the Client's Specification (usually
1.5 x design pressure). On some designs this cannot be carried out prior to complete assembly
of the valve.
Operational Tests
When actuator operated valves are specified, the tests should be carried out with the
contract actuator if this is available. The valve should be operated from fully closed to fully
open positions and back to fully closed. This should be carried out:
a) with no pressure applied
b) with both sides at operating pressure
c) with one side only at operating pressure
The Vendor must provide some means of measuring the torque required to operate the
valve in this condition.
Some specifications will require this latter test to be repeated with pressure applied in the
reverse direction. Torque required for operation must be recorded for each test.
Opening and closing times under full load to be as per Specifications and the Client Purchase
Order requirements.
Seat Testing
With the downstream side open for examination the upstream side should be pressurised
and tested for leakage. Again, depending on specification requirements, this test may have to
be repeated in the reverse direction.
Note: Some ball valve designs have provision for a sealing compound to be applied by a
pressure gun to the seal faces. Normally such sealant is only for application in service to help
in overcoming operational damage to seal faces. The Inspector must ensure that no sealant is
applied for works test unless specifically permitted by the Client Specification.
In addition to hydrostatic seat tests, some specifications may call for air pressure leakage
tests.
Care must be taken to ensure that the valve body is completely drained before these tests are
carried out.
Pup Joints
On some orders the vendor may be required to fit short lengths of pipe or "pups" to each side
of the valve. In such cases it is usual for the Client to supply the pipe on a "free issue" basis.
The welds attaching the pups may be to the Standard Pipeline Procedure or may be to a
special procedure due to difference of material specified for pipe and valve body. The welds
must be radiographed to the equivalent Pipeline Standards.
The Inspector should check for correct alignment of pup joints.
If pups are cut to length by the Valve Vendor, the Inspector should ensure that pipe numbers
are re-stencilled on each pup. The report must include a record of pipe numbers and the valve
number to which they are welded.
Valve Extensions
For below ground installation, valves may require extension drive shafts to be fitted. These
may be shipped unassembled to the valve in which case they should be placed in the shop and
match marked for re-assembly at site, if possible. Extensions normally consist of a shaft
within a tube, fitted with a bearing at the top and sometimes also at the bottom. The shaft
must rotate freely in the tube without any sign of rubbing. The length of this extension should
be checked and noted.
Final Inspection
On satisfactory completion of tests, the valve must be completely drained and examined
internally. With the valve in the closed position the visible surfaces of the ball must be
examined for freedom from scoring or scratches. Inside surfaces must be free from loose rust
or other foreign matter and must be coated with a suitable rust preventative. Plugs and/or
blanks must be fitted to any vents or other openings.
If painting is required, the outside surfaces must be thoroughly cleaned and painted as per
Specification. If site coating and wrapping is required the external surface must be free from
all loose, rust, scale etc. and must be cleaned of any oil or grease. Check the Specification to
establish whether keyed locks are required for "locked open/locked closed" positions and
ensure inclusion as necessary.