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~ QUALITY CONTROL
PROCEDURE
Date: 1st January 2009
Revision No : 0
Kencana Infrastructure
---. Cover Page
I
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Doc Ref : QCP-12
TABLE OF CONTENTS
2.0 SCOPE 2
3.0 REFERENCES 2
4.0 DEFINITION 2
5.0 PROCEDURES 2 – 13
5.2 5
TEST EQUIPMENT FOR PNEUMATIC & HYDROTEST
7.0 RECORDS 13
APPENDICES
1.0 PURPOSE
2.0 SCOPE
This procedure covers the minimum requirements for valve leak tests to
confirm the pressure – containing capability of the shell of a valve under
pressure and the pressure retaining capability of the valve seat(s) and/or
closure mechanism and describes the details for such tests.
3.0 REFERENCE
4.0 DEFINITION
5.0 PROCEDURE
i) BS 6755 Part 1
Specification for Production Pressure Testing Requirement for
Valves manufactured to BS 5351.
ii) API–6D
Specification for Pipe Line Valves (Gate, Plug, Ball and Check
Valves) for valves manufactured to API SPEC.6D.
Doc Ref : QCP-12
a) Shell Test
b) Hydrostatic Test
c) Air / Pneumatic Seat Test
5.1.2 All leak tests shall be conducted before blasting and painting of
valves.
5.1.5 Leak tests shall be carried out as appropriate for the valve to be
tested e.g. ball, gate, plug, or check valve, considering whether
the valve is a unidirectional or bi-directional type of valve.
5.1.7 The test medium e.g. dry air, treated H2O, etc. shall be free of
dirt, scale and other foreign materials. The Hydrostatic Test
Fluid shall have a chlorine content of less than 200 PPM for
carbon steel valves and less than 50 PPM for stainless steel
valves.
Doc Ref : QCP-12
Valve Tag No :
Inspection Test :
Data of Test :
QC/Client Inspector :
5.1.10 After testing, the valve shall be turned to fully open position
and the valve ends shall be covered with close fitting
protectors to protect the exposed sealing surfaces, machined
parts and prevent ingress of dirt and moisture.
5.1.11 Each valve that fails the test shall be clearly identified with a
Quarantine Tag (Test Failed – waiting for further action) and
stored in a “Quarantine Area” for necessary steps to be taken
to notify the vendor/manufacturer to have the valve
immediately replaced or repaired.
5.1.13 All test finding shall be recorded as per the appropriate check /
test record sheet as given in CSP-T20.
5.2.1 The test facilities shall permit complete isolation of the valves
being tested from the test medium pressure source.
ii) The valve has failed the seat test and is sent for repairs.
vi) For standard flanged end and standard weld end valves,
the test pressure shall be no less than that specified in
Table 5.1 API Spec. 6D
1 2 3
Valve Pressure Min. Test Pressure, psig
Class Shell Hydrostatic Seat Hydrostatic
150 425 300
300 1100 800
400 1450 1060
600 2175 1600
900 3250 2400
1500 5400 4000
2500 9000 6600
vii) For alternate valve, the test pressure shall not less than
1.5 times the 100°F pressure rating as determined in
paragraph 2.2b and 2.2c of API Spec. 6D.
viii) The duration of the shell test shall be no less than that
specified in Table 5.2.
Doc Ref : QCP-12
1 2 3
Valve Size NPS (DN) Shell Test Duration Seat Test Duration
(Minutes) (Minutes)
2 thru 4 (50 thru 100) 2 2
6 thru 10 (150 thru 250) 5 5
12 thru 18 (300 thru 450) 15 5
20 & large (500 & large) 30 5
ii) The hydrostatic shell test pressure shall be 1.5 times the
maximum permissible working pressure at 20°C,
whereas the pneumatic shell test pressure shall be 6 to 7
bars.
v) Apply the test pressure and maintain the pressure for the
period specified in the appropriate valve product
standard. If the valve product standard does not exist,
then the following test duration may be used as a guide :
ii) For alternate valves, the test pressure shall not be less
than 1.1 times the 100°F pressure rating as determined
in accordance with Paragraph 2.2b & 2.2c of API Spec.
6D.
vi) For Double Block and Bleed Valve, the test sequence is
optional, however, both of the following tests shall be
performed :
TABLE 1
viii) Repeat the steps with valve no. V2 closed and the rest in
open position, followed by valve no.V3, valve no. V4 etc.
until all valves are tested.
ix) Reverse the seat test with inlet air hose connected to the
right hand side of the valves assembly.
6.1 During the entire Pneumatic & Hydrostatic testing period, the following
safety precaution should be considered :
6.1.1 A safety relief valve shall be set at pressure 10% higher than
the test pressure and a calibrated pressure gauge shall be
fitted on the pump discharge side.
6.1.3 Barriers with safety sign shall be visible around the test area
during the entire test period.
6.1.4 Safety standards applied during the testing shall meet the
satisfaction of Client Representative prior to carrying out the
test.
7.0 RECORDS
PRESSURE GAUGE
BLEED VALVE
SIDE
PUMP A B
WATER
TANK
ISOLATION
BLANK BLANK
VALVE
FLANGE FLANGE
Notes : -
2) The reverse seat test is conducted by reversing the water inlet to side “B”
3) The valves to be tested in the open position with the exception of the valve
undergoing the seat test.
4) Please refer to figure iv – Valve Seat Leak Test Details for multiple valve
tests.
Doc Ref : QCP-12
Notes : -
2) The reverse seat test is conducted by reversing the air inlet to side “B”.
3) The valves to be tested in the open position with the exception of the valve
undergoing the seat test.
4) Please refer to Figure IV – Valve Seat Leak Test Details for multiple valve
tests.
Doc Ref : QCP-12
TAG NO. TYPE OF VALVE P & ID/SYSTEM TYPE OF LEAK TEST TO BE CONDUCTED
(2) DATE :
TIME :
(3) LOCATION
ALL PREPARATORY WORK FOR THE ABOVE MENTIONED TEST HAVE BEEN/WILL BE COMPLETED PRIOR
TO THE DATE AND TIME INDICATED ABOVE.
ITEM TEST
VALVE TYPE TAG NO. SERIAL NO. P&ID / SYSTEM REMARKS
NO. LOCATION
NAME
SIGNATURE
DATE