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PROCEDURE MANUAL

Cast Valve Production

Copyright 2008 SWI Valve Co., Ltd. All rights reserved.

www.swivalve.com

CAST STEEL VALVES


QA/QC PROCEDURE
DOC No. : SWI-QAC-002

SWI Valve Co., Ltd.


3 2 1 0 REV NO. 2007/02/06 2004/11/12 2003/09/19 2002/01/24 DATE REVISED REVISED REVISED ISSUE DESCRIPTION M.J.KO T. M. LEE T. M. LEE T. M. LEE PREPARED Y. P. CHO Y. P. CHO Y. P. CHO Y. P. CHO REVIEWED/ APPROVED

SWI VALVE CO.,LTD.

CAST STEEL VALVES QA/QC PROCEDURE


1.0 SCOPE.

Doc. No. :SWI-QAC-002 Rev. No. : 3 Page : 1 OF 8

This procedure covers inspection and pressure test requirements of cast valves produced by SWI Valve Co. Ltd. (here in after SWI) in accordance with API 598, applicable ASTM, ASME standards and client specification. 2.0 APPLICABLE STANDARDS. The following standards shall be applied. ASME B16.34: STEEL VALVES, FLANGED, THREADED AND WELDING END. ASME B16.5: PIPE FLANGES AND FLANGED FITTINGS. ASME B16.10: FACE TO FACE AND END TO END DIMENSIONS OF FERROUS VALVES. ASME B16.11: FORGED FITTINGS, SOCKET-WELDING AND THREADED. API 600: STEEL GATE VALVES-FLANGED AND BUTT-WELDS ENDS, BOLTED AND PRESSURE SEAL BONNETS. API 6D: SPECIFICATIONS FOR PIPELINE VALVES (GATE, PLUG, BALL AND CHECK VALVES) API 603 CORROSION RESISTANT, BOLTED BONNET GATE VALVES-FLANGED and BUTTWELDING ENDS. API 607: FIRE TEST FOR SOFT-SEATED QUARTER-TURN VALVES. API 598: VALVE INSPECTION AND TEST. BS 5351: VALVES-FLANGED, THREADED, AND WELDING END. MSS SP-55: QUALITY STANDARD FOR STEEL CASTINGS (VISUAL METHOD) ASTM STANDARD SPECIFICATION A216, A217, A352, A488, A703, E165, E709 3.0 MATERIAL INSPECTION. 3.1 Chemical and physical test shall be performed on charge No. and shall meet the Requirement specified in the ASTM specification A216 and other applicable ASTM standards 3.2 Material certificate shall be submitted body, bonnet. 3.3 Material to be used shall be identified as the material in approved drawing, 3.4 The charge number stamped on the material shall be identified as the charge No. referred in Relevant material certificate and the contents of the material certificate shall be in compliance With the applicable material standard/code.

SWI VALVE CO.,LTD.

CAST STEEL VALVES QA/QC PROCEDURE


4.0 ALLOY VERIFICATION (PMI)

Doc. No. :SWI-QAC-002 Rev. No. : 3 Page : 2 OF 8

Alloy Verification of stainless steel shall be performed on final product with PMI equipment at 100% in accordance with PMI Procedure (SW-PMI-01) 5.0 NDE NDE shall be performed at body and bonnet of cast steel valves conform to ASME B 16.34. For Checking casting quality level. Class 150 ~ 600 Class 900 Class 900 Class 1500 ~ 2500 Category 1 VISUAL 100% 6.0 HEAT TREATMENT 6.1 Heat treatment of stainless steel casting shall be done by solution treated at the temperature of 107025oC and carbon steel casting is normalized at 885 ~ 925oC. 6.2 Holding time for the heat treatment at the soaking temperature shall be 1 hour/inch or 1 hour at minimum. 6.3 The temperature in furnace shall be recorded on a automatic recorder and shall meet the requirements stated in paragraph 6.1 and 6.2 above. 7.0 REPAIR WELDING CHECK 7.1 If casting has to be repaired for welding, the welders shall be qualified per ASTM A488. 7.2 Casting repair shall be welded in accordance with the approved WPS 7.3. Welded areas shall be subjected to magnetic particle, dye penetrant or radiographic test. 7.4 Such castings shall be stress relieved and re-inspected per applicable ASTM standard 8.0. VISUAL INSPECTION The following points shall be visually confirmed. RT 0% MT or PT 10% VISUAL 100% RT 10% All Size Sizes up to and including 4 Sizes lager than 4 All Size Category 2 MT or PT 100%

Category 1 Category 2

SWI VALVE CO.,LTD.

CAST STEEL VALVES QA/QC PROCEDURE

Doc. No. :SWI-QAC-002 Rev. No. : 3 Page : 3 OF 8

8.1 External and internal surfaces of castings shall be free from harmful defects, such as, blow holes, fins, sand inclusion, and burning. 8.2 Machined surfaces shall be free from harmful defects such as cutting, machining burrs, blow holes, etc. 8.3 Seat surfaces shall be free from blowholes and other harmful defects. 8.4 Corners and fillets without specified dimensions shall be properly chamfered or rounded. 8.5 Flow path positioned shall be properly finished and cleaned. 9.0 DIMENSION CHECK The Valves shall be given the following dimensional examined and the dimensions shall be within tolerance in accordance with ASME B 16.5, ASME B16.11 and ASME B 16.10. Other dimensions shall be specified in approved drawing. 10.0 MARKING CHECK The marking shall be performed in accordance with MSS SP-25 and/or purchaser specification. 10.1 Casting-out on Body: Manufacturers trade mark. Class, size, material spec., flow direction and charge No. 10.2 Hand wheel and Lever: Letters symbols and arrow head to indicate OPEN and SHUT 10.3 Name Plate, Tag Plate and Material color identification shall be in accordance with purchase specification. 11.0 WELDING OF BELLOWS CHECK 11.1 10% of welding of bellows shall be performed PT (liquid penetrant examination) 11.2 He test shall be done at 10% 12.0 PRESSURE TEST The pressure gauge for inspection shall be used within one year after authorized calibration check. 12.1 The pressure test shall be tested and inspected per API 598 and ASME B 16.34 12.2 Valve type test requirement shall be in accordance with following Table 1, 2

SWI VALVE CO.,LTD.

CAST STEEL VALVES QA/QC PROCEDURE


Table 1. Valve type test requirement. (NPS 4 ASME Class 1500 or NPS> 4 ASME Class 600) Test Description Shell Test Backseat Test Low Pressure Seat Test High Pressure Seat Test N/A: Not applicable Table 2. Valve type test requirement (NPS 4 ASME Class >1500 or NPS> 4 ASME Class > 600) Test Description Shell Test Backseat Test Low Pressure Seat Test High Pressure Seat Test N/A: Not applicable Valve Type Gate Required Required Optional Required Globe Required Required Optional Required Check Required N/A Optional Required Valve Type Gate Required Required Required Optional Globe Required Required Optional Required Check Required N/A Optional Required

Doc. No. :SWI-QAC-002 Rev. No. : 3 Page : 4 OF 8

Ball Required N/A Required Optional

Ball Required N/A Required Optional

12.3 For shell, backseat and high pressure seat test, the test media shall be water. 12.4 Chloride content of water which is used for pressure test shall be less than 30 PPM in case of austenitic stainless steel material. Record of water analysis shall be preserved. 12.5 For low pressure seat test, the test media shall be air. 12.6 The test media temperature shall be not exceed 52. 12.7 Valve test pressure requirement shall be in accordance with following Table 3. 12.8 Valve test duration requirement shall be in accordance with following Table 3. 13.0 PRESSURE TEST PROCEDURE 13.1 Shell Test 13.1.1 The shell test shall be done by applying the pressure inside the assembled valve with the valve ends closed, the valve partially open, and the packing gland sufficiently tight to maintain the test pressure, thereby testing the stuffing box also. The stuffing box shall not leak During the shell test.

SWI VALVE CO.,LTD.

13.1.2 Test pressure and duration to be employed shall conform to Table 3 and Table 4.

CAST STEEL VALVES QA/QC PROCEDURE


Table 3 Test Pressure (API 598 and ASME B 16.34) Class Description Material psig
A216-WCB WCC,LCC,WC6,WC9,C5 CD4MCU, CW6MC CF8,CF8M,CF3,CF3M,CF8C LCB,LC1,WC1 CN7M,CN3MN 285 290 275 265 230

Doc. No. :SWI-QAC-002 Rev. No. : 3 Page : 5 OF 8

150# CWP Shell Kg/cm2


32 32 30 28 25

300# Seat Kg/cm2


23 23 23 21 19.5

CWP psig
740 750 720 695 600

Shell Kg/cm2
79 79 77 74 63.5

Seat Kg/cm2
58 58 56 54 47.5

Class Description Material psig


A216-WCB WCC,LCC,WC6,WC9,C5 CD4MCU, CW6MC CF8,CF8M,CF3,CF3M,CF8C LCB,LC1,WC1 CN7M,CN3MN 1480 1500 275 1390 1200

600# CWP Shell Kg/cm2


156 158 30 147 127

900# Seat Kg/cm2


116 116 23 109 93.5

CWP psig
2220 2250 720 2085 1800

Shell Kg/cm2
236 237 77 221 190

Seat Kg/cm2
172 174 56 162 141

Class Description Material psig


A216-WCB WCC,LCC,WC6,WC9,C5 CD4MCU, CW6MC CF8,CF8M,CF3,CF3M,CF8C LCB,LC1,WC1 CN7M,CN3MN 3705 3750 3600 3470 3000

1500# CWP Shell Kg/cm2


392 395 380 367 316.5

2500# Seat Kg/cm2


288 290 279 269 232.5
O

CWP psig
6170 6250 6000 5785 5000
O

Shell Kg/cm2
652 659 633 612 527.5

Seat Kg/cm2
478 483 464 448 387

CWP : The maximum allowable pressure at 20 F to 100 F(38).

SWI VALVE CO.,LTD.

CAST STEEL VALVES QA/QC PROCEDURE


Table 4 Duration of required Test pressure. (Minimum), unit: sec Valve Size Shell Test Check V/V 60 60 60 120 Other V/V 15 60 120 300 Backseat

Doc. No. :SWI-QAC-002 Rev. No. : 3 Page : 6 OF 8

Seat & Backseat Test Check V/V 60 60 60 120 Other V/V 15 15 120 120

2 and Smaller 2-1/2 to 6 8 to 12 14 and Larger

15 60 60 60

13.2. Backseat Test. 13.2.1 The backseat test for gate, globe valve shall be done by applying the pressure inside the assembled valve with the valve end closed. The valve fully open and the packing gland loose. The backseat test may be made immediately after the shell test. and all packing glands shall be retightened after the backseat test. 13.2.2 Test pressure and duration shown conform to Table 2 and Table 3. 13.3. Seat leakage test. 13.3.1 Low pressure seat test. Test fluid used is as shown in Para 11.5 Low pressure seat test method is as shown below. a.) Apply test pressure to inlet side of closed valve, fill water in outlet side and maintain for duration shown in Table 4 observe any bubbles thru seating surface, seating, or through the wedge. Test shall be carried out in both directions. b.) For the valves having a flow direction specified in the approval drawing, air pressure to be applied from the flow direction. c.) Light oil shall thinly be applied to the body and wedge seating surface after cleaning the surfaces. 13.3.2 High pressure seat test. Test valve shall be pressurized by water to test pressure shown in Table 3. seat leakage shall be checked. The duration of the test shall be per Table 4.

SWI VALVE CO.,LTD.

CAST STEEL VALVES QA/QC PROCEDURE

Doc. No. :SWI-QAC-002 Rev. No. : 3 Page : 7 OF 8

a.) Test shall be done to check if there is any leakage of water, after filling the valve body with water, close the valve, open outlet side, keep the body filled with water. b.) Apply test pressure shown in Table 3 from inlet side and maintain for duration shown in Table 4. c.) Light oil shall thinly be applied to the body and disc seating surface after cleaning the surfaces. 13.4 Acceptable criteria for pressure test. 13.4.1 For shell and backseat tests, no visible leakage is permitted. 13.4.2 For both the low and high pressure seat test shall be in accordance with following Table 5. Table 5. Maximum Allowable Leakage Rates for Closure Tests. All Valve size Resilient Seated V/V 2 and Smaller 2-1/2 to 6 8 to 12 14 and Larger 0 0 0 0 All Metal Seat Valve except Check Liquid Test
(drops per minute)
a

Metal Seat Check Valve Liquid Test c c c c Air Test N.A N.A N.A N.A

Air Test
(bubbles per minute)

0b 12 20 28

0b 24 40 56

a. For the liquid test, 1 milliliter is considered equivalent to 16 drops. b. There shall be no leakage for the minimum specified test duration. (See Table 3). For liquid test, 0 drop means no visible leakage per minimum specified test duration. For air test, 0 bubble means less than 1 bubble per minimum specified duration. c. The maximum permissible leakage rate shall be 0.18 cubic inch (3 cubic centimeters) per minute per inch of nominal pipe size. d. For check valves larger than NPS 24, the allowable leakage rate shall be per agreement between purchaser and manufacturer. 14.0 OPERATION TEST Assembly function inspection shall be carried out on valve as following.

SWI VALVE CO.,LTD.

CAST STEEL VALVES QA/QC PROCEDURE


14.1 Gate Valve.

Doc. No. :SWI-QAC-002 Rev. No. : 3 Page : 8 OF 8

14.1.1 When the valve has been fully closed, the center of seating surface on the wedge shall be located at the upper part of seating surface on the valve body. 14.1.2 When the valve has been fully opened, the bottom of the wedge shall be not intrude into the passage of fluid. 14.2 Globe Valve 14.2.1 Disc and valve seat shall place in position respectively, when the valve has been closed. 14.2.2 Valve lift shall be enough obtained. 14.2.3 The valve shall be opened during differential pressure as per the specification acts upon/from the upper part of the valve disc. 14.3 Ball Valve Stops shall be provided for both the fully open and fully closed positions of valve. Angle of fully open and fully closed positions shall be vertical(90). 15.0 PAINTING. 15.1 Carbon and Low alloy steel 1st : Inorganic Zinc Primer :25um 2nd: Silver Painted. 15.2 Austenitic Stainless steel shall not be applicable. 16.0 TREATMENT AFTER TEST AND INSPECTION. For the valve which has passed tests and inspection, openings of bore shall be protected so as to prevent dust, dirt and other foreign material from entering the valve. The serration of flange shall be protected against damage. 17.0 CERTIFICATES 17.1 Test/Inspection Certificate. a. Pressure Test b. Dimension. 17.2. Material Certificate. a. Chemical Composition. b. Mechanical Requirement. c. Heat treatment etc. c. Operation. d. Visual

SWI VALVE CO.,LTD.

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