Valve Testing
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jobertValve Testing & Inspection: An Overview
Adnan Ilyas
Arctic LNG2- Critical Valve Operability Engineer at NOVA Energies
2 articles Follow
August 22, 2019
Today, more than ever before, testing is extremely important in the valve industry. The
increase in globally sourced products and much-reduced domestic manufacturing has
caused everyone in the valve supply chain to request and require more testing.
In order to effectively test a valve, there first must be an established testing procedure,
combined with the acceptance criteria or performance standards that the valve is
expected to meet or exceed. When it comes to testing standards though, one size does
not fit all. There are different standards for industrial valves, pipeline valves, control
valves and pressure-relief valves. This article provides you with information about the
inspection of valves and valve testing in the manufacturing shop as well as in
operational plants.
Valve Shell Test
Shell Test or Body test is performed after successful completion of valve individual
components e.g. seat, disc, body, stem, etc. inspection, and assembly. The test is
conducted by valve manufacturer or a repair service provider and based on the
requirements of API STD 598 or other relevant standard ( Valve Inspection and Testing).
The valve shall be partially open and be able to hold pressure for a certain time. The
pressure shall not be less than 1.5 times of maximum working pressure. No leakage is
allowed. Leakage check points are body, bonnet, stem, plugs/fittings and flange
connections.
Valve Seat Leak Test
The Seat Leakage (Closure Test) is performed after successful completion of the valve
shell test (Body Test). One side (valve inlet or outlet) shall be subjected to the
hydrostatic pressure and amount of leak shall be measured on the opposite side of the
valve.
It means if you are pressurizing valve inlet, then you have to measure the amount of
leakage in the outlet. The limited amount of leakage is permissible. In the same manner,
you have to test and inspect both sides. Though valves have only one seat or other may
have 4 seats as per their respective types. Test pressures are determined according to
ASME B16.34.
Valve Back Seat Test
The Valve Back Seat Test is performed in the valve with a backseat feature. This is a
feature that allows valve packing being replaced while it is in the service. In this test, the
valve shall be fully opened and packing gland shall be loose or not installed. No leakage
is permissible in the backseat test. Keep in mind that the test pressure for the backseat
is same as the other seat test of the valve.
Pressure Safety Valve Testing
The pressure safety valve is a direct, spring-loaded pressure-relief valve that is opened
by the static pressure upstream of the valve and is characterized by a rapid opening or
pop action.
When the static inlet pressure reaches the set pressure, it will increase the pressure
upstream of the disk and overcome the spring force on the disk. The fluid will then enter
the huddling chamber, providing additional opening force. This will cause the disk to lift
and provide a full opening at minimal overpressure. The closing pressure will be less
than the set pressure and will be reached after the blowdown phase is completed.
Cold Differential Test Pressure (CDTP) Test: In this test, the Safety valve is mounted
on a test rig. Adjust Nozzle ring (raise) to -2 notch position (Gas trim Valve). The
operator applies the pressure (As per valve specification and data sheet) at the inlet of
the valve. A safety relief valve pops or releases pressure when it reaches the desired set
pressure. POP Test (to be repeated a minimum of 3 times to identify consistency). A
reseating pressure shall be noted and recorded. In the industry, for this type of test, the
standard which is widely followed is ASME Sec VIII Div.I. Test passing requirement and
acceptance criteria are described as per the size of the valve.
Seat Test: In the seat test, the operator raises the pressure up to 90% of the CDTP and
observes the leakage at the outlet of the valve for a particular period of time.
Acceptance criteria in bpm or meter cubic feet are described in API-527 standard based
on size and testing medium.
PSV Back Seat Test: Safety Relief Valves which contain a balanced bellow to overcome
the back pressure which is caused by different outlet aspects. For such valves, it is
mandatory to verify bellow integrity. To check the bellow you have to apply approx. 1 to
2 bar pressure at the outlet of the valve and observe leakage from the vent which is
situated in the bonnet. No leakage is allowed.
External body or Shell Test: In the shell test for a conventional safety valve you have to
apply 100 PSIG / 7 Bar at the outlet of the valve and then observe leakage at different
connecting points such as body/bonnet joint, nozzle/body, nozzle ring adjustment lock
and the stem opening on top. But for the body test of a balanced type valve, the same
pressure is to be applied at both outlet and bonnet vent. Leakage observing points are
the same which are mentioned above.
Third-Party Inspection for Valve:
TPI part guides you through all the necessary stages in the production of the valves,
from the examination of certification of procurement sources to the final inspection,
preservation, and packing, to the dispatch to site.
It is particularly suitable for the inspection of Gate, Globe, Ball and Check valves. The
following points are addressed in this article:
Valve Material Inspection
Valve Welding Inspection
Visual and Dimensional Checking
Valve Low Pressure Air Test
Valve Hydrostatic Testing
Post Hydrostatic Testing
Valve Final Inspection
Valve Name Plate Checking
Valve Painting and Coating Checking
Valve Spare Parts, Loose Items and Accessories control
Valve Packing, Marking and Shipping Inspection
Valve testing techniques definitely changing over the years and at the same time test
procedures have become more concise. To improve the performance of a plant, it is
essential for everyone working in this field to ensure that the right techniques with
enough knowledge and mandatory safe work procedures are being followed.
The purpose of this article is to guide Valve Technicians/operators for successful valve
testing and inspection and also to make them familiar with the standards used to
observe such activities.
Note: Photos used in this article are just for illustration.
Thank you,
