AL-KHAFJI JOINT OPERATIONS

APPD.
CERT.
CHKD.

Vendor’s Name : HAWA VALVES (INDIA) PVT. LTD.

COMPANY Name : Al-Khafji Joint Operations
DESCRIPTION

Purchaser Name : JGC Gulf International Co. Ltd

Plant Location : Al-Khafji
Project Name : Global Gas & NGL Recovery and Handling Project
Purchase Order No. : G-K092-0-P-216B-137-A10
Equipment/Material Name :
Document Title : HYDROSTATIC AND/OR PNEUMATIC TEST PROCEDURES
Vendor’s Document No. : M3131-HV-QC-PRO-04
HQ824PC09
JO/EWO

GLOBAL GAS & NGL RECOVERY AND HANDLING PROJECT

BY

JGC GULF REVIEW STATUS

ISSUE PURPOSE TO JGC GULF : FI X FA FC AB
DATE

RESULT CODE : A XB C D E
NEXT STATUS : FI FA X FC AB NA
NO.

REVISIONS
RESUBMISSION DATE : 17-FEB-2018 KJO comments
DRAWN:
RESPONSIBLE DEPT./PERSON: QCL / NB are awaited
BY: and will be
DATE: REVIEW DATE: 11-FEB-2018 informed later
CHKD BY:
COMPANY REVIEW STATUS
OPR’G DEPT
ISSUE PURPOSE TO COMPANY : FI FA FC AB
BY:

DATE: RESULT CODE : A B C D E

ENG. DEPT REVIEW DATE:

BY: A: Approved without Comment; B: Approved with Minor comment C: Revise & Resubmit ;
D: Not Approved ; E: No Subject to Review
DATE:
Approval or review hereunder shall not be construed to relieve Supplier / Subcontractor of his
APPD. FOR CONSTR.
responsibilities and liability under the Contract.
BY:
JGC GULF JOB No.: G-K092-00-0000
DATE:
ORIG. PURCHASE ORDER NO. SERIAL REV. TOTAL SHEETS
JGC GULF DOC. NO.:
CERTIFIED V-216B-137-A10-704 A 24
BY:

DATE: Code B
NOTE : THIS PRINT IS
Please see the comments in the next pages.
OF A CONFIDENTIAL
NATURE AND IS THE CRS to be included in the next revision. Please see the
PROPERTY OF JGC
GULF
INTERNATIONAL CO.
comments in the next
LTD. AND SHALL NOT
BE TRACED. pages
PHOTOGRAPHED,
PHOTOSTATED OR
REPRODUCED IN ANY
MANNER,NOR USED
FOR ANY PURPOSE
WHATSOEVER
EXCEPT BY WRITTEN
PERMISSION OF JGC.

JGC Gulf Doc No: V-216B-142-A10-704

 Hawa Doc. No.

M3131-HV-QC-PRO-04-02

PROCEDURE FOR PRESSURE TESTING OF

BALL VALVES TO ASME B16.34

Global Gas & NGL recovery

END USER/CLIENT : KJO and Handling Project
PROJECT NAME : KJO GGNGLRPH
PROJECT No. : -

CLIENT DOC No. : -

SCOPE OF SUPPLY : BALL VALVES

CONTRACTOR : -
CONTRACT No. : -

CUSTOMER : JGC GULF INTERNATIONAL CO. LTD.

P. O. No. : K-092-0-P-216B-137-A10

PRINCIPAL MANUFACTURER : HAWA VALVES (INDIA) PVT. LTD.

HAWA REF No. : M3131

0 19.01.2018 Issued for Approval from Client AF MKP NG

Rev Date Description Prepared Checked Approved

ADDRESS:
hawa valves (india) pvt. ltd.
Office: R-16, TTC Industrial Area, Rabale, Off Thane Belapur Road, Navi Mumbai – 400 701
Tel: +91-22-67760000(200 lines) Fax:+91-22-67760100 +91-22-2760 2472
Email: info@hawavalves.com; document.control@hawavalves.com

THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION. ALL RIGHTS (INCLUDING COPYRIGHT, CONFIDENTIAL INFORMATION, TRADE SECRETS AND
DESIGN RIGHTS) ARE OWNED BY HAWA VALVES (INDIA) PRIVATE LIMITED. NO USE OR DISCLOSURE SHALL BE MADE WITHOUT THE WRITTEN PERMISSION OF
HAWA VALVES (INDIA) PRIVATE LIMITED.

Page 1 of 7
 Rev
HAWA DOC. NO.
PROCEDURE FOR PRESSURE TESTING OF BALL No.

VALVES ACCORDANCE TO ASME B16.34 M3131-HV-QC-PRO-04-02 0

CONTENTS

SL NO DESCRIPTION

1 PURPOSE……………………………………………………………………………………………………… Provide
the
2 REFERENCES………………………………………………………………………………………………..
page
3 SCOPE…………………………………………………………………………………………………………… nos.
4 SURFACE PROTECTION.. …………………………………………………………………………….
5 PERSONNEL QUALIFICATION………………………………………………………………………
6 CALIBRATION……………………………………………………………………………………………….
7 TEST VALVE………………………………………………………………………………………………….
8 TEST FLUID………………………………………………………………………………………………….
9 TEST EQUIPMENT…………………………………………………………………………………………
10 TEST TEMPERATURE…………………………………………………………………………………….
11 TEST PRESSURE……………………………………………………………………………………………
12 TEST DURATION…………………………………………………………………………………………..
13 PRESSURE TESTING………..………………………………………………………………………….
14 RETESTING....…………………………………………………………………………………………….
15 POST TESTING ACTIVITIES ……………………………………………………………………….
16 HSE FOR INSPECTION AND TESTING………………………………………………………..
17 QUALITY RECORDS.…………………………………………………………………………………….

Page 2 of 7
 Rev
HAWA DOC. NO.
PROCEDURE FOR PRESSURE TESTING OF BALL No.

VALVES ACCORDANCE TO ASME B16.34 M3131-HV-QC-PRO-04-02 0

1. PURPOSE:
Pressure testing is carried out at ambient temperature on assembled ball valves to check integrity of pressure
containing parts and seal ability of joints and seats.
This procedure shall be applied for testing of ball valve as per ASME B16.34 and 04-SAMSS-048.

2. REFERENCES:
2.1 ASME B 16.34: 2017.
2.2 API 598: 10th Edition.
2.3 04-SAMSS-048: Valve Inspection and Testing Requirements-1 March 2016.
2.4 04-SAMSS-035: General Requirements for Valves -27 March 2017.
2.5 Approved GA Drawing.
2.6 Inspection & Test Plan.
2.7 Datasheets & Client Specification.
2.8 S.A. Form-175-043600 - 10/31/2016

3. SCOPE:
This procedure specifies general methods and acceptability criteria for (Hydrostatic) pressure testing of ball valves in
accordance to standard ASME B16.34.

Note: Customer specific ITP and where available Procedure shall be followed for all the Optional & supplementary
testing requirement.
All testing and witness points in the approved ITP shall be strictly followed.

4. SURFACE PROTECTION

Before the shell test, valves shall not be externally painted or otherwise coated with materials capable of sealing
against leakage from external surfaces of the shell. However, valves with internal liners, internal linings or internal
coatings that form a design feature of the valve may be tested with the liner, lining or coating in place. In the event a
purchaser specifies a retest of the shell test of valves that have been painted, retesting may be without removal of
external paint or coatings.

Pressure testing shall be carried out before external coating of the valve. If the valve(s) has been previously tested in
accordance with this specification, subsequent repeat hydrostatic and pneumatic testing may be performed without
removal of the valve external coating.

5. PERSONNEL QUALIFICATION:
The testing operators must have minimum 2 years experience in valve pressure testing. The testing supervisor/
Engineers must have diploma or degree in Engineering and minimum 2 years experience. All above persons must have
undergone hawa HSE training.

6. CALIBRATION:
The pressure gauges are identified, controlled and calibrated every three months. Accuracy of gauges shall be within
± 2% of the full scale reading, calibration stickers shall be available on gauges during the FAT to verify the calibration
status.

7. TEST VALVE:
The test valve shall be clean, free of oil and grease and pressure containing parts in unpainted condition. The test
valve shall be visually inspected and unique valve serial number provided for identification to be noted.

8. TEST FLUID:
The test fluid for hydrostatic shell and seat test shall be water (with chloride content 30ppm maximum) mixed with
corrosion / rust inhibitor. The test fluid for pneumatic seat test shall be clean and dry industrial air.
The test fluid temperature shall not exceed 50ºC (125ºF).

Page 3 of 7
 Rev
HAWA DOC. NO.
PROCEDURE FOR PRESSURE TESTING OF BALL No.

VALVES ACCORDANCE TO ASME B16.34 M3131-HV-QC-PRO-04-02 0

9. TEST EQUIPMENT:
Ball valves shall be tested using the clamping test bed which will not exert any external force on valves. Only when
specified on order or when the valve size or end connections limit the use of test beds the blind flanges will be used
for testing. Only trained personnel shall perform pressure testing.

10. TEST TEMPERATURE:

The test temperature & temperature of test fluid shall be ambient.

11. TEST PRESSURES:

11.1 Pressure Rating:
 The pressure rating shall be in accordance with the applicable rating table for appropriate material group in
ASME B16.34.
 Pressure rating for valves made from materials not covered by ASME B16.34 shall be determined from the
material properties in accordance with applicable design standard
11.2 Generally the test pressures are specified on approved drawings or valve data sheets.
11.3 The Hydrostatic test pressures for shell and seat shall be as per ASME B16.34 (Clause 7.1.1 & 7.2.1) as applicable
for relevant material grade.
 The hydrostatic shell pressure shall be 1.5 times of the rated test pressure.
 The hydrostatic seat test pressure shall be 1.1 times of the rated test pressure.
11.4 Valve Closure test :
 For ball valves, a low pressure gas seat test shall be executed in accordance with cl.7.2 of ASME B16.34.
 The gas closure test at gage pressure not less than 5.5 bars (80 psi).

12. TEST DURATION:

Test duration for shell test and Seat test shall be as per below table 1.

SHELL TEST DURATION SEAT TEST DURATION

VALVE SIZE DURATION SEC. VALVE SIZE DURATION SEC.
NPS≤2 15 NPS ≤ 2 15
2½ ≤ NPS ≤ 6 60 2½ ≤ NPS ≤ 8 30
8 ≤ NPS ≤ 12 120 10 ≤ NPS ≤ 18 60
14 ≤ NPS 300 20 ≤ NPS 120

The minimum test duration commences after the test pressure has stabilized.

60 ..? 04-SAMSS-48, para 5.1.1.

Page 4 of 7
 Rev
HAWA DOC. NO.
PROCEDURE FOR PRESSURE TESTING OF BALL No.

VALVES ACCORDANCE TO ASME B16.34 M3131-HV-QC-PRO-04-02 0

13. PRESSURE TESTING PROCEDURE

Note: - When a valve is ordered together with an actuator, the valve/actuator assembly shall be tested together as a
unit. As part of functional testing, the valve shall be opened under the maximum differential pressure that the actuator
has been rated for. The Hawa shall take necessary steps to ensure that the valve is not damaged during this functional
test. (04-SAMSS-048, CL.5.4)

13.1 HYDROSTATIC SHELL TEST:

Note: (As per 04-SAMSS-048, Cl.5.1.1)
For all CAST STEEL VALVES NPS 2 and below, the shell hydrostatic test shall be maintained for one minute. For
larger sizes, valve shall be subjected to cyclic hydrostatic shell test for two cycles as follow:
 Primary pressure-holding period;
 Reduction of the pressure to zero;
 Secondary pressure-holding period.
For the first cycle “Primary Period” the shell test pressure shall be maintained for a minimum of five
minutes or as required by the applicable industry standard, whichever is greater. For the second cycle
“Secondary Period” shell test pressure shall be maintained for a minimum of 15 minutes.
(Reference: 04-SAMS-048, Cl.5.1.1)

13.1.1 The test valve shall be mounted on the test bed and both ends blanked/closed off.
13.1.2 Operate the test valve to partially open position.
13.1.3 Fill all cavities of the test valve with test fluid (water).
13.1.4 Apply the specified test pressure successively and hold it for the minimum test duration as
specified in above table 1.
13.1.5 Visually examine the entire surface of the shell for leakage. If provided, visually check all
extension lines of drain, vent, sealant and any drain/vent valves.
13.1.6 Depressurize the test valve.
13.1.7 ACCEPTANCE CRITERIA:
Visually detectable leakage through the pressure boundary is not acceptable. The pressure
boundary includes, along with the body, bonnet, or cover, all gasketed joints; however, leakage
through the stem seals or stem packing shall not be cause for rejection. Stem seals or stem
packing exempted from the shell test pressure leakage requirement shall be capable of retaining
pressure up to the 38°C (100°F) pressure rating without visible leakage.

13.2 SEAT TEST.

13.2..1 HYDROSTATIC SEAT TEST:
13.2..1.1 Operate the test valve to fully closed position.
13.2..1.2 Fill the test valve with test fluid (water).
13.2..1.3 Apply the specified test pressure successively to one side and hold it for the minimum
test duration as specified above.
13.2..1.4 The seat leakage shall be monitored for each seat via the valve body cavity vent or drain
connection, where provided. For valves without a body cavity vent or drain connection,
seat leakage shall be monitored from the respective downstream end of the valve.
13.2..1.5 Repeat the test for the other side of the test valve.
13.2..1.6 Depressurize the test valve.
13.2..1.7 ACCEPTANCE CRITERIA: -
13.2..1.8 Acceptance criteria for closure test shall be as per API 598 table 5.

13.2..2 LOW PRESSURE CLOSURE PNEUMATIC SEAT TEST:

Valves specified for flare system isolation service, regardless of size, shall receive low pressure
pneumatic seat tests at 5 psig. (04-SAMSS-048, CL.5.1.3).

Page 5 of 7
 Rev
HAWA DOC. NO.
PROCEDURE FOR PRESSURE TESTING OF BALL No.

VALVES ACCORDANCE TO ASME B16.34 M3131-HV-QC-PRO-04-02 0

14 RETESTING:
14.1 Handling and Quarantine Of valves :
14.1.1 The valve that fails the pressure test shall be identified as non conforming product.
14.1.2 The valve shall be identified for traceability, using color coded tags to distinguish from conforming
product.
14.1.3 The valve shall be shifted to non conforming area for repair/rejection.
14.2 Shell Test Failure:
14.2.1 If there is a leak from body/shell, the material shall be rejected.
14.2.2 If there is body joint/ gasket leak, the failure shall be investigated and corrected and the valves shall be
retested in accordance with above procedure.
14.3 Seat Test Failure:
14.3.1 If the valve fails in seat test, the failure shall be investigated and corrected. Follow the same procedure
as above for any retesting of valve, after correcting unacceptable leakages.

15 POST TESTING ACTIVITIES:

After completion of testing drain the test fluid immediately, the valves should be blown through using dry
compressed air, followed by a visual inspection for dryness. If moisture is still found, the above process shall be
repeated until visually dry. Lubricate and provide the end protectors.
Note : It is important to ensure that the stainless steel valves are thoroughly dried.

16 HSE FOR INSPECTION & TESTING:

16.1 All relevant requirements of the Health, Safety & Environment (HSE) Procedure Manual shall be followed, in
particular the requirements for Valve Pressure Test.
16.2 Follow testing procedures and Instruction.
16.3 Do not stand very close to test valve while pressurizing and de-pressurizing.
16.4 Do not observe test duration more than as specified in the approved documents and standards.
16.5 Do not try operating any equipment in testing area unless asked to do so.
16.6 Do not use mobile phones in testing area.
16.7 Do not operate the valves or drain unless told to do so.
16.8 Always wear safety goggles while observing pressure testing.
16.9 Safety helmet shall be worn while observing high pressure gas testing.
16.10 High pressure gas testing shall be monitored from behind the safety wall.
16.11 Stay out of restricted area.
16.12 No smoking in office and shop floor area.
16.13 Report all injuries or problem immediately to safety officer, no matter how minor they are.

Page 6 of 7
 Rev
HAWA DOC. NO.
PROCEDURE FOR PRESSURE TESTING OF BALL No.

VALVES ACCORDANCE TO ASME B16.34 M3131-HV-QC-PRO-04-02 0

17 QUALITY RECORDS: Sample Pressure test reports format are enclosed below (DPTR and Daily Test Report sample
Format).
The test report shall include following information as minimum:
 Date of test
 Place at which the test is carried out
 Valve type & description
 Size & class of tested valve
 Reference standard
 hawa reference no
 Instrument detail & Calibration
 Test fluid
 Test temperature
 Test pressure
 Duration for test
 Acceptance criteria
 Signature of QA person carryout test
 Signature of client /TPI witnessing the test
 Observation
 Results

Page 7 of 7
 DIMENSION AND PRESSURE TEST REPORT
HV/QA/05 - REV 5 Effective From Dt. 17.02.2017

VALVE TYPE: CLIENT:

DPTR NO.: DATE:
END USER:

SIZE: P.O No.: DATE: SHEET NO.:

CLASS: W.O. No.: DATE:

QTY: DRG No.:

END CONNECTION : MFG & TEST STD :

PROJECT: _ CLIENT SPEC :

VALVE DIMENSIONAL DETAILS (in mm) PRESSURE TEST

HEAT NOS. BORE PRESSURE DURATION

GEAR BOX FACE TO FACE FLANGE O.D. FLANGE THK P.C.D NO. OF HOLES HOLE DIA RTJ/RF FACE R.T.J DEPTH R.T.J WIDTH TEST DETAILS
SR. MODEL NO./ (B) (BARG) (Seconds)
VALVE SR. NO. TAG NUMBER
NO. ACTUATOR SR.
NO.

E
BODY STEM COVER HYDROSTATIC SHELL

HYDROSTATIC SEAT

BACK SEAT

PL
PNUMATIC SEAT

HYDROSTATIC DBB

GAS SHELL

HYDROSTATIC SHELL

HYDROSTATIC SEAT

M
OPEARTION OPEN / CLOSE
FUNCTIONAL TEST (5 CYCLES) : FOUND
SATISFACTORY

REMARKS:VISUAL INSPECTION FOUND SATISFACTORY. VALVES

TESTED : NO VISIBLE LEAKAGE OBSERVED. ALL VALVES ARE
THOROUGHLY DRAINED, CLEANED AND DRIED AFTER TESTING.

PART MATERIAL MTC NO.

SA
INSTRUMENT CALIBRATION STATUS
BODY
STEM
COBVER THE CALIBRATION OF THE INSTRUMENT ARE WITHIN THE VALIDITY
FASTNERS

QA/QC ENGR.: TPI: SR. ENGINEER QA:

 HV/QA/08 – REV 6
DAILY TESTING REPORT
PRESSURE TEST (BAR)g

ANTISTATIC TEST
CLEANLINESS OF

REQD 10 Ω Min /
VALVE SR. NO.

DIMENSIONAL

Max
SEAT

SEAT AREA

VISUAL &
CYCLIC TEST

CHECK
HYDRO PNEUMATIC BACK
SHELL
DATE W.O NO. DESCRIPTION Down Down SEAT
Primary Secondary Upstream Upstream
stream stream

E
PL
M
SA

Page 1 of 2
 HV/QA/08 – REV 6
DAILY TESTING REPORT
AND BLEED TEST
DOUBLE BLOCK

AFTER TESTING
TORQUE TEST RESULTS

RETIGHTENING
TESTING OF

DRANING &
FUNCTION

VALVES

DRYING
JOINTS
REWORK
Both side

REJECT
REMARKS
Side A

Side B

ACC
BTO

BTO

BTO

ETC

E
PL
M
SA

INSPECTED BY QC ENGINEER NAME:- DESIGNATION:- SIGN:- DATE:-

Note:- This is an indicative format; actual format shall be as per QMS.

Page 2 of 2
 Hawa Doc. No.

M3131-HV-QC-PRO-04

PROCEDURE FOR PRESSURE TESTING OF

BALL VALVES TO API 6D

END USER : KJO

PROJECT NAME : KJO GGNGLRPH
PROJECT No. : -

CLIENT DOC No. : -

SCOPE OF SUPPLY : BALL VALVES

CONTRACTOR :
PO NO :

CUSTOMER : JGC GULF INTERNATIONAL CO. LTD.

P. O. No. : K-092-0-P-216B-137-A10

PRINCIPAL MANUFACTURER : HAWA VALVES (INDIA) PVT. LTD

HAWA REF No. : M3131

0 19.01.2018 Issued for approval from client AF MKP NG

ADDRESS:
Hawa valves (india) pvt. ltd.
Office: R-16, TTC Industrial Area, Rabale, Off Thane Belapur Road, Navi Mumbai – 400 701
Tel: +91-22-67760000(200 lines) Fax:+91-22-67760100 +91-22-2760 2472
Email: info@hawavalves.com; document.control@hawavalves.com

THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION. ALL RIGHTS (INCLUDING COPYRIGHT, CONFIDENTIAL INFORMATION, TRADE SECRETS AND DESIGN
RIGHTS) ARE OWNED BY HAWA VALVES (INDIA) PRIVATE LIMITED. NO USE OR DISCLOSURE SHALL BE MADE WITHOUT THE WRITTEN PERMISSION OF HAWA
VALVES (INDIA) PRIVATE LIMITED.
 Rev
PROCEDURE FOR PRESSURE TESTING OF HAWA DOC NO No.

BALL VALVES TO API 6D M3131-HV-QC-PRO-04 0

CONTENTS

1 PURPOSE ....………………………………………………………………………………………………………………...

2 REFERENCE ………………………………………………………………………………………………………………….

3 SCOPE ………………………………………………………………………………………………………………………….

4 SURFACE PROTECTION ……………………………………………………………………………………………….

5 PERSONNEL QUALIFICATION………………………………………………………………………………………

6 PRESSURE-MEASURING DEVICES……………………………………………………………………………

7 TEST VALVE …………………………………………………………………………………………………………………

8 TEST FLUID ………………………………………………………………………………………………………………….

9 TEST EQUIPMENT ………………………………………………………………………………………………………..

10 TEST TEMPERATURE …………………………………………………………………………………………………….

11 CHART RECORDER ……………………………………………………………………………………………………….

12 VALVE DRAINING ………………………………………………………………………………………………………….

13 VALVE PRESSURE TESTING …………………………………………………………………………………………….

14 PRESSURE /TEMPERATURE RATING……………………………………………………………………………….

15 TEST DURATION…………………………………………………………………………………………………………….

16 PRESSURE TESTING REUIREMENT…………………………………………………………………………………

17 POST TESTING ACTIVITIES ………………………………………………………………………………………………

18 RETESTING……………………………………………………………………………………………………………………….

19 HSE FOR INSPECTION & TESTING ………………………………………………………………………………

20 QUALITY REPORTS ………………………………………………………………………………………………………

21 TERMS AND DEFINATION …………………………………………………………………………………………..

22 DOCUMENTATION ……………………………………………………………………………………………………..

Page 2 of 10
 Rev
PROCEDURE FOR PRESSURE TESTING OF HAWA DOC NO No.

BALL VALVES TO API 6D M3131-HV-QC-PRO-04 0

1. Purpose:
Pressure testing is carried out at ambient temperature on assembled Valves to check integrity of pressure containing
parts and seal ability of joints and seats.
th
This procedure shall be applied for testing of valves as per API 6D: 24 edition and 04-SAMSS-048.
2. References:
th
2.1. API6D: 24 Edition.
2.2. ISO 5208:2015 edition.
2.3. ASME B 16.34:2013.
th
2.4. API 598 10 edition.
2.5. Approved GA Drawing.
2.6. Inspection & Test Plan.
2.7. Datasheets & Client Specification.
2.8. 04-SAMSS-035: General Requirements for Valves -27 March 2017.
2.9. 04-SAMSS-048: Valve Inspection and Testing Requirements-1 March 2016.

3. Scope:
This procedure specifies general methods and acceptability criteria for (Hydrostatic & Pneumatic) pressure testing of
Ball Valves in accordance to standard API 6D.
If specified by purchaser in the purchase order, Customer Specific ITP or where available in procedure valve shall be
tested as per QSL levels specified in annex J of API 6D and supplementary requirement specified in the Annex H of
API 6D
Note: Customer specific ITP and where available Procedure shall be followed for all the Optional & supplementary
testing requirement.
All testing and witness points in the approved ITP shall be strictly followed,
4. Surface Protection:
4.1. Before the shell test, valves shall not be externally painted or otherwise coated with materials capable of sealing
against leakage from external surfaces of the shell. However, valves with internal liners, internal linings or
internal coatings that form a design feature of the valve may be tested with the liner, lining or coating in place.
In the event a purchaser specifies a retest of the shell test of valves that have been painted, retesting may be
without removal of external paint or coatings.

Pressure testing shall be carried out before external coating of the valve. If the valve(s) has been previously
tested in accordance with this specification, subsequent repeat hydrostatic and pneumatic testing may be
performed without removal of the valve external coating.

5. PERSONNEL QUALIFICATION:
The testing operators must have minimum 2 years experience in valve pressure testing. The testing
supervisor/Engineers must have diploma or degree in Engineering and minimum 2 years experience. All above
persons must have undergone hawa HSE training.
6. Pressure-measuring Devices
6.1. TYPE AND ACCURACY
Test pressure-measuring devices shall be accurate to at least ± 2 % of full-scale range. If pressure gauges are
used in lieu of pressure transducers, they shall be selected such that the test pressure is indicated within 20%
and 80% of the full-scale value.

Page 3 of 10
 Rev
PROCEDURE FOR PRESSURE TESTING OF HAWA DOC NO No.

BALL VALVES TO API 6D M3131-HV-QC-PRO-04 0

6.2. CALIBRATION PROCEDURE

Pressure-measuring devices shall be periodically calibrated with a master pressure-measuring device or a
deadweight tester to at least three equidistant points of full scale (excluding zero and full scale as required
points of calibration).
6.3. CALIBRATION INTERVALS
The pressure gauges are identified, controlled and calibrated every three months. Calibration stickers shall be
available on gauges and calibration certificate during the FAT to verify the calibration status.
Calibration intervals shall be established for calibrations based on repeatability and degree of usage. Intervals
may be lengthened and shall be shortened based on recorded calibration history. Calibration intervals shall be a
maximum of three months until recorded calibration history can be established by the manufacturer and new
longer intervals (three months maximum increment) established.
7. Test Valve:
The test valve shall be in the final assembled condition and shall be clean, free of oil and grease and pressure
containing parts in unpainted condition. The test valve shall be visually inspected and unique valve serial number
provided for identification to be noted.

8. Test fluid:
Test fluid shall be fresh water and shall contain a corrosion inhibitor. Based on the end location of the valve, the test
fluid shall have, antifreeze (glycol) added unless otherwise agreed. The water temperature shall not be greater than
100 °F (38 °C) during the testing period.

The chloride content of test water in contact with austenitic and duplex stainless steel wetted components of valves
shall not exceed 30 μg/g (30 ppm by mass). The chloride content in the test water shall be tested at least annually.
The test fluid for high-pressure gas test performed using inert gas as the test medium. If the valve-body connections
are not available for direct monitoring, methods for monitoring pressures and/or leakage shall be determined by
other methods.
The test fluid temperature shall not exceed 50ºC (125ºF).

9. Test Equipment:
Valves shall be tested using the clamping test bed which will not exert any external force on valves. Only when
specified on order or when the valve size or end connections limit the use of test beds the blind flanges will be used
for testing. Only trained personnel shall perform pressure testing.
10. Test Temperature:
The test temperature & temperature of test fluid shall be ambient.
11. Chart Recorder:
Chart recorder shall be used for testing of valves to QSL-2, QSL-3 & QSL-4 or where specified by the Customer.
Chart recorder are identified, controlled and calibrated at an interval not greater than 12 months.
Copy of chart recorder used on pressure test shall be maintained.
12. Valve Draining:
Upon completion of tests, valves shall be drained of test fluids, dried, and where applicable, lubricated before
shipment.

Page 4 of 10
 Rev
PROCEDURE FOR PRESSURE TESTING OF HAWA DOC NO No.

BALL VALVES TO API 6D M3131-HV-QC-PRO-04 0

13. Valve pressures Testing:

13.1. The hydrostatic and gas test pressure and test duration shall be as per below table 1.
TABLE 1: TEST FLUID, TEST PRESSURE AND TEST DURATION.
TEST FLUID TEST Valve Type TEST PRESSURE TEST DURATION
The shell test shall be
Shell carried out at a pressure
BALL 1,5 times the pressure Table 2
(API 6D CL.9.3) corresponding to the
High pressure valve 38 °C pressure rating
Hydrostatic test
(Test Fluid The test pressure for all
Water) seat test shall be at 1,1
Seat
BALL times the rated pressure Table 3
(API 6D CL.9.4) at 38 °C (100 °F).

14. Pressure/ Temperature Rating:

14.1. Valves covered by this specification shall be furnished in one of the following pressure classes:
Class 150, Class 300, Class 400, Class 600, Class 900, Class 1500, or Class 2500.
14.1.1. Pressure-temperature ratings for class-rated valves shall be in accordance with the applicable rating
table for the appropriate material group in ASME B16.34.
Pressure-temperature ratings for Class 400 valves shall be in accordance with the applicable rating table
for the appropriate material group in ASME B16.5.
14.1.2. Pressure rating for valves made from materials not covered by ASME B16.34 shall be determined from
the material properties in accordance with applicable design standard
14.2. The test pressures are specified on approved drawings.
15. Test Duration:

TABLE 2: MINIMUM DURATION OF HYDROSTATIC SHELL TEST

Valve Size Test Duration
NPS DN (min)
≤4 ≤100 2
6 to 10 150 to 250 5
12 to 18 300 to 450 15
20 and larger 500 and larger 30

TABLE 3: MINIMUM DURATION OF SEAT TEST

Valve Size Test Duration
NPS DN (min)
≤4 ≤100 2
6 to 18 150 to 450 5
20 and larger 500 and larger 10

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16. Pressure Testing Procedure

Note: - When a valve is ordered together with an actuator, the valve/actuator assembly shall be tested together as a
unit. As part of functional testing, the valve shall be opened under the maximum differential pressure that the
actuator has been rated for. The Hawa shall take necessary steps to ensure that the valve is not damaged during this
functional test. (04-SAMSS-048, CL.5.4 ).

16.1. Hydrostatic Shell Test: (CL. 9.3. of API 6D)

16.1.1. The test valve shall be mounted on the test bed and both ends blanked/closed off.
16.1.2. Operate the test valve to partially open position.
16.1.3. Fill all cavities of the test valve with test fluid (water).
16.1.4. Apply the specified shell test pressure and hold it for the minimum test duration as specified above
(table 2).
16.1.5. Visually examine the entire surface of the shell for leakage. If provided, visually check all extension lines
of drain, vent, sealant and any drain/vent valves.
16.1.6. If provided, visually check all bypass lines and any drain/vent valves.
16.1.7. Depressurize the test valve.
16.1.8. Acceptance Criteria: No visible leakage is permitted during the hydrostatic shell test.
16.1.9. Testing of Drain, Vent, and Sealant Injection Lines
If provided as part of the final assembly, drain, vent, and sealant injection lines shall be subject to a
hydrostatic test with the valve in accordance with (CL. 9.3. of API 6D)
If testing with the fully assembled valve is not practical, these lines shall be tested separately at the test
pressure in (CL. 9.3. of API 6D). The final assembly connection is subjected to the hydrostatic test in API
6D CL. 9.3 unless otherwise agreed.
The test pressure for sealant injection lines shall be by agreement.
Note: (As per 04-SAMSS-048, Cl.5.1.1)
For all CAST STEEL VALVES NPS 2 and below, the shell hydrostatic test shall be maintained for one
minute. For larger sizes, valve shall be subjected to cyclic hydrostatic shell test for two cycles as
follow:
 Primary pressure-holding period;
 Reduction of the pressure to zero;
 Secondary pressure-holding period.
 For the first cycle “Primary Period” the shell test pressure shall be maintained for a minimum of
five minutes or as required by the applicable industry standard, whichever is greater. For the
second cycle “Secondary Period” shell test pressure shall be maintained for a minimum of 15
minutes.

16.2. Hydrostatic Seat Test: (CL. 9.4. of API 6D)

16.2.1. Operate the test valve to fully closed position.
16.2.2. Fill the test valve with test fluid (water).
16.2.3. Apply the specified seat test pressure to one side and hold it for the minimum test duration as specified
above (table 3).
16.2.4. For Valves, the seat leakage shall be monitored for each seat via the valve body cavity vent or drain
connection, (very important).
16.2.5. For valves without a body-cavity vent or drain connection, seat leakage shall be monitored from the
respective downstream end of the valve.

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16.2.6. Depressurize the test valve.

16.2.7. For Bi-directional valves repeat the test for the other side of the test valve.
16.2.8. Acceptance Criteria: Leakage for soft-seated valves shall not exceed ISO 5208; Rate A (no visible
detectable leakage for the duration of the test at test pressure).
For metal-seated valves, the liquid leakage rate shall not exceed ISO 5208, Rate D.
Seat leakage shall be monitored from each seat via the valve body cavity vent or drain connection.
Leakage detected as originating from behind seat rings or around resilient closure materials shall be
cause for rejection.
Note: Supply pressure shall be isolated from the valve being tested and shall be stabilized prior to the
start of pressure testing duration. The pressure measuring device shall be installed in the test apparatus
in such a manner that the device continuously monitors/records the test pressure of the valve
assembly. The pressure tests shall be held for the minimum test durations listed in Table 2 or Table 3
after stabilization as determined by the manufacturer.

16.3. Seat Test Procedures for Block Valves (CL.9.4.4 of API 6D): (If Applicable)
16.3.1. Unidirectional
With the valve half-open, the valve and its cavity shall be completely filled with test fluid. The valve shall
then be closed and the test pressure applied to the appropriate end of the valve.
Leakage from the upstream seat shall be monitored via the valve body cavity vent or drain connection,
where provided. For valves without body cavity or drain connection, or downstream seated valves, seat
leakage shall be monitored at the respective downstream end of the valve (the valve end downstream
of the pressurized test fluid).

16.3.2. Bidirectional
With the valve half-open, the valve and its cavity shall be completely filled with test fluid. The valve shall
then be closed and the test pressure applied successively to both ends of the valve.
Seat leakage shall be monitored from each seat via the valve body cavity vent or drain connection,
where provided.
For valves without a body-cavity vent or drain connection, seat leakage shall be monitored from the
respective downstream end of the valve.

16.3.3. Test of Cavity Relief Valve (CL .9.4.4.4 of API 6D) (For Trunnion mounted)
If provided, the external relief valve shall be set and certified to relieve to atmospheric pressure at the
specified pressure either by the relief-valve supplier or the valve manufacturer.
The set pressure of relief valves shall be between 1.1 and 1.33 times, and the reseat pressure shall not
be less than 1.05 times the valve pressure rating for class-rated valves shall be in accordance with the
applicable rating table for the appropriate material group in ASME B16.34.
Pressure-temperature ratings for Class 400 valves shall be in accordance with the applicable rating table
for the appropriate material group in ASME B16.5. for material at 100 °F (38 °C).

16.3.4. Additional Seat Testing (CL.9.4.4.3 of API 6D)

If the purchaser specifies the functionality for the valve to be that of double block and bleed (DBB)
valves, the test described in (API 6D ANNEX H CL.H.9) shall be performed.

17. Post testing activities: (Draining)

17.1 After completion of tests, the valve shall be drained off test fluids immediately, the valves should be blown
through using dry compressed air, followed by a visual inspection for dryness. If moisture is still found, the
above process shall be repeated until visually dry. Lubricate and provide the end protectors.
Note: It is important to ensure that the stainless steel valves are thoroughly dried.
17.2 Installation of Body Connections After Testing

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Parts, such as drain plug (s} and cavity-relief valves, shall be fitted, on completion of testing, in accordance
with documented procedures.

18 Retesting:

18.1 Handling and Quarantine Of valves:

18.1.1 The valve shall be identified for traceability, using color coded tags to distinguish from conforming
product.
18.1.2 The valve shall be shifted to non conforming area for repair/rejection.

18.2 Shell Test Failure:

18.2.1 If there is a leak from body/shell, the material shall be rejected.
18.2.2 If there is body joint/ gasket leak, the failure shall be investigated and corrected and the valves shall
be retested in accordance with above procedure.

18.3 Seat Test Failure:

If the valve fails in seat test, the failure shall be investigated and corrected. Follow the same procedure as
above for any retesting of valves, after correcting unacceptable leakages.
19 HSE For Inspection & Testing:
19.1 All relevant requirements of the Health, Safety & Environment (HSE) Procedure Manual shall be followed, in
particular the requirements for Valve Pressure Test.
19.2 Follow testing procedures and Instruction.
19.3 Do not stand very close to test valve while pressurizing and de-pressurizing.
19.4 Do not observe test duration more than as specified in the approved documents and standards.
19.5 Do not try operating any equipment in testing area unless asked to do so.
19.6 Do not use mobile phones in testing area.
19.7 Do not operate the valves or drain unless told to do so.
19.8 Always wear safety goggles while observing pressure testing.
19.9 Safety helmet shall be worn while observing high pressure gas testing.
19.10 High pressure gas testing shall be monitored from behind the safety wall.
19.11 Stay out of restricted area.
19.12 No smoking in office and shop floor area.
19.13 Report all injuries or problem immediately to safety officer, no matter how minor they are.

20 Quality records: Sample Pressure test reports format are enclosed below (DPTR and Daily Test Report sample
Format).
20.1 The test report shall include following information:
20.1.1 Date of test
20.1.2 Place at which the test is carried out
20.1.3 Valve type & description
20.1.4 Size & class of tested valve
20.1.5 Reference standard
20.1.6 hawa reference no
20.1.7 Instrument detail & Calibration

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20.1.8 Test pressure

20.1.9 Duration for test
20.1.10 Acceptance criteria
20.1.11 Signature of QA person carryout test
20.1.12 Signature of client /TPI witnessing the test (If applicable)
20.1.13 Observation
20.1.14 Results.
20.2 Copy of chart recorder used on pressure test. ( as applicable)

21 TERMS AND DEFINITIONS:

Bidirectional Seat
Valve seat designed to seal against pressure source in either direction.

Bidirectional Valve
Valve designed for blocking the fluid in both downstream and upstream directions.

Block Valve
Gate, plug, or ball valve that blocks flow into the downstream conduit when in the closed position.
NOTE Valves are either single seated or double seated or either bidirectional or unidirectional.

Block and bleed valve

BB
Single valve with at least one seating surface that, in the closed position, provides a seal against pressure from one
end of the valve with the body vented.

Double block and bleed valve

DBB
Single valve with two seating surfaces that, in the closed position, provides a seal against pressure from both ends of
The valve with a means of venting/bleeding the cavity between the seating surfaces.
NOTE this valve does not provide positive double isolation when only one side is under pressure. See double isolation
and Bleed valve

Double isolation and bleed valve

DIB
Single valve with two seating surfaces, each of which, in the closed position, provides a seal against pressure from a
single source, with a means of venting/bleeding the cavity between the seating surfaces.
NOTE this feature can be provided in one direction or in both directions.

Downstream
The side of the valve where there would be no pressure or a lower pressure.

Full-opening valve
Valve with an unobstructed opening, not smaller than the internal bore of the end connections.

Maximum pressure differential

MPD
Maximum difference between the upstream and downstream pressure across the obturator at which the obturator
may be operated.

Nominal Pipe Size (NPS)

Numerical designation of size in inches that is common to components in piping systems.

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Nominal size (DN)

Numerical designation of size in millimeters that is common to components in piping systems.

Obturator
Closure member
Part of a valve, such as a ball, clapper, disc, gate, or plug that is positioned in the flow stream to permit or prevent
flow.

Pressure class
Numerical pressure design class pressure-temperature (P-T) ratings are designated by class numbers defined in
ASME B16.34 and used for reference purposes.

Pressure-containing parts
A part whose failure to function as intended results in a release of contained fluid into the environment and as a
Minimum includes bodies, end connections, bonnets/covers, and stems.

Pressure-controlling parts
A part intended to prevent or permit the flow of fluids and as a minimum includes ball, disc, plug, gate, and seat.

Reduced-opening valve
Valve with the opening through the obturator smaller than at the end connection(s).

Self-relieving seat
Valve seat designed to relieve pressure in the valve cavity. Depending upon valve type, the pressure may be relieved
to the pressure source or the low-pressure side.

Shell test
Test of the assembled pressure-containing parts.

Through-conduit valve
Valve with an unobstructed and continuous cylindrical opening.

UPSTREAM
The side of the valve where the pressure is retained.

Shell Test
Test of the assembled pressure-containing parts.

Unidirectional Seat
Valve seat designed to seal the pressure source in one direction only.

Unidirectional Valve
Valve designed for blocking the flow in one direction only.

22. DOCUMENTATION:

The documentation listed below shall be retained by the manufacturer for a minimum of 10 years following the date
of Manufacture.

1. Records of test equipment calibration.

2. pressure test results (including hydrostatic and or pneumatic);

Page 10 of 10
 DIMENSION AND PRESSURE TEST REPORT
HV/QA/05 - REV 5 Effective From Dt. 17.02.2017

VALVE TYPE: CLIENT:

DPTR NO.: DATE:
END USER:

SIZE: P.O No.: DATE: SHEET NO.:

CLASS: W.O. No.: DATE:

QTY: DRG No.:

END CONNECTION : MFG & TEST STD :

PROJECT: _ CLIENT SPEC :

VALVE DIMENSIONAL DETAILS (in mm) PRESSURE TEST

HEAT NOS. BORE PRESSURE DURATION

GEAR BOX FACE TO FACE FLANGE O.D. FLANGE THK P.C.D NO. OF HOLES HOLE DIA RTJ/RF FACE R.T.J DEPTH R.T.J WIDTH TEST DETAILS
SR. MODEL NO./ (B) (BARG) (Seconds)
VALVE SR. NO. TAG NUMBER
NO. ACTUATOR SR.
NO.

E
BODY STEM COVER HYDROSTATIC SHELL

HYDROSTATIC SEAT

BACK SEAT

PL
PNUMATIC SEAT

HYDROSTATIC DBB

GAS SHELL

HYDROSTATIC SHELL

HYDROSTATIC SEAT

M
OPEARTION OPEN / CLOSE
FUNCTIONAL TEST (5 CYCLES) : FOUND
SATISFACTORY

REMARKS:VISUAL INSPECTION FOUND SATISFACTORY. VALVES

TESTED : NO VISIBLE LEAKAGE OBSERVED. ALL VALVES ARE
THOROUGHLY DRAINED, CLEANED AND DRIED AFTER TESTING.

PART MATERIAL MTC NO.

SA
INSTRUMENT CALIBRATION STATUS
BODY
STEM
COBVER THE CALIBRATION OF THE INSTRUMENT ARE WITHIN THE VALIDITY
FASTNERS

QA/QC ENGR.: TPI: SR. ENGINEER QA:

 HV/QA/08 – REV 6
DAILY TESTING REPORT
PRESSURE TEST (BAR)g

ANTISTATIC TEST
CLEANLINESS OF

REQD 10 Ω Min /
VALVE SR. NO.

DIMENSIONAL

Max
SEAT

SEAT AREA

VISUAL &
CYCLIC TEST

CHECK
HYDRO PNEUMATIC BACK
SHELL
DATE W.O NO. DESCRIPTION Down Down SEAT
Primary Secondary Upstream Upstream
stream stream

E
PL
M
SA

Page 1 of 2
 HV/QA/08 – REV 6
DAILY TESTING REPORT
AND BLEED TEST
DOUBLE BLOCK

AFTER TESTING
TORQUE TEST RESULTS

RETIGHTENING
TESTING OF

DRANING &
FUNCTION

VALVES

DRYING
JOINTS
REWORK
Both side

REJECT
REMARKS
Side A

Side B

ACC
BTO

BTO

BTO

ETC

E
PL
M
SA

INSPECTED BY QC ENGINEER NAME:- DESIGNATION:- SIGN:- DATE:-

Note:- This is an indicative format; actual format shall be as per QMS.

Page 2 of 2