Prototype
  Testing Procedure for Doc. No : MS-TP-04
  Rev.No : 00
  AWWA, UL & FM Date : 10-11-2014
Resilient
 
 
Seated Gate Valves Page : 1 of 6

1. Scope
The purpose of this procedure is to describe the approval and/or
certification/listing test requirements of valve products by the American Water
Works Association (AWWA), Underwriters Laboratories (UL) or Factory
Mutual (FM). Note this is not a production test (product verification test)
procedure.

2. Reference Standards
The latest revision of the following standards is applicable:

S. No Product Type Reference Standards

i. Hi-Pressure Resilient Seated Gate

a. AWWA C-515
Valve (RSGV) – NRS
b. UL 262
ii. Hi-Pressure Resilient Seated Gate
c. FM 1120/1130
Valve (RSGV) – OS&Y

3. Responsibility
MSPL Product Design & Development Team is responsible for the
maintenance of this document and for testing the referenced products.

4. Procedure
4.1. List of Type Tests to be carried out for AWWA, UL & FM Products
Table 1
AWWA FM
S.No Description of Test UL-262
C-515 1120/1130
a. Shell Test (Multiplier) 2.5 4 4
Hi-pressure Seat
b. 2 2 1
(Multiplier)
c. Closing Torque (NM) NA Table 2 Table 2
Proof of Design Torque
d. Table 3 Table 3 Table 3
(NM)
as per as per
e. Friction Loss Test NA Section 25 of Section 4.4
UL262 of FM 1120
Endurance / Cyclic Test
f. 500 1000 NA
(Number of Cycles)
Endurance / Cyclic Test
g. NA 10 NA
(min cycle time, seconds)
h. Stem Seal Replacement 1 1 1
Note: Pressure multipliers are applied to the desired rated pressure of the finished product.
  
Prototype
  Testing Procedure for Doc. No : MS-TP-04
  Rev.No : 00
  AWWA, UL & FM Date : 10-11-2014
Resilient
 
 
Seated Gate Valves Page : 2 of 6

4.2. Shell Test:

The shell test is a test to ensure the minimum structural burst conditions are
satisfied.
4.2.1. The shell test shall be conducted in the manner stated in the applicable
product standards (Section 2.0 Reference Standards) unless otherwise
specified herein.
4.2.2. The shell test pressure for all valve types shall be based on rated
design working pressure and tested based on the values as per Table 1.
4.2.3. The test duration shall be 5 minutes minimum or required by Table1.
4.2.4. Water shall be used as the test medium. A corrosion inhibitor may be
added.
4.2.5. Leakage or other structural failure is not acceptable.
4.2.6. Shell test results shall be recorded in a test report.

4.3. High Pressure Seat / Closure Test:

This ensures that the valve will close and seal at all pressures likely to be
encountered in service.
4.3.1. The high pressure seat test shall be conducted in the manner stated in
the applicable product standards (Section 2.0 Reference Standards)
unless otherwise specified herein.
4.3.2. The high pressure seat test pressure for all valve types shall be as
dictated by the requirements of Table 1.
4.3.3. The test duration shall be 5 minutes minimum or required by Table1.
4.3.4. Water shall be used as the test medium. A corrosion inhibitor may be
added.
4.3.5. Leakage is not acceptable.
4.3.6. High pressure seat test shall be performed on both sides of the valve.
4.3.7. High pressure seat test results shall be recorded in a test report.
  
Prototype
  Testing Procedure for Doc. No : MS-TP-04
  Rev.No : 00
  AWWA, UL & FM Date : 10-11-2014
Resilient
 
 
Seated Gate Valves Page : 3 of 6

4.4. Closing Torque:

This defines the minimum operating torque required to close and seal the
valve. All prototype valves addressed in this standard are subject to this test
even though there is no AWWA requirement for them. UL & FM
requirements are different from this procedure and the values indicated in
Table 2 should be used.
4.4.1. The valve shall be mounted in a test stand, or otherwise configured,
such that hydrostatic pressure may be applied to at least one side of
the valve.
4.4.2. The valve is opened sufficiently to allow water to pass through the
valve.
4.4.3. A torque wrench is attached to the closing nut of the valve.
4.4.4. Continuously increasing torque is applied to the nut until the valve is
leak tight at rated pressure.
4.4.5. The value of this torque is recorded in a test record.
4.4.6. This test is repeated a minimum of 5 times.
4.4.7. The high and low values are discarded and the remaining values are
averaged.
4.4.8. This value shall be known as the minimum closing torque.
4.4.9. The minimum closing torque is recorded in the test report.

Table 2
Closing Torque (UL 262 & FM 1120 Requirement)
Nominal Valve Max. Closing Torque, Max. Closing
Size in Inch UL in lb-ft (N-m) Torque,
FM in lb-ft (N-m)
2” 20 (27) 45 (61)
2.5” 28 (38) 50 (68)
3” 52 (70) 55 (68)
4” 75 (102) 75 (102)
5” NA 90 (122)
6” 110 (149) 110 (149)
8” 150 (203) 150 (203)
10” 185 (251) 185 (251)
12” 225 (305) 225 (305)
14” 225 (305) 250 (340)
16” 275 (374) NA
18” & above NA NA
  
Prototype
  Testing Procedure for Doc. No : MS-TP-04
  Rev.No : 00
  AWWA, UL & FM Date : 10-11-2014
Resilient
 
 
Seated Gate Valves Page : 4 of 6

4.5. Proof of Design Torque:

This test demonstrates that an excessive amount of torque applied over and
above the operating torque will not damage the valve, any of its components
or prevent proper operation of the valve. A torque wrench is attached to the
operating nut of the valve.
4.5.1. The torque is applied to the Operating nut/mechanism until the proof
of design torque, as indicated in Table 3, is reached.
4.5.2. The proof of design torque applied to the valve,
a. In the closed position, in the direction tending to further close the
valve and
b. In the open position, in the direction tending to further open the
valve
4.5.3. The valve is then fully opened / closed with the operator checking for
any binding or roughness in operation.
4.5.4. The valve is then disassembled and checked for any physical damage.
4.5.5. After this exposure the valve is to be reassembled and shall comply
the high pressure seat / closure test as per section 4.3
4.5.6. Test results are then recorded in the test report.

Table 3
Proof of Design Torque
Nominal AWWA C515 UL 262 FM 1120 /1130
Valve Size Proof of Design Proof of Design Proof of Design
in Inch torque torque torque in lb-ft (N-m)
in lb-ft (N-m) in lb-ft (N-m)
2” NA NA 75 (102)
2.5” NA 125 (170) 125 (170)
3” 160 (217) 150 (203)
250 (340)
4” 260 (353) 200 (271)
5” NA 290 (394) 250 (340)
6” 325 (442) 300 (407)
8” 450 (510) 400 (542)
350 (475)
10” 640 (870) 600 (814)
12” 760 (1033) 800 (1085)
14” 900 (1220) 900 (1220)
16” 1040 (1414) NA
400 (542)
18” &
NA NA
above
  
Prototype
  Testing Procedure for Doc. No : MS-TP-04
  Rev.No : 00
  AWWA, UL & FM Date : 10-11-2014
Resilient
 
 
Seated Gate Valves Page : 5 of 6

4.6. Friction Loss Test:

4.6.1. AWWA – Not applicable or required
4.6.2. UL – Required only for reduced waterway valves which is defined as a
valve whose waterway diameter is less than the nominal diameter of
the valve.
4.6.3. FM – Tested at the discretion of the examiner.
4.6.4. If the friction loss test is required to carried out means, the procedure
shall be followed as per the reference standards given in Section 2 and
Table 1.

4.7. Endurance / Cyclic Test:

4.7.1. This test is used to determine the effect of wear on the valve after
repeated operation.
4.7.2. A pressure pump with sufficient volume to completely fill the valve in
a fully opened condition shall be used if possible. If not then a test
setup that keeps the valve full of medium shall be used.
4.7.3. The line is filled with medium, air vented from the valve and flow
initiated.
4.7.4. The valve is cycled between the fully open and closed condition.
4.7.5. The valve is closed and sufficient torque is applied to seal the valve.
4.7.6. Pressure is allowed to build to the rated pressure of the valve.
4.7.7. When rated pressure is reached, the valve may be opened and the
cycle repeated.
4.7.8. Cycle times should not be less than those given in Table 1.
4.7.9. The cyclic operation may be conducted by either manual or automated
means.
4.7.10. The minimum number of cycles shall be as given in Table 1.

4.8. Stem Seal Replacement:

This test demonstrates that the stem packing can be replaced with the valve
pressurized and in service. This test is applicable to NRS and OS&Y gate
valves only.
4.8.1. Seal the valve in a test stand or using other suitable means.
4.8.2. Fully open the valve.
4.8.3. Pressurize the valve.
4.8.4. Remove the packing or stem seal.
4.8.5. Replace the packing or stem seal.
4.8.6. Cycle the valve to demonstrate proper sealing.
4.8.7. The Packing or stem seal shall be removed and replaced by one
person.
  
Prototype
  Testing Procedure for Doc. No : MS-TP-04
  Rev.No : 00
  AWWA, UL & FM Date : 10-11-2014
Resilient
 
 
Seated Gate Valves Page : 6 of 6

5. Test Report:
The Valve Test Report must contain the following details at a minimum,
a. Product type
b. Valve size
c. Pressure Rating
d. Valve Serial No.
e. Type of test conducted
f. Result of the test
g. Person who conduct the test
h. The test apparatus and measuring devices which have been
used and their calibration criteria.