MATRIX – SERENE SDN BHD

FACTORY/SITE ACCEPTANCE TEST PROCEDURE FOR ACTUATED BALL

VALVE &/OR MANUAL BALL VALVE
 INDEX

1 PURPOSE

2 SCOPE

3 REFERENCE

4 TESTING EQUIPMENT

5 SETTING

6 PROCEDURE

6.1 Hydrostatic Shell Test

6.2 Hydrostatic Seat Test
6.3 Low Pressure Seat Test

7 OPERATION AFTER TESTING

1. PURPOSE
This procedure describes the methods and the acceptance criteria for carrying out the final
acceptance valve testing procedure, which include pressure testing and supplementary testing.
The testing is carried out on actuated valve and/or manual ball valve in accordance with API
Specification 6D.

2. SCOPE
This procedure states the minimum requirement for carrying out the hydro-static/pneumatic test,
applies to actuated ball valve and/or manual ball valve.
i. Hydro-static Shell Test
ii. Hydro-static Seat Test
iii. Full Differential Pressure Test
iv. Low Pressure Gas Seat test
v. Completed Assembly (Actuated Valve System) Functional Test Without Pressure
vi. Actuator Assembly, Fittings & Control Accessories Leak Test
vii. Accessories and Control Components Function Test

3. REFERENCE
API Spec 6D: Specification for Pipeline Valves – 24th edition
ASME B16.34: Valves - Flange, Threaded and Welded-End Connection
ISO 5208 Industrial Valves – Pressure Testing of Metallic Valves

4. TESTING EQUIPMENT
i. Hydraulic test bench.
ii. Calibrated test gauges. Test gauge shall be made between 20% and 80% of the full
pressure range of the measuring device and shall be accurate to at least +/- 2.0%
(according to API 6D Clause 8.2.3.1).
iii. Test flanges.
iv. Water treated which may contain a corrosion inhibitor. The chloride content shall not
exceed 30ppm (according to API 6D Clause 9.1). Municipal service water with approved
Chlorine content is acceptable.
v. Compressed air.
vi. Calibrated Pressure Transducer and associated Computer for Pressure Graph and Full
Test recording.
5. SETTING
Before mounting the actuated valve system (AVS) on the test unit, the actuator mechanical
stops, limit switches and controls are to be checked and calibrated by opening and closing
operations. For manual valve, manual opening should be performed. Prior to start of the test all
the valve external surfaces must be dry.

6. PROCEDURE
Before performing the FAT, below applicable item to be checked:

i. Physical Inspection on completed actuated valve:

a) Dimensions as per General Assembly
b) Model and specification as per Data-sheet/Schematic Drawing
ii. Review Documentation for valve and actuator:
a) Valve and Actuator Mill Certificate and Test Certificate from manufacturer
b) Equipment Calibration Certificate
iii. Checking on Control Panel System for AVS (according to approved schematic drawing
from client). Applicable to actuated valve only.

6.1 Hydrostatic Shell Test (test medium: treated water)

HYDROSTATIC SHELL TEST PRESSURE BY CLASS
Values are in barg (psig)
Valve pressure class
150 300 600 800 900 1500 2500
Body material
29.4 76.65 153.15 204.27 229.8 382.95 638.25
ASTM A105 / A350 LF2 / LF3
(426) (1112) (2221) (2962) (3333) (5554) (9255)
ASTM A182 F304 / F316 / F321 / 28.5 74.4 148.95 198.62 223.35 372.3 620.55
A351 CF8M (413) (1079) (2160) (2880) (3239) (5400) (9000)
23.85 62.1 124.05 165.51 186.15 310.2 517.05
ASTM A182 F304L / F316L
(345) (900) (1799) (2400) (2700) (4500) (7500)
30 77.55 155.1 206.89 232.65 387.9 646.35
ASTM A182 F44 / F51 / F53 / F55
(435) (1125) (2250) (3000) (3374) (5626) (9374)
Table 6.1: Hydrostatic Shell Test Pressure
Note;
 Test pressure for hydrostatic shell test according to API 6D clause 9.3. (1.5 times
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)
 6.1.1 Apply the test flanges to the valve ends and mount the valve to the hydraulic test
bench.
6.1.2 Operate the valve to partially open position (API 6D, Clause 9.3 Hydrostatic Shell
Test, first paragraph.
6.1.3 Fill completely the valve with the test fluid, bleeding the air trapped in the valve
through the drain hose into the water collector.
6.1.4 Apply the shell test pressure according to Table 6.1 and duration as per Table
6a. The timing shall start after the stabilizing period.
6.1.5 Carefully inspect the valve for any leakage, distortion or signs of over-stressing to
component parts.
6.1.6 Depressurize the valve.

Acceptance criteria:
i. No visible leakage is permitted. There shall be no visible evidence of drop or
wetting of the external surfaces and no structural damage. No visible leakage
through the body, and body – to – connector joint is permitted ( as per API 6D).
ii. For the valve completed with drain, vent and sealant injection lines no visible
leakage is permitted during Hydro Static Shell Test.

6.2 Hydrostatic Seat Test (test medium: treated water)

HYDROSTATIC SEAT TEST PRESSURE BY CLASS
Values are in barg (psig)
Valve pressure class
150 300 600 800 900 1500 2500
Body material
21.56 56.21 112.31 149.79 168.52 280.83 468.05
ASTM A105 / A350 LF2 / LF3
(313) (815) (1629) (2172) (2444) (4073) (6787)
ASTM A182 F304 / F316 / F321 / A351 20.9 54.56 109.23 145.65 163.79 273.02 455.07
CF8M (303) (791) (1584) (2112) (2376) (3960) (6600)
17.49 45.54 90.97 121.37 136.51 227.48 379.17
ASTM A182 F304L / F316L
(254) (660) (1319) (1760) (1980) (3299) (5500)
22 56.87 113.74 151.72 170.61 284.46 474
ASTM A182 F44 / F51 / F53 / F55
(320) (825) (1650) (2200) (2475) (4126) (6875)
Table 6.2: Hydrostatic Seat Test Pressure
Note:
 Test pressure for hydrostatic seat test according to API 6D clause 9.4.2. (1.1 times
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)
 6.2.1 Operate the valve to the fully closed position.
6.2.2 Apply to one side A (Upstream) of the valve the hydrostatic seat test pressure
according to table 6.2 and duration as per table 6a. Check the leakage after
pressure is stabilized.
6.2.3 Depressurize the valve.
6.2.4 Repeat the operation 6.2.1 to 6.2.3 for the other side of the valves (side B
Downstream).

Acceptance criteria: For soft-seated valves, no visual leakage or pressure drop under
test pressure evidence of leakage is permitted (ISO 5208 Rate A – No visible detectable
leakage for the duration of the test at test pressure) .

6.3 Low Pressure Seat Test (test medium: compressed air)

LOW PRESSURE SEAT TEST BY CLASS

Values are in barg (psig)
Valve pressure class
(lbs) 150 300 600 800 900 1500 2500
Body material

ASTM A105 / A350 LF2

ASTM A350 LF3

ASTM A182 F304 / F316 5.5 (80)

/ F321 / A351 CF8M

ASTM A182 F304L / F316L

ASTM A182 F44 / F51 / F53

/ F55
Table 6.4: Low Pressure Seat Test
Note:
Test pressure for low-pressure gas seat test according to API 6D, supplementary test
requirements H.3.3 Type II.

6.4.1 Drain completely the valve and operate it to the fully closed position.
6.4.2 Apply to one side A (Upstream) of the valve the pneumatic seat test pressure
according to table 6.4 and duration as per table 6a. Check the leakage and the
bubble rate after pressure is stabilized.
6.4.3 Depressurize the valve.
 6.4.4 Repeat the operation 6.4.2 to 6.4.3 for the other side of the valves (side B
Downstream).

Acceptance criteria: For soft-seated valves, no visual leakage or pressure drop under
test pressure evidence of leakage is permitted (ISO 5208 Rate A – No visible detectable
leakage for the duration of the test at test pressure) .

Table 6a: Test Duration

HYDROSTATIC HYDROSTATIC PNEUMATIC
NOMINAL VALVE SIZE
REFERENCE SHELL TEST SEAT TEST SEAT TEST
DN
CODE DURATION DURATION DURATION
mm inch minutes minutes minutes

50 thru 100 2 thru 4 2 2 2

150 thru 250 6 thru 10 5 5 5

API 6D 300 thru 450 12 thru 18 15 5 5

500 and larger 20 and larger 30 10 10

*RATE A , *RATE A,
ACCEPTANCE CRITERIA NO VISIBLE
NO VISIBLE NO VISIBLE
SOFT SEATED VALVES LEAKAGE
LEAKAGE LEAKAGE
As per “Table 5 – Minimum Duration of Hydrostatic Shell Tests” and “Table 6 – Minimum Duration of Seat
Tests” API 6D

7. OPERATION AFTER TESTING

7.1 Drain and dry completely the valve. Clean by using compressed air and soft cloths. Anti-
rust shall be apply for all tested valve before packaging and preservation.
7.3 Install the fittings (plugs, valves) removed during the test operations.
7.4 The result of testing is classified into two sections, passed or failed. Each valve will be
tagged with coloured tagging. The colour is summarised in the table below.

Test result Colour tagging

Pass Green

On-hold Yellow

Fail Red
7.5 Each valve will be allocated in a section called “Post test area”. “Passed” valve and
“Failed” valve will be segregated and identified with coloured tagging.

END-OF-PROCEDURE