D es ig n Val i d at i o n Test P ro c ed u r e B AL L

VALVE

1.

General

2.

Design Validation Cycle

A. VALVE BODY HYDROSTATIC TEST AT ROOM TEMPERATURE AS PER

API 6A ANNEX F2.2.2.3.1
Test medium: pure water.

Test temperature: room temperature: 21C.

Test pressure : rated working pressure 35.0Mpa , The valve was half opened
and test sequence consists of three steps:
1) A primary pressure-holding period of 3 min;(Pressure :36.27-35.71Mpa)
2) A reduction of pressure to zero;
3) A secondary pressure-holding period of 15min. (Pressure: 35.11-34.82Mpa)
The test result found acceptable.
B. VALVE SEAT HYDROSTATIC PRESSURE TEST AT ROOM TEMPERATURE AS PER
API 6A ANNEX F2.2.2.3.2
Test medium: pure water. Test temperature: room temperature: 21C.
Test pressure: rated working pressure 35.0Mpa, The valve was fully closed
and test sequence consists of three steps:
1) A primary pressure-holding period of 3 min. (Pressure: 37.12-36.76Mpa)
2) A reduction of pressure to zero;
3) A secondary pressure-holding period of 15min. (Pressure: 34.98-34.68Mpa)
the test result found acceptable.
Valve seat hydrostatic pressure test are performed for both side.
C. TORQUE MEASUREMENT PRIOR TO PR2 VALIDATION TEST AS PER 5.1 OF
MANUFACTURER'S PR2 TEST PROCEDURE:
Test medium: pure water. Test Temperature: Room 21C.
Test pressure: Rated working pressure 35.0Mpa.
(Maximum open/close torque shall be less than 133 N.M.as per stated at
CDFQ's test procedure). The break-away and running torques measured are
70,68,70 N.M and 75,73,75N .M respectively: The operating torque are found
all within the CDFQ's specifications.
D. DYNAMIC TEST AT ROOM TEMPERATURE AS PER API 6A F2.2.2.2:
Test medium: pure water. Test Temperature:

21C.

A. Fill the downstream end of the valve with the test medium at 0.35Mpa (1% or
less of test pressure.)
B. Applied the upstream side pressure of the gate to the rated working pressure
Reviewed By

Approved By

D es ig n Val i d at i o n Test P ro c ed u r e B AL L
VALVE

35.0Mpa.
C. Open the valve fully, starting against the full differential pressure. Pressure
was maintained at a minimum of 50 % of the initial test pressure (about
18.0Mpa) during the opening.
D. Close the valve fully while pressure was maintained within the limits of the
preceding step.
E. Bleed the downstream pressure to 1 % or less of test pressure after the valve
is fully closed.
F. Repeated step no. B to E, the open-close cycle were carried out by 160 times.
E. DYNAMIC TEST AT MAXIMUM RATED TEMPERATURE AS PER API-6A F2.3.3.3
Test medium: nitrogen gas. Rated maximum temperature: 121C. Test
temperature: 125.9C. (Temperature variation during testing was less
than 0.5C per min.)
Temperature measure instruments location was verified on site and
acceptable.
A. Set up the valve in the right position of test room, and started the heating
process, after the measured temperature got to maximum temperature
required and
stable (variation less than 0.5 "C per minute), kept
temperature more than half hour.
B. Fill the downstream end of the valve with the test medium at 0.35Mpa (1
%or less of test pressure.)
C. Applied the upstream side pressure of the gate to the rated working
pressure 35.0Mpa.
D. Open the valve fully, starting against the full differential pressure. Pressure
was maintained at a minimum of 50 % of the initial test pressure (about
18.0Mpa) during the opening.
E. Close the valve fully while pressure was maintained within the limits of the
preceding step.
F. Bleed the downstream pressure to 1% or less of test pressure after the
valve is fully closed.
G. Repeated step c-f. The abovementioned open-close cycle were carried out
by 20 times

F. GAS BODY TEST AT MAXIMUM RATED TEMPERATURE AS PER API 6A F2.3.3.4

Rated temperature: 121"C. Test temperature :125.5"C
Test medium: Nitrogen gas.
Test pressure: rated working pressure 35.0Mpa.
Gate valve was in the partially open position during testing.
Apply test pressure to rated working pressure 35.0Mpa, held for a
minimum period of 1 hr.
Test pressure decreased was found not more than 1.75Mpa. (37.4637.06Mpa) Temperature variation during testing was less than o.sc per
min.

Reviewed By

Approved By

D es ig n Val i d at i o n Test P ro c ed u r e B AL L
VALVE

G. GAS SEAT TEST AT MAXIMUM RATED TEMPERATURE AS PER API 6A F2.3.3.5

The maximum rated temperature is 121c, Test temperature :125"C
Test medium : Nitrogen gas.
The rated working pressure 35.0Mpa is maintained on the upstream
side of the gate and released on the downstream side.
Gate valve was closed.
Apply test pressure to rated working pressure 35.0Mpa, held for a
minimum period of 1 hr. Test pressure decreased was not more than
1.75Mpa. (37.32-36.67Mpa)
Temperature variation during testing is less than o.sc per min.
H. LOW PRESSURE SEAT TEST AT MAXIMUM RATED TEMPERATURE AS PER API SA
F2.3.3.6:
The maximum rated temperature is 121c ,Test temperature :125"C
Test medium : Nitrogen gas .
Test pressure 3.5Mpa (10% of the rated) was maintained on the
upstream side of the gate and released on the downstream side.
Gate valve was closed.
Apply test pressure, hold for a minimum period of 1 hr.
Test pressure decreased was not more than 0.175 Mpa(4.01-3.79Mpa)
Temperature variation during testing is less than o.sc per min.
I. DYNAMIC TEST AT MINIMUM RATE DTEMPERATURE AS PER API SA F2.3.3.7:
Test medium: nitrogen gas.
The minimum rated temperature is -29 "C ,Test temperature :-30'C
(Temperature var iation during testing was less than 0.5'C per min.)
Temperature measure instruments location was verified on site and
acceptable
A. Set up the valve in the right position of test room, and started the heating
process, after the measured temperature got to maximum temperature
required and stable(variation less than 0.5 'C per minute) , kept temperature
more than half hour.
B. Fill the downstream end of the valve with the test medium at 0.35Mpa (1 %
or less of test pressure.)
C. Applied the upstream side pressure of the gate to the rated working pressure
35.0Mpa.
D. Open the valve fully, starting against the full differential pressure. Pressure
was maintained at a minimum of 50 % of the initial test pressure (about
18.0Mpa) during the opening.
E. Close the valve fully while pressure was maintained within the limits of the
preceding step.
F. Bleed the downstream pressure to 1% or less of test pressure after the valve
is fully closed.
G. Repeated step c-f. The abovementioned open-close cycle were carried out by
Reviewed By

Approved By

D es ig n Val i d at i o n Test P ro c ed u r e B AL L
VALVE

20 times.
J. GAS BODY TEST AT MINIMUM RATED TEMPERATURE AS PER API SA F2.3.3.8 :
The minimum rated temperature is -29 'C, Test temperature:-30'C Test
medium : Nitrogen gas.
Test pressure: rated working pressure 35.0Mpa.
Gate valve was in the partially open position during testing.
Apply test pressure to rated working pressure 35.0Mpa , held for a
minimum period of 1 hr. Test pressure decreased was found not more
than 1.75Mpa .(36.79-35.24Mpa )
Temperature variation during testing was less than o.sc per min.
K. GAS SEAT TEST AT MINIMUM RATED TEMPERATURE AS PER API SA F2.3.3.9:
The minimum rated temperature is -29'C ,Test temperature :-30'C
Test medium: Nitrogen gas.
The rated working pressure 35.0Mpa is maintained on the upstream side of
the gate and released on the downstream side.
Gate valve was closed.
Apply test pressure to rated working pressure 35.0Mpa , held for a minimum
period of 1 hr. Test pressure decreased was not more than 1.75Mpa . (40.5539.78Mpa)
Temperature variation during testing is less than O.S 'C per min.
L. LOW PRESSURE SEAT TEST AT MINIMUM RATED TEMPERATURE AS PER API SA
F2.3.3.10:
The minimum rated temperature is -29'C ,Test temperature :-30'C
Test medium: Nitrogen gas .
Test pressure 3.5Mpa (10% of the rated) was maintained on the
upstream side of the gate and released on the downstream side.
Gate valve was closed.
Apply test pressure, hold for a minimum period of 1 hr.
Test pressure decreased was not more than 0.175 Mpa (3.99-4.01Mpa).
Temperature variation during testing is less than O.S'C per min.
M. BODY PRESSURE I TEMPERATURE CYCLE TEST AS PER API SA F2.3.3.11:

Test medium: Nitrogen gas.

Raised temperature to room temperature.
Applied test pressure 35.0Mpa at room temperature and maintain 50% to
100% of test pressure while temperature increasing to maximum. (Allowable
range:121-312 'C )
Hold period 1hr minimum at test pressure.

Reviewed By

Approved By

D es ig n Val i d at i o n Test P ro c ed u r e B AL L
VALVE

Reduced temperature to minimum -29 'C while maintaining 50% to 100% of

test pressure.
Minimum held period 1hr at test pressure.
Raised temperature to room temperature while maintaining 50% to 100% of
test pressure.
Released pressure, and then raise temperature to maximum.
Apply test pressure 35.0Mpa, minimum hold period 1hr, and then release
pressure.
Reduce temperature to minimum.
Apply test pressure 35.0Mpa, minimum held period 1hr, and then release
pressure. Test pressure decreased was not more than 1.75Mpa during the
hold period. Temperature variation during testing was less than 0.5'C per
min.
N. BODY PRESSURE HOLDING TEST AT ROOM TEMPERATURE AS PER API SA
F2.3.3.12:

Test temperature :room temperature 21 'C

Test medium: Nitrogen gas.
Test pressure equal to the rated working pressure 35.0Mpa.
Gate valve is in the partially open position during testing.
Apply test pressure, held for a minimum period of 1 hr.
Test pressure decreased was not more than 1.75Mpa. (37.57Mpa-36.25Mpa )

O. GAS SEAT TEST AT ROOM TEMPERATURE AS PER API SA F2.3.3.13:

Test temperature : room temperature : 21 'C
Test medium: Nitrogen gas.
The rated working pressure 35.0Mpa was maintained on the upstream side of
the gate and released on the downstream side.
Gate valve was fully closed.
Apply test pressure, held for a minimum period of 15 minutes. Test pressure
lost is not more than 1.75Mpa. (38.31-38.28Mpa)
P. BODY LOW PRESSURE HOLDING TEST AT ROOM TEMPERATURE AS PER API SA
F2.3.3.14:

Test medium: Nitrogen gas. Test temperature : room temperature : 21 'C

Test pressure: 3.5Mpa was maintained.
Gate valve was in the partially open position during testing.
Apply test pressure, held for a minimum period of 1 hr.
Test pressure lost was not more than 0.175 Mpa (4.23-4.13Mpa)

Q. LOW PRESSURE SEAT TEST AT ROOM TEMPERATURE AS PER API SA F2.3.3.15:

Test medium: Nitrogen gas. Test temperature: room temperature : 23 C
Reviewed By

Approved By

D es ig n Val i d at i o n Test P ro c ed u r e B AL L
VALVE

Test pressure 3.5Mpa was maintained at the upstream side of the gate and
released on the downstream side.
Gate valve was fully closed.
Apply test pressure, held for a minimum period of 1 hr.
Test pressure lost was not more than 0.175 Mpa.(side A:3 .03-3.02 Mpa; side
B:3.81-3.75Mpa)
The test have been carried out at both side.
R. FINAL FORCE OR TORQUE MEASUREMENT AS PER API SA F2.3.3.16:

Test medium : Nitrogen gas .

Test pressure :rated working pressure 35.0Mpa. Fully opened the valve
under pressure.
Maximum opening torque was and running torque was 76N.m and 85N.m
respectively .
The break-away and running torques were measured. The operating
torque showed within the JMP's specifications.
S. POST TEST EXAMINATION AS PER MANUFACTURER TEST PROCEDURE 5.17:
After all of PR2 test items got completed, the Gate Valve was
disassembled. All of components have been performed visual
inspection. No defect was found, and the result is acceptable.

Reviewed By

Approved By