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HYDRO TEST VALVE - CHECKLIST

Procedure/
S.no Activity Risk / Problems Risk mitigation Specification /Code
acceptance
Pre-manufacturing activities/materials
receiving inspection

Review of material test certificate (Body,


Material specification
bonnet and disc)

Visual inspection of casting MSS-SP-55

Dimensional inspection of rough casting Drawing


Non-destructive test
Radiographic test - on BW ends ASME B16.34 App.1
Penetrant test - N/A ASME B16.34 App.III
Magnetic test - on 100% body ASME B16.34 App.II
Ultrasonic test - NA ASME B16.34 App.IV
Content of Ni,Cr & Mo
Positive material identification on (body) (one
as per material
per heat)
specification
Manufacturing steps & inspection
Hardfacing welding process WPS+PQR+WPQ/W

Penetrant test inspection of hardfacing surfacesASME B16.34 App.III


Inspection test on finished componenets
Dimensional inspection of machined inspectio Drawing
1 Fabrication Defect
Components assembly
1 Fabrication Defect
Identification of componenets Part list
Dimensional inspection of assembly valve Assembly drawing
Testing
High pressure closure
Shell test
Seat test ASME B16.34 / API 598
Back seat test Pocedure:
Packing test PRD.07
Low pressure closure (if applicable)
Functional test with closure (if applicable)
Final inspection acctivities
Marking MSS-SP-25

Hempel's silicone
Painting
aluminium 56914

Painting thickness inspection 0>= 40 µm


Phosphating for forging valves - N/A N/A
Final documents
Packing -
Quality dossier -
Inspection release note (if applicable) -
Shipping authorization -
Heat treatment -
Crane reglememtary control -
Signaller qualification -
Crane operator experience -
Sling capacity test -
Falling D-Shackle capacity test -
New hoist/ crane - capacity -
Handling of new hydro test
2
valves
Falling

Handling of new hydro test


2 Support arrangement for hoist Drawing
valves
Performing NDT in temporary support
As per ASME code
arrangements
Existing floor design data & calculating the
Floor deterioration Drawing
required reinforcement to withstand the load
Beam structure design data & calculating the
Beam structure deterioration Drawing
required reinforcement to withstand the load
Lock the hanger supports, May add additional
Pipe will move from normal locking arrangements if required Drawing
Preparatory works in existing
3 position as soon as the pipe
lines for erection Scaffolding adequacy check, removal of
is cut Drawing
insulation
Wrong orientation of valve Erect as per flow direction Drawing
4 Fit up Ensuring proper alignment with tools,
Misalignment Drawing
dimensional check
5 Welding Weld defect Everything should be followed as per WPS Reference document
Visual test -
Penetrant test ASME B16.34 App.III
Defect identification Magnetic particle test ASME B16.34 App.II
Ultrasonic test ASME B16.34 App.IV
6 After welding
Radiographic test ASME B16.34 App.1
Stress Post weld heat treatment WPS
All the locking arrangements should be
Expansion constraint Drawing
removed
Leakage Quality should be ensured -
7 Maintenance Forget the disc inside the Following the procedure of tag out key
-
valve system with lock
Record of
conformity

EN 10204.3.1
(Bonnet, Body &
disc)
Certificate of
compliance
Certificate of
compliance

Report
Report
Report
Report

Report

Certificate of
compliance
Certificate of
compliance

Certificate of
compliance
Report
Report

Report
Report
Report
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Report
Report

Certificate of
compliance
Certificate of
compliance
Certificate of
compliance
No

Report
Report
Report
Report
Report
Report
Certificate
Certificate
Report
Report
Certificate
Design calculation
Report

Design calculation

Design calculation

Report

Report
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Report
Report
Report
Report
Report
Report
Report