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Scope

This work instruction specifies minimum requirements for performing inspection


to assure the clients quality requirements pertaining to all type of Manual and
Motor Operated Valves are met.

Purpose
To ensure conformity of the valves per the international standards i.e. API, ASME,
ASTM and additional Saudi Aramco requirement.

Document Reference
API STD 600 Bolted Bonnet Steel Gate Valves for Petroleum and Natural Gas
Industries
API STD 602 Compact Steel Gate Valves-Flanged, Threaded, Welding, and
Extended-Body Ends
ASME B16.10 Face-to-Face and End-to-End Dimensions of Valves
ASME B16.34 Valves - Flanged, Threaded, and Welding End
04-SAMSS-001 Gate Valves
04-SAMSS-002 Globe Valves
04-SAMSS-005 Check Valves Swing Type
04-SAMSS-003 Additional Requirements for Low Temperature Valves
04-SAMSS-035 General Requirements for Valves
04-SAMSS-048 Valve Inspection and Testing Requirements
04-SAMSS-051 Ball Valves
Form 6233-1-ENG Valve Data Sheet
ASTM A105 - Standard Specification for Carbon Steel Forgings for Piping
Applications
ASTM A194 - Standard Specification for Carbon and Alloy Steel Nuts for Bolts for
High-Pressure or High-Temperature Service, or Both
ASTM A216 - Standard Specification for Steel Castings, Carbon, Suitable for
Fusion Welding, for High Temperature Service
ASTM A320 Standard Specification for Alloy Steel Bolting Materials for Low
Temperature Service
ASME B16.5 for flanges size upto and including 24 Inches
ASME B16.47 Series A & B for flanges size above 24 Inches
MSS SP 44 for Flanges manufactured MSS standard
Saudi Aramco Drawings AD-XXXXXX
MSS SP 55 for visual inspection
MSS SP 25 for marking inspection
02-SAMSS-011 for Aramco standard specification for WN flanges
IR Form 175 026000 for Inspection requirements for Aramco WN flanges
EN 10204 for certification requirements for metallic material

Procedure
Inspection Procedure for valves is as follows;
1) Document Review:
a. Inspector to review the purchase order and its attachments i.e. ITP, approved
drawings, approved data sheets and manufacturer catalogue (If available)
pertaining to the valves.

b. Inspector to check that the IRB supplied is in compliance with the applicable IR
form (Form 043600, 043601, 045600, 341900, 342000) by the manufacturer
contains the following documents;

Body, Bonnet (If applicable), Trim components and hardware MTCs


PMI report (if material is Low Carbon Alloy steel, Stainless Steel, Duplex
or Non Ferrous material).
NDT Reports (If applicable)
Hydrostatic and Pneumatic Test Report
Performance Test Certificate
Dimensional Inspection Report
Painting and Blasting Inspection Report
Paint certificates
Actuator certificate (If valve is MOV type)

c. Review the Material Test Certificates of the Body, Bonnet, Trim components as
per the certification requirements specified in IR Form 043000.

d. MTC should be legible, identifiable and with proper reference to the purchase
order and it is advisable to check the original copy.

e. An MTC should have the identification no. (Document/report/certificate No.). it


should show the date of issue.

f.

MTC should mention the melt/heat or any other identification so that the
material can be traced.

g. Clients additional requirements and supplementary requirements need to be


identified pertaining to the Chemical Composition, Mechanical Properties and
the Heat treatment details before reviewing the MTC.

h. Chemical Properties: Chemical properties should be verified with respect to


the applicable ASTM specification.

i.

Mechanical Properties: Mechanical properties i.e. Yield Strength, Tensile


Strength, Percentage Elongation and reduction in area etc. should be verified
with respect to the applicable ASTM specification.

j.

Heat Treatment: Heat Treatment details i.e. type of heat treatment, heating
cooling cycles and HT charts if available should be verified with respect to the
applicable ASTM specification.

k. All the MTC after review should be stamped Reviewed with signature and
position of the reviewer. Only reviewed MTC should be offered to Third party
inspector. This MTC should have the correct reference to the Purchase Order
and its item nos.

2) Physical and quantity verification: Material should be physically identified


and quantity to be verified before inspection.
3) Visual Inspection: Visual Inspection of valve body and bonnet castings shall be
performed as per applicable API Product Standard, MSS SP 55 and API 598. As per
Saudi Aramco acceptance criteria for visual inspection of valves casting, any flaw
should not exceed Example A of MSS SP 55 Type II to XII.
4) Dimensional Inspection: Calibrated measuring instruments shall be used for
dimensional inspection of valves. Valves dimensions shall be checked as per
approved drawings. If approved drawing is not available following dimensions are
to be checked without fail.

Face to Face, End to End and Center to Center Dimension as per ASME B
16.10 and applicable API product standard.

Valve flange dimensions i.e. OD, Hole Dia, Pitch Circle Diameter, Flange
Thickness, Raised Face Height and Raised Face OD as per ASME B 16.5 for
valve sizes upto 24 inches and as per ASME B 16.47 A or B 16.47 B for
valve sizes larger than 24 inches.

For flangeless valves, dimensions to be checked as per the product


standard.

5) Marking Inspection: All the valves to be inspected as per MSS SP 25 for


marking inspection. Identification plates shall be of an austenitic stainless
steel, except that for socket-weld, threaded end and instrumentation type
valves, the manufacturers standard is acceptable. As a minimum Valve
should be clearly marked with the following information;
Valve Size
Valve Rating
Body/Bonnet Material Grade
Trim Material
Manufacturers Logo
Flow mark for the direction of flow
Minimum Design Temperature for valves in low temperature
application (04-SAMSS-003)
25mm wide orange color band on flange rim for all valves in low
temperature application (04-SAMSS-003)

6) Pressure Test Reports Review: All valves to be pressure tested as per API 598
requirements.
a. Valves shall be subjected to the tests mentioned in Table 1A and 1B
according to the size and rating.
b. Test pressure shall be as per Table 2 and Table 3 of API 598.
c. Time duration of the test shall be as per table 4 of API 598.

d. Maximum reported leakage shall be limited to the allowed leakage in Table


5 of API 598. No leakage is allowed for Soft Seated valves.
7) Painting & Blasting Reports Review: As per 04-SAMSS-035 all valves to be
painted as per the applicable painting system (APCS) specified in the contract. If
no system is identified then valves painted as per 04-SAMSS-035 requirements
which states:

Vendor's standard finish or paint is acceptable for


a. All threaded end, socket-weld end, special end and instrumentation type
valves of any material type.

b. All austenitic stainless steel, high alloy, cast/ductile iron, plastic and bronze
valves of all sizes and types.

c. Steel valves not covered by paragraph a) above shall be externally painted


with APCS-26 (self priming mastic epoxy) at 200 micrometer minimum dry
film thickness system applied over abrasively blasted surface to Sa 2.5
with surface profile 40 65 microns. The paint system must be suitable for
outdoor exposure and rated to 120C.

d. When steel valves are specified with internal coating, the coating materials
and application procedures shall be in accordance with APCS-100 for baked
phenolic epoxy or APCS-102 for fusion bonded epoxy (FBE).

e. Fully and partially buried valves shall be entirely coated with a below grade
coating as specified in APCS-113A (with more than 85% volume solids)
8) NDT Report Review: NDT reports are to be review as per the PO requirements.
Additionally for Saudi Aramco 04-SAMSS-048 compliance
10% of Steel valve Body and Bonnet castings are to be MT or PT tested
Steel valve body bonnet casting of size 4 inch and larger in class 600 and
above and 24 inch and larger in all ratings shall be radiographically
examined one valve per heat per lot as per ASME B 16.34 and ASME
Section VIII Appendix 7.
Report:

A report shall be generated in standard approved format w.r.t. the activities mentioned
above.
Responsibility:
QC inspectors are responsible for performing the inspection.