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FUJI KOKI RESOURCES (M) SDN BHD
PROCEDURE FOR GENERAL VALVE SERVICE, REPAIR &
TESTING (API 598)
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part of this publication may be reproduced or utilized in any form or by any means, electronic or
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Document No:
FKR-PR-08-REV01
Last Update:
Revision No:
08/07/19
01
Prepared By
Macarthur Liu
Reviewed By
Sugan Purusothman
Approved By
Steven Yang
Arthur
Sugan
Steven
Senior Technician
Mechanical Engineer
Engineering HOD
*This is an electronic copy of the uncontrolled document; no original signatures are required. Please
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
Document No: FKR-PR-08-REV01
Date: 08/07/2019
REVISION HISTORY
Rev.
00
Effective Date
02/01/18
Affected Content
All Pages
01
08/07/19
Section 7.9 (Testing)
Description of Changes
New Issue
API 598 9th Edition, September 2009
to API 598 10th Edition, October 2016
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
Document No: FKR-PR-08-REV01
Date: 08/07/2019
TABLE OF CONTENTS
NO
1
2
3
4
5
6
7
DESCRIPTION
Objective
Definition
References
Policy
Scope
Application
Procedure
PAGE
3
3
3
3
3
3
3-14
Appendix 1 – Service Report Template
Appendix 2 – Testing Certificate
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
Document No: FKR-PR-08-REV01
Date: 08/07/2019
1.
OBJECTIVE
To establish a consistent method for the inspection, service, repair and testing of general
valves.
2.
DEFINITION
FKR – Fuji Koki Resources (M) Sdn Bhd
GENERAL VALVE – Gate, Globe, Ball, Check, Butterfly
SHOP – FKR Workshop
HP – High pressure
LP – Low pressure
DBB – Double block and bleed
DP – Differential Pressure
WORF – Work Order Requisition Form
3.
REFERENCES
API 598 10th Edition, October 2016 – Valve Inspection & Testing
4.
POLICY
All testing performed on applicable general valves shall be in accordance to this procedure.
5.
SCOPE
This procedure is limited to the type of valves specified in API 598. Type of valves not specified
by API 598 shall adhere to other international testing standards or manufacturer standards.
Manufacturer standard shall prevail against other international testing standards.
6.
APPLICATION
This procedure applies to all employees of FKR performing inspection, servicing, repair and
testing of applicable general valves.
7.
PROCEDURE
7.1 VISUAL INSPECTION
i.
Ensure the valve received has not been utilized for hazardous/toxic service
and decontamination has been carried out prior entering the shop.
ii.
If the valve entering the shop has been utilized for hazardous/toxic service
and decontamination has not been carried out, ensure that decontamination
must be performed at the cleaning bay outside of the shop’s working area.
iii.
If the valve entering the shop has been utilized for hazardous/toxic service
and decontamination has not been carried out, ensure that decontamination
must be performed at the cleaning bay outside of the shop’s working area.
iv.
Record the following information on the worksheet:
• Valve Type
• Manufacturer/Brand
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
Document No: FKR-PR-08-REV01
Date: 08/07/2019
• Customer
• Material (Body & Trim)
• Serial no/Heat no/Tag no/Any form of identification no
• Size/Class
• End Connection
v. Check body/bonnet flanges and glands for signs of leakage and appearance
for missing or incomplete parts.
vi. Check for any visible exterior damages on the valve body.
7.2
DISASSEMBLY
Valve shall be disassembled and reduced to its component parts.
7.3
CLEANING
i. After disassembly, the valve components shall be thoroughly cleaned using cleaning
solvent and treated for rust/corrosion to facilitate close inspection of each
component.
ii. Name plate, fine threads, mating/seating/sealing surfaces shall be protected if
power tools are to be used for the cleaning process.
7.4
COMPONENT/INTERNAL PART INSPECTION
i. All components shall be carefully inspected, paying particular attention to
sealing surfaces and flanges for pitting, scoring and wear.
ii. Disc spring fitted to parallel slide valve shall be checked to ensure that they
return to their free length following full compression.
iii. Where specific request has been received in writing and information is
available, valves to which it applies shall have its body shell thickness tested
in accordance to relevant standard. If no such request/information is
received, this process shall be skipped.
iv. If excessive wear is present on stem/spindle, the extent of acceptable wear
may be gauged by reference to the appropriate product standard. The
stem/spindle and the nut threads should not show excessive wear. All the
other threaded components must be carefully checked.
v. Inform customer of any excessive wear or damage before proceeding on with
the repair. If requested, an inspection/finding report shall be provided to the
customer. Additional cost incurred to replace the part, must be approved by
the customer.
7.5
MACHINING
i. Where discs, seats are scored/pitted to an extend that lapping/polishing
would not remove the defect/damage. Machining of the disc/seat/wedge
shall be carried out on a suitable machine. Since machining is not under the
scope of a normal service, any machining cost incurred to return the part to
working condition, must be approved by the customer.
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
Document No: FKR-PR-08-REV01
Date: 08/07/2019
ii. Machine inlet/outlet and bonnet flanges where necessary. API 600
“Gramophone” finish where applicable to end flanges 24/50 groove/inch,
0.001” to 0.006” deep. Flange thickness checks will be made to ensure valves
are within tolerances laid down by relevant standards.
7.6
LAPPING
i. Using suitable lapping equipment; seats, wedges, discs, ball shall be
lapped/polished to ensure a leak free metal to metal sealing surface.
ii. A contact test “blue contact” shall be performed to ensure that the sealing
between the metal mating surfaces are uniform and continuous.
7.7
DISC, PLUG, WEDGE, BALL, SEAT
i. Where necessary; the face of the disc, plug, wedge, ball, and seat may be built
up by deposit welding with a rod having a composition equivalent to the
parent metal.
ii. Austenitic steel valves may have seats integrated with the body. If the
austenitic or hardened body seat material (normally stellite), the seat material
may be welded directly to the valve body or on separate seat rings.
iii. Back seats – where applicable, for valves fitted with back seat bushing in
bonnet to correspond to shoulder on the valve stem, these seating surfaces
shall be built up using compatible welding rods prior to machining/lapping
process.
iv. The corners of the seat rings shall be chamfered at inner and outer edges to
prevent scoring of wedge disc.
7.8
ASSEMBLY
i. Reassemble the valves, taking care not to damage disc, plug, wedge, ball or
seat and ensuring no restriction to moving parts.
ii. Seating surfaces may be lubricated with a light oil to prevent galling. The use
of a sealing medium on screwed seat rings is not permissible.
iii. Packing shall be befitted into the stuffing box according to manufacturer’s
instruction and to suit the service medium/product. It should provide an
efficient seal whilst allowing reasonable freedom of operation when
opening/closing. Any special arrangement i.e. packing above, and below
metal rings shall be retained.
iv. New gasket and packing, equivalent to or superior to the original, shall be
used.
7.9
TESTING (REFER TO API 598 & ASME B16.34 FOR TEST REQUIREMENTS)
i. Reference should be made to general safety notes on pneumatic and hydro
testing.
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
Document No: FKR-PR-08-REV01
Date: 08/07/2019
ii. Test medium for hydrotest shall be water unless otherwise requested by
customer. Pneumatic testing shall be carried out using compressed air or
nitrogen.
iii. Valves shall not be freshly painted prior to testing.
iv. Where requested, a customer’s representative may witness the test.
v. The pressure tests listed in Table 1 shall be performed on each applicable
valve.
Table 1 – Pressure Tests
Retrieved from API 598 Standard.
Valve Type
Test
Description
Shell
Backseata
Size
ASME
Class
Gate
Globe &
Parallel
Slide
Gate
Required
Required
Plug
Check
Floating
Ball
Butterfly &
Trunnion
Mounted Ball
All
All
Required
Required
Required Required
Required
All
All
Required
N/A
N/A
N/A
N/A
≤ DN
≤1500 Required
Requiredf
Required
100
>1500 Optionalb
Optionalb
Optionalb
(NPS 4)
b
b
LP closure
Optional
Optional
Required
> DN
≤600
Required
Requiredf
Required
100
>600
Optionalb
Optionalb
Optionalb
(NPS 4)
≤ DN
≤1500 Optionalbe
Optionalbef
Optionalbe
100
>1500 Required
Required
Required
(NPS
4)
d
be
HP closurec
Required
Required
Optional
> DN
≤600 Optionalbe
Optionalbef
Optionalbe
100
>600
Required
Required
Required
(NPS 4)
N/A: Not applicable
a. The backseat test is required for all valve that have the backseat feature, except for bellow seal valves.
b. When an “optional” test is specified by the purchaser, the test shall be performed in addition to the required
tests.
c. The HP closure test of resilient-seated valves may degrade subsequent sealing performance in low-pressure
service.
d. For power-operated and manually operated gear actuated globe valves, including non-return type globe valves,
the HP closure test shall be performed at 110% of the design DP used for sizing the operator.
e. A HP closure test is required for all valves specified to be DBB valves, unless specified otherwise by the
purchaser.
f. For lubricated plug valves, the HP seat test is mandatory, and the LP seat test is optional.
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
Document No: FKR-PR-08-REV01
Date: 08/07/2019
vi. Backseat Test
The backseat test is required for all valves that have the backseat feature,
except for bellow seal valves. It shall be performed by applying pressure inside
the assembled valve with the valve ends closed, the valve fully open, and the
gland packing shall be loose/packing not installed.
If the backseat test is performed after the shell test, the packing shall be
installed/ gland packing shall be re-tightened after the backseat test.
If hydro backseat test (liquid) is being conducted; the backseat test shall be
conducted at a pressure of 1.1 X the 38°C (100°F) working pressure by class,
rounded off to the next higher 1 bar (14.5 psi) increment. The 38°C (100°F)
working pressure by class is identified by referring to ASME B16.34.
For example, if a valve with 2500 pressure rating and with cast steel material
such as A216 Gr. WCB is to be backseat tested, then the maximum working
pressure as per ASME B16.34 table 2-1.1 will be 425.5 bar (6169.7 psi). The
1.1 X of this value will be 468.05 bar (6786.7) psi. Round it to the next ten, and
it will be 470 bar (6800 psi). So, the backseat test shall be performed by at 470
bar (6800 psi).
If pneumatic backseat test (air) is being conducted; the backseat test shall be
conducted at a pressure of 4 to 7 bar.
For valves 4” and smaller, the backseat test may be combined with the body
shell test when volumetric devices are used to monitor leakage from the body
and backseat. When tested by this method, the gland packing shall be loose.
It shall be demonstrated that the packing will not leak at the valve’s 38°C
(100°F) working pressure by class.
vii. Shell Test (Hydrostatic)/Body shell test
All valves shall be tested at a pressure of 1.5 X the 38°C (100°F) working
pressure by class, rounded off to the next higher 1 bar (14.5 psi) increment.
The 38°C (100°F) working pressure by class is identified by referring to ASME
B16.34. It is worth to be noted that ASME B16.34 segregates the working
pressure by class according to body material groups.
For example, if a valve with cast steel material (A 216 Gr. WCB) and rating of
2500 is to be body shell tested, table 2.1.1 in ASME B16.34 should be referred.
The table says the working pressure is 425.5 bar (6169.75 psi) at 38°C (100°F).
Now multiply this value by 1.5 and the test pressure will be 638.25 bar (9254.6
psi). Round it to the next ten, and it will be 640 bar (9300 psi). Hence the shell
test pressure for the valve in this example is 640 bar (9300 psi).
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
Document No: FKR-PR-08-REV01
Date: 08/07/2019
The valve shall be in the open position and the pressure shall be applied into
the assembled valve with the valve ends closed. The gland packing shall be
tight enough to maintain the test pressure. Check valves shall have the
pressure applied to the upstream side.
Shell test pressures are described as in Table 2 below:
Table 2 – Shell Test Pressuresd
Valve Type
Class
Ductile Iron
150
300
Gray Iron
DN 50 to 300 (NPS 2 to
12)
DN 350 to 1200 (NPS
14 to 48)
Gray Iron
DN 50 to 300 (NPS 2 to
12)
DN 350 to 600 (NPS 14
to 24)
Steel & Nonferrous
Alloy
Flanged
Butt weld
Threadeda and Socket
Weld
125
250
Shell test Pressure (Minimum)
Bar Gauge
PSIG
26
400
66
975
25
350
19
265
61
875
37
525
150 to 2500
b
b
150 to 4500
b
b
800
c
c
150 to 4500
b
b
a. ASME B16.34 limits threaded-end valves to Class 2500 and lower.
b. Per ASME B16.34, the shell test pressure shall be 1.5 times the pressure rating at 38°C (100°F),
rounded off to the next higher bar (25 psig). The attachment of hubs, flanges, or other end
connections with ambient working pressures lower than the primary valve assembly will require
lower test pressures.
c. For Class 800 valves, the shell test pressures shall be 1.5 times the pressure rating at 38°C
(100°F), rounded off to the next higher bar (25 psig) (see API Standard 602[4]).
d. Shell test pressure for API Standard 609 Category A valves shall be 1.5 times the maximum
CWP of the valve.
Retrieved from API 598 Standard
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
Document No: FKR-PR-08-REV01
Date: 08/07/2019
viii. Seat Test (Pneumatic)/ Low-pressure closure test (LP seat test)
The LP seat test shall be performed with the sealing surface interface clean
and free from oil, grease and sealant. If necessary to prevent galling, the
sealing surfaces may be coated with a film of oil that is not heavier than
kerosene. This requirement does not apply to a valve that uses a lubricant as
its primary seal (i.e. lubricated plug valves.)
The testing medium shall be compressed air/nitrogen gas as requested by
customer. The valve shall be in the fully closed position. For a valve (other
than a DBB valve or globe valve) designed to close against pressure from
either direction, the pressure shall be applied successively to each side (Side
A & B) of the closed valve. The left side of the valve’s manufacturer body
marking shall be designated as Side A and the other side as Side B.
For a globe valve, pressure shall be applied in one direction with the pressure
applied under the disc.
For a valve designed to close against pressure from one direction only and so
marked (uni-direction), the pressure shall be applied on the pressure side of
the valve only. For a check valve, the pressure shall be applied on the
downstream side.
For a DBB valve, the pressure shall be applied successively to each side of the
closure through the valve port. Leakage into the body cavity between the
seats shall be checked through observation at a tapped opening between the
seats. Valves shall be tested with the stem in the vertical upright position.
A closure test is required only in one direction for a butterfly valve furnished
with encapsulation or resilient internal liners designed for use with Class 125
or Class 150 flanges (API Std. 609 Category A valves). For other resilient-seated
butterfly valves (API Std. 609 Category B valves), the closure test shall be in
both direction (bi-direction). For valves with a preferred flow direction, the
closure test in the non-preferred direction shall be based on the reduced DP
rating in that direction.
Any leakage at the seat sealing surface interface, behind the seat ring, or
through the disk on the openside of the valve shall be detected when bubbles
are observed coming from the closure (disc, seat and seat ring) which is either
covered with water or coated with a soap or similar solution (snoop oil).
Alternatively, displacement measuring devices may be used, provided that the
detectable leakage rate is equivalent to that given in API 598 Table 5. Bubble
testing, when used for valves larger than 2”, shall only be acceptable when
agreed by the customer. When volumetric devices (bubblers) are used to
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
Document No: FKR-PR-08-REV01
Date: 08/07/2019
measure leakage, the test duration shall not begin until flow through the test
tube is stabilized.
ix. Seat Test (Hydrostatic)/ High-pressure closure test (HP seat test)
HP seat test shall be conducted at a pressure of 1.1 X the 38°C (100°F) working
pressure by class, rounded off to the next higher 1 bar (14.5 psi) increment.
The 38°C (100°F) working pressure by class is identified by referring to ASME
B16.34.
For example, if a valve with 2500 pressure rating and with cast steel material
such as A216 Gr. WCB is to be seat tested, then the maximum working
pressure as per ASME B16.34 table 2-1.1 will be 425.5 bar (6169.7 psi). The
1.1 X of this value will be 468.05 bar (6786.7) psi. Round it to the next ten, and
it will be 470 bar (6800 psi). So, the seat leak test shall be performed by at 470
bar (6800 psi).
The water/liquid used for testing must be clean and free from
residue/particles to ensure no damage to the sealing/mating component of
the valve. The valve shall be in the closed position. Leakage shall be detected
when drops, not bubbles. Other than the above, the procedure for a HP seat
test shall be the same as the procedure for the LP closure test. Seat test
pressure and other test pressures are tabulated in Table 3 below:
Table 3 – Backseat & Other Test Pressures
Test Pressured
Test
Bar Gauge
Valves Except Butterfly and Check
a
HP closure & Backseat
b
a
LP closure & Backseat
5.5±1.5
Butterfly Valve
HP closure
c
LP closure
5.5±1.5
Check Valve
HP closure
Class 125 (cast iron)
DN 50 to 300 (NPS 2 to 12)
14
DN 350 to 1200 (NPS 14 to 48)
11
Class 250 (cast iron)
DN 50 to 300 (NPS 2 to 12)
35
DN 350 to 600 (NPS 14 to 48)
21
Class 150 (ductile iron)
17
PSIG
b
80±20
c
80±20
200
150
500
300
250
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
Document No: FKR-PR-08-REV01
Date: 08/07/2019
Class 300 (ductile iron)
44
640
Carbon, alloy, stainless steel,
b
b
and special alloys
LP seat test (Refer Table 1)
5.5±1.5
80±20
a. The backseat test is required for all valves that have this feature, except for bellow seal valves
b. 110% of the maximum allowable pressure at 38°C (100°F) in accordance with the applicable
purchase specification.
c. 110% of the design DP at 38°C (100°F) in accordance with the applicable purchase specification.
d. Single values shown are minimum test pressures. Values with a tolerance indicate both minimum
and maximum test pressures.
Retrieved from API 598 Standard
Table 4 – Duration of Required Tests
Minimum Test Duration (Seconds)a
Backseat (for
Closure test
valves with
Closure test
DN
NPS
Shell
Check Valves
Backseat
Other Valves
(API 594)
feature)
≤ 50
≤2
15
15
60
15
65 to 150
2 ½ to 6
60
60
60
60
200 to 300
8 to 12
120
60
120
120
≥ 350
≥ 14
300
60
120
120
a. The test duration is the period of inspection after the valve is fully prepared and is under full
pressure.
Retrieved from API 598 Standard
Valve Size
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
Valve Size
DN
(mm)
NPS
(in.)
≤ 50
65
80
100
125
150
200
250
300
350
400
450
500
600
650
700
750
800
900
1000
1050
1020
≤2
2½
3
4
5
6
8
10
12
14
16
18
20
24
26
28
30
32
36
40
42
48
Document No: FKR-PR-08-REV01
Date: 08/07/2019
Table 5 – Maximum Allowable Leakage Rates for Closure Testsc
All
Metal Seated Valves Except Check
Metal Seated Check Valves
Resilient
Valve
Seated
Liquid
Gas
Gas
Liquid Testa
Gas Testa
Valves
Test
Test
Test
(drops/minute) (bubbles/minute)
(cc/min) (m3/h) (ft3/h)
0
0b
0b
6
0.08
3
0
5
10
7.5
0.11
3.75
0
6
12
9
0.13
4.5
0
8
16
12
0.17
6
0
10
20
15
0.21
7.5
0
12
24
18
0.25
9
0
16
32
24
0.34
12
0
20
40
30
0.42
15
0
24
48
36
0.50
18
0
28
56
42
0.59
21
0
32
64
48
0.67
24
0
36
72
54
0.76
27
0
40
80
60
0.84
30
0
48
96
72
1.01
36
0
52
104
78
1.09
39
0
56
112
84
1.18
42
0
60
120
90
1.26
45
0
64
128
96
1.34
48
0
72
144
108
1.51
54
0
80
160
120
1.68
60
0
84
168
126
1.76
63
0
96
192
144
2.02
72
a. For liquid test, 1mL is considered equivalent to 16 drops. For the gas test 1mL is considered equivalent to
100 bubbles.
b. There shall be no leakage for the minimum specified test duration (Refer Table 4.). For liquid test 0 drops
means no visible leakage per minimum specified test duration. For standard gas test, 0 bubbles mean less
than 1 bubble per minimum specified test duration.
c. Leakage rates for sizes above DN 1200 (NPS 48) shall be calculated by the following formula:
Liquid Test for Metal Seated Valves except Check: 2 X NPS (drops/min)
Gas Test for Metal Seated Valves except Check: 4 X NPS (bubbles/min)
Liquid Test for Metal Seated Check Valves: 3 X NPS (cc/min)
Gas Test for Metal Seated Check Valves: 0.042 X NPS (m3/h)
Gas Test for Metal Seated Check Valves: 1.5 X NPS (ft3/h)
Retrieved from API 598 Standard
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
7.10
Document No: FKR-PR-08-REV01
Date: 08/07/2019
REPORT & CERTIFICATE
Each valve shall have a service & repair report and a test certificate. If the work done does not
involve any repair/machining works; the report shall be classed as a Service Report. If the work
done involves repair/machining works; the report shall be classed as a Service & Repair
Report.
The report and test certificate shall contain the below information as a minimum:
▪ FKR Job No
▪ Customer name
▪ Certificate Number
▪ Date of Issue
▪ Valve Type, Manufacturer, Size, Pressure Rating
▪ Valve Tag Number/Identification Number
▪ Test pressure and duration for the tests conducted
If the valve could not pass testing after the service/repair has been performed, a NonConformance Report (NC Report) shall be issued to the customer.
i.
Service/Repair Report
A service/repair report shall be issued to the customer not longer than 1 working week
after the completion of the service/repair works upon request.
The report shall be of a photo report format and all-important aspects of the scope of
work including testing shall be highlighted in the report.
Refer attached template of this report in Appendix 1.
ii. Testing
A test certificate shall be issued to the customer not longer than 3 working days after the
completion of the testing.
The certificate shall be of a non-photo report format.
Refer attached template of the test certificate in Appendix 2.
iii. Approval of Report & Certificate
Each report & certificate shall be signed by the technician, engineer and/or a third
party/customer witness if requested.
iv. Certificate Number
Each individual valve shall have its own unique certificate number for recording and
tracking purpose. It shall be noted that the Service/Repair Report, NC Report (if
applicable), & Test Report shall be of the same certificate number for a valve. The
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
Document No: FKR-PR-08-REV01
Date: 08/07/2019
certificate number shall be obtained from the Work Certificate Number Running No Form
(FKR-FM-20-REV00).
7.11
PAINTING
i. Touch-Up Painting
Touch up painting shall be performed if requested by customer only and it will be
performed according to the existing surface paint color of the valve unless otherwise
specified by customer or on the WORF.
ii. Blasting & Painting
Unless not specified by the customer in writing or documented in the WORF, blasting &
painting will not be performed.
If specified, the blasting & painting will be performed, and a subsequent blasting &
painting report shall be issued to the customer not longer than 1 working week after the
blasting & painting was performed on the valve.
7.12
PACKING & PRESERVATION
All valves shall be packed according to Handling, Storage, Packing, Unpacking & Preservation
Procedure FKR-PR-26-REV00 unless otherwise specified by customer or in the WORF.
14 | P a g e
QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 01
Title: Procedure for General Valve Service, Repair &
Testing
Document No: FKR-PR-08-REV01
Date: 08/07/2019
APPENDIX 1 – SERVICE REPORT TEMPLATE
15 | P a g e
FUJI KOKI RESOURCES (M) SDN BHD.
SERVICE REPORT
CUSTOMER
JOB NO.
CERTIFICATE NO.
IDENTIFICATION NO.
VALVE DETAILS
DATE OF ISSUE
INCOMING INSPECTION
Remarks:
DISASSEMBLY & CLEANING
Remarks:
LAPPING & REPLACEMENT OF PARTS
Remarks:
Lot 2 to 8, The Highway Center, Jalan 51/205, 46050
Petaling Jaya, Selangor Darul Ehsan, Malaysia
Tel: +603 7781 4493
FUJI KOKI RESOURCES (M) SDN BHD.
SERVICE REPORT
CUSTOMER
JOB NO.
CERTIFICATE NO.
IDENTIFICATION NO.
VALVE DETAILS
DATE OF ISSUE
INCOMING
LP SEAT TEST
INSPECTION
(SIDE A)
Remarks:
LP SEAT TEST (SIDE B)
Remarks:
HP SEAT TEST (SIDE A)
Remarks:
Lot 2 to 8, The Highway Center, Jalan 51/205, 46050
Petaling Jaya, Selangor Darul Ehsan, Malaysia
Tel: +603 7781 4493
FUJI KOKI RESOURCES (M) SDN BHD.
Lot 2 to 8, The Highway Center, Jalan 51/205, 46050
Petaling Jaya, Selangor Darul Ehsan, Malaysia
Tel: +603 7781 4493
SERVICE REPORT
CUSTOMER
JOB NO.
CERTIFICATE NO.
VALVE DETAILS
IDENTIFICATION NO.
DATE OF ISSUE
INCOMING
INSPECTION
HP SEAT TEST
(SIDE B)
Remarks:
SHELL TEST
Remarks:
TOUCH-UP PAINTING
Before
Remarks:
After
FUJI KOKI RESOURCES (M) SDN BHD.
Lot 2 to 8, The Highway Center, Jalan 51/205, 46050
Petaling Jaya, Selangor Darul Ehsan, Malaysia
Tel: +603 7781 4493
SERVICE REPORT
CUSTOMER
JOB NO.
CERTIFICATE NO.
VALVE DETAILS
IDENTIFICATION NO.
DATE OF ISSUE
NOTICES/RECOMMENDATIONS
INCOMING INSPECTION
1. Testing performed according to API 598.
2. Valve pass testing.
3. Valve is in good condition after service.
TEST RESULT: LOW PRESSURE SEAT TEST SIDE A & B (PASS), HIGH PRESSURE SEAT TEST SIDE A & B (PASS), BODY SHELL (PASS)
SIGNATORIES
PREPARED BY (TECHNICIAN):
CHECKED BY (SERVICE ENGINEER):
DATE:
DATE:
QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 00
Title: Procedure for General Valve Service, Repair &
Testing
Document No: FKR-PR-08-REV00
Date: 02/01/2018
APPENDIX 2 – TESTING CERTIFICATE TEMPLATE
FUJI KOKI RESOURCES (M) SDN BHD.
Lot 2 to 8, The Highway Center, Jalan 51/205, 46050 Petaling Jaya, Selangor Darul Ehsan, Malaysia
Tel: +603 7781 4493
TESTING CERTIFICATE
CUSTOMER
:
CERTIFICATE NO.
:
JOB NO.
:
DATE
:
IDENTIFICATION NO. :
MANUFACTURER
:
VALVE TYPE
:
FIGURE NO
:
BODY TYPE
SIZE
CLASS
BODY
TRIM
SEAT
OPERATION
END CONNECTION
:
:
:
:
:
:
:
:
SCOPE OF WORK
1. Identification number designation.
2. Physical inspection on valve exterior.
3. Disassembly.
4. Cleaning of valve exterior and internal parts.
5. Lapping/Polishing.
6. Replacement of internal parts.
7. Pressure-test (API 598).
8. Touch-up painting.
9. Issuance of inspection & testing photo report and testing certificate.
10. Packing & delivery.
INSPECTION FINDINGS
1. The condition of the valve exterior is corroded and rusty.
2. Open/close operation is rough.
3. Internal parts i.e ball has scratch marks. Requires lapping/polishing. Seat (2pcs) has worn out and damaged. Requires replacement.
4. Flange surface is corroded and rusty.
WORK DONE
1. As listed in scope of work
2. Low pressure seat test (LP) - Side A. Pressure - 6 Bar. Duration - 1 minute. Medium - Compressed Air
3. Low pressure seat test (LP) - Side B. Pressure - 6 Bar. Duration - 1 minute. Medium - Compressed Air
4. High pressure seat test (HP) - Side A. Pressure - 22 Bar. Duration - 1 minute. Medium - Water
5. High pressure seat test (HP) - Side B. Pressure - 22 Bar. Duration - 1 minute. Medium - Water
6. Hydro shell test (Body). Pressure - 30 bar. Duration - 1 minute. Medium - Water
TEST RESULTS (API 598)
LP SEAT TEST SIDE A
LP SEAT TEST SIDE B
HP SEAT TEST SIDE A
HP SEAT TEST SIDE B
BODY SHELL
BACKSEAT TEST
6
6
22
22
30
N/A
BAR
BAR
BAR
BAR
BAR
BAR
DURATION
DURATION
DURATION
DURATION
DURATION
DURATION
1
1
1
1
1
N/A
MINUTE (s)
MINUTE (s)
MINUTE (s)
MINUTE (s)
MINUTE (s)
MINUTE (s)
REMARKS/ RECOMMENDATION
TESTING RESULT: No leakage detected for low & high pressure seat test SIDE A.
No leakage detected during low & high pressure seat test SIDE B.
No leakage is detected during shell test.
Testing performed based on API 598 standard.
1. Valve is in working condition and fit to be installed to pipeline after service.
PREPARED BY
SIGNATURE
NAME
DESIGNATION
DATE
:
:
:
:
Technician
CHECKED BY
SIGNATURE
NAME
DESIGNATION
DATE
:
:
:
:
Service Engineer
PASS
PASS
PASS
PASS
PASS
N/A