1、Process Valve Qualification ProcedureAPI RECOMMENDED PRACTICE 591 FIFTH EDITION, FEBRUARY 2014Special NotesAPI publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed.Neither API nor an
2、y of APIs employees, subcontractors, consultants, committees, or other assignees make any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any use, or th
3、e results of such use, of any information or process disclosed in this publication. Neither API nor any of APIs employees, subcontractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights.API publications may be used by anyone desi
4、ring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility f
5、or loss or damage resulting from its use or for the violation of any authorities having jurisdiction with which this publication may conflict.API publications are published to facilitate the broad availability of proven, sound engineering and operating practices. These publications are not intended
6、to obviate the need for applying sound engineering judgment regarding when and where these publications should be utilized. The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices.Any manufacturer marking equipment or materials
7、in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard.Users of this Recommended Prac
8、tice should not rely exclusively on the information contained in this document. Sound business, scientific, engineering, and safety judgment should be used in employing the information contained herein.All rights reserved. No part of this work may be reproduced, translated, stored in a retrieval sys
9、tem, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, NW, Washington, DC 20005.Copyright 2014 American Petroleum InstituteForewordNothing con
10、tained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liabilit
11、y for infringement of letters patent.Shall: As used in a standard, “shall” denotes a minimum requirement in order to conform to the specification.Should: As used in a standard, “should” denotes a recommendation or that which is advised but not required in order to conform to the specification.This d
12、ocument was produced under API standardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this publication or comments and questions concerning the proc
13、edures under which this publication was developed should be directed in writing to the Director of Standards, American Petroleum Institute, 1220 L Street, NW, Washington, DC 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addre
14、ssed to the director.Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. A one-time extension of up to two years may be added to this review cycle. Status of the publication can be ascertained from the API Standards Department, telephone (202) 682-8
15、000. A catalog of API publications and materials is published annually by API, 1220 L Street, NW, Washington, DC 20005.Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, standardsapi.org.iiiContentsPage1 Scope . . . . .
16、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Normative References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17、 . . . . . . . 13 Terms and Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Purchaser Responsibilities and Recommended Actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18、. . . . . 35 Manufacturer Quality Management System Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19、. . . . . . . . . . 45.2 Record and Documentation Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.3 Right of Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20、. . . . . . . . . . . . . . . . . . . . 45.4 Document Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Valve Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.1 Data to be Provided by Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46.2 Valve Qualification Facility . . . . . . . . . . . . . . . . . . . . .
22、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.3 Selection of Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.4 Required Examination and Testing . . . .
23、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66.5 Documentation of Examination and Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Post Qualification . . . . . . . . . . . . . .
24、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Annex A (normative) Selection Quantities for Examination and Test of Valves Made in Accordance with API Valve Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Annex B (normative) Strength Tests for Stem Shaft-to-closure Element Connections . . . . . . . . . . . . . . . . . . . 14Annex C (informative) Suggested Minimum Acceptable Casting Radiographic Results for Wall Thickness 50 mm (2 in
26、.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Annex D (normative) Examination and Testing Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Fig
27、ureB.1 Torsional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Tables1 Material Examination Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28、. . . . . . . . . . . . . . . . . 7A.1 Valve Selection Material Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A.2 Suggested Size and Class to be Tested for Each Type Check Valve (Single Plate, Dual Plate, Swing Type) Made
29、 in Accordance with API 594 or ASME B16.34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A.3 Suggested Size and Class to be Tested for Each Type Plug Valve (Lubricated, Non-lubricated, Elastomer Lined, Wedge Type) Made in Accordance with API 599 . . . . . . . . . . . . . . . . .
30、. . . . . . . . . . . . . . 11A.4 Suggested Size and Class to be Tested for Steel Gate Valves Made in Accordance with API 600 . . . . . 11A.5 Suggested Size and Class to be Tested for Flanged Steel Gate Valves Made in Accordance with API 602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A.6 Suggested Size and Class to be Tested for Threaded/SW Steel Gate Valves Made in Accordance with API 602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32、. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12A.7 Suggested Size, Class and Type to be Tested for Steel Globe and Check Valves Made in Accordance with API 602 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33、 12A.8 Suggested Size and Class to be Tested for Steel Gate Valves Made in Accordance with API 603 . . . . . 12vA.9 Suggested Size and Class to be Tested for Each Type Ball Valve (Floating Type: End Entry, Split Body, Three Piece and Top Entry; Trunnion Type: Split Body, Three Piece) Made in Accorda
34、nce with API 608 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.10 Suggested Size and Material Type to be Tested for Butterfly Valves (Class 150, Ductile Iron, Grey Iron) Made in Accordance with API 609 (Category
35、A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A.11 Suggested Size and Class to be Tested for Each Type of Offset Butterfly Valves Made in Accordance with API 609 (Category B). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36、 . . . . . . . 13A.12 Suggested Size and Class to be Tested for Steel Globe Valves Made in Accordance with ASME B16.34 or API 623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13C.1 Acceptable Casting Rad
37、iographic Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16D.1 Dimension and Finishes Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17D.2 Visual Examinations
38、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19vi1Process Valve Qualification Procedure1 ScopeThis recommended practice (RP) provides recommendations for evaluation of a manufacturers valve construction and
39、 quality management system for the purpose of determining a manufacturers capability to provide new valves manufactured in accordance with the applicable standards listed in Section 2.Qualification of valves under this RP is “manufacturing facility specific” and does not cover valves manufactured by
40、 other manufacturing facilities, whether owned by the same manufacturer or a third party.2 Normative ReferencesThe following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition o
41、f the referenced document (including any amendments) applies. API RP 578, Material Verification Program for New and Existing Alloy Piping SystemsAPI 594, Check Valves: Flanged, Lug, Wafer, and Butt-weldingAPI 598, Valve Inspection and Testing API 599, Metal Plug ValvesFlanged, Threaded and Welding E
42、ndsAPI 600, Bolted Bonnet Steel Gate Valves for Petroleum and Natural Gas Industries API 602, Steel Gate, Globe and Check Valves for Sizes DN 100 and Smaller for the Petroleum and Natural Gas IndustriesAPI 603, Corrosion-resistant, Bolted Bonnet Gate ValvesFlanged and Welding EndAPI 607, Fire Test f
43、or Quarter-turn Valves and Valves Equipped with Nonmetallic SeatsAPI 608, Metal Ball ValvesFlanged, Threaded, and Butt-welding Ends API 609, Butterfly Valves: Double Flanged, Lug- and Wafer-typeAPI 623, Steel Globe Valves-Flanged and Butt-welding Ends, Bolted BonnetsAPI 624, Type Testing of Rising S
44、tem Valves Equipped with Flexible Graphite Packing for Fugitive EmissionsASME B1.1 1, Unified Inch Screw Threads (UN b) organizational structure and functional responsibilities with levels of authority;c) approved supplier list;d) most recent supplier evaluation record;e) inspection and test plan fo
45、r purchased pressure containing components;f) confirmation of sub-supplier quality management system following the principals of ISO 9001;g) documents and records relating to special processes such as those used in welding, heat treatment, and nondestructive examination;h) final product examination
46、and testing documents;i) test equipment list; andj) traceability procedures of pressure containing components:1) certified mill test reports (CMTRs),2) certificates of compliance (CoCs).5.3 Right of AccessThe manufacturers procurement documents shall require their suppliers to provide access to thei
47、r plant facilities and records for inspection or audit by the manufacturer, his/her designated representative, or other parties authorized by the manufacturer.5.4 Document ControlDocuments supplied during valve qualification shall be controlled documents.6 Valve Qualification 6.1 Data to be Provided
48、 by Manufacturer6.1.1 General assembly drawings of one valve size of each design for each pressure class shall be available to the qualification facility. These drawings shall show all applicable construction details, including: stem-to-wedge, disk, ball, or plug connection; guides; bearings; stem s
49、eals; body joint, body joint gasket, seat(s) and seal(s). They shall PROCESS VALVE QUALIFICATION PROCEDURE 5also include descriptions of the construction materials for all of the parts, including fasteners. The manufacturer shall also identify the trim and sealing materials used. 6.1.2 If welding, including casting repair, was used in the manufacture of the valves being evaluated, the applicable qualification and procedure documents shall be included for evaluation.6.1.3 The manufacturer shall make available a tabulation of the foundries and forge shops from which castings or forgin
