1、THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION A Guide to the Production Testing of Valves for the Energy, Process and related Industries PUBLICATION 205 Released by IHS. Not for resale.THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION A Guide to the Production Testing of Valves f
2、or the Energy, Process and related Industries PUBLICATION 205 Copyright 2008 The Engineering Equipment and Materials Users Association A company limited by guarantee. Registered in England. Company number 477838. ISBN 0 85931 151 1 Imprint reference 06-2008 Registered and Trading Address 10-12 Lovat
3、 Lane London EC3R 8DN Telephone: +44 (0)20 7621 0011 Fax: +44 (0)20 7621 0022 E-mail: saleseemua.org Website: www.eemua.org EEMUA Publication 205 - Production Testing of Valves EEMUA iiENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION The Engineering Equipment and Materials Users Association, mo
4、re commonly known as EEMUA, is a European based, non-profit distributing, industry Association run for the benefit of companies that own or operate industrial facilities. EEMUA aims to improve the safety, environmental and operating performance of industrial facilities in the most cost-effective way
5、. EEMUA Members pursue these aims by sharing engineering experiences and expertise, and by the promotion of their distinct interests as the users of engineering products. More specifically, the aims of EEMUA Member companies are achieved by: providing the organisation within which networking, inform
6、ation sharing and collaboration on non-competitive technical matters can take place; influencing the way written regulations are interpreted and applied in practice; presenting and promoting Members views, and encouraging the application of good, sound engineering practices; developing and publishin
7、g user guides, specifications and training materials; facilitating Members participation in national and international standards making; influencing relevant national and European legislation and regulations. Formed in 1949 as the Engineering Equipment Users Association, and re-named in 1983 (as a r
8、esult of taking over the materials association, OCMA), EEMUA has for more than fifty years given companies that own and operate process plants, power stations and other significant industrial facilities, a collaborative voice in addressing technical and engineering related issues that impact on good
9、 integrity management and asset management practices. The Association is open to companies of all sizes that meet the engineering user criteria. A list of current Members of EEMUA is maintained on the Associations website at www.eemua.org/about.htm. EEMUA activities often lead to the production of p
10、ublications. These are prepared primarily for Members use, but may be offered for sale as well. A list of EEMUA publications for sale is given at the end of this Publication. The full list is also on the Associations website at www.eemua.org/acatalog/shop.html, together with on-line shopping facilit
11、ies. To enquire about corporate Membership, write to infoeemua.org or call +44 (0)20 7621 0011. EEMUA Publication 205 - Production Testing of Valves EEMUA iiiABOUT THIS PUBLICATION Legal Aspects All rights, title and interest in this Publication shall belong to EEMUA. All rights are reserved. No par
12、t of this Publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means: electronic, mechanical, photocopying, recording or other, without the express prior written agreement of the EEMUA Executive Director. Infringement of copyright is not only illegal, but
13、 also reduces the Associations income thereby jeopardising its ability to fund the production of future publications. It has been assumed in the preparation of this Publication that: the user will ensure selection of those parts of its contents appropriate to the intended application; and that such
14、selection and application will be correctly carried out by appropriately qualified and competent persons for whose guidance this Publication has been prepared. EEMUA does not, and indeed cannot, make any representation or give any warranty or guarantee in connection with material contained in its pu
15、blications, and expressly disclaims any liability or responsibility for damage or loss resulting from their use. Any recommendations contained herein are based on the most authoritative information available at the time of writing and on current good engineering practice, but it is essential for the
16、 user to take account of pertinent subsequent developments and/or legislation. Any person who encounters an inaccuracy or ambiguity when making use of this Publication is asked to notify EEMUA without delay so that the matter may be investigated and appropriate action taken. Consultation and Feedbac
17、k EEMUA encourages constructive comments on this Publication from both Members of the Association and others. Comments should be sent on the standard feedback form, a copy of which is provided towards the end of this Publication. An electronic version of the form is available from EEMUA - e-mail you
18、r request for a copy to infoeemua.org, telephone your request to +44 (0)20 7621 0011, or download the form from the EEMUA website at www.eemua.org. Submit comments by e-mail (preferred) or post. Comments will be considered by the relevant EEMUA Technical Committees and may be incorporated in future
19、editions of this Publication. New editions will be publicised on the EEMUA website. EEMUA Publication 205 - Production Testing of Valves EEMUA ivEEMUA Publication 205 - Production Testing of Valves EEMUA vContents Foreword .1 1. Scope 3 2. Equipment, Facilities and Procedures for Pressure Testing 5
20、2.1 General Responsibilities for the Manufacturer .5 2.2 Equipment and Facilities: Particular Requirements 5 2.3 Test Fluid6 2.4 Witnessing and Test Reporting .7 2.5 Removal and/or Refitting of Parts .7 3. Types and Sequence of Tests.9 3.1 Recommended Test Requirements 9 3.2 Information to be Provid
21、ed by the Purchaser9 3.3 Test Sequence.9 4. Shell Test .11 4.1 Purpose 11 4.2 Hydrostatic Shell Test . 11 4.3 Low Pressure Air Shell Test 12 4.4 Acceptance Criteria 12 5. Body Cavity Relief Test13 5.1 Purpose 13 5.2 Frequency of Testing 13 5.3 General 13 5.4 Test Procedure for Trunnion-Mounted Ball
22、or Slab Gate Valve with Internal Cavity Relief 13 5.5 Test Procedure for Floating Ball Valve with Internal Cavity Relief. 13 5.6 Test Procedure for Ball Valve, Expanding Gate Valve or Expanding Plug Valve with External Cavity Relief 14 5.7 Acceptance Criteria 14 6. Seat Test 15 6.1 Purpose 15 6.2 Ge
23、neral 15 6.3 High Pressure (HP) Hydrostatic Seat Test Procedure 16 6.4 High Pressure (HP) Hydrostatic Seat Test Procedure 16 6.5 High Pressure (HP) Hydrostatic Seat Test Procedure 17 6.6 Low Pressure (LP) Air Seat Test Procedure. 17 6.7 Low Pressure (LP) Air Seat Test Procedure. 18 6.8 Low Pressure
24、(LP) Air Seat Test Procedure. 19 6.9 High Pressure Gas Seat Test 19 6.10 Acceptance Criteria 20 7. Operational Test21 7.1 Purpose 21 7.2 Frequency of Testing 21 7.3 Procedures 21 7.4 Acceptance Criteria 21 8. Anti-static Test23 8.1 Purpose 23 8.2 Frequency of Testing 23 8.3 Procedure . 23 8.4 Accept
25、ance Criteria 23 EEMUA Publication 205 - Production Testing of Valves EEMUA vi9. Back Seat Test (Globe and Gate Valves) 25 9.1 Purpose 25 9.2 General 25 9.3 Frequency of Testing 25 9.4 Procedure . 25 9.5 Acceptance Criteria 25 10. Disc Strength Test (Butterfly Valves) 27 10.1 Purpose. 27 10.2 Freque
26、ncy of Testing . 27 10.3 Procedure 27 10.4 Acceptance Criteria . 27 11. Test Times 29 12. References31 13. Definitions 33 Appendix A: Typical Valve Test Report 37 Appendix B: Information relevant to testing to be supplied by the purchaser 39 Appendix C: Leak rates typically achievable by good qualit
27、y valves40 Tables Table 1 Recommended Valve Test Requirements 10 Table 2 Hydrostatic Shell Test Minimum Durations 29 Table 3 Hydrostatic and Air/Gas Seat Test Minimum Durations . 29 EEMUA Publication 205 - Production Testing of Valves EEMUA 1Foreword This Guide, developed by the EEMUA Piping Systems
28、 Technical Committee Valves section, is aimed at providing guidance to users, specifiers and inspectors with regard to production testing of ball, plug, gate, butterfly and globe valves designed to internationally recognised standards and intended for use in the energy, process and related industrie
29、s. It is a common assumption that valve test and product standards contain all that is required to ensure adequate performance, but this is not always the case. Standards committees dominated by manufacturers, and the difficulties involved in achieving universal agreement, often result in a lowest c
30、ommon denominator which may not always fulfil the users expectations, particularly for critical services. For example, seat leak test pressures should ideally reflect the seating mechanism of the valve (i.e. whether it utilises externally applied force or differential pressure) and the differential
31、pressure against which valves are required to seal in service, but often do not. Also, minimum required test times are often very short. Purchasers should consider the value of such short test times, when the time taken for conditions to stabilise might be several minutes. Terminology In this docume
32、nt, the words will and should, when used in the context of actions or requirements of or by the purchaser or other parties, have specific meanings as follows: will is used in connection with an action by the purchaser, or with an action or requirement normally expected of the manufacturer or supplie
33、r; should indicates a recommendation; where a recommendation is of particular importance, phrases such as need to are used. EEMUA Publication 205 - Production Testing of Valves EEMUA 2EEMUA Publication 205 - Production Testing of Valves EEMUA 31. Scope This Guide sets out the recommended production
34、tests to be applied to the following types of valves: ball, plug, gate, butterfly and globe. It does not apply to valves used exclusively for control purposes. Tests of an optional nature are included. Tests outside the scope of this Guide include material sampling and non-destructive testing of val
35、ve materials to verify their physical properties, chemical composition and quality. Type approval tests, fire type tests and tests at high and low temperature, are also excluded. EEMUA Publication 205 - Production Testing of Valves EEMUA 4EEMUA Publication 205 - Production Testing of Valves EEMUA 52
36、. Equipment, Facilities and Procedures for Pressure Testing 2.1 General Responsibilities for the Manufacturer 2.1.1 Testing will normally be carried out by the manufacturer who will be responsible for providing all the necessary facilities, labour and equipment required to perform the tests and insp
37、ections, and for overall safety in the preparation for and conduct of the test. 2.1.2 The manufacturer will need to be able to demonstrate to the satisfaction of the purchaser the adequacy of the methods and equipment used to carry out and monitor the test. 2.1.3 The manufacturer will normally be re
38、sponsible for the safety and design of test equipment and for providing adequate safeguards for personnel in the areas of the test. 2.2 Equipment and Facilities: Particular Requirements 2.2.1 The valve needs to be adequately illuminated and accessible for inspection. 2.2.2 The test equipment and met
39、hod of pressurising the valve need to ensure that all pressure containing parts of the valve are strength tested and it is not subjected to external constraint. Axial loads should, ideally, not be reduced by the method adopted to blank the ends (see Note 1 below). Where this is not practical or econ
40、omical, in all cases a minimum of one valve of each unique size, material and rating should be tested. Approved methods of blanking valve ends for pressure sealing are: blank flanges or covers for flanged end valves; weld end caps with or without pups for weld end valves; screwed plugs for threaded
41、end valves. Alternative pressure sealing methods may be used when agreed by the purchaser, but it is recommended that these be considered only where the validity of the valve design has been proven by prototype or sample testing with blank ends attached to the valve (see Note 2). Note 1: When blank
42、ends are attached to a valve, then maximum longitudinal tensile stresses are developed when the valve is internally pressurised. This assists in detecting cracks in the valve materials and weaknesses in bolted joints and other connecting parts. This is particularly important if valves have a body jo
43、int transverse to the pipe axis. Note 2: A reduction in longitudinal stresses in the valve body can result from some alternative pressure sealing methods, e.g. clamping the valve ends in a press and internally sealing valve bores with floating bungs. The ends of valve bores sealed by floating bungs
44、are not subjected to the test pressure and may require supplementary non-destructive testing (NDT). 2.2.3 The test facilities need to permit complete (and demonstrable) isolation of the valve from the pressure source. EEMUA Publication 205 - Production Testing of Valves EEMUA 62.2.4 In order to ensu
45、re that the accuracy and sensitivity of volumetric measuring devices are adequate, their calibration needs to be performed with the same test fluid, at the same temperature, and to be within the same tolerances as required for the tests. Note: Guidance on measurement and calibration systems can be f
46、ound in ISO 10012. 2.2.5 The manufacturer should be required to have valid, uniquely identifiable calibration certificates available for, and traceable to, each item of measuring equipment used for testing, with calibration carried out in accordance with an approved quality standard. 2.2.6 The accur
47、acy of pressure gauges used in testing should be in accordance with EN 837-1, Table 11, Class 1.6 or better. It is recommended that the gauges display the test pressure between 25% and 75% of full gauge pressure and have a minimum face diameter of 150 mm. The purchaser may agree the use of alternati
48、ve devices to pressure gauges. 2.2.7 Safety relief devices need to be incorporated in the pressurising system in order to prevent overpressuring the valve and test equipment. 2.2.8 No valve undergoing pressure testing is to be subjected to any form of shock loading. 2.2.9 Temperature measuring devic
49、es are to be capable of indicating fluctuations of 1C. 2.2.10 If testing with gas supplied from high pressure storage, the test arrangement needs to be such that the gas entering the valve does not lower the temperature to the extent that the validity of the test is affected. 2.3 Test Fluid 2.3.1 The preferred test fluid for hydrostatic tests is clean fresh water at ambient temperature (but see 2.3.2 below) containing a suitable corrosion inhibitor, or a non-corrosive liquid whose viscosity at ambient temperature is
