Standard Test and Inspection Procedure

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Standard Test and Inspection Procedure

Lead Free Bronze・Brass for Cold Water Service Gate Valves, Globe Valves, Check Valves

Ball Valves and Strainer

2014-10-10

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KITZ Technical Sheet Document No. : KTS-AE-102B-02

1. Scope

This procedure covers the test and inspection requirements of lead free bronze and brass threaded, solder or flanged ends gate valves, globe valves, check valves, ball valves and strainer which are applied to cold water service.

2. Reference Standards

The latest revision of standards shall be used unless otherwise stated.

2.1 JIS B0203

…… Taper pipe threads 2.2 JIS B0253

…… Gauge for Taper Pipe Threads 2.3 JIS B2002

…… Face-to-Face and End-to-End Dimensions of Valves 2.4 JIS B2003

…… General rules for inspection of valves 2.5 JIS B2011

…… Bronze, gate, globe, angle, and check valves 2.6 JIS B2240

…… Copper alloy pipe flanges 2.7 JIS S3200-4

…… Equipment for water supply service – Test method of prevention from back current 2.8 JIS Material Standard

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3. Test and Inspection

3.1 Classification of Test and Inspection

Test and inspection are classified on table 1.

Table 1 Classification of Test and Inspection

NO. Test/Inspection Items Inspection by 1 Material Test (Chemical Composition,

Mechanical Properties) KITZ

2 Visual Inspection (Including

Marking & Identification) KITZ

3 Dimensional Inspection KITZ

4 Operation Test KITZ

5 Pressure Test KITZ

3.2 Material Test

Valve parts materials of body, bonnet/cap, disc/ball and stem shall have chemical composition and mechanical properties as stipulated in JIS standards.

However, for purchased items, mill certificates issued by the manufacturers shall be reviewed by KITZ and transferred to KITZ format.

3.3 Visual Inspection 3.3.1 On Castings

(1) All castings shall be free of harmful defects such as blowholes, hot tears, cracks, shrinks, sand inclusions, gas porosities, wrinkles and laps.

(2) Fluid passage section shall be cleaned and prepared with utmost care.

3.3.2 On Forgings

The forging shall be free of injurious imperfections such as seams,laps,tears or slivers.

3.3.3 On Machined Surface

(1) Machined surfaces shall be free of injurious dent,burr and unevenness in finished conditions.

(2) The seating surfaces shall be free of scratches and dents.

(3) Appropriate chamfer or rounding shall be provided to corners and edges for which no dimensions are specified.

(4) Gasket contact surfaces of end flange shall be free of scratches and dents.

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KITZ Technical Sheet Document No. : KTS-AE-102B-02

3.3.4 Marking

(1) Marking items on the body shall be clearly and correctly.

(2) Descriptions on the name plate shall be clearly and correctly.

3.3.5 On Completed Valves

Valves shall have a configuration as specified on the Outline and Assembly Drawing.

3.4 Dimensional Test

3.4.1 Dimension of Threaded Ends

Dimension of threaded ends that is machined in accordance with JIS B 0203 shall be checked using taper pipe threads gauge specified in JIS B0253.

3.4.2 Dimension of Solder Ends

Dimension of solder ends shall be specified in the Outline and Assembly Drawing, and its dimensional tolerance shall be JIS B2011.

3.4.3 Dimension of Flanged Ends

Dimension of end flange shall be specified in the Outline and Assembly Drawing, and its dimensional tolerance shall be based on JIS B2240.

3.4.4 Dimension of Face to Face (End to End)

Dimension of face to face (end to end) shall be specified in the Outline and Assembly Drawing, and its dimensional tolerance shall be as shown in table 2 or 3.

Table 2 shall be applied to the threaded and solder ends valves.

Table 3 shall be applied to the flanged ends valves.

Table 2 Dimensional Tolerance (as per JIS B2003)

Valve Nominal Size

Tolerance Straight

Valve

Angle Valve 1-1/2B and smaller ±1.0 mm ±0.8 mm 2B and over ±1.5 mm ±0.8 mm

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Table 3 Dimensional Tolerance (as per JIS B2002)

Face-to-Face Dimension Tolerance 250mm and smaller ±2.0mm

3.4.5 Allowable Value of Parallelism and Coaxiality

Allowable value of parallelism of face-to-face for end flanges and coaxiality between axial lines of threaded & solder ends shall be JIS B2003.

3.4.6 Overall Dimensions

The overall dimensions specified in the Outline and Assembly Drawing other than above shall be within dimensional tolerance of ±10%.(as per KITZ standard) 3.5 Operation Test

3.5.1 Ensure the trouble-free operation of handle without causing galling or being stuck.

3.5.2 Ensure that the connection between the stem and the disc/ball is firm and secured.

3.5.3 Additional Operation Test on Gate Valve

Ensure that the center of the disc is located upwards from the center of the body seat at fully closed position.

Ensure that lower end of the disc is not remained in the valve port at fully open position.

3.5.4 Additional Operation Test on Globe Valve

Ensure that the disc and seat is located in the same center and the disc is seated in the body seat perfectly at fully closed position.

3.5.5 Additional Operation Test on Check Valve

Ensure that the disc can be fully open until it contacts the stopper provided inside the body/cap and fully closed without any disturbance.

3.5.6 Additional Operation Test on Ball Valve

Ensure no offset of both ports of ball and body in lateral direction at fully open position.

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KITZ Technical Sheet Document No. : KTS-AE-102B-02

3.6 Pressure Test 3.6.1 General

(1) Test Medium

Test medium shall be clean water and air, and the test fluid temperature shall be room temperature.

(2) Two pressure gauges shall be used which have valid calibration.

Pressure gauge shall have a scale of over 1.5 times and within 3 times of the maximum test pressure.

3.6.2 Shell Test

(1) Hydrostatic Test

With the valve partially open, inside of the body shall be filled with water so that no air remains.

The hydrostatic shell test pressure shown in table 4 shall be applied.

It shall be held for longer than the duration shown in table 6.

No visually detectable leaking or oozing of water and no abnormal deformation shall be observed from the body,bonnet/cap and others.

This test shall be performed one (1) production valve per each month for representative test.

(2) Pneumatic Test

With the valve partially open,the pneumatic shell test pressure of 0.60 MPa shall be applied.

It shall be held for longer than the duration shown in table 6.

Apply the bubble solution to valve body surfaces, and no occurrence of bubbles shall be observed from the body,bonnet/cap and others.

This test shall be performed all valves.

3.6.3 Seat Leakage Test

3.6.3.1 For Gate Valves (Pneumatic)

The pneumatic seat leakage test pressure of 0.60 MPa shall be applied to the partially open valve inside and the valve shall be closed, and then both side opening to atmosphere.

It shall be held for longer than the duration shown in table 6.

There shall be no visible leakage from both side opening.

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3.6.3.2 For Globe Valves (Pneumatic)

With the valve fully closed,the pneumatic seat test pressure of 0.60 MPa shall be applied from the upstream side (inlet side) with the downstream side (outlet side) opening to atmosphere

It shall be held for longer than the duration shown in table 6.

There shall be no visible leakage from the downstream side (outlet side) opening.

3.6.3.3 For Metal Seat Swing Check Valves (Hydrostatic)

The hydrostatic seat test pressure shown in table 5 shall be applied from the downstream side (outlet side) with the upstream side (inlet side) opening to atmosphere.

It shall be held for longer than the duration shown in table 6, and gradually reduced to 1/3 of specified seat test pressure (Refer to below table 4)..

The maximum allowable leakage rate shall be 0.1mm3/s x Valve Size (A).

For 25A and smaller valves, the maximum allowable leakage shall be 2.5 mm3/s.

3.6.3.4 For Soft Seat Lift Check Valves (1) Pneumatic Test

With the valve fully closed,the pneumatic seat test pressure 0.03 MPa shall be applied from the downstream side (outlet side) with the upstream side (inlet side) opening to atmosphere.

It shall be held for longer than the duration shown in table 6.

There shall be no visible leakage from the upstream side (inlet side) opening.

(2) Hydrostatic Test

In addition of above, valves shall be tested of prevention from back current according to JIS S3200-4 as below.

Test Pressure (Hydrostatic)

Test

Duration Acceptance Sampling

3 KPa

60 Sec. No leakage to the up stream One (1) production valve per each month

1.5 MPa

3.6.3.5 For Ball Valves (Pneumatic)

The pneumatic seat leakage test pressure of 0.60 MPa shall be applied to the partially open valve inside and the valve shall be closed, and then both side opening to atmosphere.

It shall be held for longer than the duration shown in table 6.

There shall be no visible leakage from both side opening.

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KITZ Technical Sheet Document No. : KTS-AE-102B-02

Table 4 Hydrostatic Shell Test Pressure (Unit : MPa) Nominal

Pressure

5K 10K Type 125

Type 150

Type 400 Test

Pressure 1.75 2.10 1.80 2.10 2.10

Table 5 Hydrostatic Seat Test Pressure for Check Valves(Unit : MPa) Nominal

Pressure 10K Type 125 Specified

Pressure 1.54 1.32 Reduced

Pressure 0.51 0.44

Table 6 Test Duration (Unit : Seconds)

Valve Nominal Size Shell Test

Seat Leakage Test Hydrostatic Pneumatic

50A(2B) and smaller

60 15 15

65A(2-1/2B) and over 30 30

Note : The test duration is the minimum period of inspection after the valve is fully prepared and is under full pressure.

Figure

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References

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