Materials System Specification

04-SAMSS-048 21 December 2005

Valve Inspection and Testing Requirements
Valves Standards Committee Members
Shiha, Saad Mohammed, Chairman
Akroosh, Fahad Ahmad, Vice Chairman
Mugbel, Wajdi Mohammad
Amri, Omar Mohammad
Arfaj, Essam Ahmed

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 Conflicts and Deviations................................ 2
3 References..................................................... 2
4 General Requirements................................... 4
5 Pressure Tests............................................... 4
6 Hardness Testing........................................... 5
7 Impact Testing................................................ 5
8 Inspection and Testing of Castings................ 6
9 Plating Tests.................................................. 7
10 Sampling Criteria........................................... 7
11 Documentation Requirements....................... 7

Previous Issue: 28 February, 2005 Next Planned Update: 1 March 2010

Revised paragraphs are indicated in the right margin Page 1 of 8
Primary contact: Shiha, Saad Mohammed on 966-3-8733658
Copyright©Saudi Aramco 2005. All rights reserved.
Document Responsibility: Valves 04-SAMSS-048
Issue Date: 21 December 2005
Next Planned Update: 1 March 2010 Valve Inspection and Testing Requirements

1 Scope

1.1 This Specification, together with the Purchase Order and appropriate data sheets,
cover the minimum requirements for inspection and testing of metallic and
nonmetallic valves normally classified under Saudi Aramco Materials System
(SAMS) Class 04. Such valves include gate, globe, angle, check, needle, ball,
plug, piston, butterfly, choke, diaphragm, etc., used for on-off, manual control
service or for prevention of reverse flow, as appropriate.

1.2 Specifically excluded from the scope are: control, safety-relief, relief, surge
relief, solenoid, pilot and other valves classified under SAMS Class 34; and
wellhead valves classified under SAMS Class 45.

1.3 Requirements for SAMS Class 04 API STD 6A 10,000 psi (1-13/16 inch size
and above) valves and chokes are covered in 04-SAMSS-049.

1.4 The typical quality characteristics to be witnessed and the documents to be

reviewed by and/or provided to Buyer's Representative by the Vendor, are
specified on Saudi Aramco Inspection Requirements Forms 175-043000,
175-043600 and 175-043601 which shall be included as part of the Purchase
Order, as applicable.

2 Conflicts and Deviations

2.1 Any conflicts between this specification and other applicable Saudi Aramco
Materials System Specifications (SAMSSs), Engineering Standards (SAESs),
Standard Drawings (SASDs), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer Representative through the
Manager, Consulting Services Department, of Saudi Aramco, Dhahran.

2.2 Direct all requests to deviate from this specification in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Consulting Services Department, of
Saudi Aramco, Dhahran.

3 References

Material or equipment supplied to this specification shall comply with the latest edition
of the references listed below unless otherwise noted:

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a
Mandatory Saudi Aramco Engineering

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Document Responsibility: Valves 04-SAMSS-048
Issue Date: 21 December 2005
Next Planned Update: 1 March 2010 Valve Inspection and Testing Requirements

Requirement

Saudi Aramco Materials System Specification

04-SAMSS-003 Additional Requirements for Low Temperature
Valves

Saudi Aramco Inspection and Testing Requirements

Form 175-043000 Valve Materials Certification Requirements
Form 175-043600 Metallic & Non-Metallic Valves
Form 175-043601 Low Severity, Valves
Note: Please check the above form numbers and make sure they are correct.

3.2 Industry Codes and Standards

American Petroleum Institute

API STD 598 Valve Inspection and Testing

American Society of Mechanical Engineers

ASME B16.34 Valves-Flanged, Threaded, and Welding End
ASME SEC VIII Boiler & Pressure Vessel Code

American Society for Testing and Materials

ASTM A956 Standard Test Method for Leeb Hardness Testing
of Steel Products
ASTM B733 Standard Specification for Autocatalytic Nickel-
Phosphorus Coatings on Metals
ASTM E10 Test Method for Brinnell Hardness of Metallic
Materials
ASTM E18 Test Methods for Rockwell Hardness and
Rockwell Superficial Hardness of Metallic
Materials

German Standards
DIN EN 10204 Metallic Materials

Manufacturers Standardization Society

MSS SP-53 Quality Standard for Steel Castings - Magnetic
Particle Examination Method

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Document Responsibility: Valves 04-SAMSS-048
Issue Date: 21 December 2005
Next Planned Update: 1 March 2010 Valve Inspection and Testing Requirements

MSS SP-54 Quality Standard for Steel Castings -

Radiographic Inspection Method
MSS SP-55 Quality Standard for Steel Castings - Visual
Method
MSS SP-93 Quality Standard for Steel Castings - Liquid
Penetrant Examination Method

4 General Requirements

4.1 Each individual valve shall be at least tested, examined and qualified as
specified in the industrial standard (such as ASME, API, AWWA, MSS)
referenced in the Purchase Order or to the manufacturer's approved standard if
no industrial standard has been specified. Nothing in this Specification shall be
construed as waiving any mandatory requirement of the referenced Standard.

Steel valves shall not be painted or externally coated before the shell pressure
tests are completed. Internally epoxy coated or internally lined steel valves shall
be shell tested before and after application of the coating or lining unless
specified otherwise by the Valves Standards Committee Chairman.

4.2 Repairs of valve components with unacceptable defects shall be in accordance

with the governing material specification for the component. Proposed weld
repairs that are not covered by the applicable material specification shall require
the approval of Saudi Aramco's Engineer prior to the performance of repair
work. All pressure tests shall be repeated on valves after any weld repair to the
pressure retaining components. Repair by grinding or redressing of the casting
surface is acceptable, provided that during the repair not more than 10% of the
original wall thickness will be removed and provided that the minimum required
wall thickness is not affected, the weld repair documentation shall be submitted
to CSD for Valves RSA evaluation and approval.

4.3 When valve installation orientation is specified in the Purchase Order,

applicable tests shall be conducted with the valve in the specified position.

5 Pressure Tests

5.1 When there is an industrial standard referenced in the Purchase Order, valves
shall be tested to the requirements of that standard (e.g., ASME, API, MSS,
AWWA, etc.). In addition to tests per the applicable standard, the testing
requirements in the following paragraphs shall apply for steel valves:

5.1.1 For all cast steel valves NPS 2 and below, the shell hydrostatic test shall
be maintained for one minute. For all other sizes, the shell test pressure

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Document Responsibility: Valves 04-SAMSS-048
Issue Date: 21 December 2005
Next Planned Update: 1 March 2010 Valve Inspection and Testing Requirements

shall be maintained for a minimum of five minutes or as required by the

applicable industry standard, whichever is greater.

5.1.2 When specified in the Purchase Order, steel valves shall be subjected to
a pneumatic high-pressure shell test per API STD 598 paragraph 3.5.
The holding time shall be a minimum of 5 minutes and no visible
leakage is allowed.

5.1.3 Valves specified for flare system isolation service, regardless of size,
shall receive low pressure pneumatic seat tests at 5 psig.

5.2 When there is a governing industrial standard, but it does not specify test
durations or leakage acceptance criteria, paragraph 5.1.1 and API STD 598
requirements for durations and leakage shall apply, unless specified otherwise
by the Valves Standards Committee Chairman.

5.3 When there is no referenced governing industrial standard, valve testing shall be
in accordance with the following requirements:

5.3.1 Metallic valves NPS 2 and smaller, and all non-metallic valves, shall be
tested per Vendor's procedure as approved by the Valve Standards
Committee Chairman or his delegate.

5.3.2 Metallic valves larger than NPS 2, shall be tested in accordance with
paragraph 5.1.1 and API STD 598 requirements for shell tests and
closure tests, unless specified otherwise by the Valve Standards
Committee Chairman.

5.4 When a valve is ordered together with an actuator, the valve/actuator assembly
shall be tested together as a unit. As part of functional testing, the valve shall be
opened under the maximum differential pressure that the actuator has been rated
for. The vendor shall take necessary steps to ensure that the valve is not
damaged during this functional test.

6 Hardness Testing

Hardness tests, when required by specified service and/or material specification, shall
be conducted by the Vendor on all wetted parts in accordance with ASTM E10, ASTM
E18 or ASTM E956 Leeb hardness test.

7 Impact Testing

When 04-SAMSS-003 is specified in the Purchase Order, the Vendor shall conduct
impact tests as required by the Specification.

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Document Responsibility: Valves 04-SAMSS-048
Issue Date: 21 December 2005
Next Planned Update: 1 March 2010 Valve Inspection and Testing Requirements

8 Inspection and Testing of Castings

8.1 Visual Inspection

All castings shall be visually inspected in accordance with MSS SP-55. A

casting shall be rejected if any surface irregularity exceeds example "a" of any
defect type as per MSS SP-55.

8.2 Surface Examination

For cast steel valves NPS 3 and larger, the internal and external surface areas of
10% (minimum one) of all pressure retaining steel castings (bodies, bonnets,
covers) per heat shall be magnetic particle or liquid penetrant inspected in
accordance with MSS SP-53 or MSS SP-93. If any unacceptable defect is
detected, all castings from that heat shall be inspected.

8.3 QA Program Casting qualification and Volumetric Examination

8.3.1 As part of their QA program, the Vendor shall implement a qualification

procedure for all pressure containing steel castings. As a minimum, the
vendor shall have qualified each foundry's casting patterns by
radiographic examination of the initial casting. Records of these
qualifications shall be made available upon request.

8.3.2 In addition to 8.3.1, for cast steel valves (a) NPS 4 and larger in ASME
Class 600 (or API STD 6A rating 2000 psi) and higher and (b) NPS 24
and larger in all ratings, radiography shall be performed in accordance
with 8.3.3. The examination shall be in accordance with and have
included all critical areas as defined in ASME B16.34, paragraph 8.3.1.1.
For valves other than those included in ASME B16.34 figures, ASME
SEC VIII , app. 7, section 7.3(a).1 Footnote 1 shall be used to determine
the critical areas. See paragraph 8.3.4 for valves that are exempt.

8.3.3 The Vendor shall radiographically examine and qualify one valve per
size per heat from the lot on order. If this radiographic sampling results
in a rejection (defined as requiring weld repair) then an additional 10%
sample from the same size and foundry shall be subjected to
radiographic examination as defined in 8.3.2. Further radiographic
rejects resulting from this inspection mandates 100% Radiography of
castings as defined in 8.3.2.

8.4 Valves fabricated by welding shall be qualified in accordance with ASME

B16.34, paragraph 2.1.5.

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Document Responsibility: Valves 04-SAMSS-048
Issue Date: 21 December 2005
Next Planned Update: 1 March 2010 Valve Inspection and Testing Requirements

9 Plating Tests

The Vendor's Quality Assurance program shall include the following tests of carbon and
low alloy steel electroless nickel plated parts on a sample basis:

9.1 Bend Test per ASTM B733 paragraph 9.4.1.

There shall be no evidence of lifting upon insertion of a sharp probe at any

ENP-Base Metal interface.

9.2 Ferroxyl Test per ASTM B733 paragraph 9.6.1.

There shall be no indications in primary service exposure areas. When this test
is impractical due to the size of the parts, the Vendor shall submit an alternate
procedure for approval by the Valves Standards Committee Chairman.

10 Sampling Criteria

Visual inspection and witnessing shall be based on Table 1 sampling plan. At

minimum, the sample shall include at least one valve from each Purchase Order item.

The sampling plan does not relieve the Vendor of the responsibility to ensure
compliance of each valve with specified requirements and to test each valve.

When a discrepancy is found, the entire lot shall be rejected. The lot shall be
re-inspected and re-tested by the Vendor, prior to presenting them again for inspection.

Table 1
Minimum Sample Size
Valve Category (% of Item Quantity)
All valves NPS 2 and smaller all ratings 10%
2< valves < 14 NPS and less than ASME Class 600 25%
All valves NPS 14 and above 100%
All valves >2" and ANSI Class 600 and above
All valves >2" and API rating 2000 psi and above

However, if Buyer's Representative witnesses a failure of a hydrostatic shell test, all

valves in the lot shall be re-tested and witnessed by Buyer's Representative. The cause
of failure shall be investigated and reported.

11 Documentation Requirements

11.1 Material Test Reports and Certificates shall be supplied in accordance with
Saudi Aramco Inspection Requirements Form 175-043000.

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Document Responsibility: Valves 04-SAMSS-048
Issue Date: 21 December 2005
Next Planned Update: 1 March 2010 Valve Inspection and Testing Requirements

11.2 All certificates and test reports shall identify the valve(s) by stating Purchase
Order and Item number, Vendor's name, type, size and rating of valves, and
quantity of valves covered.

11.3 Certificates of castings shall include weld repair data including extent of repair,
WPS, welder qualifications, post weld heat treatment and NDE following the
repair(s).

Revision Summary
28 February 2005 Major revision.
21 December 2005 Minor revision.

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