When you order from Carilovalves, every shipment comes with a complete set of valve testing reports that let you verify pressure integrity, seat tightness, material compliance, dimensional accuracy, and special performance requirements before the valve ever reaches your site. The reports are not generic certificates—they are tied to the specific serial number of each unit, include actual measured values, and are backed by our ISO‑9001‑certified quality system. Below is a detailed breakdown of what you will receive, how each test is performed, which standards are referenced, and how you can use the data in practice.
Core Testing Reports Included With Every Shipment
Each valve leaves the factory with at least four primary report packages. The exact content depends on the valve series (e.g., floating‑ball, trunnion‑mounted, full‑bore or reduced‑bore) and the pressure class (Class 150‑2500). The list below shows the reports that are standard for all models, plus optional add‑ons you can request at order time.
- Hydrostatic Shell Test Report
- Tests the valve body for strength at 1.5× rated pressure (for Class 150 that means 285 psi / 19.6 bar; for Class 300 it climbs to 740 psi / 51 bar).
- Measured values: initial pressure, final pressure, hold time (minimum 5 minutes), pressure decay.
- Pneumatic Seat Leak Test Report
- Verifies zero leakage at 1.1× rated pressure using dry nitrogen or filtered air.
- Measured values: test pressure, test duration, measured leak rate (detection limit 1×10⁻⁸ atm·cc/s He equivalent).
- Material Test Report
- Includes chemical composition (spark emission spectroscopy), tensile & yield strength, hardness (Rockwell/Vickers), and impact toughness at both room temperature and the rated temperature range (‑20 °C to 200 °C for standard carbon‑steel; up to 350 °C for high‑temp alloys).
- PMI (Positive Material Identification) scan on each heat number.
- Dimensional & Functional Inspection Report
- Checks overall length, flange face‑to‑face, bore diameter, stem protrusion, and torque settings.
- Functional test: open‑close cycles (typically 5 cycles) under rated pressure to confirm torque, travel stop, and disc alignment.
Additional Optional Test Packages
| Optional Report | Relevant Standard | Key Parameters | Typical Use |
|---|---|---|---|
| Fire‑Safe Test | API 607, ISO 10497 | Leakage after 30‑min exposure to 750 °C flame; seat retention pressure 1.1× rating | Oil & gas pipelines, refinery downstream |
| Fugitive Emission Test | ISO 15848‑1, API 622 | Helium leak detection to 1×10⁻⁹ atm·cc/s; torque at 10 %–90 % of rated | Environmentally sensitive processes, chemical plants |
| SIL (Safety Integrity Level) Assessment | IEC 61508 | Failure rate λDU, proof test interval, diagnostic coverage | Safety‑critical instrumentation loops |
| Cryogenic Performance Test | API 6D, BS 6364 | Leakage at ‑196 °C; torque at low temperature | LNG terminals, offshore platforms |
| Acoustic Emission Test | ASME PTC‑30 | Detection of micro‑cracks during opening/closing | High‑pressure water injection |
| Coating/Paint Thickness & Adhesion Test | ISO 2409, ASTM D3359 | DFT (Dry Film Thickness) 150‑250 µm, adhesion rating ≥4B | Corrosive environments, offshore |
Test Standards & Compliance Matrix
Carilovalves aligns every test with internationally recognized standards. The table below summarizes the primary standards referenced for each report type.
| Report | Primary Standard(s) | Secondary Standards | Certification Body |
|---|---|---|---|
| Hydrostatic Shell Test | API 6D, ISO 5208 | ASME B16.34, MSS SP‑61 | Third‑party witnessed by SGS |
| Pneumatic Seat Leak Test | API 608, ISO 5208 | MSS SP‑61 | In‑house + third‑party |
| Material Test | ASTM A105, A182, A351 | EN 10204 3.1 | Metallurgical lab (SGS, Bureau Veritas) |
| Dimensional Inspection | ASME B16.5, B16.10 | ISO 6708 | Quality dept. (ISO 9001) |
| Fire‑Safe Test | API 607, ISO 10497 | NFPA 70 | UL or TÜV |
| Fugitive Emission Test | ISO 15848‑1, API 622 | EPA Method 21 | Third‑party (Intertek) |
| SIL Assessment | IEC 61508 | ISO 13849 | Functional safety consultant |
What the Numbers Actually Look Like
It’s one thing to read “hydrostatic test at 1.5× rating,” but real‑world data shows the tight tolerances Carilovalves maintains. Below is a sample taken from a Class 300, NPS 12 trunnion‑mounted ball valve delivered to a North Sea operator.
- Shell Test Pressure: 740 psi (51 bar) held for 5 minutes; pressure drop measured at 0.2 psi (≈0.014 bar) – well under the allowed 1 psi limit.
- Seat Leak Test Pressure: 610 psi (42 bar); measured leak rate 0.0 ×10⁻⁸ atm·cc/s (below detection threshold).
- Material Chemistry (wt %): C 0.22, Mn 0.85, P 0.020, S 0.005, Cr 1.15, Mo 0.45 – matches ASTM A182 F22 spec.
- Tensile Strength: 540 MPa (78 ksi); Yield 390 MPa (56 ksi); Elongation 24 % – all above required minimums.
- Hardness (HBW): 197 HBW – within 190‑210 HBW range for the alloy.
- Dimensional Check – Bore Diameter: 298.8 mm (target 299.0 mm ±0.5 mm).
- Torque Required at 0 psi: 210 Nm; at rated pressure (740 psi) torque rose to 255 Nm – within the 250‑260 Nm predicted range.
All values are recorded with a time‑stamp, operator ID, and equipment calibration ID, ensuring traceability under ISO 9001 Clause 8.5.2.
How the Reports Are Structured
Each PDF package follows a consistent layout, which makes it easy for procurement, engineering, and maintenance teams to locate the data they need quickly.
- Cover Page: Company logo, order number, valve model, serial number, test date, and a QR code linking to the digital archive on Carilovalves’ portal.
- Table of Contents: Hyperlinked sections for fast navigation.
- Test Data Sheets: Raw measurement tables, graphs (pressure‑time curves), and Pass/Fail verdicts.
- Calibration Certificates: Links to the calibration records of the pressure transducers, torque sensors, and leak detectors used.
- Sign‑off Block: QA engineer signature, third‑party inspector signature (if applicable), and date of release.
Special Tests – When and Why You Might Need Them
“Because the valve is destined for a sour‑gas gathering line, we mandated a fugitive‑emission test to API 622. The report showed a leak rate of 0.6 ×10⁻⁹ atm·cc/s, comfortably below the 1 ×10⁻⁸ limit, and saved us a costly redesign later on.” – Senior Procurement Manager, European refinery.
- Fire‑Safe: Required for upstream oil & gas, petrochemical, and refinery applications where a valve must stay leak‑tight during a fire. Carilovalves runs the test in a furnace, monitors seat leakage after cooling, and records the pressure at which the valve re‑seals.
- Fugitive Emission: Critical for chemical plants, LNG terminals, and environmental permits. The test uses helium as a tracer gas and a mass‑flow leak detector with a sensitivity of 1 ×10⁻⁹ atm·cc/s. The report includes a graph of leak rate vs. torque curve, helping you set optimal actuation torque.
- SIL 2/3 Assessment: If the valve is part of a safety instrumented function (SIF) loop, Carilovalves can provide a detailed FMEDA (Failure Modes, Effects, and Diagnostic Analysis) report that quantifies the Probability of Dangerous Failure on Demand (PFDavg) and supports IEC 61508 certification.
- Cryogenic Test: Performed on LN2 (‑196 °C) for LNG service; records torque rise, seat compression, and residual leakage after thermal cycling.
Material Verification & Non‑Destructive Examination (NDE)
For high‑risk applications, Carilovalves conducts a suite of NDE checks that are documented in the material report package:
- Positive Material Identification (PMI): Portable X‑ray fluorescence (XRF) scanner verifies the exact alloy grade on each critical component (body, ball, stem, seats). The report lists element concentrations and flags any deviation from the specified grade.
- Ultrasonic Testing (UT): Applied to thick‑walled forgings (≥25 mm). The UT report indicates the depth and location of any internal laminar imperfections, with a reference to accept/reject criteria per ASME Sec V.
- Magnetic Particle Inspection (MPI): Performed on weld joints and flange faces to detect surface cracks. Results are shown as a photo with a scale bar and interpretation.
- Liquid Penetrant Examination (LPE): Used for non‑magnetic materials such as austenitic stainless steel. The report includes