Valve Testing Services are a critical, mandatory operation that is necessary to provide effective, safe, and reliability in the working of fluid control systems in the marine, offshore, industrial, and refinery conditions. Periodic testing of the valves avoids failure of components and reduces risky leakages and operational disturbances in the processes, thus transferring to the required maximum safety standards of the industries. Sun Marine Engineering also offers professional Valve testing services to ensure that all the valves are functioning within their required operational specifications and performance standards.
What are Valve Testing Services?
A valve test is a specialized quality control process that consists of performing a test of the reliability and safety of a valve in specified conditions. It guarantees that the component is able to satisfy its design and performance requirements over its lifespan of service.
Valve testing includes:
- Performance Checking: Checks on actuator speed, travel, and position.
- Leak Detection: Checking the integrity of test seals with process fluids.
- Pressure Check: This is to ensure that the valve body and the shell retain maximum pressure in the system.
- Checking of Functions: The valve should be checked under simulated working conditions.
The most common ones, such as gate, ball, butterfly, globe, safety relief, and control valves, are tested, and valve functionality test and valve compliance inspection are guaranteed.
Importance of Valve Testing in Marine & Industrial Applications
The control points of any fluid system are valves; failure of them may have serious consequences.
- Provides Free Operations: This stops the catastrophic failures and dangerous leaks, which satisfy the operational safety standards.
- Maintains Pressure System Integrity: Checks that the valve is reliable in isolating sections and maintaining pressure, which is essential to the equipment integrity test.
- Eliminates Failures: Erosion, corrosion, or wear can be detected before significant failures occur in the system.
- Adheres to Compliance: Testing is also required to meet Compliance to Classification Bodies such as DNV, ABS, BV and LR of offshore safety compliance.
- Saves Money: Proactive testing will reduce the number of surprises and thereby the maintenance costs, and the unexpected downtime will be cut to a huge extent.
Types of Valve Testing Services Offered by Sun Marine Engineering
We use modern methods of carrying out thorough tests that are based on the types of valves and application.
Hydrostatic Valve Testing
It is a standard test of a hydrostatic valve in which water is used to check its pressure resistance (shell test) and seating ability (seat leak test).
Pneumatic Valve Testing
This is a very sensitive technique that can be used by using air or nitrogen (nitrogen valve testing) and are used when leakage is to be detected in gas system or water contamination should be prevented.
Seat Leakage Testing
A necessary process that tests the quality of the surfaces of the valves (the seat) to act as a proper sealer at pressure and avoid through-leaking (valve seat leak test).
Shell Testing
Checks the strength of the valve body by putting the exterior shell under the maximum allowable pressure to make sure it is structurally sound.
Functional & Operation Testing
Checks the full rotation of the valve without any obstruction, inspects the automated valve mechanisms of opening/closing, and verifies the accuracy of the control of the automated valves.
Safety Relief Valve Testing
Maintains the proper opening and closing of the valve at the correct set pressure and the correct opening at the correct closing pressure, which is essential in the calibration of the safety valve and safety valve over-pressurization.
Our Valve Testing Process
We have a detailed procedure when it comes to testing of our valves in order to be precise and conforming.
- Preliminary Inspection: Visual inspection, identification, and review of design specification and test requirements.
- Cleaning and Preparation of Valves: Cleaning internal parts and sealing test bench ports.
- Testing Method Selection: As required, the appropriate pressure medium (hydrostatic / pneumatic) should be chosen.
- Pressurization: Added the medium and pressure gradually to the necessary test levels (checking of the valve pressures).
- Monitoring: Maintaining the pressure during careful observation of leaks, drops in pressure, and structural alterations ( leak monitoring).
- Functional Testing: Testing the performance of the valve by opening and closing it.
- Documentation: Providing test documentation procedures, test certificates, and compliance reports needed by Class and clients.
Types of Valves We Test
We have experience in all of the main types of valves utilized in the marine and heavy industry:
- Ball valves
- Gate valves
- Globe valves
- Butterfly valves
- Check valves
- Relief & safety valve testing
- Analysis of the solenoid and control valve.
- Marine & offshore valves
Industries We Support
Our core offshore valve services and customized support are offered to the high-demand industries:
- Marine ships and shipyards (marine engineering solutions)
- Offshore platforms & FPSOs
- Oil and Gas refineries (refinery valve testing)
- Petrochemical plants
Electrical power institutions. - Manufacturing industries
Benefits of Professional Valve Testing
Professional preventive maintenance of the valve ensures the reliability of the assets.
- Better Safety and Reliability: Prevention of defects will mean safer and predictable operations.
- Assures Leak-Free Operations: Ensures hazardous media containment and performance that is leak-free.
- Prolongs the life of the Valve: Due to the regular testing, the problems are revealed at the earliest stage, and it allows the type of cost-effective repair instead of total replacement.
- Reduces Downtime: Minimizes the Risk of Unplanned Downtime and Unplanned Operations and Costs.
- Meets Compliance: Supplies certified test reports that are needed by the regulatory body and insurance compliance.
Frequently Asked Questions (FAQ)
Q1. What distinguishes a Shell Test from a Seat Leak Test?
Ans: Shell Test is the one that confirms the strength and the stability of the outer body (shell) of the valve under pressure. It makes sure that there are no leaks arising from the casting or the bonnet seals. Seat Leak Test is the one that confirms the closeness of the sealing surfaces inside the valve. It makes sure that there are zero or only a very minimal leakage across the seat when the valve is closed (shut-off performance).
Q2. How often should valves that are vital, such as SRVs, be tested?
Ans: The question of how often valves that are vital, especially Safety Relief Valves (SRVs), should be tested is answered by regulatory bodies and classification societies’ requirements (usually every 1 to 5 years). The period between the tests depends on factors like the type of service, the fluid, and the operating conditions. It is essential to perform SRV testing as it ensures that they will open when the set pressure is reached, thus preventing over-pressurization.
Q3. Is it possible to conduct valve testing on the vessel or offshore rig?
Ans: Sun Marine Engineering has different flexible service plans to meet the customers’ needs, which include testing onboard, onsite, and in the workshop. When valves are infrequently large or non-removable, or when it is necessary for systems to be verified immediately, our offshore valve experts with portable, advanced testing equipment can be brought to the client’s location to perform the tests required.
Q4. The materials to which your testing services apply to?
Ans: We are capable of performing the procedures and setting up the equipment for the materials which are frequently found in marine and industrial applications. Furthermore, these materials include carbon steel, stainless steel, alloy steels, and specially made materials such as copper-nickel and duplex. This ensures that we fulfill all the requirements of the industrial valve service
Why Choose Sun Marine Engineering
We are the Singapore valve specialists and your reliable partner for fluid system integrity.
- Experienced Technicians: The team we boast of comprises certified marine engineers and valve technicians who qualify for their positions and are well-experienced in the industry.
- Advanced Equipment: By using up-to-date hydrostatic and pneumatic test benches that are capable of accurate testing across a wide range of pressures and sizes.
- Compliance Guaranteed: The procedures that are carried out strictly rely on the set standards of the international marine and industrial standards, thus certificated valve services are guaranteed.
- Fast Turnaround: The time taken to diagnose the problem is short, and the speed of service delivery is also high; thus, your operational downtime will be very little.
- Flexible Support: We offer testing on board, onsite, and in a workshop that are suitable for your project requirements.
Conclusion
Marshtak Professional Valve Testing Services is the only way to go for maintaining system integrity and ensuring safe, compliant marine and industrial operations. When you work with Sun Marine Engineering, you get the peace of mind that comes with knowing that your fluid control systems are dependable, leak-free, and certified.
Get in touch with Sun Marine Engineering if you want reliable and certified Valve Testing Services in Singapore.