Valve Factory Acceptance Test (FAT) Checklist

API 598 Witness Inspection Worksheet — Print or save as PDF

Vajra Industrial Solutions

VALVE FACTORY ACCEPTANCE TEST (FAT) CHECKLIST

API 598 Hydrostatic & Functional Inspection Witness Record

Doc: VIS-FAT-005 Rev.01

PO No.: _______________

Valve Tag: _____________

Mfr. / Works Order: _____

Inspection Date: ________

VALVE IDENTIFICATION

Valve Type

NPS / DN

Pressure Class

Body Material (MTC)

Trim Material

Seat Material

End Connection

Design Standard

Testing Standard (API 598)

Test Type	Pressure Factor	Standard	Acceptance Criteria
Shell Hydrostatic	1.50 × MAWP	API 598 / ASME B16.34	Zero visible leakage — body, packing, joints
Seat — Liquid	1.10 × MAWP	API 598 Table 2	Metal seat: Class IV (10 drops/min); Soft seat: Class VI (zero)
Seat — Gas (air/N2)	0.70 MPa (7 bar) or full rated	API 598 Table 2	Per API 598 Table 2 or purchase spec
Backseat — Liquid	1.10 × MAWP	API 598 Cl. 6.4	Gate/Globe only — zero visible leakage through packing
Safety Valve Set Pressure	Set point ± 3%	API 526 / ASME Sec VIII	Lift and reseat at certified set pressure
Actuator Function Test	Rated supply pressure	API 6D / Mfr. std.	ESD trip, fail-safe, position indication, torque switch

PHASE 1 — PRE-TEST: DOCUMENTATION REVIEWRef: ASME B16.34 / EN 10204

#	Inspection Item	Pass	Fail	N/A	Remarks / NCR Ref.
1	Confirm purchase order number, valve tag, and revision match shop order
2	Review material test certificates (MTCs) — verify EN 10204 3.1 or 3.2 as specified
3	Verify MTC heat numbers match valve body/bonnet/trim stamping
4	Confirm body, bonnet, trim, stem, and seat material grades match purchase spec
5	Check bolting material certificates (A193 B7, B8M, etc.) match valve BOM
6	Review dimensional drawings — confirm latest revision issued for construction
7	Confirm applicable standards listed in PO are referenced in shop traveller
8	Verify IBR Form III-C or III-E present (steam service IBR valves only)
9	Review actuator sizing calculation (if actuated valve)
10	Confirm NACE material compliance documented (sour service valves only)

PHASE 2 — DIMENSIONAL INSPECTIONRef: ASME B16.10 / B16.34 / B16.5

#	Inspection Item	Pass	Fail	N/A	Remarks / NCR Ref.
1	Verify face-to-face (F2F) or end-to-end (E2E) dimension against ASME B16.10 table
2	Verify flange face dimensions (OD, bolt circle, bolt holes) per ASME B16.5 / B16.47
3	Confirm flange facing (RF / RTJ / FF) — check finish: 125–250 AARH for RF
4	Measure bore diameter — confirm full bore or reduced bore per spec
5	Check valve NPS / DN and pressure class stamping on body
6	Verify body material grade stamping (e.g. WCB, CF8M) and heat number
7	Inspect flanges for pitting, scoring, or damage that could cause leakage
8	Verify stem extends correctly — rising stem visible (gate/globe valves)
9	Check handwheel / gear operator direction markings (OPEN/CLOSE arrows)
10	Inspect body drain plug or vent fitting if specified
11	Measure stem/shaft runout — must be within manufacturer tolerance
12	Confirm body wall thickness at minimum section per ASME B16.34 (spot check)

PHASE 3 — API 598 HYDROSTATIC SHELL TESTRef: API 598 Section 5

#	Inspection Item	Pass	Fail	N/A	Remarks / NCR Ref.
1	Confirm test medium: water (preferred), kerosene, or light oil — NOT compressed gas
2	Verify test pressure = 1.5 × valve body rated pressure at 38°C (per ASME B16.34)
3	Confirm pressure held for minimum duration: NPS ≤ 2 = 60 sec; NPS 2.5–8 = 120 sec; NPS ≥ 10 = 300 sec
4	Check all body joints (body-bonnet, body-cover, flange joints) for visible leakage — ZERO leakage allowed
5	Inspect packing gland area during shell test — seepage (less than 1 drop/min) may be acceptable for gate/globe before adjustment
6	Record test pressure, temperature, and duration on test report
7	Confirm pressure gauge calibration certificate is current (within 6 months)
8	Verify pressure bleed-down after test — valve body must hold pressure without drop
9	Inspect test fill ports for proper sealing after test

PHASE 4 — API 598 SEAT LEAKAGE TESTRef: API 598 Section 6 / ISO 5208

#	Inspection Item	Pass	Fail	N/A	Remarks / NCR Ref.
1	Confirm test type: liquid (water / kerosene) or gas (air / nitrogen) per specification
2	Confirm seat test pressure: 1.1 × rated pressure (liquid) or per API 598 Table 2 (gas)
3	Verify test duration per NPS — same as shell test durations
4	Confirm acceptable leakage rate: metal seat = Class IV (10 drops/min); soft seat = Class VI (zero visible leakage)
5	For ESD/safety-critical valves: confirm Class VI zero-leakage achieved and recorded
6	For check valves: confirm back-pressure seat test in correct direction with zero leakage
7	For safety/relief valves: confirm set pressure within ±3% of specified set point
8	Record actual measured leakage rate (drops/min or mL/min) on test report
9	Confirm valve operates (open/close) minimum 3 times before final seat test

PHASE 5 — FUNCTIONAL OPERATION TESTRef: Manufacturer standard / API 598

#	Inspection Item	Pass	Fail	N/A	Remarks / NCR Ref.
1	Operate valve full open to full closed and back — confirm smooth operation with no binding
2	Check handwheel torque — must not exceed specified maximum operating torque
3	Confirm backseat test (gate / globe) — stem packing leak must stop when backseat engaged
4	Verify direction of operation: clockwise to close (standard), confirm with marking
5	For actuated valves: confirm air supply/electrical supply per spec; test ESD trip
6	For pneumatic actuated: test fail-safe position (fail-open or fail-closed per spec)
7	Confirm position indicator shows OPEN / CLOSED correctly at both limit positions
8	For electric actuated: test torque switch setting; confirm limit switch cut-off at each end
9	For gear-operated valves: confirm gear ratio provides adequate torque margin
10	Check all external fasteners are fully tightened — no loose nuts/bolts

PHASE 6 — FINAL INSPECTION & DOCUMENTATION REVIEWRef: EN 10204 / Purchase Spec

#	Inspection Item	Pass	Fail	N/A	Remarks / NCR Ref.
1	Drain all test fluid — confirm body cavity dry before shipping
2	Apply corrosion protection to wetted surfaces (VCI oil or nitrogen blanket)
3	Fit flange protectors / end caps — confirm bolted or wired on
4	Apply identification tag with P&ID tag number, PO number, and valve data
5	Review and accept all documentation: MTCs, test certs, dimensional report, IBR forms
6	Confirm PMI (Positive Material Identification) report matches valve materials if required
7	Confirm Charpy impact test report for low-temperature or high-pressure valves if required
8	Review paint/coating — confirm correct colour, DFT reading on record
9	Sign and witness all test records with date, company, and witness name
10	Confirm packing list matches actual goods — verify quantity, NPS, class, material

NCR No.	Phase	Description of Non-Conformance	Disposition	Closed By	Date

Role	Name	Company	Signature	Date
Manufacturer QC Inspector
Buyer's Representative / TPI
Third-Party Inspector (if applicable)

Overall FAT Result: ACCEPTED REJECTED ACCEPTED WITH NCR (see above)

VIS-FAT-005 Rev.01 — Vajra Industrial Solutions — www.vajravyuh.comEmergency supply: +91 9979774557 | sales@vajravyuh.com

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