Inspection and Test Plan (ITP) for Control Valves

The Inspection and Test Plan (ITP) of Control Valves establishes procedures to satisfy both industrial guidelines and engineering specifications and project requirements. Throughout fabrication and assembly and installation stages the ITP defines all required inspections combined with tests. Control valves must fulfill reliability and operational performance requirements within the oil and gas sector alongside petrochemicals and refineries due to this inspection and test plan.

Definition of Terms

• Client: The company or organization leading project operations functions as the client.
• Company: The main entity responsible for project execution.
• Contractor/Purchaser: The entity which obtains control valves serves as both Contractor/Purchaser.
• Engineering: The design and technical team.
• Supplier: A supplier stands as the entity which manufactures or offers products to customers.

Scope

This document provides detailed specifications which describe minimum standards for inspections and tests and preparations of control valves before their shipment and installation. The supplier maintains full responsibility to meet standards and specifications that apply to their work.

Key points:

• Defines inspection and testing obligations.
• Establishes supplier responsibilities.
• Summarizes contractor and purchaser expectations.
• Quality standards of the project must be followed.

Applicable Codes and Standards – ITP for Control Valves

The equipment data sheet includes primary references for inspections and tests which use approved codes and standards. The supplier requires adherence to all codes and standards from both COMPANY engineering documents and technical specifications. The table below lists essential documentation which applies to control valve design alongside its fabrication and testing procedures and inspection requirements.

As the manufacturing supplier the responsibility falls to ensure total compliance with every mandatory regulation that pertains to control valve manufacturing procedures. The manufacturer together with the contractor need to follow all current versions of applicable codes and standards.

Applicable Standards for Inspection and Testing

Standard	Title
ASME Section II-Part A/B	ASME Boiler & Pressure Vessel Code – Materials
ASME Section IX	ASME Boiler & Pressure Vessel Code – Welding and Brazing Qualifications
ASME Section V	ASME Boiler & Pressure Vessel Code – Non-Destructive Testing (NDT)
ASME Section VIII-Div.1	ASME Boiler & Pressure Vessel Code – Rules for Construction of Pressure Vessels
ASME B16.34	Valves – Flanged, Threaded, and Welding End
API 598	Valve Inspection and Testing
API 591	Process Valve Qualification Procedure
API 600	Bolted Bonnet Steel Gate Valves
API 602	Steel Gate, Globe, and Check Valves (DN100 and smaller)
API 603	Corrosion-Resistant Bolted Bonnet Gate Valves – Flanged and Butt-Welding Ends
API 607	Fire-Type Testing Requirements for Valves
API 609	Butterfly Valves – Double Flanged, Lug, and Wafer Type
API RP 553	Refinery Control Valves
IPS-C-IN-160(1)	Construction and Installation Standard for Control Valves
IPS-E-IN-160(1)	Engineering Standard for Control Valves
IPS-M-IN-160(1)	Material Standard for Control Valves
IPS-C-TP-101(1)	Construction Standard for Surface Preparation
IPS-E-TP-100(1)	Engineering Standard for Paint
BS EN 10204:2004	Metallic Products – Type of Material Inspection

Refer the below link to access the Codes and Standards for Control Valve Selection in Industrial Applications

Codes and Standards for Control Valve Selection in Industrial Applications

Reference Documents

The inspection and testing process requires examination of engineering documents together with drawings/specifications while using material requisitions along with purchase orders plus industry codes as reference materials.

Conflicting Requirements

A disagreement will be resolved beginning with the following order of priority:

1. Purchase order
2. Clarification
3. Material Requisition
4. Data sheet/Drawing
5. Project Specification
6. IPS standard
7. International codes and standard

Written authorization from “COMPANY” must always be obtained before resolving potential conflicts.

Change Management and Revision Control- Conflict Resolution Procedure

• Process for modifying the ITP when project requirements change.
• Approval workflow for revisions.
• Version control and documentation updates.

Inspection Requirements

General Requirements

• The inspection team receives complete access to supplier and sub-supplier operational sites.
• Compliance with EN 10204:2004 for certification and inspection documentation.
• The inspection points defined in the ITP table require a minimum number of locations.
• Safety procedures during testing (e.g., handling pressurized systems).
• Environmental considerations (waste disposal, emissions compliance).
• PPE requirements for testing personnel.

Inspection and Test Activities

A summary table includes essential inspection and test operations for validating control valves meet their safety and quality requirements. All activities require reference standard approvals and specific documentation needs and actions. The control valve ITP requires editing according to your purchase order specifications.

Task Objectives for the Inspection and Testing of Control Valves	Vendor	TPI Inspection	Client
The certificate for material and actuator tests of control valves	H	H	R
The minimum required checks during characteristics examination should evaluate 1) Body, seat, stem, packing, accessories and actuator together with 2) The material certificates for body, trim, seat, plug, disc or ball, bolting, gasket/packing.	H	H	R
Control System Valves require nondestructive testing according to specification requirements.	H	R	R
Testing the valve body under pressure (Note: A witness should participate for bodies above class 300)	H	W	R
A Pneumatic test on control valves must be performed upon specified requirements.	H	W	R
Control valve Seat leakage test	H	S	R
Control valve Calibration test	H	S	R
Control valve Performance/function test	H	H	R
Control valve Stroke test	H	H	R
Control valve Air failure test	H	W	R
Control valve Linearity check	H	R	R
Control valve Response and stabilization time and hysteresis	H	W	R
Control valve Insulation resistance test	H	W	R
Control valve Final visual / Dimension inspection	H	H	R
The final step of technical inspection requires a review of control valve documentation before releasing it for use (Final activity of Technical inspection).	H	H	R
Control valve Pre-shipment inspection	H	H	R

Note: Calibration and Verification Procedures

• Define how calibration is performed (e.g., reference instruments, procedures).
• Acceptable tolerances for control valve operation.
• Frequency of recalibration and validation criteria.

Witness and Hold Points

• Hold (H): The Hold point marks an essential step in the procedure which stops work from advancing until authorities approve or conduct inspections. The process requires taking necessary corrections before moving forward following inspection failure.
• Witness (W): The inspection requires viewing by either an independent designated inspector or a third-party witness. Work will proceed and a test result record must be documented provided witnesses are not present.
• Review (R):Tests and inspections need review for successful compliance with project specifications to continue with the process.
• Review & Approval (RA): The final stage of Review & Approval (RA) requires verification and approval of results followed by documentation before the control valve continues toward future stages or shipment.

Refer the below link to download the Task Objectives for the Inspection and Testing of Control Valves in Excel form 

Supplier’s Quality Control Plan (SQCP)

Every supplier needs to present their Quality Control Plan that shows:

• Sequence of inspections and tests.
• Reference standards and acceptance criteria.
• Recording and certification of tests.
• Quality control personnel involvement.
• Corrective actions for non-conformities.
• Criteria for selecting and approving suppliers.
• Requirements for supplier audits and performance tracking.
• ISO 9001 or other quality system compliance checks.

Inspection and Test Execution

The inspection and testing operational plan includes these subsequent phases.

Pre-Inspection Meeting (PIM)

• Conducted after the Purchase Order (PO) is issued.
• Review of project specifications and quality control plans.
• Agreement on hold and witness points.
• Qualifications of inspectors and test personnel.
• Required certifications for handling control valves.
• Ongoing training programs for inspection teams.

Material Inspection

• Verification of raw material certificates.
• The inspection includes visual and dimensional measurements for body sections as well as bonnet parts and trims.
• Material composition analysis.

Fabrication Inspection

• The welds undergo inspection procedures according to the standards defined in ASME IX.
• NDT (Radiography, Ultrasonic, Magnetic Particle, and Dye Penetrant Testing).
• The inspection process evaluates both surface preparation along with paint application methods.

Assembly and Functional Testing

• Hydrostatic testing of body and seat leakage.
• Functional and calibration checks of actuator and accessories.
• Low/high-pressure closure tests.

Final Inspection

• The inspection confirms the accuracy of nameplate and tagging documentation.
• Packing and marking inspection.
• Documentation review and compliance verification.
• Requirements for testing control valves after installation.
• System integration testing with plant control systems.
• Verification of valve performance under actual process conditions.

Non-Conformance and Corrective Action

• Non-Conformance Reports (NCR) need to be filed for every deviation that occurs.
• All corrective procedures need client authorization to proceed with additional work.

Failure Analysis and Root Cause Investigation- Non-Conformance and Corrective Action

• Procedure for root cause analysis in case of valve failure.
• Criteria for classifying non-conformities.
• Implementation of corrective and preventive measures.

Documentation Requirements

• Standardized formats for test reports.
• Digital record-keeping and archiving methods.
• Frequency and responsible parties for documentation submission.

Final documentation must include:

• Material Test Certificates (MTC).
• Welding Procedure Qualification Records (WPQR).
• NDT reports and calibration certificates.
• Functional and hydrostatic test reports.
• Final Inspection Release Note (IRN).
• Shipping Release Note (SRN).

The Inspection and Test Plan (ITP) for Control Valves outlines all necessary quality tests with specified evaluation methods to verify control valve compliance with project specifications. The document functions as a standardized framework that guides suppliers and installation professionals and inspectors to carry out high-quality production steps and building processes to enhance operational reliability while improving efficiency throughout the project.

FAQ On Control Valve ITP

What is the ITP inspection and Test Plan?

An Inspection test plan functions as an inspection checklist which establishes the necessary inspection requirements. The document shows all inspection tasks together with straightforward instructions to boost quality control measures.

How to prepare ITP inspection and Test Plan preparation?

How to Write an Inspection Test Plan with a Template

• Record inspections for both activities and tasks on lists.
• Code and reference documents should also be included.
• Set the inspection criteria
• Setting the acceptance criteria
• Use checklist as a direct supplementation to your inspection plans.

What is the procedure for valve inspection?

The valve manufacturer implements tests under API STD 598 ( Valve Inspection and Testing) procedures. The valve needs to maintain partial opening while undergoing pressurization tests for designated durations. The test must maintain a pressure which exceeds 1.5 times the maximum operating pressure. No leakage is allowed.

What is the quality control inspection and Test Plan?

The Inspection and Test Plan through its contents highlights which materials need testing and inspection when who should conduct them and which stages require attention including Hold and Witness points directions for standard references plus acceptance standards along with recordkeeping requirements.

What is the difference between ITP and control plan?

The Quality Control Plan establishes an extensive quality framework for project management yet the Inspection and Test Plan defines the procedures used to verify compliance with set standards.

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