How to read a valve pressure test report — and 6 red flags in weak factory test sheets

6 red flags in weak factory test sheets

1. No serial numbers or heat numbers. A line that reads “DN50 PN40 × 120 pcs — PASS” cannot be tied to any physical valve, or to its material certificate.
2. No gauge ID, or an expired or uncalibrated gauge. If the gauge cannot be identified, the recorded pressure cannot be trusted. Ask for the calibration certificate and compare the due date with the test date.
3. No test fluid or temperature. Water and air tests answer different questions; for stainless steel valves, the water quality may be specified too. A blank here usually means nobody checked.
4. No hold duration, or no start and end pressure. Without the hold time you cannot tell whether the minimum duration was met; without end pressure you cannot see a drop.
5. An “all passed” summary with no individual readings. Identical results printed for every size, or one PASS stamp for the whole lot, is a declaration — not a test record.
6. Valves tested after coating. Paint and primer can seal porosity and pinholes for the duration of a shell test. If the record shows painted valves, ask whether the shell test was repeated bare, or treat body tightness as unverified.

How to check a report in ten minutes

1. Pick three serial numbers from the packing list and find them on the test report.
2. Match their heat numbers against the EN 10204 3.1 certificates — see EN 10204 3.1 vs 3.2.
3. Check the gauge calibration due date is after the test date.
4. Compare the standard, edition and leakage rate on the report with your PO — see leakage rates explained.
5. Look for every test your PO requires — a missing low-pressure air seat test is common. See shell, seat and backseat tests.

Sources

• API 598, Valve Inspection and Testing — API publications store
• API 6D, Specification for Pipeline and Piping Valves — API publications store
• EN 12266-1:2012, Industrial valves — Testing of metallic valves — Part 1 — BSI (BS EN 12266-1:2012)
• ISO 5208:2015, Industrial valves — Pressure testing of metallic valves — iso.org
• EN 10204, Metallic products — Types of inspection documents — BSI

We report facts from the samples inspected. Standards named in these guides are public standards we work to, not certifications or accreditations we hold. We do not issue product certificates or accreditation marks. Test pressures, durations, leakage rates and acceptance numbers must be read from the licensed edition named in your purchase order; we do not reproduce copyrighted tables from the standards.