In critical industries such as oil and gas, petrochemicals, power generation, LNG, hydrogen and carbon capture, valve manufacturers must gain approval from the end user or global operator, before they can be considered for a project.
For many manufacturers, this approval is one of the most demanding and valuable milestones in their development. It involves a comprehensive assessment of the company’s engineering capability, manufacturing controls, quality systems and, ultimately, the performance of its products.
Building on certification
Many valve manufacturers already operate under internationally recognised quality standards such as ISO 9001. These certifications provide independent verification of a quality management system, and major operators treat them as a baseline requirement.
Global operators are responsible for facilities where equipment failure can have serious safety, environmental and commercial consequences. They need confidence that both the manufacturer and the product can perform reliably under the most demanding service conditions. The approval process is how they gain that confidence.
What does the approval process look like?
The qualification route varies between operators and industries, but typically includes one or more of the following:
- Portal-based supplier qualification
- Documentation and desktop audits
- Remote technical audits
- On-site factory technical audits
- Product design validation testing
The most comprehensive programmes combine an in-depth technical audit with witnessed design validation testing. Together, these give the operator assurance that the manufacturer can consistently produce valves suitable for critical service.
The technical audit
A technical audit establishes whether a manufacturer has the engineering expertise, manufacturing capability, quality controls and testing facilities to meet the operator’s requirements consistently.
The operator’s specialists will typically examine:
- Engineering capability: design and development processes, design calculations, drawing and revision control, and the competence of the engineering team.
- Manufacturing capability: machining, assembly, welding and heat treatment, coatings, and how production is managed across the factory.
- Quality systems: how ISO 9001 is applied in practice, from quality planning and inspection to non-conformance and corrective action.
- Testing and inspection: hydrostatic, pneumatic and fugitive emissions testing, NDE, calibration and inspection records.
- Material traceability: certification controls and full traceability from raw material to finished product.
- Supply chain control: how suppliers and subcontractors are qualified and managed, and how incoming materials are inspected.
Ultimately, the operator is looking for the answer to one fundamental question: can this manufacturer consistently design, manufacture, test and supply valves that will perform safely throughout their intended service life?
Design validation testing
Following a successful technical assessment, operators may require a witnessed design validation test. Where routine production testing confirms that each valve meets its specification, design validation testing deliberately takes a valve to the limits of its design envelope. It demonstrates that the design can maintain performance under extreme operating conditions and throughout its expected life cycle.
These tests are normally witnessed by the operator’s representatives at the manufacturer’s facility.
Typical requirements include:
- Seat sealing performance: verification that the valve maintains acceptable seat leakage throughout testing.
- Fugitive emissions performance: assessment of emissions control under vacuum, at operating pressure, at elevated temperatures and through extended mechanical cycling.
- Mechanical endurance: repeated operating cycles to demonstrate long-term reliability and durability.
- Operating torque verification: torque measurement during pressure testing, throughout cycling and after exposure to temperature extremes.
- Temperature performance: verification that the valve functions correctly at its specified high and low temperature limits.
The value of approval
For the operator, approval reduces technical and operational risk by confirming that products are fit for purpose before they go into service.
For the manufacturer, it shows that its organisation, systems and products have been independently assessed against some of the most demanding requirements in industry. Approval demonstrates the capability to deliver safety, reliability and performance consistently across the whole lifecycle of a product.
As LNG, hydrogen, carbon capture and wider energy transition projects develop, rigorous technical audits and design validation testing will become ever more important.
Colson Valves’ operator approvals
Colson Valves has been through this process with some of the world’s leading energy operators. Our approvals include:
- Shell
- BP
- ExxonMobil
- National Gas
These approvals mean our instrumentation and Double Block and Bleed valves can be specified with confidence on projects where safety and reliability are critical.
Global operator approval is how the industry gains confidence that a manufacturer and its products are ready for the world’s most demanding applications. To find out more about our approvals, or to discuss your next project, get in touch with our team.