Quality Control, Inspection & Testing

At Halcyon Valves Automation, we believe that consistent quality and reliability are the foundation of industrial trust. Every product—whether a cast steel gate valve, forged check valve, actuated ball valve, fabricated sluice gate, or slip-on flange—undergoes rigorous inspection, material traceability, and multiple stage-wise tests to ensure compliance with national and international standards.

1. Material Identification & Traceability

Raw materials are procured only from approved vendors and verified through Material Test Certificates (MTCs) conforming to EN 10204 3.1 / 3.2. Each casting, forging, and plate is visually examined and permanently marked with heat numbers to maintain traceability throughout machining, fabrication, and assembly.

• Positive Material Identification (PMI) for stainless and alloy steels
• Chemical and mechanical properties verified per ASTM / IS standards
• Dimensional and surface tolerance checks on receipt
• Storage and handling as per ISO 9001 material preservation standards

2. Welding Control & Procedure Qualification

Welding is performed under qualified WPS / PQR / WPQ as per ASME Section IX or equivalent. Our welders are certified, and consumables are stored under controlled conditions to prevent moisture absorption.

• Weld maps maintained for traceability
• Fit-up, root, and intermediate visual inspections at every stage
• Preheat and PWHT monitored and recorded
• Weld electrodes baked and issued per batch log

3. NDT & Radiographic Inspection

All welding joints and pressure-retaining components are subjected to appropriate Non-Destructive Testing (NDT) per project requirements and applicable codes:

• Ultrasonic Testing (UT) for plates and forgings
• Magnetic Particle Testing (MT) for carbon steel welds
• Liquid Penetrant Testing (PT) for stainless steel and overlays
• Radiography (RT) for critical joints as per ASME Section V
• Acceptance criteria as per ASME / API / ISO / EN standards

4. Machining, Assembly & Functional Tests

Dimensional inspections are carried out using calibrated measuring instruments, gauges, and templates. Valve assemblies undergo alignment, seat lapping, and torque verification before testing. Pneumatic or electric actuators are tested for stroke, travel, and limit switch adjustments.

• Face-to-face and flange dimensions verified per ASME B16.10 / EN 558-1
• Stem and seat torque values measured and recorded
• Actuator mounting alignment per ISO 5211 / DIN 3337
• Function tests: open/close cycles, travel time, and leak verification

5. Hydrostatic & Pneumatic Pressure Tests

Every pressure-retaining product is hydrostatically tested using calibrated gauges. Pneumatic and helium leak tests are performed when specified. Test pressures and durations conform to API 598, ISO 5208, BS 6755, or IS 14846 standards.

6. Surface Preparation & Coating

Valves and sluice gates are surface-prepared to SA 2.5 finish as per ISO 8501-1. Coating and painting are carried out according to ISO 12944 standards with approved paint systems.

• Surface profile measurement using calibrated gauges
• Primer, intermediate, and finish coats as per Technical Data Sheets (TDS)
• Dry Film Thickness (DFT) measured and logged
• Holiday and adhesion testing when applicable

7. Calibration & Instrumentation

All measuring instruments and pressure gauges are calibrated at ISO/IEC 17025 accredited laboratories. Calibration cycles are maintained with traceability to national standards.

8. Documentation & Certification

Every product is supplied with a complete Data Dossier including:

• Material Test Certificates (EN 10204 3.1)
• WPS / PQR / WPQ records
• NDT and test reports
• Calibration certificates
• Final Inspection Release Note (IRN)
• Performance Guarantee Certificate (if applicable)

9. Third-Party Inspection (TPI)

We welcome inspection by leading agencies such as BV, TUV, DNV, SGS, Lloyd’s, RITES, IBR, and ABS. Stage-wise inspection categories include:

• R – Review of document
• W – Witness during process
• H – Hold point requiring approval before proceeding

Remote witnessing and digital test report submission are available on request for overseas clients.

10. Final Inspection & Dispatch

Final inspection ensures all dimensional, visual, and test parameters meet customer requirements. Each product is tagged with item code, serial number, pressure class, and manufacturing date. Valves are packed with protective caps and anti-rust preservative coating to prevent damage during transit.

11. Continuous Improvement & CAPA

All non-conformities are analyzed under a Corrective and Preventive Action (CAPA) system. Inspection trends, rework reports, and customer feedback are periodically reviewed for quality enhancement.

Disclaimer: All inspections and tests are performed in accordance with customer purchase orders, data requirements, and applicable codes such as API, ASME, BS, EN, and IS. Customers are requested to confirm testing parameters, media, and acceptance criteria prior to dispatch. Halcyon Valves Automation reserves the right to update procedures in line with continuous quality improvement.