Design Validation Test

What is a design validation test?

A design validation test is an extensive design trial in which the functioning, tightness and operability of a valve are validated under realistic conditions. Unlike a one-off test, the valve is repeatedly loaded.

The valve undergoes multiple thermal and mechanical cycles, with performance during and after each phase measured and recorded in detail. This produces a reliable picture of how the design behaves over its service life, even under severe and varying loads.

Design validation test according to international standards

For DVT testing ITIS works according to internationally recognised standards and project specifications. Which standard applies depends on the sector, application and customer requirements. We test according to the following frameworks, among others:

• ISO 23632:
  Design validation testing for ball and butterfly valves, with thermal and mechanical cycles and measurement of seat performance and operating torque per step
• Shell MESC SPE 77/300 (TAT):
  Project specification with a fixed test programme for cycles and temperature steps, including seat sealing and optionally in combination with fugitive emissions requirements
• API 6A Annex F PR2:
  Design validation for upstream oil & gas applications, with combined pressure, temperature and operating cycles that are more severe than PR1

When is DVT applicable?

A design validation test is mainly used when design reliability is critical and risks at a later stage must be prevented. DVT is relevant in the following situations:

• New or modified designs from OEMs
• Pre-qualification for tenders and projects
• Changes in materials, seats or sealing concepts
• Critical applications such as hydrogen, cryogenic service, high temperatures or erosive and abrasive conditions

In all these cases DVT provides objective and reproducible evidence that a design is suitable for its intended use.

The structure of a design validation test programme

Every design validation test starts with a carefully prepared test plan. This plan is tailored to the application, the applicable standard and the specific wishes of the customer. Within this programme various steps are taken to fully assess the design:

• Tailor-made test plan
  Defining P×T profiles, number of cycles, stabilisation and hold times and measurement moments
• Thermal cycles
  Alternately cooling and heating according to the test profile, with full logging of the temperature course per step
• Mechanical cycles
  Operating and switching the valve, including recording torque or force and actuator settings
• Pressure loading
  Testing with liquid or gas, with controlled pressurisation steps and safe venting or evacuation
• Seat leakage
  Measurement at inlet and outlet, with limits according to standard or project specification at hot and cold conditions
• Functional checks
  Re-start after loading, visual inspections and analysis of the torque profile

Fugitive emissions fall outside the scope of ISO 23632. If desired, the DVT can be combined with ISO 15848-1 or ISO 15848-2 for a complete performance picture.

Full insight during the test

ITIS believes it is important that you have full insight into what is happening during the test process. Therefore we offer various possibilities to follow or verify the process:

• Live viewing via a secure stream or portal
• Third-party witnessing by an independent party
• Certification by external bodies if required

This keeps the entire trajectory transparent and controllable.

Why perform a DVT at ITIS?

ITIS combines in-depth technical knowledge with a practical and transparent working method. Customers choose ITIS because they can count on:

• An independent and ISO 17025-accredited laboratory and conformity assessment body
• Extensive experience with DVT, TAT, pressure and emissions testing
• Custom test setups and short turnaround times
• Clear digital reporting with data logging, photos, videos and documentation in one central location

Do you want to be sure your valve design is ready for practical use? ITIS is happy to support you with a reliable and well-founded design validation test.

Transparent report you can rely on

After completion of the test, the results are assessed against pre-agreed acceptance criteria. The outcomes are recorded in a complete and transparent test report so you know exactly where you stand. This report contains, among other things:

• Pass/fail criteria according to ISO 23632, SPE 77/300 or API PR2
• Full data logging of pressure, temperature, cycles, torque or force and leakage
• Clear summary per test step, including any deviations and corrective actions
• Clear final conclusion passed or failed
• Where applicable carried out under ISO 17025 accreditation

This approach increases traceability and the international value of the test results.

Accredited, certainty for you

ITIS is accredited by the Dutch Accreditation Council (RvA) under accreditation number L656. For you this means certainty. Our test and measurement results are demonstrably reliable and meet established quality standards.

Thanks to international recognition via the ILAC MRA, results within scope are also accepted worldwide. This avoids re-inspections, speeds up processes and builds confidence with customers, regulators and partners.

You work with an independent party that operates according to controlled procedures. This delivers clarity, consistency and a strong foundation for your decisions, both technical and commercial.