Forged Steel Valve Inspection and Test Plan (ITP): Hold, Witness and Review Points

A forged valve can pass its final pressure test and still arrive with the wrong document revision, a broken material traceability chain, an unapproved repair, or an incomplete manufacturing record book. A project-specific forged steel valve inspection and test plan (ITP) prevents those gaps by controlling the entire manufacturing route—not just the last test.

For buyers, EPC contractors, project owners and third-party inspection agencies, the practical value of an ITP is timing. It places verification before an identity is machined away, before a special process becomes hidden and before a packed valve leaves the factory.

Quick answer: A valve ITP is an agreed manufacturing and inspection roadmap. Each line should state the activity, inspection characteristic, acceptance basis, inspection frequency, required record, responsible parties and whether work may continue. Hold, Witness, Review and Surveillance codes are contractual controls; the legend in the approved project ITP always governs their exact meaning.

Why a Passed Pressure Test Is Not a Complete ITP

A shell or closure test provides important evidence about a particular valve under specified test conditions. It cannot reconstruct evidence that was never collected earlier. A final test alone does not confirm that:

• the material certificate belongs to the physical valve body and bonnet;
• heat treatment and mechanical test records match the relevant heat or lot;
• required NDE, PMI or impact testing was performed to an approved procedure;
• machining dimensions and end connections match the approved drawing;
• a repair or concession was formally accepted and re-inspected;
• the nameplate, body marking and final dossier identify the same valve.

The purpose of an ITP is therefore not to add signatures after production. It is to create a controlled evidence chain from contract review to shipping release. For the pressure-test details that belong inside that chain, see our guide to forged valve seat leakage testing.

Hold, Witness, Review and Surveillance Points

The letters H, W, R and S are widely used, but they are not universal acceptance grades. They describe how a named party intervenes at a manufacturing stage. The approved ITP must define the legend, notice period, release authority and waiver process.

Code	Typical meaning	Practical control
H — Hold	Work must not pass the defined point without written release or a formally documented waiver from the named party.	Use where the next operation would remove identity, conceal evidence, make recovery difficult or authorize shipment.
W — Witness	The named party receives advance notice and an opportunity to attend or observe the activity.	The ITP must say whether work may proceed after a properly notified no-show; never assume that it may.
R — Review	The named party reviews a document or record such as an MTC, procedure, qualification, calibration certificate or test report.	Define whether review occurs before work, before release or in the final dossier.
S — Surveillance	Periodic monitoring or sampling of an activity without a formal stop point.	Useful for stable, repeatable operations, but only when the project legend defines it.

A third-party signature does not transfer the manufacturer’s quality responsibility, and a Review point is not automatically a Witness point. If a project uses different letters or definitions, the contract-specific legend takes precedence.

What an Executable Valve ITP Must Contain

A useful ITP row should answer all of the following questions without relying on verbal knowledge:

1. What happens? Name the manufacturing or inspection activity in process order.
2. What is checked? Identify the characteristic—material identity, dimensions, surface condition, test result, marking or record completeness.
3. Against what? Cite the approved drawing, purchase specification, procedure and applicable standard revision.
4. How often? State 100%, per heat, per lot, per size/class, sample quantity or another defined frequency.
5. How is it checked? Reference the method, equipment or approved procedure.
6. What is the evidence? Name the form, report, certificate, photograph or electronic record.
7. Who participates? Assign the manufacturer, buyer/EPC contractor, project owner and third-party inspection agency separately.
8. May work continue? Apply the agreed intervention code and release rule.

Vague entries such as “visual OK,” “as per standard” or “documents checked” are not enough. A reviewer should be able to identify the controlled document, its revision, the acceptance characteristic and the resulting record.

Which Standards Belong in a Forged Valve ITP?

An ITP does not replace a product or test standard. It translates the order’s requirements into an executable sequence. The governing hierarchy should be agreed during contract review and normally includes:

• the purchase order, valve data sheet and project specification;
• approved drawings, bills of materials and manufacturing procedures;
• the applicable product standard—for example, API 602 for applicable small-bore forged steel gate, globe and check valves;
• ASME B16.34 where specified for valve materials, ratings, construction, examination, testing and marking;
• API 598 or ISO 5208 when designated as the pressure-test basis;
• ASME B16.10 or the approved drawing for applicable face-to-face or end-to-end dimensions;
• project-specific requirements for low-temperature service, sour service, NDE, PMI, fugitive emissions, coating, preservation and documentation.

Do not silently combine acceptance criteria from API 598 and ISO 5208, or use API 602 as a universal standard for every valve design. Ball valves and other valve types require their own applicable product and project requirements. The ITP should identify the selected edition and resolve conflicts before manufacturing begins.

Illustrative Eight-Stage Forged Valve ITP

The following matrix is an example for discussion, not a ready-to-sign project ITP. Final points, frequencies and acceptance criteria must be agreed by the contractual parties for the actual valve type, service and order.

Stage	Control objective	Typical evidence	Possible intervention
1. Contract and document review	Confirm specifications, standards, drawings, procedures, inspection frequency and document hierarchy before production.	Approved ITP, drawings, procedures and revision register	R / H
2. Incoming material and identity	Match material certificates, heat/lot identity and physical markings before any identity transfer.	MTCs, receiving report, heat-number traceability record	H or W
3. Forging, heat treatment and specified examination	Verify required process records, mechanical properties and contract-required NDE or PMI.	Heat-treatment chart, test report, NDE/PMI report, personnel and procedure qualifications	R / W
4. Machining and dimensional inspection	Check pressure-boundary dimensions, wall thickness, end connections, face-to-face/end-to-end dimensions and critical fits.	Dimensional inspection report and approved drawing	W / S
5. Assembly and functional checks	Confirm component identity, orientation, cleanliness, specified torque or assembly controls and smooth operation.	Assembly traveler and functional inspection checklist	S / W
6. Pressure and closure testing	Verify valve identity, approved procedure, calibrated instruments, test conditions, result and acceptance basis.	Pressure-test report, instrument details and witness record	W
7. Marking, coating, preservation and packing	Match nameplate and body markings to the order; confirm finish, protection and packing requirements.	Final visual, marking and packing inspection report	R / W
8. Final dossier and shipping release	Confirm required records are complete and all NCRs, concessions, repairs and retests are closed.	Manufacturing record book, release note and packing list	R / H

Ask CLDG to review your valve ITP before production starts. Send the valve data sheet, purchase specification, required standard editions and third-party inspection requirements so the intervention points can be aligned with the actual order.

Where Hold Points Deliver the Most Value

A Hold point creates schedule cost, so it should protect a real risk. Making every row a Hold point can produce queues, repeated notifications and informal bypasses. A small number of precise Hold points is usually more effective.

1. Before original material identity is removed

If machining will remove the original heat marking, identity transfer should be verified before the mark disappears. The traceability record must connect the material certificate, physical component and subsequent identification.

2. Before an irreversible or concealed operation

Special processes, internal features and surfaces that become inaccessible after assembly deserve risk-based attention. The exact point depends on the design and contract; not every forged valve requires the same NDE or special-process controls.

3. Before critical assembly is closed

When later disassembly would be costly or could disturb controlled conditions, the ITP may require verification of component identity, cleanliness, orientation and specified assembly records before closure.

4. Before final shipping release

A final Hold point is valuable when shipment must not occur until open NCRs, repair records, retests and dossier comments are closed. It prevents physical delivery from outrunning document acceptance.

Our broader forged valve quality control page explains how traceability and inspection records fit into the manufacturing system. For a material-specific example, see why an ASTM A350 LF2 impact-test result must still be tied to the correct heat, specimen and service requirement.

How to Witness a Pressure Test Properly

Witnessing is more than watching a pressure gauge. Before accepting the test record, the inspector should verify:

• the valve tag, size, class, type and traceable identity match the ITP line;
• the approved test procedure and acceptance document are at the correct revision;
• the instruments are within their calibration period and suitable for the measurement;
• the test medium and required test condition are identified;
• actual readings, duration and observations are recorded rather than pre-filled;
• the closure, shell and applicable backseat tests are recorded separately where required;
• any leakage is evaluated against the contractually selected acceptance basis;
• the witness status, date, signatures and linked report number are unambiguous.

The article should not be used as a source for project test pressure, duration or allowable leakage. Those values must come from the order’s approved standard and procedure. Specialized activities such as high-pressure helium leak testing also require their own approved method and acceptance basis; they are not automatically part of every valve ITP.

Write the Notification and Release Logic into the ITP

Many inspection delays are caused by undefined administration rather than technical failure. The approved legend or cover sheet should state:

• the minimum notice period and the time zone used;
• the approved contacts and method of notification;
• which document revision accompanies the notice;
• what information identifies the valve, lot and activity;
• whether a correctly notified no-show permits work to proceed;
• who can waive or downgrade a point and how the waiver is recorded;
• whether remote witnessing is allowed and what live or recorded evidence is required;
• how a missed point, NCR or changed schedule resets notification and release.

A Witness point should never be interpreted as an automatic release rule. If the buyer or inspector does not attend, the approved ITP must say what happens next.

NCR, Repair, Retest and Release

An effective ITP also defines the route when a result is unacceptable:

1. Identify and segregate: link the nonconformance to the exact valve, component, heat, lot and affected records.
2. Evaluate and approve disposition: record repair, rework, use-as-is or rejection through the agreed authority. An inspector’s observation alone is not a design concession.
3. Re-inspect or retest: repeat the applicable inspection after the approved action and preserve both the original and new results.
4. Close before release: verify that the NCR, concession, repair procedure and retest record appear in the final dossier when contractually required.

Traceability must survive the entire loop. Replacing the original failed report with a clean retest report destroys the evidence chain.

What Belongs in the Final Manufacturing Record Book?

The document index should be defined at the beginning of the order, not assembled from memory at dispatch. Depending on contract scope, the final package may include:

• approved ITP, drawings, data sheets and procedure index;
• material certificates and heat/lot traceability records;
• heat-treatment and required mechanical test records;
• specified NDE, PMI or coating reports and relevant qualifications;
• dimensional and functional inspection reports;
• pressure-test records with valve identity and instrument information;
• marking, preservation and packing inspection records;
• NCRs, concessions, repairs, retests and closure evidence;
• release note, certificate of conformity and final document index where specified.

For an overview of forged valve types that may require different product standards and inspection routes, visit our forged steel valve types guide.

Buyer and EPC ITP Review Checklist

1. Does the scope identify the exact valve types, sizes, classes, materials and service?
2. Are all standards and project documents named with controlled revisions?
3. Is the hierarchy clear when documents conflict?
4. Does every row define an inspection characteristic, frequency, method and record?
5. Are manufacturer, buyer/EPC, project owner and third-party roles shown separately?
6. Are H, W, R and S defined in the project legend?
7. Are notice period, no-show, waiver and written-release rules explicit?
8. Are material identity transfer and final nameplate traceability controlled?
9. Are NCR, repair, retest and re-notification steps linked?
10. Is the final dossier index agreed before manufacturing starts?

Common ITP Failures to Avoid

• Issuing the ITP after production starts: early verification opportunities may already be lost.
• Turning every activity into a Hold point: the plan becomes difficult to execute and encourages informal workarounds.
• Using “per standard” as the acceptance criterion: the inspector cannot see which document, revision or clause governs.
• Leaving frequency blank: 100%, lot sampling and document review are not interchangeable.
• Ignoring identity transfer: valid certificates become useless if they cannot be connected to the physical components.
• Closing NCRs outside the dossier: the final record no longer tells the complete manufacturing story.
• Treating witness as certification: attendance does not create a product certification or remove the manufacturer’s responsibility.

Frequently Asked Questions

Is an ITP the same as a quality plan?

Not exactly. A quality plan can describe the broader system, resources and controls for an order. The ITP is the sequenced inspection-and-test route, with acceptance evidence and intervention points. Projects may combine them, so the approved document definitions matter.

Who approves a valve ITP?

The contract determines the approval route. It may involve the manufacturer, buyer or EPC contractor, project owner and an authorized third-party inspection agency. Each party’s review or signature authority should be explicit.

Does every forged valve require 100% PMI, UT or impact testing?

No. Required examinations depend on material, service, design, applicable standards and project specification. The ITP should implement agreed requirements, not invent a universal test package.

Is API 602 alone sufficient for an ITP?

No. API 602 may be the applicable product standard for certain small-bore forged steel gate, globe and check valves, but the order also needs its designated pressure-test basis, approved drawings, material requirements and project-specific controls. Other valve types require their applicable product standards.

Can a pressure test be witnessed remotely?

Yes, if the contract parties approve the method in advance. The ITP should define the live view, valve identity, instrument visibility, communication, recording, data retention and release evidence. Remote attendance should not be improvised after the test starts.

Engineering References

• ASME B16.34-2025 — Valves: Flanged, Threaded, and Welding End
• API Standards Plan — current published editions and standards in development
• API notification — API 602, 11th Edition
• ISO 5208:2015 — Industrial valves, pressure testing of metallic valves
• ISO 10005:2018 — Guidelines for quality plans
• API Source Inspector Fixed Equipment program and API RP 588 context
• U.S. DOE/WIPP quality assurance requirements — hold-point control example

Standard editions and project requirements can change. The purchase order, approved project documents and officially issued standards govern the actual inspection and acceptance criteria.

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Build the ITP Before the First Hold Point

A strong valve ITP turns a specification stack into a practical release route. It finds problems while evidence is still visible, gives each stakeholder a clear intervention role and delivers records that remain connected to the shipped valve.

Contact CLDG for a project-specific forged valve ITP review. Include the valve data sheet, applicable standard editions, inspection scope, document requirements and required witness parties. We will help organize the manufacturing, inspection and release sequence around the actual order.