Safe Operating Procedure:

Normally Opened Ball Valve Functionality

Test
Author: Ken Kuboshima

Department: Mechanical Engineering

Building/Room: Design Lab (503/2226)

Date Approved:

Approved by: Signature:

[Approver’s name. Should be the
person in charge of the space you will
be performing the procedure in.]

1. Description
This SOP outlines a functionality test of Sharpe Series 89 ball valves, which serves a key function in the
rocket feed system. This test confirms a ball valve’s ability to isolate a pressure-fed medium on one end
of the closed ball valve. A general design for this test consists of a pressurizer in line with a ball valve and
a reservoir that acts as an inlet for the pressurizer. The first test uses an air compressor to pressurize
atmospheric air into a controlled pressure tank and to channel that gas into a manifold that separates
the air flow to two necessary air inlets. One flow of air is used to pneumatically actuate the ball valve,
while the latter is used to build pressure inside the isolated valve system. The second test uses a hand-
operated hydrostatic test pump to create a static pressure condition inside the isolated valve system.
Instead of pressurizing air, this part will pressurize water. This device suctions water from a bucket
through a tube and pushes the fluid into the isolated valve system.

Ideally, all ball valves will properly eliminate fluid flow. However, one should expect for some leakage to
occur. In addition, one should expect a larger volume of leak in the air test than the water test due to
the incompressibility of water. With the data acquired from these tests, one can calculate the rate of
leakage at higher pressures and evaluate the functionality of each ball valve.

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2. Hazards Overview
The two mediums used in this test are atmospheric air and water, and therefore this test does not
pose many chemical hazards. Nevertheless, the following potential hazards can cause harm:

 Over pressurizing poses a threat of an explosion that can cause hazards like flying shrapnel of
tank, pipe, pipe fittings, or other components in the test. Preventative measures:
o Handle the air compressor carefully to minimize damage, and do not use if it looks old,
rusty, or unreliable.
o Be sure that the air vents on the air compressor are not blocked, covered, or clogged.
o Always keep an eye on the pressure gauge.
 Detachment of a loose fitting during a high-pressure static water test may pose a threat of flying
objects such as valves, gauges, and fittings. Preventative measures:
o Tighten fittings with a torque wrench, to avoid over-tightening and under-tightening.
 Operating air compressor with wet hands is an electrical hazard, as it can electrically shock the
operator or damage the electronics on the compressor.

3. Required Personal Protective Equipment (PPE)

 Safety goggles
 Towels/rags
o For drying hands to prevent an electrical shock
 Closed toed footwear

4. Waste Disposal
Wastewater can be disposed of in a nearby sink, down a drain, or, ideally, outside on a lawn.

5. Accident and Spill Procedure

In the event of an emergency, remain calm at all times. Evaluate the status of the accident scene:
A. Tank rupture or explosion due to pressure buildup:
 Evacuate the area away from any debris and ensure proper ventilation.
 In the event of an accident involving personnel, see “5.1) First Aid and Medical Emergency
Procedure”.
B. Water spillage or leak on to the floor:
 Use a towel or a mop to dry off any spilled water to avoid a slippery hazard.

5.1) First Aid and Medical Emergency Procedure

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A. Liquid nitrogen spillage onto personnel:

 Immediately call 911 (or 9-911 from a campus phone) to contact emergency services, then
notify UCSB Environmental Health and Safety at 805‐893‐3194.
o Your location is: [Enter room/building], UC Santa Barbara, Santa Barbara, CA 93106
o The closest hospital is: Goleta Valley Cottage Hospital, 351 S Patterson Ave, Goleta, CA
93111
o Carefully and accurately explain accident and any injuries to dispatcher. Be prepared to
answer:
 What is the problem or incident?
 What is the victim’s age?
 Is the victim conscious?
 Is the victim breathing?
 What is your location?
 If safe, remove the victim away from any source of liquid nitrogen into a well-ventilated area.
 Remove contaminated garments and footwear.
o Clean garments and footwear thoroughly before reuse.
 In case of direct skin exposure:
o Warm affect area with lukewarm water not exceeding 105 °F, body heat, or warm air.
o Maintain skin warming for at least 15 minutes or until normal coloring and sensation
has returned.
o In the event of massive exposure, warm victim using emergency shower (if possible,
warm). All clothing must be removed prior to using shower. Seek medical evaluation and
treatment as soon as possible. Maintain affected areas at normal body
temperature until emergency services arrive.
o Keep victim calm and avoid aggravating injury. Do NOT rub or massage affected areas.
Frostbitten feet should not be used to walk.
 In case of eye exposure:
o Rinse eyes thoroughly with warm water for at least 15 minutes. Hold eyelids open and
away from the eyeballs.
o Check for and remove any contact lenses.
o Seek immediate medical attention and contact an ophthalmologist immediately.
 Provide necessary information, including Safety Data Sheets to emergency responders.

B. Other serious or life-threatening injuries

 Includes: uncontrolled bleeding, deep cuts, severe burns or heatstroke, badly broken bones,
head/spine injuries, sudden unconsciousness, etc.
 Immediately call 911 (or 9-911 from a campus phone) to contact emergency services, then notify
UCSB Environmental Health and Safety at 805‐893‐3194.
o Your location is: [Confirm room/building], UC Santa Barbara, Santa Barbara, CA 93106
o The closest hospital is: Goleta Valley Cottage Hospital, 351 S Patterson Ave, Goleta, CA
93111
o Carefully and accurately explain accident and any injuries to dispatcher. Be prepared to
answer:
 What is the problem or incident?
 What is the victim’s age?

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 Is the victim conscious?

 Is the victim breathing?
 What is your location?
 Administer first aid as required or instructed.
 Provide necessary information, including Safety Data Sheets to emergency responders.

C. Moderate or minor injuries:

 Includes: minor cuts and scrapes, sprains, dislocations, mild suspected bone breaks (no bleeding
or cold sensation), mild heat-related illness, small or localized burns, etc.
 If safe, move victim to a safe and well-ventilated location.
 Ensure the victim is in a stable condition.
o If not, refer to “Other serious or life-threatening injuries” above.
 Administer first aid as required or instructed.
 Have the personnel stop all testing activities and rest.
 If necessary, transport victim to nearby hospital or UCSB Student Health Services.
 The closest hospital is: Goleta Valley Cottage Hospital, 351 S Patterson Ave, Goleta, CA 93111

The lab manager must be notified in the event of any significant injury. A significant injury is any
injury that cannot be addressed by the contents of the room’s Band-Aid station.

6. Equipment

 FFIL/DRN-1, OFIL/DRN-1, PRISO-2: Normally opened ball valves

 Torque wrench
 Pneumatic actuator assembly (air compressor, air filter, manifold, solenoid, and actuator)
 Pressure transducer 
 Compression tee joint
 Hydro-static test pump
 Output water hose 10ft
 Lead water hose 5ft
 Water-filled bucket
 Stainless steel tubing (x3)
 Fitting #1: ¼ “FNPT to ½ “Compression (x2)
 Fitting #2: ½ “MNPT to ½ “Compression
 Fitting #3: ¾ “FNPT to ¾ “MGHT

7. Approvals Required
1. Permission of the feed system lead (Mitchell Aslo) is required before running the tests.
2. Permission of the lab manager (Trevor Marks) is required before using the lab’s location.

8. Procedure

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8.1) General Preliminary Steps for OFIL/DRN-1, FFIL/DRN-1 & PRISO-2 Internal Air
Leak Test
1. Ensure all personal protective equipment is in working condition. 
2. Locate nearest first-aid supply kit and confirm supply kit is stocked.
3. Locate all objects listed in “6. Equipment”.
4. Assemble the test rig shown in the figure below using appropriate fittings and tubes:

a) Cap all the unused ends of a Manifold.

b) Connect Fitting #1(1) to an Output hose (10ft).
c) Compression-fit Steel tubing(1) to Fitting #1(1).
d) Compression-fit Steel tubing(1) to a Tee joint.
e) Compression-fit Steel tubing(2) to the Tee joint.
f) Compression-fit Steel tubing(3) to the Tee joint.
g) Connect Fitting #1(2) to a Pressure transducer, and compression-fit it to Steel tubing(2).
h) Connect Fitting #2 to OFIL/DRN-1, and compression-fit it to Steel tubing(3)
i) Finally, install the Pneumatic actuator assembly by attaching Output hose to the
Manifold and DAPA to OFIL/DRN-1.

Ensure that all connections and fittings are correctly and properly secured before proceeding.

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8.1a) OFIL/DRN-1 Internal Air Leak Test

1. Pre-run
a. Visually check that the ball valve is opened.
b. Be sure all electrically powered components are connected to power and ready to go.
2. Process
a. Turn on the air compressor to 80 psi.
b. Energize the solenoid to close the ball valve.
c. Report the readings from the pressure transducer every 15 seconds over a period of 5
minutes. TURN OFF the air IF this reading exceeds 100 psi at ANY POINT.
d. Clear the area near the ball valve in preparation for post-run.
3. Post-run
a. Turn off the air supply.
b. Deenergize the solenoid to open the normally opened ball valve.
c. Remove the OFIL/DRN-1 from Fitting #2 and replace it with FFIL/DRN-1.

Ensure that all connections and fittings are correctly and properly secured before proceeding.

8.1b) FFIL/DRN-1 Internal Air Leak Test

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1. Pre-run
a. Visually check that the ball valve is opened
b. Be sure all electrically powered components are connected to power and ready to go.
2. Process
a. Turn on the air compressor to 80 psi.
b. Energize the solenoid to close the ball valve.
c. Report the readings from the pressure transducer every 15 seconds over a period of 5
minutes. TURN OFF the air IF this reading exceeds 100 psi at ANY POINT.
d. Clear the area near the ball valve in preparation for post-run.
3. Post-run
a. Turn off the air supply.
b. Deenergize the solenoid to open the normally opened ball valve.
c. Remove the FFIL/DRN-1 from Fitting #2 and replace it with PRISO-2.

8.1c) PRISO-2 Internal Air Leak Test

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1. Pre-run
a. Install a spring action pneumatic actuator, which requires one air inlet.
b. Visually check that the ball valve is opened.
c. Be sure all electrically powered components are connected to power and ready to go.
2. Process
a. Turn on the air compressor to 80 psi.
b. Energize the solenoid to close the ball valve.
c. Report the readings from the pressure transducer every 15 seconds over a period of 5
minutes. TURN OFF the air IF this reading exceeds 100 psi at ANY POINT.
d. Clear the area near the ball valve in preparation for post-run.
3. Post-run
a. Turn off the air supply.
b. Deenergize the solenoid to open the normally opened ball valve.
c. Remove the PRISO-2 from Fitting #2.

Disassemble the test rig to proceed to Water Leak Test.

8.2) General Preliminary Steps for OFIL/DRN-1, FFIL/DRN-1, & PRISO-2 Internal
Water Leak Test
1. Assemble the test rig shown in the figure below using appropriate fittings and tubes:

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a) Locate the inlet and outlet fittings on the Hydro-static test pump.
b) Connect Fitting #3 to one end of a Lead hose (5ft).
c) Connect Fitting #3 from Step b. to the test pump’s inlet fitting.
d) Connect an Output hose (10ft) to the test pump’s outlet fitting.
e) Connect Fitting #1 to the other end of the Output hose.
f) Compression-fit a Steel tubing to Fitting #1.
g) Compression-fit Fitting #2 to the Steel tubing from Step f.
h) Connect OFIL/DRN-1 to Fitting #2.
i) Finally, install the Pneumatic actuator assembly by attaching DAPA to OFIL/DRN-1.

Ensure that all connections and fittings are correctly and properly secured before proceeding.

8.2a) OFIL/DRN-1 Internal Water Leak Test

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1. Pre-run
a. Fill a bucket with water and place the Lead hose inside the bucket.
b. Place an empty bucket next to the ball valve to collect leaked water.
c. Visually check that the ball valve is opened.
d. Be sure all electrically powered components are connected to power and ready to go.
2. Process
a. Turn on the air compressor to 80 psi.
b. Energize the solenoid to close the ball valve.
c. Operate the pump handle until the pressure gauge on the pump reads a water pressure
of 80-100 psi. Twist the pump’s valve to isolate at this pressure. Immediately mark the
water level inside the inlet bucket at this pressure. This water level should not rise
above the mark at any point (unless there is a failure in the pump’s isolation valve).
d. Report the readings from the pressure gauge every 15 seconds over a period of 5
minutes.
e. Clear the area near the ball valve in preparation for post-run.
3. Post-run
a. Hold and point the ball valve into the empty bucket.
b. Deenergize the solenoid to open the normally opened ball valve.
c. Turn off the air supply.
d. Dry off the area if any water spilled out of the bucket.
e. Remove the OFIL/DRN-1 from Fitting #2 and replace it with FFIL/DRN-1.

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Ensure that all connections and fittings are correctly and properly secured before proceeding.

8.2b) FFIL/DRN-1 Internal Water Leak Test

1. Pre-run
a. Fill a bucket with water and place the Lead hose inside the bucket.
b. Place an empty bucket next to the ball valve to collect leaked water.
c. Visually check that the ball valve is opened.
d. Be sure all electrically powered components are connected to power and ready to go.
2. Process
a. Turn on the air compressor to 80 psi.
b. Energize the solenoid to close the ball valve.
c. Operate the pump handle until the pressure gauge on the pump reads a water pressure
of 80-100 psi. Twist the pump’s valve to isolate at this pressure. Immediately mark the
water level inside the inlet bucket at this pressure. This water level should not rise
above the mark at any point (unless there is a failure in the pump’s isolation valve).
d. Report the readings from the pressure gauge every 15 seconds over a period of 5
minutes.
e. Clear the area near the ball valve in preparation for post-run.
3. Post-run
a. Hold and point the ball valve into the empty bucket.
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b. Deenergize the solenoid to open the normally opened ball valve.

c. Turn off the air supply.
d. Dry off the area if any water spilled out of the bucket.
e. Remove the FFIL/DRN-1 from Fitting #2 and replace it with PRISO-2.

8.2c) PRISO-2 Internal Water Leak Test

1. Pre-run
a. Install a spring action pneumatic actuator, which requires one air inlet.
b. Fill a bucket with water and place the Lead hose inside the bucket.
c. Place an empty bucket next to the ball valve to collect leaked water.
d. Visually check that the ball valve is opened.
e. Be sure all electrically powered components are connected to power and ready to go.
2. Process
a. Turn on the air compressor to 80 psi.
b. Energize the solenoid to close the ball valve.
c. Operate the pump handle until the pressure gauge on the pump reads a water pressure
of 80-100 psi. Twist the pump’s valve to isolate at this pressure. Immediately mark the
water level inside the inlet bucket at this pressure. This water level should not rise
above the mark at any point (unless there is a failure in the pump’s isolation valve).

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d. Report the readings from the pressure gauge every 15 seconds over a period of 5
minutes.
e. Clear the area near the ball valve in preparation for post-run.
3. Post-run
a. Hold and point the ball valve into the empty bucket.
b. Deenergize the solenoid to open the normally opened ball valve.
c. Turn off the air supply.
d. Dry off the area if any water spilled out of the bucket.
e. Remove the PRISO-2 from Fitting #2.

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