phos eRe Ta TOMAS ONY TUS Lei of CASES - EST Ac DIG eA 598, AIT 10]. ASSP. DO SEHDARD 508 EXPLORE the WORLD of PIPING DOCS MATL SOCY PIPES FLANGES FITG [VALVES] BOLTS GASKETS EQPT SPECIALS STEEL DIN STEAM OTHERS Introduction to Valves - Leak testing of Valves standards for acceptable Rates of Valve Leakage nome skemap abot abbreviations fun question conversion a q American Petroleum Institute (API) The API standard 598: Valve Inspection and Testing, covers the testing and inspection requirements for gate, globe, check, ball, plug & butterfly valves. It has acceptable leakage rates for liquid as well as gas testing. All valves built to the various API standards are required to meet API-598 leakage criteria prior to shipment from the manufacturer or supplier. API 598 states for shell and backseat tests, no visible leakage is permitted. If the fluid is a liquid, there shall be no visible evidence of drops or wetting of the external surfaces (no visible leakage through the body, body liner, if any, and body-to-bonnet joint and no structural damage). If the test fluid is air or gas, no leakage shall be revealed by the established detection method. For both the low-pressure closure test and the high-pressure closure test, visual evidence of leakage through the disk, behind the seat rings, or past the shaft seals (of valves that have this feature) is not permitted (Plastic deformation of resilient seats and seals Is not considered structural damage), The allowable rate for leakage of test fluid past the seats, for the durationsetsthe tests, is listed in the following table: Valve Size ait Resilient (except Check Valves) Check Valves NPS Seated Valves Liquid Test Gas Test id Test Gas Test (drops/min.) | (bubbles/min.) ps/min.) | (bubbles/min.) <2 0 oa) oa) @ 8 2-6 ° 12 @ @ 8-12 ° 20 40 @ @) >12 ° 28 56 @ @) General Notes: +L militar is considered equivalent to 16 drops. ‘+ For check valves larger than NPS 24, the allowable leakage rate shall be per agreement between purchaser and manufacturer. Notes: 1 There shall be no leakage for the minimum specified test duration. For liquid test, 0 drop means no visite leakage per ‘minimum spectfied test duration. For gas test, 0 bubble means less then 1 bubble per minimum specified test duration. 2, The maximum permissible leakage rate shall be 0.18 cubie inch (3 cubic centimeters) per minute per inch of nominal pipe size. 3. The maximum permissible leakage rates shall be 1.5 standaré cubic Feet (9.042 cubic meter) of gas per hour per inch ion eo RYAN eke To wsSpanos Ree Ta TOMAS ONY TUS Lei CASES - EST dc DIG eA 98, AIT 10], ASSP. DI SEMDARD 508 of nominal ppe size. q Manufacturer's Standardisation Society (MSS) ‘The MSS standard MSS-SP-61: Pressure Testing of Valves was originally adopted in 1961. It was developed for the purpose of providing a uniform means of testing valves commonly used in the “full open" and “full closed” type of service. It is not intended for use with control valves. Refer to standard ANSI/FCI 70-2 for Control Valves. Section 5 of their Pressure Testing of Steel Valves, relates to seat closure tests, and defines the following leakage rates + Gate, Globe, Ball valves: 10 cefhr per inch of nominal pipe diameter. (Example: A 6" globe valve is allowed to leak 60 cc/hr in a test) = Check valves: 40 cc/hr per inch of nominal pipe diameter Al shutoff or Isolation valves specified to MSS-SP-61 must pass the above standards, The seat closure test must be performed at a fluid (liquid or gas) pressure no less than 1,1 times the 1000°F (380°C) rating rounded to the next 5 psi (0.5 bar). q American National Standards Institute (ANSI) ‘The ANSI standard FCI 70-2: Control Valve Seat Leakage, establishes a series of six seat leakage classes for control valves and defines the test procedures, Class |. 1s also know as dust tight and can refer to metal or resilient seated valves. Class II This class establishes the maximum permissible leakage generally associated with commercial double-seat control valves or balanced single-seat control valves with a piston ring seal and metal-to- metal seats. Class Ill. This class establishes the maximum permissible leakage generally associated with Class (4.2.2), but with a higher degree of seat and seal tightness, Class IV. This class establishes the maximum permissible leakage generally associated with ‘commercial unbalanced single-seat control valves and balanced single-seat control valves with extra tight piston rings or other sealing means and metal-to-metal seats, Class V. This class is usuelly specified for critical applications where the control valve may be required to be closed, without a blocking valve, for long periods of time with high cifferential pressure across the seating surfaces, It requires special manufacturing, assembly and testing techniques. This class is. generally associated with metal seat, unbalanced single-seat control valves or balanced single-seat designs with exceptional seat and seal tightness. CLASS VI. This class establishes the maximum permissible seat leakage generally associated with resilient seating control valves either unbalanced or balanced single-seat with "O" rings or similar gapless seals. Leakage Maximum Test Test Test Procedure Class Leakage Medium Pressure Allowable | . os No test required, as long as purchaser and vendor both agree. |] 0-5% of rates Air or 45-60 psig Pressure applied to valve inlet with outlet capacity water ator max, open to atmosphere or connected to a low 50-125°F operating _ head loss measuring device full normal (10-52°) differential closing thrust provided by actuator. ion eo RYAN eke To YsSpanos eRe Ta TO MAS-OAY TUS Lei of MANES - EST ACD eA 98, AIT 10]. ASSP. DO SEHDARD 5108 whichever is lower JI] 02% of rates ‘As above Asabove As above capacity JV 0.01% of rated As above Asabove As above capacity \V__ 0.0005 ml per Water at Max service Pressure applied to valve inlet after filling minute of water per SOto pressure _entire body cavity and connected piping inch of port diameter 125°F (10 drop across _ with water and stroking valve plug closed. per psi differential to 52°C) valve plug, Use net specified max actuator thrust, but not to no more, even if available during test. exceed ANSI Allow time for leakage flow to stabilize. body rating. \y|__ Not to exceed Air or SO psig or Actuator should be adjusted to operating amounts shown in nitrogen max rated _conditions specified with full normal following table based at 50 to differential closing thrust applied to valve plug seat, fon port diameter. 125 F pressure Allow time for leakage flow to stabilize and (10t052C) across valve _use suitable measuring device. plug whichever Is lower. CONTROL VALVE SEAT LEAKAGE CLASSIFICATIONS nS te 3 76 0.9 6 4 102 7 W 6 152 4 2” 8 203 6.75 45 10 250 wa 12 300 16 14 350 216 Note: Bubbles per minute as tabulated are 2 suggested alternative based an a sultable calibrated measuring device, in this case a 0.25-inch OD X 0.032-inch wall tube submerged in water to a depth of from 1/8 to 1/4 inch, ‘The tube end shall be cut square and smooth with no chamfers or burrs, The tube axis shall be perpendicular to the ‘surface of the water. Other measuring devices may be constructed and the number of bubbles per minute may differ from those shown as long as they correctly indicate the flow in miliiters per minute 4 International organization for standardization (ISO) The purpose of ISO standard 5208: Industrial valves - Pressure testing of metallic valves, Is the establishmer basic requirements and practices for pressure testing valves of various configurations that are used in general purpose, power generation, petroleum, and petrachemical or allied industry applications. The intent is to provide a consistent set of procedural requirements and acceptance criteria that can be considered in conjunction with valve specific standards appropriate for specific applications. Account has been taken of the valve testing requirement needs of EN 12266 and ion eo RYAN eke To a5Bpbnons eRe TOMAS-ONY TRUSS Lei of MANES - EST dc DIG eA 98, AIT 10]. ASSP. DO SEHDARD 508 ‘API 598 with requirements referenced for PN designated valves for the former and Class designated valves for the latter. Prescribed pressure tests on ous FLOATING BALL | BUTTERFLY OR care close cnc eg nO UNNTON est yO Valve Valve YALYE | QAIVE orapetacy MOUNTED : ) WAIVE BALLVALVE suet TEST ALL AL REQUIRED REQUIRED REQUIRED) REQUIRED REQUIRED UIRED trquio SHELL TEST AL ALL TIONAL OPTIONAL OPTIONAL | OPTIONAL PTIONAL )P TIONAL LT OPTIONAL OPHHONAL OPTIONAL O=rtONAL__oPtiO orn BACKSEAT TEST (BG | AL | ALL OPTIONAL OPTIONAL peuineo|ReQUIRED, REQUIRED | REQUIRED uuib class « 1500 AND REQUIRED OPTIONAL REQUIRED OPTIONAL, REQUIRED uiRe p's 250 on 100 class »1500 cLosure test en s2s0 AS Low-eneSsuRE class «600 AND "REQUIRED OPTIONAL OPTIONAL OPTIONAL, REQUIRED vine pws 100 bw 5100 class >600 ‘AND. OPTIONAL OPTIONAL OPTIONAL OPTIONAL REQUIRED OPTIONAL class + 1500 AND" OPTIONAL REQUIRED OPTIONAL REQUIRED OPTIONAL OPTIONAL ons 250 ow s 100 class »1800 AND. REQUIRED REQUIRED REQUIRED REQUIRED OPTIONAL REQUIRED closure rest pu s2s0 tiguio iciHsReSSURE CuASS < 600 ‘AND “"” oPTIONAL REQUIRED OPTIONAL REQUIRED OPTIONAL OPTIONAL b's 100 bw > 100 ‘AND REQUIRED REQUIRED REQUIRED REQUIRED) OPTIONAL vine pn ss00 Notes: 1, Successful completion of an optional test does net relieve the manufacturer from also successfully completing the required test, 2. In the case of resilient seated valves, a high-pressure closure test may degrade subsequent closure sealing performance in low-pressure applications. + (8) Plug valves that rely on 2 sealing compound to effect a closure seal may be closure tested with the compound installed, + (8) Successful completion of a backseat test should not be interpreted as a recommendation by the valve manufacturer that, while an installed valve s pressurized, the stem seal may be altered, repaired or replaced when backseated, + (C)n the case of bellows stem sealed valves, a backseat testis not require. Maximum allowable closure test leakage rate yest | UNI. | eave RATE | RATE | RATE | RATE | RATE RATE | RATE | RATE | RATE fuuiD a wares ooo | o@i | 00 | 008 | oa | 03 039 2 | 2 mars ee ucuo ® 0.0001 | 800016 | 0.0005 | 10013 | 0.0016 | o0048 | wane? 0.016 | 0032 rors/s See ee ee oe Oe oie) 033 | «a3 3 a00 | 470 | 3000 000 in eo RYAN eke To, 4sSpanos eRe Ta TOMAS ONY TUS Lei of LANES - EST Ac DIG eA 98, AIT 10]. ASSP. DI SEHDARD 5108 Mays x x x x x x x x x cas w 9.003 | 0.0046 | 0,0458 0.3407 0.4584 4.5837 7.1293 | 45.837 91.673 BuseLes/s x x x x x x x x x oN BN DNDN NON DNDN ON Notes: (1) No visually detectable leakage for the duration of the test 4. The leakage rates only apply when discharging test fuid to the atmesphere. 2, The closure leakage rate that apples is elther that identified in a valve product standard or a leakage rate identified in @ purchaser's valve procurement purchase order that is mora stringent than that specified inthe product stancard, 3, The meaning of "No visually detectable leakage” fs that there is no visible weeping or leakage in the form of drops or bubbles 4, Thre is @ loosely defined correspondence between the leakage rate acceptance values of API S98 and the leakage values Rate A as applied to DN <50, Rate AA-Gas and Rate CC-Liquid for other than metal seated check valves and for check valves Rate EE-Gas and Rate G-Liquld. Rates A,B, C, D E, F and G correspond to values in 22266-4, Remark(s) of the Author Types of Leakage There are two types of leakage from a valve, namely; fugitive emissions from the valve to atmosphere, and leakage through the valve but contained within the piping sy: Fugitive emissions can both be detrimental to the environment and a potential safety hazard Valves are considered to be the major contributors to fugitive emission losses. Leakage through the valve can also be a safety hazard, and can be detrimental the process. Reasons that Valves leak Common causes of leakage through the valve include: + Valve is not fully closed. This can be due to various reasons, including; ‘+ Valve seat is prevented from closing fully due to dirt, rus ‘+ Insufficient actuator travel ‘+ The seat is damaged, e.g. scored + The seal is damaged or line debris Common causes of leakage to atmosphere: * Gasket between valve-body and valve-bonnet is damaged * Stem Pakking is worn, loose or damaged Both of them can have several causes bey Oy its reserved. ot wa 2 you mine are stil greater. Albert Einstein ion eo RYAN eke To ss