Spec No.

- HW-PS-1024
Rev. -0
Date - 30.0l.~o16
Page - 1of12

TITLE:

GENERAL TESTING PROCEDURE FOR BALL VALVE AS PER AP/ 60

REV. DESCRIPTION PreparedBy Checked By Approved By Date

0 FIRST ISSUE JAYDEEP VYAS AMIT VERMA C. MYLSWAMI 30.01.2016

Attention:
Uncontrolled copy when downloaded by the network, check the revision index before use.

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approval of CESAREBONETTI IND/APVT. UM/TED..
 ---·--·----·-----·-·r•.--.-·.--
.. ; i Spec No.·· BW-1'8-f024
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INDEX

1.0 Scope

2.0 Reference

3.0 General Requirements

3.1. Test Fluid
3.2. Preparing The Test
3.3. Tests & their sequence

4.0 Test

4.1. Hydrostatic Shell Test -:»:

4.2. Hydrostatic Seat Test ../"
4.2.1 Seat Test Procedure for Block Valves /

5.0 Supplementary Test Requirements

5.1 High Pressure Hydrostatic Testing /

5.2 Low Pressure Gas Seat Testing ----./
5.3 High Pressure Gas Testing ~
5.3.1 High Pressure Gas Shell Testing -J
5.3.2 High Pressure Gas Seat Testing V

5.4 Antistatic Testing

5.5 Torque/Thrust Functional Testing
5.6 Drive Train Strength Test
5. 7 Cavity ReliefTesting

5.8 Double Block And Bleed (DBB) Valves

5.9 Double Isolation And Bleed, DIB-1 {Both Seats Bidirectional)
5.10 Double Isolation And Bleed, DIB-2 (One Seat Unidirectional And One Seat Bidirectional)

6.0 Pressure Testing Requirements - Based On Quality Specification Level (QSL)

7.0 Draining

8.0 Tables

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 .--..---------~---- ..·--·------- -------- --·----- ..... -
Spec No. - BW-1'~-l024
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This document definesthe testing procedures of BallValve as per API 60.

a) API 60 (Latest version)

b] ISO 5208 (Latest version)
c) ASMEB16.34 (Latest version)

3.0 GENERAL REQUIREMENTS

• Each valve shall be tested in the final assembled condition.

• When air or nitrogen gas is used as a test fluid, proper method of leakage detection shall be
-
provided.
•
•
~ -
Pressure testing shall be carried out before external coating of the valve (unpainted condition).
If it is required to retest the valve which is previously tested as per this specification, the test
·'shall be performed without removal of external coating or gainting.
• During test, keep valve seating and s'ealing su~ree from sealant except where the sealant
is the primary means of sealing.
• Antistatic testing shall be performed on dry valves before pressure testing.

3.1 Test Fluid

Hydrostatic Test· These tests shall be performed with water (chloride llmlt s; 3Q..J;wm) at an
~
ambient temperature.

Pneumatic Test-These tests shall be performed with air.

3.2 Preparing The Test:

Before testing the valve, close and open the valve 3 times with the lever/gear/Actuato.!:

-
- Check if the valve operates correctly with the lever I gear/Actuator;
- Check the cafibration of the limit switches, if applicable
-
- Check the alignment of the opened ball with the bore.
.,
-
In caseof double piston effect ball valve, replace the safety valve with a plug

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approvalof CESARE BONETTI IND/APVT. UM/TEO.
 . ' : ·'

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A.o TEST

The test shall be performed at ambient temperature according to the rating, the type.of material
and the applicable standard.

for Test Pressure: ReferTable· 1

for Min. Test Duration: Refer Table - 3

4.1 Hydrostatic Shell Test:

1. Place the valve on the test bench; v

2. Operate the valve in full open condition; (unidirectional valve)../
3. Operate the valve In half p~on; (bidirectional valve)
4. Fill the valve with the medium; ...../
5. Apply the Test Pressure as specified; ../
6. Check if there is some leakage through the body and the stern. >"
No visible leakage is permitted.
<
7. Drain the valve.

4.2 Hydrostatic Seat Test

1. Close the valve -;»:

2. Fill one side of the valve with the medium and apply the test pressure;

4. -
3. Check if there is some leakage through the seats; (unidirectional valves)
Repeat the steps 2} and 3) on the other side of the valve; (bidirectional valves)
-
5. Drain the valve.

Acceptance Criteria for Leakage: Refer Table - 5

For Soft Seated Valves: Rate A
For Metal Seated Valves: Rate D

4.2.1 Seat Test Procedure For Block Valves

Unidirectional:

1. Fill the valve and its cavity with test fluid in half-open position.
2. Close the valve
3.
-
Apply the test pressure to upstream end of the valve
4. Monitor leakage from the upstream seat via the valve body cavity vent/drain connection
5. For valves without vent/drain connection or downstream seated valves, se.atleakege shall
be monitored at the respective downstream end of the valve.

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 ----- -
Spec No. - BW-PS-102.t
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,!!klirectional:

1. Fill the valve and its cavity with test fluid in half-open position.
2. Close the valve
3. Apply the test pressure to both ends of the valve
4. Monitor leakage from each seat via the valve body cavity vent/drain connection
5. For valves without vent/drain connection, seat leakage shall be monitored from the
respective downstream end of the valve.

5.0 8P.Q[flONA!:_1~lR_EQUIREMENTS

These tests are additionally required, if specified by the purchaser.

5.1 High Pressure Hydrostatic Testing

This test may be performed at -

- Pressure - Higher than specified in Table 1

- Duration - Longer than specified in Table 3

The Hydrostatic testing procedure for shell and seat is same as specified in 4.1 and 4.2 respectively.

* For Testing Pressure and Duration, refer customer approves GAD.

5.2 Low Pressure Gas Seat Testing:

Drain the valve of hydrostatic test fluid prior to the start of this test.

~ - The seat test specified in 4.3 shall be repeated at a test pressure between
0.34 barg and 1 bar using air as the test medium.

~. The seat test specified in 4.3 shall be repeated at a test pressure between
5.5 bar and 6.9 bar using air as the test medium.

Acceptance Criteria For Leakage: Refer Table - 5

For Soft Seated Valves:
Rate A For Metal Seated
Valves: Rate D

5.3 High Pressure Gas Testing

- High-pressure gas testing involves potential hazards.

Appropriate safety precautions should be taken.

Accordmglywith applicable laws, the use, copy and communtcetion to third patty of this documentts prohibitedwithoutthe pnor
approval of CESARE BONETTI /NOIA PVT. LIMITED..
For Test Pressure: Refer Table - 1
For Min. Test Du ration: Refer Table - 4

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approval of CESARE BONETTI /NOIA PVT. LIMITED..
 --- .,, -·,,- ... ~·-···- ..... , ....... ..._.,9',,..._ ........... _,..,,.
Spec No. - BW-l'S-1024
Rev, - 0
Date- 30.01.2016
Page - 6 of 12

5.3.1 High Pressure Gas ShellTesting.

• Use inert gas as the test medium to perform this test.

• Test shall be performed using99 % nitrogen with a 1 % helium tracer measured using a mass
spectrometer.
• As an alternate the valve may be submerged in .water during this test using nitrogen as the test
medium.

Acceptance Criteria for Leakage:

- Less than 0.27 ml/min of (nitrogen+ helium) from any leak path.
- When the valve is tested by submerged method, no visible leakage is allowed.

5.3.2 High Pressure GasSeat Testing

• Use inert gas as the test medium to perform this test.

AcceptanceCriteria for Leakage: Refer Table - 5

For Soft Seated Valves: Rate A

For Metal Seated Valves: s 2 x Rate D

5.4 Antistatic Testing

• The electrical resistance between the ball & the valve body and between the stem & the valve body
shall be measured using a DC power source ( s 12 V ).
• The resistance shall be measured using ohmmeter and shall be s 10 0.

5.5 Torque/Thrust Functional Testing

The maximum torque or thrust required to operate the valve shall be measured at the pressure specified by
the customer for the following valve operations:

a) Open To Closed - With the bore-pressnrtzed and the cavity at atmospheric pressure, if applicable
to the valve design;
b) Closed To Open - With both sides of the ball pressurized and the cavity at atmospheric pressure;
c) Closed To Open - With one side of the ball pressurized and the cavity at atmospheric pressure;
d) As in Item c) but with the other side of the ball pressurized.

If necessary for assembly, a lubricant with a viscosity not exceeding that of SAE lOW motor oil or equivalent
may be used.

Th rust and torque testing shall be performed after high-pressure hydrostatic seat testing and, if specified,
prior to any low-pressure gas seat testing.

Accordmg/y with applicable laws, the use. copy and commun/cafton to tnuaparty of this document ts prohibited without the prior
approval of CESARE BONETTI IND/A PVT. LIMITED..
 ... -~-·· ------·--~----·-·-----~ -. I ; -~Spec_. No. - BW-PS·-I024
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·. F .: i .

5.6 Drive Train Strength Test

ihe drive train strength test for ball valves shall be measured when specified by the customer.
r=:

lhe test torque shall be the greater of:

a) Twice the manufacturer's predicted breakaway torque/thrust; or

b] Twice the measured breakaway torque/thrust.

The test torque shall be applied with ball blocked for a minimum time of 1 min.

Acceptance Criteria

The test shall not cause any permanent visible deformation of the drive train.

For bat! valves, the total torsional deflection of the extended drive train when delivering the design torque
shall not exceed the overlap contact angle between the seat and closure.

5.7 Cavity ReliefTesting

Cavity relief testing Is not required if protection of the cavity against over-pressure is ensured, for both the
open and the closed position, by a hole in the obturator.

The procedure for cavity-relief testing ofTrunnion Mounted Ball Valves is as follows:

a) Fill the valve in the half-open position with water.

b) Close the valve and allow water to overflow from the test connection at each end of the valve.
c) Apply pressure to the valve cavity until one seat relieves the cavity pressure into the valve end;
record this relief pressure.
d) For valve types with second-seat relief, continue to increase the pressure to the cavity until the
second seat relieves; record the relief pressure of the secondseat.

Failure to relieve at a pressure less than the valve cavity relief pressure shall be cause for rejection.

5.8 Double Block And Bleed (DBB) Valves

Procedure

1. Fill the valve and its cavity with test fluid in half-open position
2. Close the valve
3. Open the Vent Valve to allow excess test fluid to overflow from the
valve-cavity test connection
4. Apply the test pressure simultaneously from both ends of Valve
5. Monitor seat leakage via overflow through the valve cavity connection

Acceptance Criteria for Leakage: Refer Table - 5

For Soft Seated For Metal Seated Valves:
Valves:
approval of CESARE BONETTI IND/A PVT. LIMITED..
Rate A :5 2 x RateD

Accordingly with app/Jcable laws, the use, copy and communicstton to third party of this document 1s prohibited without the prior

approval of CESARE BONETTI IND/A PVT. LIMITED..

 _. ,._·-----~----~-
.. Spee No. - BW-l'S-1024
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Page·· 8of12

5.9 Double Isolation And Bleed, DIB-1 (Both Seats

Bidirectional)

Each seat shall be tested in both directions. Cavity-relief valves shall be removed if fitted.
Procedure

1. Fill the valve and its cavity with test fluid in half-open position, until the
test fluid overflows through the cavity relief connection.
2. To test the seat leakage in the direction of cavity, the valve shall be closed
and apply test
pressure successivelyto
eachvalve end.
3. Leakage shall be monitored via the valve cavity pressure relief connection.
4. To test the seat leakage in the downstream side, both valve ends shall open
to atmosphere.
5. Fill the valve cavity with the test fluid. Apply the test pressure at the valve
cavity.
6. Monitor the seat leakage through each at both ends of the valve.

Some valve types can require the balancing of the upstream and valve cavity
pressure during the downstream seat test in which case only one end of the valve shall
be open to atmosphere.

Acceptance Criteria for Leakage: Refer Table - 5

For Soft Seated Rate A
Valves: s 2 x Rate D
For Metal Seated
Valves:

5.10 Double Isolation And Bleed, DIB-2 (One Seat Unidirectional And One Seat
Bidirectional)

The bidirectional seat shall be tested in both directions. Cavity-relief valves shall be
removed, if fitted.

Procedure

1. Fill the valve and its cavity with test fluid in half-open position, until the
test fluid overflows through the cavity relief connection.
2. To test the seat leakage in the direction of cavity, the valve shall be closed
and apply test`
approvalof pressure
CESARE successively
BONETTI IND/A to each valve end.
PVT. LIMITED..
 3. Leakage shall be monitored via the valve cavity pressure relief connection.
4.. To test the seat leakage from downstream side, Test pressure
shall be applied simultaneously to the valve cavity and the upstream end
only.
5. Monitor leakage at the downstream end of the valve.

Acceptance Criteria for Leakage: Refer Table - 5

For Soft Seated Valves: Rate A
For Metal Seated Valves: s 2 x Rate D

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approvalof CESARE BONETTI IND/A PVT. LIMITED..

 ---
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Spec No. - BW-PS-!02.t
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1 .1·.~·: ~;·~ Date - 30.01.2016
Page - 9of12

6.0 PRESSURETESTING REQUIREMENTS - BASED ON QUALITY SPECIFICATION LEVEL (QSL)

The 241h edition of API 6D specifies quality levels for pipeline valves.

QSL-1 is the quality level as specified in API 6D.

Quality Levels QSL-2 to QSL··4, which are optional and may be specified
by the purchaser.

7.0 DRAINING

Upon completion of all tests, Valves shall be drained of test fluids, dried, and

where applicable, lubricated before shipment.

8.0 TABLE

TABLE 1: Standard Teat Pressure Values

TABLE 2: Rated Pressure Value for Class and Material as Per ASME B16.34
TABLE 3: Minimum Test Duration for Hydrostatic Shell/Seat Test
TABLE 4: Minimum Test Duration for High Pressure Gas Shell/Seat Test
TABLE 5: Acceptance Criteria for Leakage as per IS0-5208
TABLE 6: Pressure Testing Requirements Based on Quality Specification Level

Attachment: Test cum Warranty Certificate

Accordingly with applicable laws, the use, copy and communication to third party of this document is prohibited withoutthe
prior approval of CESARE BONETTI /NOIA PVT. LIMITED..
 ~~· -------·--'-
Spec No. - BW-PS-1024
\
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,. ' :.·: Rev. - 0
",:·-~--~~ ( ', :-~-~ 1. Uatc- 30.01.2016
.. •·.
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Page - 10of12

Table 1: Standard Test Pressure Values

Test Pressure (According To Type Of Material At 38°C For
Test Description
Mentioned Valve Rating)
_llY_ci~~~~"~~~ ~l~e_lJ_Tesl 1.5 x Rated Pressure
. ... ····---·-· .. . ··--- ·---
flydrpstatic Seat lest 1.1 x Rated Pressure
fligh Pressure Gas Shell Test Pressure
1.1 x Rated --~~~~-~~~~~-i
High Pressure Gas Seat Test 1.1 x Rated Pressure

Table 2: Rated Pressure Value For Class And Material As Per ASME 816.34 At 38°C
Group 1.1 1-2,1-9,1-101-lS,2 ·83-5,3·8 2.1·2.2-2.4-2.5-3.6 2.3-3.4

A216WCC A351 CFS

A105 A217 WC6, WC9, A351 CFBM A182 F304l
Material
A2016WCB A182 F22 cl.3, Fll cl.2, F44 Al82 F316, Al82 F304 Al82 F316l
A350LF2 Al82 f51,f53, FSS F91 A182 F321
Rating Rating
Body(bar) Seat (bar) Rating eody(bar) Scat (bar)
Cl ss/Rating Rating
Body(bar) Seat (bar) Body(bar) Seat (bar)
ASME (bar) (bar) (bar) (bar)

150 20 30 22 20 30 22 19 28.S 21 16 24 18
300 52 78 57 52 78 57 50 75 55 42 63 15
...
600 103 154.5 113 104 155 114 100 150 110 ~ 124.S 91
90(> 154 231 169 156 234 172 149 223.5 164 125 187.S 137.5
1500 256 384 282 259 388.5 285 249 373.5 274 207 310.S 228
2500 426 639 469 431 646.5 474 414 621 455 345 517.5 379.5

,...---·- -·· -------------------------- -------~

Table 3 : Min. Test Duration For Hydrostatic Shell/Seat Test
,
Valve Size Min. Test Duration (Sec.)

NPS SHELL CLOSURE

--- -- - - - ·-
:54 120 120

6TO 10 300 300

-----
12TO18 900 300

2:20 1800 600

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 .. :
...... . .,.~.~~-- ....."'---·
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Table 4: Min. Test Duration For High Pressure Gas

Shell/Seat Test

- -·--------- VC!lw Sile (NPS)

::; 18
·-- ---·--·--·-----------·----
Test Duration

900
(Sec.)

--- ..... . ... ... .. ·---- ·- --·-·-·

~ 20 1800

Note: The test duration is the period of inspection after the valve is fully prepared and is under full
pressure.

Table 5: Acceptance Criteria For leakage ( IS0-5208)

Test Fluid Unit leakage rates Rate A Rate B Rate C Rate D

0.01 0.03 0.1

mm•/sec x x x
No Visually Detectable
DN DN DN
Liquid Leakage For The
0.00016 0.0005 0.0016
Duration Of The Test
drops/sec x x x
ON ON DN
·----
0.3 3 30
mm•/sec x x x
No Visually Detectable
DN ON DN
Gas/Air Leakage For The
0.0046 0.0458 0.4584
Duration Of The Test
bubbles/sec x x x
ON ON ON

Note 1: Leakage rates for Reduced Bore valves shall be based on DN (NPS) of the valve.
Note 2: "DN" stands for 'Nominal Diameter' & it is Numerical designation of Valve size in millimetres (mm).
Note 3: The leakage rates only apply when discharging test fluid to the atmosphere.
Note 4: The meaning of "No visually detectable leakage" is that there is no visible weeping or leakage in the
form of drops or bubbles.

Accordingly with applicable laws, the use, copy and communceuon to third party of this document
.. tedwithout
ts pmh 1b1 the pnor
approval of CESARE BONETTI IND/A PVT. LIMITED..
 --· ----···--·
Spec No. - HW-PS--1024
--
..
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!l!i !:.~ .~·.~J~:~!: . . 1. - . ,' ; :~ . ' .· ! ,-·;I Rev. - 0

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Date- 30.01.2016
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-
~--------·---··- ·- . ·---·· ·--··
.,..
Table 6 - Pressure Testing Requirements Based on Quality Specification Level
-··- -·-·--··
Test T... ype QSL-1 QSL-2 QSL-3 QSL-4
-··-·- ·--··· -·

Tests 1 and 3 shall

3 tests are
High Pressure 2 tests required. have test duration as
required.
Hydrostatic Shell After 1st test specified in Table 3.
Reduce
Test @ 1.5 times Required Required reduce pressure Test 2 shall have an
pressure to
the rated pressure to zero and extended duration of
zero between
as per 4.1 repeat test. four times that stated
each test.
in Table 3.

2 tests each seat 3 tests each

Tests 1 and 3 shall
required. After seat is required.
High Pressure have test duration as
1st test reduce Reduce
Hydrostatic Seat specified in Table 3.
pressure to zero pressureto
Test@ 1.1 times Required Required Test 2 shall have an
and cycle fully zero and cycle
the rated pressure extended duration of
open and fully fully open and
as per 4.2 four times that stated
closed and fully closed
in Table 3.
repeat test. after each test.
2 tests each seat 3 tests each
Tests 1 and 3 shall
required. Reduce seat is required.
Low-Pressure have test duration as
Test each pressure to zero Reduce
Pneumatic Seat specified in Table 3.
seat as and cycle valve pressure to
Test@ 80 psi to None Test 2 shall have an
per 5.2 fully open and zero and cycle
100 psi as per 5.2 extended duration of
Type II fully closed and fully open and
Type II four times that stated
repeat test of fully closed
in Table 3.
each seat. after each test.
Tests 1 and 3 shall
3 tests are
High-pressure 2 tests required. have test duration as
required.
pneumatic shell After 1st test specified in Table 4.
Reduce
test @ 1.1 times None None reduce pressure Test 2 shall have an
pressure to
the rated pressure to zero and extended duration of
zero between
as per 5.3.1 repeat test. four times that stated
each test.
in Table 4.
2 tests each seat 3 tests each
Tests 1 and 3 shall
required. After seat is required.
High-pressure have test duration as
1st test reduce Reduce
pneumatic seat specified in Table 4.
pressure to zero pressure to
test@ 1.1 times None None Test 2 shall have an
and cycle fully zero and cycle
the rated pressure extended duration of
open and fully fully open and
as per 5.3.2 four times that stated
closed and fully closed
in Table 4.
repeat test. after each test.

..
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