K-Flow Engineering Co., Ltd No.120-1 , Niaosong 3rd. St., Yongkang District , Tainan City , Taiwan .Tel. +886-6-242 3111
SPEC. NO.
KF-HT-001
ISSUED BY
Tiffany
APPROVED BY
Andy
Fax.+886-6-242 5699 Web:www.kffilters.com.tw
REVISION
0
TATAL PAGE
10
Hydro Test Procedure
Acc. to API 598 Standard
3 2 1 0
FOR APPROVAL
2012/10/24
Tiffany
Jane
Andy
Rev
Description
Date
Prepared By
Checked By
Approved By
TEST PROCEDURE
SPEC. NO.
KF-HT-001
ISSUED BY
Tiffany
APPROVED BY
Andy
METAL SEATED
REVISION
0
GATE / GLOBE & CHECK VALVES TATAL PAGE 2 OF 10
1
PURPOSE To define the factory test requirements for K-Flow metal seated Gate / Globe & Check valves. Standard testing comprises hydrostatic testing of the pressure envelope (body), backseat and seat tightness testing (hydrostatic and /or pneumatic) as applicable.
2
RELEVANT STANDARD The requirements set out in this standard are in accordance with the following National / International Standards, BS6755 Pt.1, pr EN 12266 Pt.1, API 598. The hydrostatic test pressures expressed in this standard comply with British Standard BS1560 and ASME B16.5 for flanges and fittings and ASME B16.34 for valves and API Std.602 for Class 800 valves.
3
SCOPE This specification applies to metal seated Gate / Globe & Check valves including bellows sealed valves, tested according to API 598 Table 1A & 1B as described below. Valves specified for double block & bleed are not covered by this procedure.
Test Description
NPS ≦ 4"& ASME Class ≦ 1500
NPS ≦ 4"& ASME Class ＞ 1500
NPS ＞ 4"& ASME Class ≦ 600
NPS ＞ 4"& ASME Class ＞ 600
Gate
Globe
Check
Gate
Globe
Check
Required
Required
Required
Required
Required
Required
Required (4)
Required(4)
N/A
Optional (2)
Required(3)
Required
Required
Required(3)
Required
Required
Optional(2)
Optional(2)
Optional(2)
Optional(2)
Optional(2)
Shell (Hydrostatic Body Test) Baskseat (1) (Hydrostatic Seat Test) High Pressure Closure (Hydrostatic Seat Test)
Required(4) Required(4)
N/A
Low Pressure Closure (Pneumatic Seat Test)
(1) The backseat test is required for all valves, except bellows seal valves, that have the backseat feature. (2) When and optional test is specified by the purchaser, the test shall be performed in addition to the required test. (3) For power-operated and manually operated gear actuated globe valves, including non-return type globe valves, the high-pressure closure test shall be performed at 110% of the design differential pressure used for sizing of the operator. (4) Unless stipulated otherwise by the purchaser, back seat test shall be the High-pressure (Hydrostatic) closure test.
TEST PROCEDURE
SPEC. NO.
KF-HT-001
ISSUED BY
Tiffany
APPROVED BY
Andy
METAL SEATED
REVISION
0
GATE / GLOBE & CHECK VALVES TATAL PAGE 3 OF 10
4
TEST REQUIREMENTS 4.1 General Surface treatments of pressure containing valve components to prevent corrosion during storage prior to and during manufacture with a single primer coat (maximum 25 microns thickness) or phosphate treatment is acceptable provided these preservations do not hide any porosity. 4.2 Test Apparatus Valves which have a split body design must not be tested on equipment which subjects the valve to externally applied loads which may affect the body joint sealing performance. Single piece bodies valves may be clamped. 4.3 Shell Test (Hydrostatic Body Test) Every valve shall be subjected to a hydrostatic test of the body shell at 1.5 times the maximum permissible working pressure at 100℉(38℃), see Table 1. The body should remain tight for the test duration given in Table 2. The test shall show no leakage, no wetting of the external external surfaces, and no permanent distortion under the full test pressure. No device shall be used in testing the valve that will reduce the stress in body. The valve shall be set in the partially open position for this test, and completely filled with test fluid. Any entrapped air should be vented from both ends and the body cavity via either (A) The upper test flange with the valve axis vertical. (B) The body vent connection with the valve axis horizontal. After venting the body, vent plugs should be replaced.
TEST PROCEDURE METAL SEATED
SPEC. NO.
KF-HT-001
ISSUED BY
Tiffany
APPROVED BY
Andy
REVISION
0
GATE / GLOBE & CHECK VALVES TATAL PAGE 4 OF 10
The gland or bellows and any body jointing shall be deemed as part of the pressure envelope. Where a bellows is fitted, the stuffing box packing & gland shall not be fitted. The valve shall then be brought to the required test pressure. All external surfaces should be dried and the pressure held for at least the minimum test duration. There shall be no visible leakage during the test duration specified in Table 2. Note: For valves with adjustable stem seals, leakage through the stem seals during the shall test shall not be cause for rejection, provided the stem seals are capable of retaining pressure at least equal to the 100℉(38℃)valve rating without visible leakage. If leakage is found, corrective action may be taken to eliminate the leakage and the test repeated. 4.4 Backseat Test (Hydrostatic Seat Test) When applicable(with exception of bellows seal valves), every valve shall be subjected to a hydrostatic test of the backseat at 1.1 times the maximum permissible working pressure at 100℉(38℃), see Table 1. The seat sealing surface / closure interface shall be free from oil, grease and sealant. The backseat should remain tight for the test duration given in Table 2. The test shall show no leakage, no wetting of the external surfaces, and no permanent distortion under the full test pressure. The valve shall be set in the fully open position with the packing gland loose or packing not installed. If the backseat test is performed after the shell test, the packing shall be installed and/or packing gland re-tightened after the backseat test. The valve shall be completely filled with test fluid. Any entrapped air should be vented from both ends and the body cavity via either
TEST PROCEDURE METAL SEATED
SPEC. NO.
KF-HT-001
ISSUED BY
Tiffany
APPROVED BY
Andy
REVISION
0
GATE / GLOBE & CHECK VALVES TATAL PAGE 5 OF 10
(A) The upper test flange with the valve axis vertical or via the stem with the packing removed. (B) The body vent connection with the valve axis horizontal. After venting the body, vent plugs should be replaced. The valve shall then be brought to the required test pressure. All external surfaces should be dried and the pressure held for at least the minimum test duration. There shall be no visible leakage during the test duration specified in Table 2. If unacceptable leakage is found, corrective action may be taken to eliminate the leakage and the test repeated. If the valve is disassembled to eliminate the leakage, all previous testing must be repeated upon re-assembly. 4.5 High-pressure Closure Test (Hydrostatic Seat Test) When applicable or specified by purchaser, every valve shall be subjected to a hydrostatic seat test to 1.1 times the maximum permissible working pressure at 100℉(38℃), see Table 1 for the test duration specified in Table 2. The seat sealing surface / closure interface shall be free from oil, grease and sealant. Depending on the valve design and size a "varying settling in period" is allowed. The allowable leakage of test fluid from the seat seal interface shall be according to those listed in Table 3. The test shall show no leakage through the disc, behind the seat rings or past the shaft seals. With the valve in the partially open position, the cavity shall be completely filled with test fluid and any entrapped air should be vented from both ends and the body cavity via either (A) The upper test flange with the valve axis vertical. (B) The body vent connection with the valve axis horizontal.
TEST PROCEDURE METAL SEATED
SPEC. NO.
KF-HT-001
ISSUED BY
Tiffany
APPROVED BY
Andy
REVISION
0
GATE / GLOBE & CHECK VALVES TATAL PAGE 6 OF 10
The valve should be closed and the body cavity vent (where fitted) shall remain open. Gate valve & Screw Down Non-return Globe Valve: The pressure shall be applied successively to each side of the closed valve with the other side open to the atmosphere to check for leakage at the atmospheric side of the closure. Globe Valve: The pressure shall be applied in one direction with the pressure applied under the disc(upstream side) of the closed valve with the other side open to the atmosphere to check for leakage at the atmospheric side of the closure. Check Valve: The pressure shall be applied in one direction with the pressure applied behind the disc(down stream side) of the closed valve with the other side open to the atmosphere to check for leakage at the atmospheric side of the closure. If unacceptable leakage is found, corrective action may be taken to eliminate the leakage and the seat test repeated. Of the valve is disassembled to eliminate the leakage, all previous testing must be repeated upon re-assembly. 4.6 Low-pressure Closure Test(Pneumatic Seat Test) When applicable or specified by purchaser, every valve shall be subjected to an air seat test at a minimum gauge pressure differential of 4 to 7 bar (60-100 psig) for the test duration specified in Table 2. The seat sealing surface / closure interface shall be free from oil, grease and sealant. Depending on the valve design and size a "varying settling in period" is allowed. The allowable leakage of test fluid from the seat seal interface shall be according to those listed in Table 3. The test shall show no leakage through the disc, behind the seat rings or past the shaft seals. The valve should be moved to the half open position and any test fluid drained via either: (A) The lower test flange with the valve axis vertical. (B) The body drain connection with the valve axis horizontal.
TEST PROCEDURE METAL SEATED
SPEC. NO.
KF-HT-001
ISSUED BY
Tiffany
APPROVED BY
Andy
REVISION
0
GATE / GLOBE & CHECK VALVES TATAL PAGE 7 OF 10
Gate Valve & Screw Down Non-return Globe valve: The pressure shall be applied successively to each side of the closed valve with the other side open to the atmosphere to check for leakage at the atmospheric side of the closure. Globe Valve: The pressure shall be applied in one direction with the pressure applied under the disc (upstream side) of the closed valve with the other side open to the atmosphere to check for leakage at the atmospheric side of the closure. Check Valve: The pressure shall be applied in one direction with the pressure applied behind the disc (down stream side) of the closed valve with the other side open to the atmosphere to check for leakage at the atmospheric side of the closure. Check for leakage using either a soap film solution or an inverted "U" tube with its outlet submerged under water. If the seat pressure is held successfully then the other seat shall be tested in the same manner where applicable. If unacceptable leakage is found, corrective action may be taken to eliminate the leakage and the seat test repeated. If the valve is disassembled to eliminate the leakage, all previous testing must be repeated upon re-assembly. 5
TEST LIQUID 5.1 Test Liquid Hydrostatic tests shall be carried out with water at ambient temperature, within the range of 41℉ (5℃) and 122℉ (50℃), unless the use of another liquid is agreed between the purchaser and the manufacturer. If water is used, it will contain water-soluble oil or rust Inhibitor. Potable water used for pressure test of austenitic stainless steel valves shall have a chloride content less than 30ppm and for carbon steel valves shall be less than 200ppm. 5.2 Cleaning Austenitic and duplex stainless steel valves and valves made of 9% nickel alloy, shall be flushed with demineralized water (chloride content of 1ppm maximum) immediately after the hydrostatic test.
TEST PROCEDURE METAL SEATED
SPEC. NO.
KF-HT-001
ISSUED BY
Tiffany
APPROVED BY
Andy
REVISION
0
GATE / GLOBE & CHECK VALVES TATAL PAGE 8 OF 10
5.3 Drying After Hydrostatic testing, the valves should be blown through using dry compressed air, followed by a visual inspection for dryness. If moisture is still found, the above process shall be repeated until visually dry. 6
TEST GAUGES Test bay gauges shall be calibrated at intervals not exceeding three months.
7
TEST CERTIFICATION When specified by the Purchaser, the manufacturer shall issue a BS EN10204 Type 3.1 test certificate confirming that the valves have been tested in accordance with the requirements of this specification.
TEST PROCEDURE METAL SEATED
SPEC. NO.
KF-HT-001
ISSUED BY
Tiffany
APPROVED BY
Andy
REVISION
0
GATE / GLOBE & CHECK VALVES TATAL PAGE 9 OF 10
TABLE 1-TEST PRESSURE (ASME B 16.34 & API Std. 602 for Class 800 Valves) Class
150#
Description
CWP
Shell
300# Seat
CWP 2
Shell
Seat
Material
psig
kg/cm
kg/cm
Psig
kg/cm
kg/cm2
A105, A350-LF2
285
32
23
740
80
59
A182-F5,F9,F11,F22
290
32
23
750
80
59
A182-F304,F316
275
30
23
720
78
57
A182-F304L, F316L
230
25
20
600
64
48
Class
2
600#
2
800#
CWP
Shell
Seat
CWP
Shell
Seat
Material
psig
kg/cm2
kg/cm2
Psig
kg/cm2
kg/cm2
A105, A350-LF2
1480
157
117
1975
210
153
A182-F5,F9,F11,F22
1500
159
117
2000
211
155
A182-F304,F316
1440
153
113
1920
204
150
A182-F304L, F316L
1200
127
94
1600
169
125
Description
Class
1500#
Description
CWP
Shell
2500# Seat
2
CWP 2
Shell
Seat 2
Material
psig
kg/cm
kg/cm
Psig
kg/cm
kg/cm2
A105, A350-LF2
3705
392
289
6470
653
478
A182-F5,F9,F11,F22
3750
396
291
6250
660
484
A182-F304,F316
3600
380
280
6000
633
465
A182-F304L, F316L
3000
317
233
5000
528
387
CWP: The maximum allowable pressure at -20℉ to 100℉ (38℃).
TEST PROCEDURE METAL SEATED
SPEC. NO.
KF-HT-001
ISSUED BY
Tiffany
APPROVED BY
Andy
REVISION
0
GATE / GLOBE & CHECK VALVES TATAL PAGE 10 OF 10
TABLE 2-Test DURATION MINIMUM TEST DURATIONS (Seconds)
NOMINAL SIZE(NPS)
Hydro Shell Test
Backseat Test
Hydro Seat Test
Air Seat Test
≦2”
15
15
15
15
2 1/2”－6”
60
60
60
60
8” －12”
120
60
120
120
≧14”
300
60
120
120
TABLE 3-MAXIMUM ALLOWABLE LEAKAGE RATES NOMINAL SIZE(NPS)
Gate & Globe Valves Liquid
Gas Test
Test(a)(Drops
(Bubbles Per
Per Minute)
Minute)
≦2”
0(b)
0(c)
2 1/2”－6”
12
8” －12” ≧14”
Check Valves
Liquid Test
Gas Test
24
3 scc ×NPS /
700 scc ×NPS /
20
40
minute.
minute.
d
e
(a) For the liquid test, 1 millilitre is considered equivalent to 16 drops (b) For the liquid test, 0 drops means no visible leakage per minimum specified duration of the test. (c) For the gas test. 0 bubbles means less than 1 bubble per minimum specified duration of the test. (d) For valves greater than or equal to 14”(NPS 14), the maximum permissible leakage rate shall be 2 drops per minute per inch NPS size. (e) For valves greater than or equal to 14|”(NPS 14), the maximum permissible leakage rate shall be 4 bubbles per minute per inch NPS size.
