1.
Scope:
This procedure specifies general methods and acceptability criteria for pressure testing of Ball Valves in
accordance to standard API 6D.
If specified by purchaser in the purchase order, Customer Specific ITP/PQP or where available in
procedure valve shall be tested as per QSL levels specified in Annex I of API 6D and supplementary
requirement specified in the Annex L of API 6D.
All testing and witness points in the approved ITP/PQP shall be strictly followed.
Note: - Supplementary test shall be performed, if specified by purchaser.
2. Reference
2.1. API 6D: 25th Edition Errata 1,2.
2.2. ISO 5208: 2015 Edition.
2.3. ASME B 16.34: 2020.
2.4 SP 2342 Ver 03
3. PRESSURE-MEASURING DEVICES
(Ref: API 6D, CL.9.2)
3.1. Type and accuracy
A test pressure-measuring device (analog or electronic) shall be accurate to at least ±2.0 % of full scale. If
an analog pressure gauge is used in lieu of a pressure transducer, it shall be selected such that the test
pressure is indicated within 20 % and 80 % of the full-scale value.
3.2. Calibration procedure
A pressure-measuring device shall be calibrated with a master pressure-measuring device or deadweight
tester to at least three points, which shall be equidistant across the full scale of the device. The full-scale
end points (zero and 100 %) are not required calibration points; however, if included in the calibration,
the scale end points shall be in addition to the required points used for calibration.
3.3. Calibration intervals
Calibration intervals shall be established for calibrations based on repeatability and degree of usage.
The initial interval between calibrations shall be a maximum of 90 days until recorded calibration history
can be established by the manufacturer. Increases to the interval between calibrations shall be limited to
90-day increments, with a maximum calibration interval between calibrations to not exceed 1 year.
Calibration intervals shall be adjusted based on review of the recorded calibration history, and
determination of interval adjustments shall be defined in the manufacturer’s documented procedure.
The calibration interval shall start on the date of first use, not to exceed three months from the date of
calibration. The date of first use shall be recorded. If the calibration interval is not started within three
months of the date of calibration, the equipment shall be identified as out of calibration.
4. VALVE TESTING PERSONNEL
Only Qualified, Experienced, Trained and competent Personnel shall perform valve pressure testing.
All testing personnel shall have undergone HSE training.
5. HSE for valve Testing Personnel
5.1. All relevant requirements of the Health, Safety & Environment (HSE) Procedure
Manual shall be followed, in particular the requirements for Valve Pressure Test.
5.2. Follow testing procedures and Instruction.
5.3. Do not stand very close to test valve while pressurizing and de-pressurizing.
5.4. Do not observe test duration more than as specified in the approved documents and
standards.
5.5. Do not try operating any equipment in testing area unless asked to do so.
5.6. Do not use mobile phones in testing area.
5.7. Do not operate the valves or drain unless told to do so.
5.8. Always wear safety goggles while observing pressure testing.
5.9. Safety helmet shall be worn while observing high pressure gas testing.
5.10. High pressure gas testing shall be monitored from behind the safety wall or Stay out
of restricted area during valve in pressurized condition.
5.11. No smoking in the office and shop floor area.
5.12. Report all injuries or problem immediately to safety officer, no matter how minor they are.
GENERAL REQUIREMENTS:
6.1 Procedure:
Testing shall be performed in the sequence detailed in cl. 9.2 to 9.6. Of this procedure, Backseat test that
is only applicable to valves per 9.2 of this procedure. Shall be performed before or after the hydrostatic
shell test in 9.3 of this procedure.
Pressure testing shall be carried out before external coating of the valve. If the valve(s) has been
previously tested in accordance with this specification, subsequent repeat hydrostatic and gas testing
may be performed without removal of the valve external coating.
Testing shall be performed in the following order based on the applicable valve configuration:
a) hydrostatic shell (see 9.2):
— standard (9.2.1);
b) hydrostatic seat (see 9.3):
— standard (9.3.1,9.3.2,9.3.3,9.4.4,9.3.4);
c) Low-pressure gas/air seat test (see 9.4):
— standard (9.4.1);
6.2 Test Conditions:
Test fluid shall be fresh water and shall contain a corrosion inhibitor. Based on the end location of the
valve, the test fluid shall have, antifreeze (glycol) added unless otherwise agreed. The water temperature
shall not be greater than 100 °F (38 °C) during the testing period.
The chloride content of test water in contact with austenitic and duplex stainless steel wetted
components of valves shall not exceed 30 μg/g (30 ppm by mass). The chloride content in the test water
shall be tested at least every 06 months.
Valves shall be tested with the seating and sealing surfaces free from sealant except where the sealant is
the primary means of sealing. A secondary seat and/or stem packing sealant system, if provided, shall
not be used before or during tests.
6.3 All hydrostatic and gas shell tests specified shall be :
- performed with the valve unseated and partially open or
- be performed with the valve fully open, provided the body cavity is
simultaneously filled and pressurized through a cavity connection.
The supply pressure shall be isolated from the valve during hydrostatic/gas shell testing and shall be
stabilized prior to the start of pressure testing duration. The stabilization period shall start when the
required test pressure is reached and pressure supply source is isolated.
The pressure-measuring device shall be installed in the test apparatus in such a manner that the device
indicates the test pressure of the valve assembly. The minimum test pressures shall be maintained for
the duration of the test and shall be held for the minimum test durations as specified in 9.2, 9.3, or 9.4.
6.4 Leakage:
For hydrostatic or gas testing, visible leakage shall be any release of test fluid observed during the
pressure test duration. Test fluid released during the seat test pressure build-up or pressure bleed-down
shall not be recognized as visible leakage.
Visible leakage shall be observed directly, including through a window or by video equipment.
If video equipment is used, resolution and brightness shall be sufficient to detect leakage.
7. TEST EQUIPMENT
Valves shall be tested using the clamping test bed which will not exert any external force on valves. Only
when specified on order or when the valve size or end connections limit the use of test beds the blind
flanges will be used for testing.
8. Pressure/Temperature Rating:
(Ref: API 6D, CL.4.3)
Valves covered by this procedure shall be furnished in one of the following pressure classes:
Class 150, Class 300, Class 600, Class 900, Class 1500, or Class 2500.
Pressure-temperature ratings for class-rated valves shall be in accordance with the applicable rating
table for the appropriate material group in ASME B16.34.
Pressure rating for valves made from materials not covered by ASME B16.34 shall be determined from
the material properties in accordance with applicable design standard.
The pressure–temperature rating applied shall be based on the material group of the valve end
connection. Where the valve ends are made from material in two different groups, the material with the
lower pressure–temperature rating shall govern.
9. PRESSURE TESTING:
9.1. General Each valve shall be tested in the final assembled condition prior to shipment.
The required operating orientation of the valve shall be specified when other than stem-vertical, pipeline
horizontal. When the operating orientation has been specified, the manufacturer shall provide
installation, operation, and maintenance instructions for the valve.
Pressure testing shall be performed on one valve at the specified orientation unless
otherwise specified by the purchaser.
9.2. HYDROSTATIC SHELL TEST:
(Ref: API 6D, CL.10.3)
9.2.1 Hydrostatic Shell Test Preparation, Method, and Acceptance Criteria:
Valve ends shall be blocked, and the closure member placed in any position according to 6.3
when present, external relief valves shall be removed, and their connections plugged.
Injection ports that are equipped with an internal non-return valve shall be tested without the injection
fitting installed. The test pressure shall be minimum 1.5 times the pressure rating determined in
accordance with ASME B16.34 (Cl.4.3 of API 6D), for material at 100 °F (38 °C) based on the valve end
connection material. The duration shall not be less than that specified in Table 1 of this procedure.
Table 1: Minimum Duration of Hydrostatic Shell Tests
Valve Size Test Duration
NPS DN (min)
≤4 ≤100 2
6 to 10 150 to 250 5
12 to 18 300 to 450 15
20 and larger 500 and larger 30
a. Test duration starts once the valve is stabilized according to the manufacturer’s procedures.
Acceptance criteria: There shall be no visible leakage permitted during the hydrostatic shell test.
9.3. HYDROSTATIC SEAT TEST
(Ref: API 6D, CL 10.4)
9.3.1. Preparation
Lubricants or sealants shall be removed from seats and closure member sealing surfaces except where
the lubricant or sealant is the primary means of sealing.
Assembly lubricants for metal-to-metal contact surfaces may be used by agreement.
9.3.2. Test Pressure and Duration
The test pressure for all seat tests shall not be less than 1.1 times the pressure rating determined in
accordance with ASME B16.34 (Cl. 4.3 of API 6D), for material at 100 °F (38 °C) based on the valve end
connection material. The test duration shall be based on the end connector size of the valve and shall
conform to Table2 .
Table 2: Minimum Duration of Seat Tests
Valve Size Test Duration
NPS DN (min)
≤4 ≤100 2
6 to 18 150 to 450 5
20 and larger 500 and larger 10
Seat leakage shall be monitored from the downstream side of the seat when under hydrostatic seat test.
9.3.3. Acceptance Criteria:
Seat test acceptance criteria shall be based on the bore diameter of the closure member. Seat test
duration and acceptance criteria for noncircular opening valves shall be based on the NPS of the valve
end connector size.
Leakage for soft-seated valves and lubricated plug valves shall not exceed ISO 5208, Rate A (no visible
detectable leakage for the duration of the test at test pressure).
9.3.4. Installation of Body Connections After Testing
On completion of hydrostatic seat testing Parts, such as drain plug(s), injection fittings and cavity-relief
valves, shall be fitted, on completion of testing, in accordance with documented procedures. (Refer Work
instruction no WI)
9.4 LOW PRESSURE GAS SEAT TESTING—Type II
When specified, the valve shall be seat tested as specified in Cl 9.3 and repeated at a test pressure
between 80 psi and 100 psi (5.5 bar and 6.9 bar) using air or nitrogen as the test medium.
The valve shall be drained of hydrostatic test fluid and the inner parts shall be fully purged with air prior
to the start of the low-pressure gas testing. Pressure shall be identified as stabilized when the rate of
change is no more than 5 % of the test pressure within 5 minutes.
9.4.1 Acceptance Criteria
The acceptable leakage rate for low-pressure gas seat testing shall be:
• ISO 5208, Rate A (no visible leakage) for soft-seated valves.
9.5 DRAINING
Upon completion of tests, valves shall be drained of test fluids, dried, and where applicable, lubricated
before shipment.
10.0 Testing required as per SP 2342 Ver 03
1) All ASME rated valves shall be qualified with the following pressure tests as per ISO 5208 for ball
valves and API 598 for rest of type of valves.
High pressure hydrostatic shell as mentioned in Cl 9.2 of this procedure.
High pressure hydrostatic seat test as mentioned in Cl 9.3 of this procedure.
Low-pressure gas/air seat test as mentioned in Cl 9.4 of this procedure..
Duration of the test shall be followed as per API 6D
2) Valve samples (applicable for casting only) from each category (Based on each MESC/Non-MESC) of
ordered lot shall be hydrostatic shell tested with minimum duration of one hour at rated pressure.
Criteria for selecting the number of samples from each category shall be as per the below requirement.
If valve quantity in category is :
- <10, then 1 no. of valve shall be selected for testing.
- >10 & < 500, then 2% or 5 nos. of valves whichever is less shall be selected for testing.
- >500 & < 1000, then 1% of valves shall be selected for testing.
- >1000, then 10 nos. of valves shall be selected for testing.
3) Acceptable leakage rate shall be followed as per the respective design standard, except as
specified below.
4) Metal seated ball valves which are subjected to hydrostatic seat test, the allowable leakage rate
shall be ISO 5208 Rate B and ISO 5208 Rate D for high pressure gas seat test. (Contractor/Buyer
shall identify such requirements during enquiry stage). For check valves designed as per BS 1868,
acceptable leakage rate for Low pressure gas/air seat test is Rate EE - ISO 5208.
5) For trunnion mounted ball valves, 2% of valves for pressure rating 1500# and above (For each
MESC item) high pressure gas seat test shall be conducted.
6) For early tie-in valves: The high-pressure gas seat test shall be applied for the trunnion mounted
ball valves in gas/multi-phase service (including flare, vent & drain service) as per Cl H.4.3.1 of
API 6D. High pressure Gas seat test is not required for the floating ball valves. Instead, floating
ball valves shall be Low pressure gas seat test as per H.3.2 and H.3.3 of API 6D. Since these
requirements are additional to MESC valves, the valve shall be identified with SP-tag in
PEFS/Isometric for easing the traceability. (The Contractor / Consultant shall identify such
requirements during engineering and enquiry stage. No new SAP creation is required, as these
additional requirements can be captured in RFQ/PO notes.)
7) 2% of valve from each category shall be tested as per H11 or H10 of API 6D in case the valves are
identified with single and double piston effect combination or both seats are with double piston
effect respectively.
8) For ball valves, vendor to perform antistatic feature testing (one test per size/class) as per
Supplementary requirement H.5. of API 6D.
9) Torque testing shall be conducted (one test per size/class)
A RETESTING:
A.1. Handling and Quarantine Of valves:
a. The valve that fails the pressure test shall be identified as non-conforming product.
b. The valve shall be identified for traceability, using color coded tags to distinguish from conforming
product.
c. The valve shall be shifted to non-conforming area for repair/rejection.
A.2. Shell Test Failure:
a. If there is a leak from body/shell, the material shall be rejected.
b. If there is body joint/ gasket leak, the failure shall be investigated and corrected, and the valves shall
be retested in accordance with the above procedure.
A.3. Seat Test Failure:
If the valve fails in seat test, the failure shall be investigated and corrected. Follow the same procedure
as above for any retesting of valves, after correcting unacceptable leakages.
A.5 Torque/Thrust Functional Testing
(Ref: API 6D, ANNEX I- I.6)
A.5.1 Method
The maximum torque or thrust required to operate axial, ball, gate, or plug valves shall be measured at
the pressure specified by the purchaser for the following valve operations:
a) open-to-closed with the bore pressurized and the cavity at atmospheric pressure, for valves with an
upstream seat;
b) closed-to-open with both sides of the closure member pressurized and the cavity at atmospheric
pressure, for valves with an upstream seat;
c) closed-to-open with one side of the closure member pressurized and the cavity at atmospheric
pressure for upstream seated valves and the cavity at upstream pressure for valves with a downstream
seat;
d) as in item c), but with the other side of the closure member pressurized;
e) closed-to-open and open-to-closed without pressure.
Torque or thrust values shall be measured with seats free of sealant, except for valve designs that
require sealant as the primary means of sealing (e.g., lubricated plug valves).
When used for the assembly of pressure-controlling parts, the lubricant shall not exceed the viscosity
range of SAE 10W motor oil or equivalent.
A.5.2 Measuring Device Calibration
Calibration of torque/thrust-measuring devices shall be as follows:
— Torque/thrust measuring devices shall be accurate to within ±2.0% of the full scale.
— Torque/thrust measuring devices shall be calibrated with a master device to at least
three equidistant points of full scale (excluding zero and full scale as required points of
calibration).
A.5.3 Acceptance Criteria
The measured thrust or torque shall not exceed the design thrust or torque. The results
shall be recorded.
