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MUSHTARI MAINTENANCE SERVICES SDN. BHD.

STANDARD OPERATING PROCEDURE

Title : Date :
Valve Testing Procedure 2/6/2018

Revision : 2 Document No. : MMSSB/RP/SOP-58 Page 1 of 9

1.0 INTRODUCTION
This generic procedure is guideline for testing valves for TSET COMPLEX TURNAROUND 2018

2.0 APPLICABLE CODE / STANDARD

This Valve Testing Procedure is carried out and in accordance with the following standard:

2.1 API Standard 598 - Valve Inspection and Testing


2.2 API Standard 602 -Compact steel gate valve-flange ,threaded, welding and extended body
2.3 ASME B16.34 - Valve-flange threaded and welding end.

3.0 TEST REQUIRED

3.1 Valve testing will be follow with step below:


a. Request for material inspection(valve inspection)
b. Inspection valve by PGB representative
c. If reject repeat step a and b
d. If accept proceed with the valve testing procedure(shell test, backseat test, low closure
pressure test, high pressure closure test) All document shall be ready prior to Hydrotest
including Material Inspection Form
e. Documentation all test in hydrotest form(if fail, recognize cause of failure and repeat testing
procedure)

3.2 The following test and examination are specified in this standards:

a. Shell test
b. Backseat test
c. Low-pressure closure test
d. High-pressure closure test.

3.3 Type of testing list as per table A and table B shall be perform on each valve accordance with written
procedure that comply with API 598 standards

3.4 The pressure test, type of testing and material are listed in table Valve Testing PLOC TSET COMPLEX
TA 2018 as per attached.
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STANDARD OPERATING PROCEDURE

Title : Date :
Valve Testing Procedure 2/6/2018

Revision : 2 Document No. : MMSSB/RP/SOP-58 Page 2 of 9

3.5 Table A

Valve NPS 4 and smaller having pressure up to and including ASME Class 1500 and valves larger than
NPS 4 having pressure rating up to and including ASME Class 600.

- Valve ≤ NPS 4 & ASME Class ≤ 1500


- Valve > NPS 4 & ASME Class ≤ 600

Valve Type
Test Gate Globe & Plug Check Floating Ball Butterfly &
Description Parallel Slide Trunnion-Mounted
Gate Ball
Shell Required Required Required Required Required Required
a Required Required NA NA NA NA
Backseat
Low-pressure Required Optionalc Requiredb Optionalc Required Required
closure
High-pressure Optionalc,f Requirede Optionalb,c,f Required Optionalc,f Optionalc,f
closured
Table A: Valve ≤ NPS 4 & ASME Class ≤ 1500, Valve > NPS 4 & ASME Class ≤ 600

Note:
NA = Not Applicable
a
The backseat test is required for all valves, except for bellows seal valves, that have the backseat feature.
b
For lubricated plug valves, the high-pressure closure test mandatory and the low-pressure closure test is
optional.
c
When the purchaser specifies an “optional” test, the test shall be performed in addition to the required tests.
d
The high-pressure closure test of resilient-seated valves may degrade subsequent sealing performance in low-
pressure service.
e
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.
f
High-pressure closure test is required for all valves specified to be double block and bleed valves.
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STANDARD OPERATING PROCEDURE

Title : Date :
Valve Testing Procedure 2/6/2018

Revision : 2 Document No. : MMSSB/RP/SOP-58 Page 3 of 9

3.6 Table B

Valve NPS 4 and smaller having pressure ratings greater than ASME class 1500 and valve larger than
NPS 4 having pressure rating greater than ASME class 600.

- NPS ≤ 4 & ASME Class > 1500


- NPS > 4 & ASME Class > 600

Valve Type
Test Gate Globe & Plug Check Floating Ball Butterfly &
Description Parallel Slide Trunnion-Mounted
Gate Ball
Shell Required Required Required Required Required Required
a Required Required NA NA NA NA
Backseat
Low-pressure Optionalc, Optionalb Optionalb Optionalb Required Optionalb
closure
High-pressure Required Requiredd Required Required Optionalb,e Required
closurec
Table B: Valve NPS ≤ 4 & ASME Class > 1500, Valve NPS > 4 & ASME Class > 600

Note:

NA = Not Applicable
a
The backseat test is required for all valves, except for bellows seal valves, that have the backseat feature.
b
When and “optional” test is specified by purchaser, the test shall be performed in addition to the required tests.
c
The high-pressure closure test of resilient-seated valves may degrade subsequent sealing performance in low-
pressure services.
d
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.
e
High-pressure closure test is required for all valves specified to be double block and bleed valves.

4.0 TEST EQUIPMENT


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Title : Date :
Valve Testing Procedure 2/6/2018

Revision : 2 Document No. : MMSSB/RP/SOP-58 Page 4 of 9

Test equipment to perform required pressure test shall not apply external force that effect seat leakage. Test
equipment shall be as below:
4.1 Hydro test pump
4.2 Calibrated Pressure Gauge
4.3 On-spec test Flange
4.4 Calibrated Chart Recorder (optional)
4.5 Nitrogen or air supply (optional)
4.6 Snoopy

5.0 TEST FLUID

5.1 Water or non-corrosive liquid with a viscosity not higher than water. The test fluid temperature shall be
within the range 41◦ F (5 ◦) to 100o F (38O C).
5.2 For low-pressure closure, the test fluid shall be air or inert gas
5.3 Water used for any test may contain water-soluble oil or rust inhibitor.
5.4 For testing of austenitic stainless steel valves, demin water shall be used for this test.

6.0 SHELL TEST

The shell test is performing to identify any leak at shell and it should be perform by following the step below:

6.1 Valve partially open.


6.2 Tight all gland packing enough to maintain pressure test
6.3 Apply pressure inside assemble test valve with the valve ends close
6.4 If pressure not drop or any leakage or no deformation detected at shell valve’s, shell test is acceptable

7.0 BACKSEAT TEST

Backseat test is required for all valve, that have the backseat feature and shall be performed by following step:

7.1 Open valve totally and packing gland loose/packing not installed.
7.2 Apply pressure inside assemble test valve with the valve ends closed
7.3 Packing gland shall be retightened after test.
7.4 Leakage is not permitted.

8.0 LOW-PRESSURE CLOSURE TEST


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Title : Date :
Valve Testing Procedure 2/6/2018

Revision : 2 Document No. : MMSSB/RP/SOP-58 Page 5 of 9

8.1 Low pressure closure test shall be perform with the sealing surface clean and free from oil, grease and
sealant if necessary to prevent galling, the sealing surfaces may be coated with a film of oil that is not
heavier than kerosene. This requirement does not apply to a valve that use a lubricant as its primary
seal (for example, lubricated plug valves).
8.2 Low-pressure closure test will be perform by following step:
a) Install test flange one side valve(one side for inject pressure air and other side to fill with water or
any liquid that similar to other test liquid)
b) Valve fully close closed
c) Inject air pressure into valve, then snoop at inlet point of valve.
d) Make sure valve at vertical position (air hose at bottom valve).
e) Attach seat sealing surface at outlet flange, the valve shall be detected when bubbles observed
coming from the closure (disk, seat, and seat ring), covered with water.
f) If no bubble detected, low- pressure closure test acceptable leakage and repeat step a – d to other
side valve

9.0 HIGH-PRESSURE CLOSURE TEST

The procedure for high-pressure closure test shall be the same as the procedure for low-pressure closure
Test except that, in the case of liquid test, leakage shall be detected when drops not bubble.

10.0 TEST PRESSURE

10.1 The shell test pressure shall be in accordance with the table below. (According API 598, Table 2-
Test shell pressure)
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Title : Date :
Valve Testing Procedure 2/6/2018

Revision : 2 Document No. : MMSSB/RP/SOP-58 Page 6 of 9

Shell Test Pressure (Minimum)


Valve Type Class Pounds per Square Inch Bar
Gauge (PSI)
Ductile Iron 150 400 26
300 975 66
Cast Iron 125
NPS 2-12 350 25
NPS 14-48 265 19
Cast Iron 250
NPS 2-12 875 61
NPS 14-48 525 37
Steel
Flanged 150-2500 b
Buttweld 150-4500 b
Threadeda and socketweld 800 c
150-4500 b

Table C: Test Shell Pressure (Minimum)

Notes:
a
ASME B16.34 limits threaded-end valves to class 2500 and lower.
b
Per ASME B16.34.
c
For Class 800 valves, the shell test pressure shall be 1 ½” times the pressure rating at 100◦F (38◦C), round off
to the next higher increment of 25 pounds per square in. gauge (or 1 bar) (see table 2 of API Std 602).

10.2 Other Test Pressure (According API 598, Table 3- Other Test Pressure)

Test Pressured
Test Pounds per Square Inch Bar
Gauge (PSI)
Valves Except Butterfly and Check

High-Pressure closure and backseata b


Low-Pressure closure and backseata 60-100 4-7
Butterfly Valve

High-pressure closure C
Low-Pressure closure 60-100 4-7
Check Valve
High-pressure closure
Class 125 (cast iron)
NPS 2-12 200 14
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STANDARD OPERATING PROCEDURE

Title : Date :
Valve Testing Procedure 2/6/2018

Revision : 2 Document No. : MMSSB/RP/SOP-58 Page 7 of 9

NPS 14-48 150 11


Class 250 (cast iron)
NPS 2-12 500 35
NPS 14-24 300 21
Class 150 (ductile iron) 250 17
Class 300 (ductile iron) 640 44
Carbon, alloy, stainless steel and special b
Alloys.
Low-pressure closure (See table A and B) 60-100 4-7

Table D: Other Test Pressure by Type Valve


Notes:
a
The backseat test is required for all valves that have this feature.
b
110% of the maximum allowable pressure at 100◦F (38◦C) in accordance with the applicable purchase
specification.
c
100% of design differential pressure of 100◦F (38◦C) in accordance with applicable purchase
specification.
d
Single values shown are minimum test pressure. A range of values indicated both minimum and
maximum test pressures.

11.0 TEST DURATION

Minimum Test Duration (Second)a


Valve Size Shell Backseat Closure
(NPS”
Check Valve Other valves All Valves with Check Valves Other Valves
(API std 594) backseat Feature (API Std 594)
≤2 60 15 15 60 15
2 ½-6 60 60 60 60 60
8-12 60 120 60 60 120
≥ 14 120 300 60 120 120

Table E: Duration of Required Test Pressure


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

12.0 TEST LEAKAGE

12.1 For shell tests, visually detectable leakage through the pressure boundary walls and fixed body joint
is not permitted.
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STANDARD OPERATING PROCEDURE

Title : Date :
Valve Testing Procedure 2/6/2018

Revision : 2 Document No. : MMSSB/RP/SOP-58 Page 8 of 9

12.2 For backseat tests, visually detectable leakage is not permitted.

12.3 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 seal (of valves that have this feature) is not
Permitted and structural damage is not detected. The allowable rate for leakage of test fluid at the
seat-sealing surface interface, for the duration of the test listed in table D.

12.4 The allowable leakage rate for closure tests of valves with non-metallic (e.g. ceramic) seat material
shall be equal to that specified in table 6 for a metal-seated valve of equivalent size and type.
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STANDARD OPERATING PROCEDURE

Title : Date :
Valve Testing Procedure 2/6/2018

Revision : 2 Document No. : MMSSB/RP/SOP-58 Page 9 of 9

Table F: Allowance Leakage Rate for Closure Test