HYDROSTATIC TEST API 598 PROCEDURE MANUAL

Issued By : Approved By : Date Version

Kumaran Bernard Wong 18th Oct 2011 02

QA Managing Director 18th Oct 2011

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HYDROSTATIC TEST API 598 1. Purpose

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To define the retesting requirements for the metal seated Gate / Globe & Check valves and Resilience seat Butterfly valve. 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 International Standards API 598,BS6755Pt.1, pr EN12266 Pt.1.The hydrostatic test pressures expressed in this standard comply with 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 1 & 2 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 600 Gate Globe Check Required Required Required

NPS 4 & ASME Class > 1500 NPS > 4 & ASME Class > 600 Gate Required Globe Required Check Required

Shell (Hydrostatic Body Test) Backseat (1) (Hydrostatic Seat Test) High Pressure Closure (Hydrostatic Seat Test) Low-pressure Closure (Pneumatic Seat Test)

Required(4)

Required(4)

N/A

Required(4)

Required(4)

N/A

Optional (2) Required

Required (3) Optional (2)

Required Optional (2)

Required Optional (2)

Required (3) Optional (2)

Required Optional (2)

(1) The backseat test is required for all valves, except bellows seal valves, that have the backseat feature. (2) When an optional test is specified by the purchaser, the test shall be performed in addition to the required tests.

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HYDROSTATIC TEST API 598

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(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.

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 bodied 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 100F (38C), see Table 1. The body should remain tight for the test duration given in Table 1. The test shall show no leakage, no wetting of the 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 the 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

1) The upper test flange with the valve axis vertical. 2) The body vents connection with the valve axis horizontal. After venting the body, vent plugs should be replaced. The gland or bellows and anybody 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.

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HYDROSTATIC TEST API 598

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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 100F (38C) 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 F (38C), 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 1. 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 a) The upper test flange with the valve axis vertical or via the stem with the packing removed. b) The body vents 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.

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HYDROSTATIC TEST API 598
4.5. High-pressure Closure Test (Hydrostatic Seat Test)

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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 F (38C), see Table 1 for the test duration specified in Table 1. 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 2. 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 vents connection with the valve axis horizontal. 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 (downstream 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. If the valve is disassembled to eliminate the leakage, all previous testing must be repeated upon re-assembly.

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HYDROSTATIC TEST API 598
4.6. Low-pressure Closure Test (Pneumatic Seat Test)

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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 1. 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 2. 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 drains connection with the valve axis horizontal. 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 (downstream side) of the closed valve with the other side open to the atmosphere to check for leakage at the atmospheric side of the closure.

5. TEST LIQUID
5.1. Test Liquid

Hydrostatic tests shall be carried out with water at ambient temperatures, within the range of 41F (5C) and 122F (50C), 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 chloride content less than 30ppm and for carbon steel valves shall be less than 200ppm.

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HYDROSTATIC TEST API 598
5.2. Cleaning

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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. 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 once a year.

7. TEST CERTIFICATION
According to attached model test certificate confirming that the valves have been tested in accordance with the requirements of this specification. Table 1 Test Pressure & Time duration Class Description Material A105, A350-LF2, A216WCB, A352 LCC A182-F5,F9,F11,F22 A182-F304,F316 A182-F304L, F316L Class Description Material A105, A350-LF2 A216WCB, A352 LCC A182-F5,F9,F11,F22 A182-F304,F316 A182-F304L, F316L CWP psig 1480 1500 1440 1200 CWP psig 285 290 275 230 150# Shell Kg/cm2 32 32 30 25 600# Shell Kg/cm2 157 159 153 127 Seat Kg/cm2 117 117 113 94 CWP psig 1975 2000 1920 1600 Seat Kg/cm2 23 23 23 20 CWP psig 740 750 720 600 300# Shell Kg/cm2 80 80 78 64 800# Shell Kg/cm2 210 211 204 169 Seat Kg/cm2 153 155 150 125 Seat Kg/cm2 59 59 57 48

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HYDROSTATIC TEST API 598

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1500#

Class Description Material A105, A350-LF2 A216WCB, A352 LCC A182-F5,F9,F11,F22 A182-F304,F316 A182-F304L, F316L Class Description Material A105, A350-LF2 A216WCB, A352 LCC A182-F5,F9,F11,F22 A182-F304,F316 A182-F304L, F316L CWP psig 6170 6250 6000 5000 CWP psig 2225 2250 2160 1800

900# Shell Kg/cm2 235 233 224 187 2500# Shell Kg/cm2 653 660 633 528 Seat Kg/cm2 478 484 465 387 CWP psig Seat Kg/cm2 173 172 164 137 CWP psig 3705 3750 3600 3000

Shell Kg/cm2 392 396 380 317 Shell Kg/cm2 -

Seat Kg/cm2 289 291 280 233

Seat Kg/cm2 -

CWP: The maximum allowable pressure at 20 OF to 100 OF 38C). TABLE 2 TEST DURATION NOMINAL SIZE (NPS) 2 2 1/2 6 8 12 14 MINIMUM TEST DURATIONS (Seconds) Hydro Shell Test 15 60 120 300 Backseat Test 15 60 60 60 Hydro Seat Test 15 60 120 120 Air Seat Test 15 60 120 120

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HYDROSTATIC TEST API 598

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Table 2 Maximum Allowable Leakage for Seat Test Valve Size Metal Seated Valves Except Check Liquid Test (drops/minute) 0 5 6 8 10 12 16 20 24 28 32 36 40 48 52 56 60 64 72 80 84 96 Gas Test (bubbles/minut e) 0 10 12 16 20 24 32 40 48 56 64 72 80 96 104 112 120 128 114 160 168 192 Metal Seated Check valves Liquid Test (cc/min) 6 7.5 9 12 15 18 24 30 36 42 48 54 60 72 78 84 90 96 108 120 126 144

DN (mm) < 50 65 80 100 125 150 200 250 300 350 400 450 500 600 650 700 750 800 900 1000 1050 1200

NPS (in.) <2 2 1/2 3 4 5 6 8 10 12 14 16 18 20 24 26 28 30 32 36 40 42 48

All Resilient Seated Valves 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Gas Test (m3/h) 0.08 0.11 0.13 0.17 0.21 0.25 0.34 0.42 0.50 0.59 0.67 0.76 0.84 1.01 1.09 1.18 1.26 1.34 1.51 1.68 1.76 2.02

Gas Test (ft3/h) 3 3.75 4.5 6 7.5 9 12 15 18 21 24 27 30 36 39 42 45 48 54 60 63 72

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HYDROSTATIC TEST API 598
a b For the Liquid test, 1 ml is considered equivalent to 16 drops.

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There shall be no leakage for minimum specified test duration (see table 2). For Liquid test, 0 drops means no visible leakage per minimum specified test duration. For gas test, 0 bubbles means less than 1 bubble per minimum specified test duration.