Neles North America

Seat Leakage Guide

August 28, 2009

Neles North America Seat Leakage Guide

Leakage testing of metal seated valves can be a subject of much confusion and conflicting
expectations. This booklet presents summaries of three common leakage testing standards as
well as comparisons between them and actual product examples.

Important Notes:
1) The information in this booklet is not intended as a replacement for the official leakage
standards referenced on these pages.
2) Examples are for demonstration purposes only. All leakage rates are not available for all
valves. Please consult with the factory to determine the available leakage rates for a
specific valve model.
3) Leakage rates are measured for new valves on the bench after assembly. The
standards referenced in this booklet do not set any requirements for leakage
performance for valves once in service. Long term leakage rate performance is
dependent on the valve and application and cannot be guaranteed.

Table of Contents

Guide To ANSI/FCI 70-2-2006.. Page 1

Guide To ISO 5208 Third edition... Page 2

Guide To API 598 Eighth edition... Page 3

Comparison of Leakage Rates.. Page 4

Examples... Page 5

Leakage Rates in Context.. Page 7

Leakage Rates Available for Standard Products Page 8

Guide To ANSI/FCI 70-2-2006

Class I Modified class II, III or IV valves. No test required by agreement between user and
supplier
Classes II, III and IV
Media Clean air or water
Temperature 50 to 125 F
Pressure 45 to 60 psig or within +/- 5% of max operating dP, whichever is less
Acceptable Leakage for Class II 0.5% of rated valve capacity (12,100 ml/min for a 2RE)
Acceptable Leakage for Class III 0.1% of rated valve capacity (2,420 ml/min for a 2RE)
Acceptable Leakage for Class IV 0.01% of rated valve capacity (242 ml/min for a 2RE)
Class V
Media Clean water
Temperature 50 to 125 F
Pressure Within +/- 5% of max operating dP, not to exceed max pressure rating of valve body
at ambient temperature per ASME B16.34 and B16.5
Acceptable Leakage 0.0005 ml/min of water per inch of seat diameter per psi dP
-orMedia Air or Nitrogen Gas
Temperature 50 to 125 F
Pressure 50psig
Acceptable Leakage 4.7 standard ml/min of air per inch of seat diameter
Class VI
Media Air or Nitrogen Gas
Temperature 50 to 125 F
Pressure Maximum rated valve dP or 50 psig, whichever is less
Acceptable Leakage per ANSI Class VI
Seat Diameter
Leakage
Leakage (ml/min)
(inches)
(bubbles/min)*
1
0.15
1.5
0.30
2
0.45
2.5
0.60
3
0.90
4
1.70
6
4.00
8
6.75
10
11.1
12
16.0
14
21.6
16
28.4
* 1 bubble is equivalent to 0.15 ml

1
2
3
4
6
11
27
45

Notes for all leakage classes:

1) Leakage rates shall be measured once flow is stabilized
2) Seat diameter is measured at the point of seating contact to the nearest 1/16inch (2mm).

Neles North America Seat Leakage Guide Page 1 Aug 28, 2009

Guide To ISO 5208 Third edition

Closure Test

Low Pressure
Gas

High Pressure
Liquid

Sizes
4"
> 4"
4"
> 4"

Required Closure Tests

Seat Supported Trunnion Mounted
ASME Class
Ball Valve
Ball Valve
1500
> 1500
600
> 600
1500
> 1500
600
> 600

Required
Required
Required
Required
Optional
Optional
Optional
Optional

Butterfly Valve

Required
Optional
Required
Optional
Optional
Required
Optional
Required

Required
Optional
Required
Optional
Optional
Required
Optional
Required

Minimum Test Duration

Valve Size

Time (sec)

2"
2.5" to 6"
8" to 12"
14"

15
60
120
120

Low Pressure Gas Test

Media Air or other suitable gas
Temperature 5C to 40C (41F to 104F)
Pressure 6bar +/- 1bar (87psi +/- 14.5psi)
High Pressure Liquid Test
Media - Water with optional corrosion inhibitor, kerosene or other appropriate liquid having a
viscosity not greater than that of water. If the valve shell is an austenitic stainless steel, water
chloride content is not to exceed 100ppm.
Temperature 5C to 40C (41F to 104F)
Pressure 1.1 x CWP of full rated valves or 1.1 x rated differential pressure of reduced rated
valves.
Maximum Acceptable Leakage Rates
(mm3/second x DN number)*
Test Media

Rate A

Liquid
0
Gas
0
* 1000 mm3 = 1 ml
DN numbers
Valve Size 1/2" 3/4"
DN
15
20

Rate B

Rate C

Rate D

0.01
0.3

0.03
3.0

0.1
30.0

1"
25

1.5"
40

2"
50

2.5"
65

3"
80

4"
100

6"
150

Neles North America Seat Leakage Guide Page 2 Aug 28, 2009

8"
200

10"
250

12"
300

14"
350

16"
400

Guide To API 598 Eighth edition

Closure Test

Sizes
4"

Low Pressure
> 4"
4"
High Pressure
> 4"

Required Closure Tests

Seat Supported Trunnion Mounted
ASME Class
Ball Valve
Ball Valve
1500
> 1500
600
> 600
1500
> 1500
600
> 600

Required
Required
Required
Required
Optional
Optional
Optional
Optional

Required
Optional
Required
Optional
Optional
Required
Optional
Required

Butterfly Valve
Required
Optional
Required
Optional
Optional
Required
Optional
Required

Minimum Test Duration

Valve Size

Time (sec)

2"
2.5" to 6"
8" to 12"
14"

15
60
120
120

Low Pressure Test

Media Air or inert gas
Temperature 41F to 122F (5C to 50C)
Pressure 60 to 100psig (4 to 7barg)
High Pressure Test
Media Air, inert gas, kerosene, water with optional corrosion inhibitor, or a non-corrosive liquid
having a viscosity not greater than that of water. If the valve shell is an austenitic stainless
steel, water chloride content is not to exceed 100ppm.
Temperature 41F to 122F (5C to 50C)
Pressure 110% of maximum rated pressure at 100F for ball valves, and 110% of design
differential pressure at 100F for butterfly valves
Maximum Acceptable Leakage Rates
Liquid Test
Gas Test
Valve Size
(drops/min)*
(bubbles/min)**
2"
2.5" to 6"
8" to 12"

0
0
12
24
20
40
2 drops/min per
4 bubbles/min per
14"
inch of valve size
inch of valve size
* 1 milliliter is considered equivalent to 16 drops
** 1 bubble is considered equivalent to 0.15 ml

Neles North America Seat Leakage Guide Page 3 Aug 28, 2009

Comparison of Leakage Rates using gas test media (Air, Nitrogen)

ANSI/FCI 70-2-2006
Test Pressure (psig)

class V

class VI

50

50

4.7
7.05
9.4
11.75
14.1
18.8
28.2
37.6
47
56.4
65.8
75.2

0.15
0.30
0.45
0.60
0.90
1.70
4.00
6.75
11.1
16.0
21.6
28.4

Valve Size (inches)*

1
1.5
2
2.5
3
4
6
8
10
12
14
16

ISO 5208 Third edition

rate A

rate B

rate C

API 598 Eighth edition

rate D

Low Pressure Test

73 to 102

60 to 100

Maximum Acceptable Leakage (ml/min)

0
0
0
0
0
0
0
0
0
0
0
0

0.45
0.72
0.9
1.17
1.44
1.8
2.7
3.6
4.5
5.4
6.3
7.2

4.5
7.2
9
11.7
14.4
18
27
36
45
54
63
72

45
72
90
117
144
180
270
360
450
540
630
720

0
0
0
3.6
3.6
3.6
3.6
6
6
6
8.4
9.6

* Seat diameter for ANSI/FCI 70-2-2006

Comparison of Leakage Rates using liquid test media (Water)

Pressures based on ASME class 300 carbon steel test valve - body rating 740psig per ASME B16.34
ANSI/FCI 70-2-2006
class V
Test Pressure (psig)

rate A

rate B

740

Valve Size (inches)*

1
1.5
2
2.5
3
4
6
8
10
12
14
16

ISO 5208 Third edition

rate C

API 598 Eighth edition

rate D

814

High Pressure Test

814

Maximum Acceptable Leakage (ml/min)

0.37
0.56
0.74
0.93
1.11
1.48
2.22
2.96
3.70
4.44
5.18
5.92

0
0
0
0
0
0
0
0
0
0
0
0

0.015
0.024
0.03
0.039
0.048
0.06
0.09
0.12
0.15
0.18
0.21
0.24

0.045
0.072
0.09
0.117
0.144
0.18
0.27
0.36
0.45
0.54
0.63
0.72

0.15
0.24
0.3
0.39
0.48
0.6
0.9
1.2
1.5
1.8
2.1
2.4

* Seat diameter for ANSI/FCI 70-2-2006

Neles North America Seat Leakage Guide Page 4 Aug 28, 2009

0
0
0
0.75
0.75
0.75
0.75
1.25
1.25
1.25
1.75
2

Valve Test Example - XT04CWTAS6SJHADD

ANSI/FCI 70-2-2006
Class V water test
Test pressure = 275 psig based on CF8M body rating from ASME B16.34 class 150
Seat diameter = 4
Acceptable Leakage = 0.0005 ml/min x 4x 275 psi = 0.55 ml/min
Class V air test
Test pressure = 50 psig
Seat diameter = 4
Acceptable Leakage = 4.7 ml/min x 4= 18.8 ml/min
Class VI air test
Test pressure = 50 psig
Seat diameter = 4
Acceptable Leakage = 1.70 ml/min

ISO 5208 Third edition

Low Pressure air test
Test pressure = 87 psig
DN number = 100 for a 4valve
Rate A = 0 ml/min
Rate B = 0.3 mm3/sec x 100 x 1 ml/1000 mm3 x 60 sec/min = 1.8 ml/min
Rate C = 3.0 mm3/sec x 100 x 1 ml/1000 mm3 x 60 sec/min = 18 ml/min
Rate D = 30.0 mm3/sec x 100 x 1 ml/1000 mm3 x 60 sec/min = 180 ml/min
High Pressure water test
Test pressure = 302 psig based on 1.1 x CF8M body rating from ASME B16.34 class 150
DN number = 100 for a 4valve
Rate A = 0 ml/min
Rate B = 0.01 mm3/sec x 100 x 1 ml/1000 mm3 x 60 sec/min = 0.06 ml/min
Rate C = 0.03 mm3/sec x 100 x 1 ml/1000 mm3 x 60 sec/min = 0.18 ml/min
Rate D = 0.1 mm3/sec x 100 x 1 ml/1000 mm3 x 60 sec/min = 0.6 ml/min

API 598 Eighth edition

Low Pressure air test
Test pressure = 60 to 100 psig
Acceptable Leakage = 24 bubbles/min x 0.15 ml/bubble = 3.6 ml/min
High Pressure air and water tests
Test pressure = 302 psig based on 1.1 x CF8M body rating from ASME B16.34 class 150
Acceptable Leakage (air test) = 24 bubbles/min x 0.15 ml/bubble = 3.6 ml/min
Acceptable Leakage (water test) = 12 drops/min x 1 ml/ 16 drops = 0.75 ml/min

Neles North America Seat Leakage Guide Page 5 Aug 28, 2009

Valve Test Example D5FA16DAS02

ANSI/FCI 70-2-2006
Class V water test
Test pressure = 1480 psig based on WCB body rating from ASME B16.34 class 600
Seat diameter = 14, this is a reduced bore valve
Acceptable Leakage = 0.0005 ml/min x 14x 1480 psi = 10.36 ml/min
Class V air test
Test pressure = 50 psig
Seat diameter = 14, this is a reduced bore valve
Acceptable Leakage = 4.7 ml/min x 14= 65.8 ml/min
Class VI air test
Test pressure = 50 psig
Seat diameter = 14, this is a reduced bore valve
Acceptable Leakage = 21.6 ml/min

ISO 5208 Third edition

Low Pressure air test
Test pressure = 87 psig
DN number = 400 for a 16valve
Rate A = 0 ml/min
Rate B = 0.3 mm3/sec x 400 x 1 ml/1000 mm3 x 60 sec/min = 7.2 ml/min
Rate C = 3.0 mm3/sec x 400 x 1 ml/1000 mm3 x 60 sec/min = 72 ml/min
Rate D = 30.0 mm3/sec x 400 x 1 ml/1000 mm3 x 60 sec/min = 720 ml/min
High Pressure water test
Test pressure = 1628 psig based on 1.1 x WCB body rating from ASME B16.34 class 600
DN number = 400 for a 16valve
Rate A = 0 ml/min
Rate B = 0.01 mm3/sec x 400 x 1 ml/1000 mm3 x 60 sec/min = 0.24 ml/min
Rate C = 0.03 mm3/sec x 400 x 1 ml/1000 mm3 x 60 sec/min = 0.72 ml/min
Rate D = 0.1 mm3/sec x 400 x 1 ml/1000 mm3 x 60 sec/min = 2.4 ml/min

API 598 Eighth edition

Low Pressure air test
Test pressure = 60 to 100 psig
Acceptable Leakage = 4 bubbles/min x 16x 0.15 ml/bubble = 9.6 ml/min
High Pressure air and water tests
Test pressure = 1628 psig based on 1.1 x WCB body rating from ASME B16.34 class 600
Acceptable Leakage (air test) = 4 bubbles/min x 16x 0.15 ml/bubble = 9.6 ml/min
Acceptable Leakage (water test) = 2 drops/min x 16x 1 ml/ 16 drops = 2 ml/min

Neles North America Seat Leakage Guide Page 6 Aug 28, 2009

Leakage Rates in Context

It is often easier to understand the comparisons between different leakage rates if they are put
in the context of everyday values.
Here are some real world examples to illustrate the leakage rates for our 4valve example.

Valve Test Example - XT04CWTAS6SJHADD

Leakage
Gas Test
Rate
(ml/min)
ISO 5208 Third edition Rate A
0
ANSI/FCI 70-2-2006 class VI
1.7
ISO 5208 Third edition Rate B
1.8
API 598 Eighth edition
3.6
ISO 5208 Third edition Rate C
18.0
ANSI/FCI 70-2-2006 class V
18.8
ISO 5208 Third edition Rate D
180

Valve Test Example - XT04CWTAS6SJHADD

Leakage
Liquid Test
Rate
(ml/min)
ISO 5208 Third edition Rate A
0
ISO 5208 Third edition Rate B
0.06
ISO 5208 Third edition Rate C
0.18
ANSI/FCI 70-2-2006 class V
0.55
ISO 5208 Third edition Rate D
0.60
API 598 Eighth edition
0.75

Time to fill the volume

of a basketball
about 3 days
a little less than 3 days
about a day and a half
6.6 hours
6.3 hours
40 minutes

Time to fill a medium

cup of coffee (14oz)
a little less than 5 days
about a day and a half
12.5 hours
11.5 hours
9 hours

Neles North America Seat Leakage Guide Page 7 Aug 28, 2009

Leakage Rates Available for Standard Products

ANSI/FCI 70-2-2006
Valve Series Seat Style

X-MBV seat
supported

M2 seat
supported
S6
X-MBV
trunnion
M2 trunnion

LG/LW
L1/L2
L6
R-series
Finetrol
ZX

H
S (1)
K (1)
G
J (2)
S (1)
P (1)
E
H,X,K
J (2)
H
S
B
L
S
H
S
E
B
C
K
all (3)
all (3)
all (3)
S
T
all
all

class IV
(water)

class V
(water)
standard
standard
standard
standard

ISO 5208 Third edition

Low Press. Air Test High Press. Water

class V class VI
Rate C
Rate D
(air)
(air)
optional
optional
optional
optional
optional
optional
optional
optional
optional
optional
optional
optional
optional
standard
standard optional
optional
optional
standard optional
optional
optional
standard optional
optional
optional
standard optional
optional
optional
optional
standard
standard optional
optional
standard optional
optional
optional
standard optional
optional
optional
standard optional
optional
optional
standard optional
optional
optional
standard optional
optional
standard optional
optional
optional
standard optional
optional
optional
standard optional
optional
optional
standard optional
optional
standard optional
optional
optional
standard optional
optional
optional
standard optional
optional
optional
standard optional
optional
optional
class IV (water) standard, optional test to 1/10 class IV (air)
standard
standard
standard

Rate C

Rate D

standard
standard
standard
standard
optional
optional
optional
standard
standard
standard
standard
standard
standard
standard
standard
standard
standard
standard
standard
standard
standard
standard

standard
standard
standard

API 598 Eighth edition

(Only for valves larger than 2")
Low Pressure
Air Test
optional
optional
optional
optional

High Pressure
Water Test
optional
optional
optional
optional

optional
optional
optional
optional

optional
optional
optional
optional

optional
optional
optional
optional

optional
optional
optional
optional

optional
optional
optional

optional
optional
optional

optional
optional
optional
optional

optional
optional
optional
optional

Notes:
1) Seat supported ball valves with locked seat designs require a minimum dP of 30psi to meet required leakage rates
2) J-seated valves with UOP construction "UU" are tested with helium per customer specification UOP-671
3) Optional leakage rates are for the preferred direction with shaft on high pressure side. Non preferred direction is tested to ISO 5208 rate C (water)
or ANSI class V (water)
Neles North America Seat Leakage Guide Page 8 Aug 28, 2009