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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
Examples…………………………………………………………………………………………... Page 5
Class V
Media – Clean water
Temperature – 50º to 125º 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
-or-
Class VI
Media – Air or Nitrogen Gas
Temperature – 50º to 125º 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
1.5 0.30 2
2 0.45 3
2.5 0.60 4
3 0.90 6
4 1.70 11
6 4.00 27
8 6.75 45
10 11.1
12 16.0
14 21.6
16 28.4
* 1 bubble is equivalent to 0.15 ml
Neles North America Seat Leakage Guide Page 1 Aug 28, 2009
Guide To ISO 5208 Third edition
Required Closure Tests
Seat Supported Trunnion Mounted
Closure Test Sizes ASME Class Butterfly Valve
Ball Valve Ball Valve
1500 Required Required Required
4"
Low Pressure > 1500 Required Optional Optional
Gas 600 Required Required Required
> 4"
> 600 Required Optional Optional
1500 Optional Optional Optional
4"
High Pressure > 1500 Optional Required Required
Liquid 600 Optional Optional Optional
> 4"
> 600 Optional Required Required
2" 15
2.5" to 6" 60
8" to 12" 120
14" 120
DN numbers
Valve Size 1/2" 3/4" 1" 1.5" 2" 2.5" 3" 4" 6" 8" 10" 12" 14" 16"
DN 15 20 25 40 50 65 80 100 150 200 250 300 350 400
Neles North America Seat Leakage Guide Page 2 Aug 28, 2009
Guide To API 598 Eighth edition
Required Closure Tests
Seat Supported Trunnion Mounted
Closure Test Sizes ASME Class Butterfly Valve
Ball Valve Ball Valve
1500 Required Required Required
4"
> 1500 Required Optional Optional
Low Pressure
600 Required Required Required
> 4"
> 600 Required Optional Optional
1500 Optional Optional Optional
4"
> 1500 Optional Required Required
High Pressure
600 Optional Optional Optional
> 4"
> 600 Optional Required Required
2" 15
2.5" to 6" 60
8" to 12" 120
14" 120
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 ISO 5208 Third edition API 598 Eighth edition
class V class VI rate A rate B rate C rate D Low Pressure Test
Test Pressure (psig) 50 50 73 to 102 60 to 100
Valve Size (inches)* Maximum Acceptable Leakage (ml/min)
1 4.7 0.15 0 0.45 4.5 45 0
1.5 7.05 0.30 0 0.72 7.2 72 0
2 9.4 0.45 0 0.9 9 90 0
2.5 11.75 0.60 0 1.17 11.7 117 3.6
3 14.1 0.90 0 1.44 14.4 144 3.6
4 18.8 1.70 0 1.8 18 180 3.6
6 28.2 4.00 0 2.7 27 270 3.6
8 37.6 6.75 0 3.6 36 360 6
10 47 11.1 0 4.5 45 450 6
12 56.4 16.0 0 5.4 54 540 6
14 65.8 21.6 0 6.3 63 630 8.4
16 75.2 28.4 0 7.2 72 720 9.6
* Seat diameter for ANSI/FCI 70-2-2006
ANSI/FCI 70-2-2006 ISO 5208 Third edition API 598 Eighth edition
class V rate A rate B rate C rate D High Pressure Test
Test Pressure (psig) 740 814 814
Valve Size (inches)* Maximum Acceptable Leakage (ml/min)
1 0.37 0 0.015 0.045 0.15 0
1.5 0.56 0 0.024 0.072 0.24 0
2 0.74 0 0.03 0.09 0.3 0
2.5 0.93 0 0.039 0.117 0.39 0.75
3 1.11 0 0.048 0.144 0.48 0.75
4 1.48 0 0.06 0.18 0.6 0.75
6 2.22 0 0.09 0.27 0.9 0.75
8 2.96 0 0.12 0.36 1.2 1.25
10 3.70 0 0.15 0.45 1.5 1.25
12 4.44 0 0.18 0.54 1.8 1.25
14 5.18 0 0.21 0.63 2.1 1.75
16 5.92 0 0.24 0.72 2.4 2
* Seat diameter for ANSI/FCI 70-2-2006
Neles North America Seat Leakage Guide Page 4 Aug 28, 2009
Valve Test Example - XT04CWTAS6SJHADD
ANSI/FCI 70-2-2006
Neles North America Seat Leakage Guide Page 5 Aug 28, 2009
Valve Test Example – D5FA16DAS02
ANSI/FCI 70-2-2006
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 4”valve example.
Neles North America Seat Leakage Guide Page 7 Aug 28, 2009
Leakage Rates Available for Standard Products
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