Pressure Test Procedure

CLIENT TPL Doc No. B224-CDU-TPL-000-PP-

HPCL RAJASTHAN REFINERY LTD. QD-PR0063-0004
PMC
EPCC 01 JOB NO B224 ENGINEERS INDIA LTD.
PROJECT Page.: 1 of 6
PR No. CDU/VDU WITH HOT WELL OFF GAS TREATMENT UNIT, SAT-
B224-CDU-TPL-000-PP-PR-0063 URATED LPG TREATING UNIT & SATURATED FUEL GAS REV : 00
TREATING UNIT

HPCL RAJASTHAN REFINERY LIMITED

RAJASTHAN REFINERY PROJECT

BARMER, RAJASTHAN

PACKAGE NAME: Alloy Steel Ball Valves

VENDOR NAME: Niton Valves
VENDOR DOC. NO. NVI/HPT/QC-HP1
PO No.: 18868

HPCL RAJASTHAN REFINERY LTD

1. No Comments/Const. as per document
2. Proceed with Manufacturing

3. Rejected – Resubmit
R Retained for Records
V Void

0 06.03.2023 FOR APPROVAL YUSUF AJAZ KADRI

CHECKED/
REV DATE PURPOSE REVIEWED APPROVED
PREPARED BY
BY BY
 Pressure Test Procedure

CLIENT TPL Doc No. B224-CDU-TPL-000-PP-

HPCL RAJASTHAN REFINERY LTD. QD-PR0063-0004
PMC
EPCC 01 JOB NO B224 ENGINEERS INDIA LTD.
PROJECT Page.: 1 of 6
PR No. CDU/VDU WITH HOT WELL OFF GAS TREATMENT UNIT, SAT-
B224-CDU-TPL-000-PP-PR-0063 URATED LPG TREATING UNIT & SATURATED FUEL GAS REV : 00
TREATING UNIT

Table of Contents
 NITON VALVE INDUSTRIES PVT.LTD.
D-115,Ghatkopar Industrail Estate, L.B.S.Marg,Ghatkopar (West),
Mumbai - 400086 Maharashtra, India. www.niton-valve.com, Tel. : 022-67539800, 2500 8315

PROCEDURE NO. NVI/HPT/QC-HP1 Rev.00

PROCEDURE FOR HYDRO & PNEUMATIC TESTING

1.0 SCOPE
This procedure describes the testing requirements of Ball Valves.
Visual inspection and NDE shall be performed on the valves prior to hydrostatic tests.
The body of the valves shall be free from rust, paint, oil and grease. Tests shall be carried
out prior to any painting of valves.

2.0 REFERENCE
1. BS EN 12266 (P-1) / API 6D

3.0 TEST MEDIA

1. The Hydrostatic test fluid shall have a chloride content of less than 20 ppm for CS valves. Water Test certificate shall be
provided. Test fluid temperature shall be within the range 5 DegC to 50 DegC. When a liquid is used as the test fluid, the
valve shall be essentially free from the trapped air during the test. Required protective coating shall not be applied to any
surface before pressure testing.
2. The test pressures & duration shall be as per approved Drawings & API 598 or test standard as mentioned on approved
drawing / datasheet.

4.0 PRESSURE GAUGE REQUIREMNT

Pressure Gauge Selection : Test pressure within 25% to 75% of FSR
Accuracy (of Full Scale Reading) : ± 2%
Calibration : Calibration of pressure gauge shall be performed once in 3 months

5.0 APPLICABILITY OF PRESSURE TEST

5.1 Applicability of Pressure test for Ball Valves
a) Shell Test
b) High Pressure Closure Seat Test (Hydro Seat Test)
c) Low Pressure Closure Test (Air Test)

Page 1 of 4
A. SHELL TEST
 Now operate the valve so that valve shall be partial open condition.
 Apply the pressure inside the assembled valve as specified in standard and maintain the pressure for
the minimum period specified in the standard.
 No hammering shall be done. Suitable wetting agent may be added to Hydrotest water to improve
wetting properties.
 Check the casting of body and bonnet with the help of lamp or torch.
 Make sure that there should be no leakage from casting and joints of valve.
 Visually detectable leakage or pressure drop is not permitted.
 After that release the pressure of valve.

B. HIGH PRESSURE CLOSURE SEAT TEST (HYDRO SEAT TEST)

 After shell test, operate the valve so that valve shall be fully closed condition.
 Remove the blind testing plate from the top,
 Apply the hydro seat pressure inside the valve as specified in standard and the pressure for the
minimum period specified in standard.
 Remove the water above the seat surface.
 Clean the bore and seat area completely.
 Check the leak, there should be no leakage or pressure drop & it should be within the acceptable limit
as per specified in standard.
 During closure test, Excessive forces shall not be used to close the valve. The applied force may be
determined from the appropriate figures in MSS SP 91, but in any case shall not exceed the values
published by the valve manufacturer.
 Follow the same procedure to second side of seat test.

C. LOW PRESSURE CLOSURE TEST (AIR TEST)

 After Hydro seat test release the pressure.
 The seat sealing surface interface shall be clean and free from oil, grease and sealant.
 Drain the water from assembled valves.
 Open the valve partially.
 Close the Hydro line and open the air Line.
 A method of testing shall be used that fills & fully pressurizes the body cavity to the test
pressure between the seats & the bonnet area with test fluid.
 Fill the water up to seat surface or apply soap bubbles around the seat surface to check the leakage.
 Check the leak there should be no leakage from seat and seat joint or should be within an acceptable
limit as per standard.
 Follow the same procedure for second side of seat test.
 After completing the air test close the air line and remove the valve from testing bench.
 Dry the valve with air so that it should not be contain water inside and close the valve and put end
protectors for both flange faces.
 When no visually detectable leakage is permitted, the following definition apply:
a) If the test fluid is a liquid, there shall be no visible evidence of drops or wetting of the external
surfaces of the test valve.

Page 2 of 4
Test Duration for Shell & Seat Test as per BS EN 12266-1
Minimum Test Duration
Nominal Size
Shell Seat
Up to DN 50 15 second 15 second
From DN65 to DN200 60 second 15 second
DN 250 and above 180 second 30 second (DN250 to 450)
60 second (DN500 and above)
Leakage Rate as per BS EN 12266-1
Maximum allowable seat leakage for each leakage rate in cubic millimeters per second
Test Fluid Rate A Rate B Rate C Rate D Rate E Rate F Rate G
No visually
Liquid detectable 0.01 X DN 0.03 X DN 0.1 X DN 0.3 X DN 1.0 X DN 2.0 X DN
leakage for the
duration of the
Gas 0.3 X DN 3.0 X DV 30 X DN 300 X DN
test 3000 X DN 6000 X DN

Test Duration for Shell & Seat Test as per API 6D

Minimum Test Duration
Valve Size
Shell Seat
≤ DN 100 2 minute 2 minute
DN150 to DN250 5 minute 5 minute
DN 300 to DN450 15 minute 5 minute
500 and larger 30 minute 10 minute

Leakage Rate as per API 6D

Leakage for soft seated valves shall not exceed ISO 5208, Rate A (no visible detectable leakage for the
duration of the test at test pressure)

Page 3 of 4
Test Report Format
Annexure -I

Page 4 of 4