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Engineering Specification

Title: Hydrostatic and Proof Test of Pressure Relief Valves

Summary: The purpose of this specification is to test and verify the integrity of pressure retaining parts as well
as the ability of assembled valves to contain pressure within the body / bonnet envelop. The application of this
specification is mandatory unless one of the more stringent optional hydrostatic test procedures is specified on
the factory order. Separate tests are performed for setting and seat tightness.

A. SCOPE:

This specification applies to all pressure relief valves and parts where the primary and secondary pressure
containing components are made from castings, bar stock, forgings or weldments. In certain cases,
components made from bar stock are exempt from testing (See Appendix A). Exposed spring (open yoke)
and open lever valves are exempt from the secondary zone hydrostatic test and secondary pressure zone air
test of assembled valves due to their inability to contain back pressure.

B. DEFINITIONS:

Primary Pressure Zone Parts: Those parts which are in direct contact with pressure at the inlet of a pressure
relief valve. This includes the nozzle on full nozzle designs; semi-nozzle and body inlet on semi-nozzle
designs; bodies on threaded designs; and semi-nozzle, body inlet, piston, guide/cover, guide, cover and
PCM body on pilot operated valves. Discs when used in open bonnet/yoke designs.

Secondary Pressure Zone Parts: Those parts which serve to contain pressure existing in the passage
between the valve seat and the valve outlet in a Pressure Relief Valve. This includes flanged valve bodies
and bonnets / covers, threaded valve bonnets and plain and packed caps.

Cast Parts: Part whose shape is directly controlled by a pattern into which molten metal is poured.

Bar & Forged Parts: Parts made from materials that are drawn, rolled or formed under pressure.

Welded Parts: Valve parts which are joined by fusion welding process.

Maximum Design Pressure: For the primary zone it is the maximum set pressure and for the secondary
zone it is the maximum back pressure for the appropriate product as listed in the current published catalog.
Alternately, for special or non-catalog products the maximum pressure for a specific valve type into which a
given part is going to be used.

C. TEST OF INDIVIDUAL PARTS:

Primary Pressure Zone Parts:

The primary pressure zone of all parts, regardless of material form shall be hydrostatically tested at no less
than 1.5 times the maximum design pressure. Some parts made from bar stock or forging may be exempt
(See appendix A). Testing is to be performed on fully machined parts using water as the test fluid. Testing
may be performed using air at 1.25 times the maximum design pressure provided proper safety precautions
are taken to compensate for the additional hazards involved when performing pneumatic tests.

Farris Engineering, 10195 Brecksville Road, Brecksville, Ohio 44141 USA

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C. TEST OF INDIVIDUAL PARTS: (continued)

Secondary Pressure Zone Parts:

The secondary pressure zone of all parts, regardless of material form shall be hydrostatically tested at no less
than 1.5 times the maximum design pressure. Some parts made from bar stock or forging may be exempt (See
Appendix A) Testing is to be performed on fully machined parts using water as the test fluid. Testing may be
performed using air at 1.25 times the maximum design pressure provided proper safety precautions are taken
to compensate for the additional hazards involved when performing pneumatic tests.

Testing Hold Times:

The individual parts shall be held at no less than the hydrostatic test pressure for the following length of time;

Bodies, Bonnets, Covers & Guide/Covers; valve inlet size 2” and less - 1 minute
valve inlet size from 2 1/2" up to 8" - 2 minutes
valve inlet size above 8" - 3 minutes

All nozzles, discs & 3800 guides - 30 seconds.

All caps - 15 seconds.

Acceptance is noted by stamping each part with the symbol (H). Stamping will be made as noted in Appendix
B. This testing is mandatory for ASME Code Stamped valves.

Pressure Testing Of Bellows Sub-Assembly:

The bellows sub assembly consisting of the disc holder, stem retainer, bellows and bellows gasket shall be
tested on air prior to assembly in the valve. Air pressure at 30 PSI shall be applied to the inside wall of the
bellows to check for leakage past the bellows and the stem retainer / disc holder joint. Testing will be done on
the assembly department bellows test fixture by coating the exterior surface of the bellows and gasket joint with
a suitable leak detection solution. In addition, the disc holder should be filled with water to determine if there is
any leakage past the disc holder lock screw.

D. TEST OF ASSEMBLED VALVES:

Primary Pressure Zone:

No additional tests are required.

Secondary Pressure Zone:

The secondary pressure zone (outlet side) of all valves exceeding 1” inlet size and which are designed to
discharge to a closed system shall be tested on air (or other gas) at a pressure equal to 30 PSI or the
maximum back pressure indicated on the sales order, whichever is greater. Valves with 1” inlet size and
smaller may be tested upon customer request. A suitable leak detection solution will be used to verify tightness
of all gasket joints, vent / drain plugs and cast surfaces. Testing should be performed with the actual plain cap
or packed lever assembly installed. Use of a test cap is prohibited. This test shall not be applied to exposed
spring (open yoke) or open lever design valves.

Farris Engineering, 10195 Brecksville Road, Brecksville, Ohio 44141 USA

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Testing Time Limit (Assembled Valves):

Holding time at test pressure meets or exceeds ANSI B16.34 as follows. One minute for valves up to 6 inch
inlet size, 2 minutes for inlet sizes 8" through 12" and 5 minutes for inlet sizes 14 inch and larger.

E. ACCEPTANCE CRITERIA (All Tests):

No visible leakage is permitted through the pressure boundary wall. Parts exhibiting no sign of leakage or
permanent material deformation shall be considered acceptable. Hydrostatic test acceptance is noted by
stamping each cast or welded part (except bellows) with the symbol (H) per Appendix B. No leakage is
permitted through gaskets during the air test of the bellows assembly or the air test of assembled valves.

Farris Engineering, 10195 Brecksville Road, Brecksville, Ohio 44141 USA

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APPENDIX A

GENERAL GUIDE TESTING & EXEMPTION OF PARTS BY VALVE SERIES

Material Form / Material Form /

Normal Material Normal Material
1 Hydrostatic Test 1 Hydrostatic Test
Form 1
Form 1
Requirement Requirement
Part Part

3
Standard

Standard
Optional

Optional
Required

Required
Hydro

Hydro
Form

Form
2600 Series 2700 Series
Cast Yes Cast Yes
Body2 Cast None Body2 Cast Bar
Bar N/A Bar No

Bonnet2 Cast Yes Cast Yes

(Closed)
Cast Bar Bonnet2 Cast Bar
Bar No Bar No
Cast Yes Cast N/A
2
Nozzle Cast Bar Disc Bar None
Bar Note 3 Bar No
Cast N/A Cap Cast Yes
Disc Bar None Cast Bar
Bar Note 3 (Plain) Bar No
Disc Holder Cast N/A Cast Yes
Cap
(D to K "O" Bar None Cast Bar
Bar No (Packed) Bar No
Ring)
Cast /
Cast Yes Yes
Cap Body or Bonnet Weld
Cast Bar Weldments Cast Bar
(Plain) Bar /
Bar No Yes
Weld
Cap Cast Yes
Cast Bar
(Packed) Bar No
General Notes:
1. Indicates the form of material the part is normally manufactured from as well as any optional materials.
2. Designates cast parts that are currently hydrostatically tested under the existing ASME Code.
3. Most bar stock or forged parts are exempt from hydrostatic testing.
4. N/A indicates material form not normally used for the part.

Farris Engineering, 10195 Brecksville Road, Brecksville, Ohio 44141 USA

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APPENDIX A

GENERAL GUIDE TESTING & EXEMPTION OF PARTS BY VALVE SERIES

Material Form / Material Form /

Normal Material Normal Material
1 Hydrostatic Test 1 Hydrostatic Test
Form 1 Form 1
Requirement Requirement
Part Part

3
Standard

Standard
Optional

Optional
Required

Required
Hydro

Hydro
Form

Form
3800 Series 4200 / 6400 & 6600 Series

2
Cast Yes 4
Cast No
Body Cast None Body Cast None
Bar N/A Bar N/A

2
Cast Yes Bonnet Cast No
Nozzle Cast Bar Cast Bar
Bar Note 3 (Open) Bar No
Cast Yes Bonnet Cast Yes
Guide /
2 Cast Bar (Closed) Cast Bar
Cover Bar N/A Bar No
(6600)
Cast Yes 2
Cast Yes
Cover Forged Cast Nozzle Cast Bar
Bar Note 3 Bar No
Cast N/A Cast N/A
Piston Bar None Disc Bar None
Bar No Bar No
Cast Yes Cap Cast Yes
Pilot Control
Body PCM Cast Bar (Plain) Cast Bar
Bar No (6600) Bar No
Cast N/A Cap Cast Yes
Pilot Control
Body PCF5 Bar None (Packed) Cast Bar
Bar No (6600) Bar No
General Notes:
1. Indicates the form of material the part is normally manufactured from as well as any optional materials.
2. Designates cast parts that are currently hydrostatically tested under the existing ASME Code.
3. Most bar stock or forged parts are exempt from hydrostatic testing.
4. When used on closed bonnet 6600 series, body must be hydrostatically tested on outlet.
5. N/A indicates material form not normally used for the part.

Farris Engineering, 10195 Brecksville Road, Brecksville, Ohio 44141 USA

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APPENDIX A

GENERAL GUIDE TESTING & EXEMPTION OF PARTS BY VALVE SERIES

Material Form / Material Form /

Normal Material Normal Material
1 Hydrostatic Test 1 Hydrostatic Test
Form 1 Form 1
Requirement Requirement
Part Part

3
Standard

Standard
Optional

Optional
Required

Required
Hydro

Hydro
Form

Form
2800 / 2856M Series 1890 / 1896M Series
Cast Yes Cast Yes
2 2
Body Cast Bar Body Bar Cast
Bar Yes Bar No
Cast Yes Cast Yes
2 2
Bonnet Cast Bar Bonnet Cast Bar
Bar No Bar No
Cast N/A Cast N/A
Disc Bar None Disc Bar None
Bar No Bar No

Cap Cast Yes Cap Cast Yes

Bar Cast Bar Cast
(Plain) Bar No (Plain) Bar No

Cap Cast Yes Cap Cast Yes

Bar Cast Bar Cast
(Packed) Bar No (Packed) Bar No
Bar / Cast /
Body or Yes Body or Yes
Weld Weld
Bonnet Cast Bar Bonnet Bar Cast
Bar / Weldments Bar /
Weldments Yes Yes
Weld Weld
General Notes:
1. Indicates the form of material the part is normally manufactured from as well as any optional materials.
2. Designates cast parts that are currently hydrostatically tested under the existing ASME Code.
3. Most bar stock or forged parts are exempt from hydrostatic testing.
4. N/A indicates material form not normally used for the part.

Farris Engineering, 10195 Brecksville Road, Brecksville, Ohio 44141 USA

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APPENDIX B

MARKING SYMBOLS & LOCATION ON COMPLETION OF HYDROSTATIC TESTING

Upon successful completion of the hydrostatic test all tested parts shall be marked as noted below at the
location indicated.

Valve
Part Name Mark Location
Series
Directly above the Blow Down Ring Lock Screw Hole, or
Body H in line with the Blow Down Ring Lock Screw Hole on the outside
edge of the inlet flange
Directly under the pipe plug hole on the back of the flange or on
Bonnet H
the outside edge of the flange
2600
Nozzle H On Edge of Nozzle Flange
Disc, Metal Seat H On Disc Face or Underline Heat Number
Disc, "O" Ring Seat H Side of Wrenching Flat
Cap, Plain H Side of Wrenching Flat (Bar Stock Caps Exempt
Cap, Packed H Top of Flange Between Bolt Holes
Body, Main Valve H Top flange edge, in line with outlet flange
Nozzle H On Wrenching Flat
Guide H Under Heat Number
3800 Guide / Cover H Under Heat Number or Top of Guide
Cover H On Edge Adjacent to Material Designation
Piston H On Top Face Next to Return Spring Opening
Body, Modulating H On Edge of Body Flange Adjacent to Flange with Heat Number
Body H On Wrenching Flat Adjacent to Flat that Contains Heat Number
Bonnet H Under Heat Number
Disc --- Exempt
2700 Cap, Plain H On Wrenching Flat (Bar Stock Caps Exempt)
Cap, Packed H On Wrenching Flat (Bar Stock Caps Exempt)
Weldment, Body 1 W On Wrenching Flat Adjacent to Flat that Contains Heat Number
1 W Under Heat Number
Weldment, Bonnet
Body H On Wrenching Flat Adjacent to Flat that Contains Heat Number
Bonnet H Under the Heat Number
1800 &
Disc H On Disc Face or Underline Heat Number
2800
Cap, Plain H On Wrenching Flat
Cap, Packed H On Wrenching Flat
Body --- Exempt
Bonnet --- Exempt
4200
Nozzle H On Edge of Nozzle Flange
Disc --- Exempt
Body --- Exempt
Bonnet --- Exempt
6400
Nozzle H On Edge of Nozzle Flange
Disc --- Exempt
Directly above the Blow Down Ring Lock Screw Hole, or
Body H in line with the Blow Down Ring Lock Screw Hole on the outside
edge of the flange (Plain or Packed Cap Only)
Directly under the pipe plug hole on the back of the flange or on
Bonnet H
6600 the outside edge of the flange (Plain or Packed Cap Only)
Nozzle H On Edge of Nozzle Flange
Disc --- Exempt
Cap, Plain H On Wrenching Flat (Bar Stock Caps Exempt)
Cap, Packed H Top of Flange Between Bolt Holes
General Notes:
1. After the weldment has been hydro tested, the "W" stamp will be placed next to the "H" stamp
if the individual body or bonnet part had been previously hydrotested.

Farris Engineering, 10195 Brecksville Road, Brecksville, Ohio 44141 USA

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