ISO 9001:2008 closure 7.

Document No : QP-ENG-03
PRESSURE TEST PROCEDURE FOR GATE, GLOBE, Revision : 00
CHECK, BALL, BUTTERFLY AND PLUG VALVES FOR Date of Issue : 1st June 2011
PROJECT SUPPLY IN ACCORDANCE WITH API 598 Page : 1 of 7

1.0 PURPOSE

This document defines the pressure test procedure to be used at place of manufacture to ensure valves
GLOBAL for project clients comply with the applicable standard and/or client contract
supplied by CRANE Indonesia
requirements.

2.0 SCOPE

This procedure covers the Shell test and Closure test requirements for Gate, Globe, Check, Ball, Butterfly and
Plug valves of all designs and materials.
Every valve (100%) must undergo pressure testing after manufacture to ensure the integrity of the valve body
and the valve seat and that seat leakage (if any) is within the allowable tolerance.

3.0 DEFINITIONS

3.1 Shell Test: a pressure test in excess of the valve’s cold working pressure rating to validate the
soundness and strength of the pressure containing areas.

3.2 Closure Test: a pressure test to confirm leakage past or through a valve’s closure mechanism.
3.3 Backseat Test: a pressure test to verify leakage past the stem or shaft to bonnet seal.
3.4 Visually leakage: leakage during a valve pressure test that is validated by normal vision.
3.5 Witness Test: a pressure test carried out in front of the client or client representative at a pre-agreed
sample rate; usually done after 100% factory testing is complete.

4.0 KEY REFERENCE

This procedure shall follow the requirements of API 598 “Valve Inspection and Testing”

OTHER REFERENCES
4.1 API 6D : Specification for Pipeline Valves
4.2 API 600 : Steel Gate Valves
4.3 API 602 : Steel Gate, Globe and Check Valves for Sizes 
4.4 API 594 : Check Valves
4.5 ASME/ANSI B1.20.1 : Pipe Threads, General Purpose (Inches).

4.6 ASME/ANSI B16.1 : Gray Iron Pipe Flanges and Flanged Fitting.

4.7 ASME/ANSI B16.11 : Forged Fittings, Socket Welding and Threaded.

4.8 ASME/ANSI B16.34 : Valves – Flanged, Threaded and Welding end.

4.9 ASME/ANSI B16.42 : Ductile Iron Pipe Flanges and Flanged Fittings

4.10 MSS SP-55 : Quality Standard for Steel Castings for Valves Flanges and Fittings and
Other Piping Components - Visual Method for Evaluation of Surface
Irregularities.

F/ISO/02 Rev.00
 ISO 9001:2008 closure 7.2

Document No : QP-ENG-03
PRESSURE TEST PROCEDURE FOR GATE, GLOBE, Revision : 00
CHECK, BALL, BUTTERFLY AND PLUG VALVES FOR Date of Issue : 1st June 2011
PROJECT SUPPLY IN ACCORDANCE WITH API 598 Page : 2 of 7

5.0 RESPONSIBILTIES

5.1 Factory Manager shall ensure all employees and contractors assigned to pressure testing are adequately
trained and comply with the requirements of this procedure.
5.2 Quality Assurance Manager is responsible for the oversight and operation of this procedure and shall
ensure that all necessary records are kept.
5.3 Project clients are responsible for approving this procedure before commencement of manufacture. Any
requested amendments such as the inclusion of optional tests or witnessing activities must be agreed with
Crane as soon as possible as there may be an impact on delivery time and price. Re-testing for
witnessing purposes of    

6.0 TESTS REQUIRED

Tests to be performed shall be as stated in API 598 in accordance with those “checked” in the following tables:

For Valves:   

  
Floating B'fly and
Test Description Gate Globe Plug Check
Ball Trun.Ball
Shell      
Backseat  
Low-pressure closure   
High-pressure closure  

For Valves:   

> DN100 and ASME Class > 600#
Floating B'fly and
Test Description Gate Globe Plug Check
Ball Trun.Ball
Shell      
Backseat  
Low-pressure closure
High-pressure closure     
(The above tables correlate directly to API 598 Table 1 & Table 2)

F/ISO/02 Rev.00
 ISO 9001:2008 closure 7.2

Document No : QP-ENG-03
PRESSURE TEST PROCEDURE FOR GATE, GLOBE, Revision : 00
CHECK, BALL, BUTTERFLY AND PLUG VALVES FOR Date of Issue : 1st June 2011
PROJECT SUPPLY IN ACCORDANCE WITH API 598 Page : 3 of 7

7.0 TEST PRESSURES

Minimum Test Pressures shall be determined by referencing the appropriate table in ASME B16.34 (or Table 2
of API 602 for class 800# valves)
For Pneumatic tests, the Low Pressure (LP) Closure and Backseat test pressures are as in the table below.
For Pneumatic High Pressure (HP) Closure and Shell tests the stated working pressure shall be multiplied by
1.1.
For Hydrostatic tests, the stated working pressure shall be multiplied by 1.5 for HP shell tests and 1.1 for HP
closure tests.
The minimum test pressures for common “Group 1.1 Materials” which include carbon steel A105 and A216
WCB have been calculated and tabulated below. For other materials refer to ASME B16.34 (or API 602 for
class 800# valves only).

API 598 Minimum Test Pressures (Group 1.1 Materials)

For other materials Groups refer to B16.34 and API 602
LP Closure
HP Shell HP Closure HP Shell
Valve and Backseat
(Pneumatic) (Hydro) (Hydro)
Class (Pneumatic)
Psi Bar Psi Bar Psi Bar Psi Bar
150 100 7.0 315 21.6 315 21.6 428 29.4
300 100 7.0 814 56.3 814 56.3 1110 76.7
600 100 7.0 1628 112.4 1628 112.4 2220 153.2
800 100 7.0 2175 150.0 2175 150.0 2963 205.0
900 100 7.0 2442 168.6 2442 168.6 3330 229.8
1500 100 7.0 4078 280.9 4078 280.9 5558 383.0
2500 100 7.0 6787 468.1 6787 468.1 9255 638.3

8.0 TEST DURATIONS

Test durations shall be in accordance with the following table.

API 598 Table 5 - Minimum Test Duration (Seconds)

Closure Closure
Valve
Shell Backseat Check Other
Size
Valves Valves
0” - 2” 15 15 60 15
2.1/2” – 6” 60 60 60 60
8” – 12” 120 60 120 120
14 “ 300 60 120 300

F/ISO/02 Rev.00
 ISO 9001:2008 closure 7.2

Document No : QP-ENG-03
PRESSURE TEST PROCEDURE FOR GATE, GLOBE, Revision : 00
CHECK, BALL, BUTTERFLY AND PLUG VALVES FOR Date of Issue : 1st June 2011
PROJECT SUPPLY IN ACCORDANCE WITH API 598 Page : 4 of 7

9.0 TEST LEAKAGE

Shell, Stem, Backseat Tests

No visually detectable leakage is permitted through the pressure boundary walls, any fixed body joint, stem
seal or backseat.
Closure Tests
No visually detectable leakage is permitted through the disc, behind the seat rings or past the shaft seals (if
present). The maximum allowable leakage rate of test fluid at the seat-sealing surface interface is in
accordance with the following table.

API 598 (Table 6) Maximum Allowable Leakage Rate for Closure Tests
All Metal Seated Valves Except
Valve Size Metal Seated Check Valves
Resilient Check
DN NPS Seated Liquid Testa Gas Test Liquid Test Gas Test Gas Test
(mm) (in.) Valves (drops/minute) (bubbles/min) (cc/min) (m3/h) (ft3/h)
b b
< 50 <2 0 0 0 6 0.08 3
65 2 1/2 0 5 10 7.5 0.11 3.75
80 3 0 6 12 9 0.13 4.5
100 4 0 8 16 12 0.17 6
125 5 0 10 20 15 0.21 7.5
150 6 0 12 24 18 0.25 9
200 8 0 16 32 24 0.34 12
250 10 0 20 40 30 0.42 15
300 12 0 24 48 36 0.50 18
350 14 0 28 56 42 0.59 21
400 16 0 32 64 48 0.67 24
450 18 0 36 72 54 0.76 27
500 20 0 40 80 60 0.84 30
600 24 0 48 96 72 1.01 36
650 26 0 52 104 78 1.09 39
700 28 0 56 112 84 1.18 42
750 30 0 60 120 90 1.26 45
800 32 0 64 128 96 1.34 48
900 36 0 72 144 108 1.51 54
1000 40 0 80 160 120 1.68 60
1050 42 0 84 168 126 1.76 63
1200 48 0 96 192 144 2.02 72
a. For the liquid test, 1 ml is considered equivalent to 16 drops.

b. There shall be no leakage for the minimum specified test duration. For liquid test, 0 drops means no visible
leakage for minimum test duration. 0 bubbles means less than 1 bubble per minimum test duration.

F/ISO/02 Rev.00
 ISO 9001:2008 closure 7.2

Document No : QP-ENG-03
PRESSURE TEST PROCEDURE FOR GATE, GLOBE, Revision : 00
CHECK, BALL, BUTTERFLY AND PLUG VALVES FOR Date of Issue : 1st June 2011
PROJECT SUPPLY IN ACCORDANCE WITH API 598 Page : 5 of 7

10.0 PROCEDURE

10.1 In Preparation for testing the operator:

a) Shall assemble necessary testing apparatus and record sheets
b) Shall perform a safety check of equipment
c) Shall check the equipment is functioning correctly
d) Shall check pressure gauges are in current calibration and the “zero set” is correct
e) Shall visually inspect the valves and if required remove any dirt or foreign objects present

10.2 Environment and test media

a) Test fluid for shell, high-pressure back seat, and high-pressure closure tests, the fluid shall be air,
insert gas, kerosene, water, or a non corrosive liquid with a viscosity not higher than of water.
b) The test fluid temperature shall within the range 5oC (41oF) to 50oC (122 oF).

c) Water used for any test may contain water-soluble oil or rust inhibitor. For testing of austenitic
stainless steel valves, water with chloride content not exceeding 100 ppm shall be used.
10.3 Shell Test
The shell test is performed to check the soundness and integrity of the valve body by applying fluid
pressure inside the assembled valve with the valve ends closed off, the valve closure mechanism
partially open and the packing gland (if any) tight enough to maintain the test pressure.
10.3.1 Shell Test
- Select the correct blanking plates and secure in position
- Open valve partially
- Close the outlet line
- Fill valve with fluid
- Dry external areas of valve using compressed air or other means
- Open inlet valve and pressurize to the required level by referring to the pressure tables. Use
pressure booster pump if necessary.
- Check for any leaks
- There shall be no visible evidence of drops/bubbles or wetting of the external surfaces. This
includes leakage through the body and through any joints in the valve.

10.4 Backseat Test

The backseat test is performed to check for leakage between the stem and the bonnet seal by applying
pressure inside the assembled valve with the valve ends closed, the valve fully open, and the packing
gland loose. The backseat test may be performed immediately after the shell test. All packing glands
shall be retightened after the backseat test.
10.4.1 Backseat Test
- Select correct blanking plates and secure in position
- Open valve fully so that stem chamfer seats against the backseat bush
- Close the outlet line
- Loosen the packing gland
- Fill valve with test fluid
- Dry external areas of valve using compressed air or other means
- Open inlet valve and pressurize to the required level by referring to the pressure tables. Use
pressure booster pump if necessary.
- Check for any leaks. For backseat test no visible leakage is permitted.

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 ISO 9001:2008 closure 7.2

Document No : QP-ENG-03
PRESSURE TEST PROCEDURE FOR GATE, GLOBE, Revision : 00
CHECK, BALL, BUTTERFLY AND PLUG VALVES FOR Date of Issue : 1st June 2011
PROJECT SUPPLY IN ACCORDANCE WITH API 598 Page : 6 of 7

- Close inlet valve slowly to avoid damage to gauges

- Open outlet valve carefully to release the internal pressure
- Allow all fluid to drain out.
- Unclamp valve from test rig.
- Dry the internal and external areas of the valve
- Close the valve fully
- Fill in the results Pressure Test Report sheet.

10.5 Closure Test

The closure test (also called seat test) is performed to check for leakage past or through the valve’s
closure mechanism (disc, ball, plug, wedge, flap etc.)
As a minimum, the manufacturer will perform either the Low-Pressure Closure Test or the High-
Pressure Closure Test in accordance with the requirement or API 598 Table 1.
The seat test shall be performed with the sealing surfaces clean and free oil, grease, and sealant. If
necessary to prevent galling, the sealing surfaces may be coated with a film of oil that is not heavier
than kerosene.
Closure Test Rules
Gate Valves: Test in two directions
Plug Valves: Test in two directions
Butterfly Valves Class 125 & 150 API 609 Cat. A with resilient seat: Test in one direction
Butterfly Valves API 609 Cat. B with resilient seat: Test in two directions
Ball Valves: Test in two directions
Double Block & Bleed Valves: Test in two directions using the valve port where fitted
Globe Valves: Test in one direction from under the disc
Check Valves: Test in one direction from the downstream side
For Any Other Valve Marked as Unidirectional: Test in one direction from the pressure side
Any leakage at the seat, behind the seat or through the disc/ball/plug on the open side of the valve shall
be detected when bubbles (for low pressure closure test) or drops (for high-pressure closure test) are
observed.
10.5.1 Low - Pressure Closure Test
- The valve shall be clamped securely to the test rig (or have end plate(s) bolted in place)
- Close the outlet valve
- Close the valve to be tested firmly (using no more force than would be achieved by hand
tightening)
- Open the low pressure air inlet valve
- Cover the entire closure mechanism (disc/plug/ball) and seat area on the non pressurized
side with clean fluid
- Hold the air pressure in valve at the specified test pressure and duration.
Watch for air bubbles during test and record results
- Turn air pressure off slowly to avoid possible damage to gauges.
The allowable leakage rate of test fluid past the seats, for the duration of the
low pressure is listed in API 598 Table 6 (repeated in this procedure for convenience)

F/ISO/02 Rev.00
 ISO 9001:2008 closure 7.2

Document No : QP-ENG-03
PRESSURE TEST PROCEDURE FOR GATE, GLOBE, Revision : 00
CHECK, BALL, BUTTERFLY AND PLUG VALVES FOR Date of Issue : 1st June 2011
PROJECT SUPPLY IN ACCORDANCE WITH API 598 Page : 7 of 7

10.5.2 High – Pressure Closure Test

- The valve shall be clamped securely to the test rig (or have end plate(s) bolted in place)
- Close the outlet valve
- With the valve in the open position fill the valve with fluid to above the level of the closure
mechanism and seat area
- Close the valve to be tested firmly (using no more force than would be achieved by hand
tightening)
- Open the inlet valve
- Increase pressure to specified value (use booster pump as necessary) and hold for the
specified test duration
- Remove excess water from seat area to aid observation
- Watch for leakage past the seat
- Release pressure slowly to avoid possible damage to gauges.

The allowable leakage rate of test fluid past the seats, for the duration of the
high pressure is listed in API 598 Table 6 (repeated in this procedure for convenience)

10.6 Observation During Testing

During testing any leaks detected that are outside of the specified standard acceptance criteria shall be
recorded and the Supervisor informed so that the Valve can be examined and re-worked in accordance
with the relevant ISO 9001 procedure(s). Such valves shall be clearly marked to differentiate them from
other valves.

10.7 Valve Care After Testing

After testing all valves shall be handled and stored correctly and if wet, thoroughly dried to prevent
possible corrosion from remnant water.

11.0 TEST EQIPMENT

11.1 Test equipment shall not influence seat leakage by applying excessive external forces
11.2 Pressure gauges and other measurement devices shall be in current calibration
11.3 Blanking plates may be clamped against the valve ends by mechanical or hydraulic means in test rigs
designed for that purpose or bolted on using studs/bolts and nuts
11.4 Equipment shall be in safe working order
11.5 Equipment operators shall wear appropriate protection

12.0 RECORDS
12.1 Test Records
12.2 Test Report
12.3 Certificate of Compliance

F/ISO/02 Rev.00