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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.
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.
4.9 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
Tests to be performed shall be as stated in API 598 in accordance with those “checked” in the following tables:
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
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).
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
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
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.
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 : 6 of 7
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
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)
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.
12.0 RECORDS
12.1 Test Records
12.2 Test Report
12.3 Certificate of Compliance
F/ISO/02 Rev.00