Doc Ref: QCP-12

Date: 1st January 2009

QUALITY CONTROL
PROCEDURE

Kencana Infrastructure

Revision No : 0
Cover Page

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VALVE LEAK TEST

PROCEDURE

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Doc Ref : QCP-12

VALVE LEAK TEST

PROCEDURE

Date : 1st January 2009

Revision No : 0
Page 1 of 17

TABLE OF CONTENTS
SECTION

DESCRIPTION

PAGE

1.0

PURPOSE

2.0

SCOPE

3.0

REFERENCES

4.0

DEFINITION

5.0

PROCEDURES
5.1
5.2

GENERAL REQUIREMENTS
TEST EQUIPMENT FOR PNEUMATIC & HYDROTEST

5.3

SHELL TEST

5.4

HYDROSTATIC SEAT TEST

5.5

AIR / PNEUMATIC SEAT TEST

2 13
24
5
58
8 10
10 13

6.0

SPECIAL REQUIREMENTS

13

7.0

RECORDS

13

FIGURE I

BODY HYDROSTATIC TEST ARRANGEMENT

14

FIGURE II

VALVE SEAT HYDROSTATIC TEST ARRANGEMENT

15

FIGURE III

VALVE SEAT PNEUMATIC TEST ARRANGEMENT

16

FIGURE IV

VALVE SEAT LEAK TEST DETAILS

17

APPENDICES
APPENDIX I : REQUEST FOR VALVE LEAK TEST
APPENDIX ll : VALVE LEAK TEST RECORD

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1.0

PURPOSE
To establish guidelines to be followed on the execution of the pneumatic and
Hydrostatic Leak Test of valves intended for the Projects.

2.0

SCOPE
This procedure covers the minimum requirements for valve leak tests to
confirm the pressure containing capability of the shell of a valve under
pressure and the pressure retaining capability of the valve seat(s) and/or
closure mechanism and describes the details for such tests.

3.0

4.0

REFERENCE

ANSI/ASME B31.3.

Chemical Plant and Petroleum Refinery Piping

BS 6755 Part 1

Specification for Production Pressure Testing

Requirement

API-6D

Specification for Pipe Line Valves (Gate, Plug, Ball

and Check Valves)

DEFINITION
PPM
PPE

5.0

- Parts per million

- Personal Protective Equipment

PROCEDURE
5.1

General Requirements
The test procedures described are to be conducted based on the
above mentioned standards and particular the following:i)

BS 6755 Part 1
Specification for Production Pressure Testing Requirement for
Valves manufactured to BS 5351.

ii)

API6D
Specification for Pipe Line Valves (Gate, Plug, Ball and Check
Valves) for valves manufactured to API SPEC.6D.

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5.1.1 The minimum valve tests to be conducted shall be the following

for all 100% shut off valves which perform duties such as vent,
drain, blow down and shut-down valves including isolating and
main block valves unless otherwise stated in the relevant
specifications, codes and standards or manufacturers
recommendations.
a) Shell Test
b) Hydrostatic Test
c) Air / Pneumatic Seat Test
Ball valves shall be subject to a Hydrostatic Seat Test and
Pneumatic Seat Test in both direction as required for :-

Soft Seat Valves

Metal Seat Valves

All leak tests may be conducted at either the Manufacturers

Plant or Kencana Infrastructure premises as applicable.
5.1.2 All leak tests shall be conducted before blasting and painting of
valves.
5.1.3 Valve internals shall be visually inspected to ensure that the
valve seat is thoroughly cleaned from dirt and grit prior to
testing.
5.1.4 Valves shall be properly supported and connected when
installed on the test manifold or header.
5.1.5 Leak tests shall be carried out as appropriate for the valve to be
tested e.g. ball, gate, plug, or check valve, considering whether
the valve is a unidirectional or bi-directional type of valve.
5.1.6 Only calibrated instruments e.g. pressure gauge/recorder, flow
meter shall be used during test.
5.1.7

The test medium e.g. dry air, treated H2O, etc. shall be free of
dirt, scale and other foreign materials. The Hydrostatic Test
Fluid shall have a chlorine content of less than 200 PPM for
carbon steel valves and less than 50 PPM for stainless steel
valves.

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5.1.8

There shall be no visible leakage or deformation when the test

pressure has been applied successively to both sides of the
valves.

5.1.9

All successfully tested valves shall be clearly identified with a

sticker (Leak test completed) indicating the following :Valve Tag No
Inspection Test
Data of Test
QC/Client Inspector

:
:
:
:

5.1.10 After testing, the valve shall be turned to fully open position
and the valve ends shall be covered with close fitting
protectors to protect the exposed sealing surfaces, machined
parts and prevent ingress of dirt and moisture.
Inspection of the valve in a full open position and valve
protector shall be carried out by both the Site Supervisor and
QC Inspector to ensure adequacy of the valve(s) protection
prior to painting.
5.1.11 Each valve that fails the test shall be clearly identified with a
Quarantine Tag (Test Failed waiting for further action) and
stored in a Quarantine Area for necessary steps to be taken
to notify the vendor/manufacturer to have the valve
immediately replaced or repaired.
Repair works may be carried out under the supervision of the
vendor / manufacturer to maintain the valves warranty and retested as per the specified test procedure.
5.1.12 Kencana Infrastructure shall submit a Request for Valve Leak
Test from (Appendix I) to Client 48 hours in advance prior to
such test.
All preparations for the test shall be completed on or before
the scheduled tests.
5.1.13 All test finding shall be recorded as per the appropriate check /
test record sheet as given in CSP-T20.
All test records shall be prepared and submitted within 48
hours after completion of test to Client for approval / signature.

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5.2

Test Equipment For Pneumatic and Hydro test

5.2.1

The test facilities shall permit complete isolation of the valves

being tested from the test medium pressure source.

5.2.2

As a minimum, the Equipment and instrument to be used to

facilitate testing are as follows :a)
b)
c)
d)
e)

5.3

Air Compressor or Hydro test Pump.

Isolation Valve and Bleed Valve/Vent Valve.
Calibrated Pressure Gauge, the pressure range shall not
exceed twice the test pressure, flow meter.
Testing Manifold/Header.
Miscellaneous items, air filter regulator, soap solution,
gasket, bolts and nuts, blinds etc.

Shell Test
A preliminary shell test shall be conducted prior to seat testing to
ensure adequate tightness of valve fastenings.
The shell test shall be conducted on the following conditions:
i)

There are no supporting documents to show that the valve has

been shell tested.

ii)

The valve has failed the seat test and is sent for repairs.

5.3.1 Valves Manufactured to API-6D.

i)

Each valve shall be tested as set out in API Spec 6D

Section 5 prior to shipment from the manufacturers work.

ii)

These tests shall be performed in accordance with the

manufacturers written procedures.

iii)

The manufacturer shall complete shell pressure tests

before painting the valves.

iv)

Test shall be made in the sequence shown in this

procedure or API Spec 6D Section 5.

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v)

Valves subjected to hydrostatic shell test shall have no

visible leakage or harmful inelastic deformation under the
test pressure when both ends are blanked and the gate,
plug, ball or check element is partially open.

vi)

For standard flanged end and standard weld end valves,

the test pressure shall be no less than that specified in
Table 5.1 API Spec. 6D

TABLE 5.1 (API 6D)

SCHEDULE OF TEST PRESSURE FOR STANDARD FLANGED
END AND STANDARD WELD END VALVES

Valve Pressure

Min. Test Pressure, psig

Class

Shell Hydrostatic

Seat Hydrostatic

150

425

300

300

1100

800

400

1450

1060

600

2175

1600

900

3250

2400

1500

5400

4000

2500

9000

6600

The test pressure listed is not valve operating pressure

rating.
vii)

For alternate valve, the test pressure shall not less than
1.5 times the 100F pressure rating as determined in
paragraph 2.2b and 2.2c of API Spec. 6D.

viii)

The duration of the shell test shall be no less than that

specified in Table 5.2.

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TABLE 5.2 (API 6D)

MINIMUM DURATION OF HYDROSTATIC TEST
1
Valve Size NPS (DN)

2
Shell Test Duration
(Minutes)

3
Seat Test Duration
(Minutes)

2 thru 4 (50 thru 100)

6 thru 10 (150 thru 250)

12 thru 18 (300 thru 450)

15

20 & large (500 & large)

30

5.3.2

Valves Manufactured to BS 5351.

i)

A preliminary shell test shall be conducted prior to Seat

Testing to assess the pressure containing capability of
the valve shell including the packing chamber.

ii)

The hydrostatic shell test pressure shall be 1.5 times the

maximum permissible working pressure at 20C,
whereas the pneumatic shell test pressure shall be 6 to 7
bars.

iii)

Blank off the ends of the assembled valve.

iv)

Ensure that the obdurator (sealing orifice in body) is

positioned such that the body cavity, if any, is fully
pressurized with test fluid.

v)

Apply the test pressure and maintain the pressure for the
period specified in the appropriate valve product
standard. If the valve product standard does not exist,
then the following test duration may be used as a guide :

Nominal Valve Size DN

Minimum Test Duration

Up to and including DN 50

15 seconds

DN 65 up to and including DN 200

60 seconds

DN 250 up to and including DN 450

180 seconds

DN 500 and greater

180 seconds

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vi)

For hydrostatic shell test, there shall be no visually

detectable leakage.

vii)

Unless otherwise specified in the appropriate valve

product standard, seepage from stuffing boxes and
other stem sealing mechanism is permissible at the
shell test pressure provided that there is no visually
detectable leakage when the pressure is reduced to the
seat test pressure.

viii)

For pneumatic shell test, if the valve is immersed in

clean water, the upper surface of the valve shell shall
not be more than 50mm below the surface of the water
and there shall be no bubbles breaking the surface of
the water.

ix)

If the valve is coated with leak detection fluid, there

shall be no continuous formation of bubbles.

Note : Assemble the valve as illustrated in Figure 1 or other

similar arrangement for Schematic Arrangement of
Shell Hydrostatic Test.

5.4

Hydrostatic Seat Test

5.4.1

Soft Seat Valves

i)

Valve with rated pressure classes shall be tested at

pressure specified in Section 5, Table 5.1 of API 6D.

ii)

For alternate valves, the test pressure shall not be less

than 1.1 times the 100F pressure rating as determined
in accordance with Paragraph 2.2b & 2.2c of API Spec.
6D.

iii)

Test duration shall be as specified in Section 5, Table 5.2

of API 6D.

iv)

For unidirectional valve, close valve and apply pressure

to the appropriate end of the valve.

v)

For directional valve, close valve and apply pressure

successively to each end of the valve.

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vi)

For Double Block and Bleed Valve, the test sequence is

optional, however, both of the following tests shall be
performed :
-

Close valve, open body vent, apply seat test pressure

to one end of the valve. Release pressure and repeat
test for the other end of the valve.

Close valve, open body vent, apply seat test pressure

simultaneously to both ends of the valve.

vii) There shall be no visible leakage for the duration of the

test.

5.4.2

Metal Seated Valves (For both manufactured to BS5351

and API 6D)
i)

Metal seated valve shall be tested in accordance with

BS6755 Part 1.

ii)

The maximum allowable leakage rate shall be rate B, as

shown in Table 1 of BS6755 Part 1 Section 2.

TABLE 1
MAXIMUM PERMISSIBLE SEAT TEST LEAKAGE RATES
TEST

RATE B (MM/S)

Hydrostatic Test

0.01 x DN

Pneumatic Test

0.3 x DN

iii)

The leakage rate only applies when discharging to

ambient condition.

iv)

There shall be no detectable leakage at the test time and

pressure other than the rate shown in Table 1.

v)

The hydrostatic seat test pressure shall be 1.1 times the

maximum permissible working pressure at 20C.

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vi)

Valves with a seat rating less than the maximum

permissible working pressure at 20C shall be seat
tested at a pressure of 1.1 times the maximum seat
rating.

vii) Valves which have obdurator and/or actuating devices

would be damaged if the seat test pressure required by
(v) were applied, shall be seat tested at a pressure of 1.1
times the maximum operating differential pressure.
viii) Test duration shall be as specified in the appropriate
valve product standard. If such standard does not exist,
then following test duration may be used as a guide :

Nominal Valve Size

Minimum Test Duration

Up to and including DN 50

15 seconds

DN 65 up to and including DN 200

30 seconds

DN 250 up to and including DN 450

60 seconds

DN 500 and greater

120 seconds

ix)

Test procedure shall be as specified in BS6755 Part 1 D8

for various types of valves.
Note : Refer to figure II or other similar arrangement for
Valve Seat Hydrostatic Test Arrangement.

5.5

Air / Pneumatic Seat Test

5.5.1

Soft Seated Valves

i)

Valve with rated pressure classes shall be tested at

pressure specified in Section 5, Table 5.3 of API 6D.

ii)

Test duration shall be as specified in Section 5, Table 5.4

of API 6D. Air seat test pressure shall be held for a
maximum setting period of five(5) minutes for all valves
sizes prior to starting the specified test duration.

iii)

Refer to figure III for Pneumatic Seat Test Arrangement.

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iv)

Assemble the valves as illustrated in Figure III or other

similar arrangement.

v)

To start the test, valve no. V1 on the extreme left shall be

closed, whereas the rest of the valves shall be in open
position. (Refer Figure IV Valve Seat Leak Test Details).

vi)

Apply pressure up to the desired test pressure and hold

for the specified duration.

vii) To detect for leaks, a soap solution may be applied on

the connection of the valves. If no bubbles are observed
on both the valve connection and inside the basin tank
with no drop in pressure, the test shall be considered
satisfactory.
There shall be no visible leakage for the duration of the
test
viii) Repeat the steps with valve no. V2 closed and the rest in
open position, followed by valve no.V3, valve no. V4 etc.
until all valves are tested.
ix)

Reverse the seat test with inlet air hose connected to the
right hand side of the valves assembly.

SECTION 5, TABLE 5.3. API 6D

Valve Pressure Class

Air Seat Test Pressure (psig)

150

80

300

80

400

80

600

80

900

80

1500

80

2500

80

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SECTION 5, TABLE 5.4. API 6D

Valve Size, NPS (DN)

Duration (Minutes)

2 thru 4 (50 thru 100)

6 and large (150 and large)

5.5.2

Metal Seated Valves

i)

Metal seated valves shall be tested in accordance with

BS6755 Part 1.

ii)

The maximum allowable leakage rate for a metal seated

valve shall be rate B (please refer to table 1 of item
5.4.2).

iii)

The leakage rate only applies when discharging to

ambient condition.

iv)

No visual leakage is accepted as being within the

requirements of rate shown.

v)

The pneumatic seat test pressure shall be 6 bar to 7 bar.

vi)

Valves with a seat rating less than the maximum

permissible working pressure at 20C shall be seat
tested to a minimum of 6 bars pneumatic.

vii) Valves which have obdurators and/or actuating devices

that would be damaged if the seat test pressure required
by (v) were applied, shall be seat tested to a maximum of
6 bars pneumatic.
viii) The test duration shall be as specified in the appropriate
valve product standard. If such standard does not exist,
then the recommended test duration shown in 5.4.2 (viii)
may be used as a guide.
ix)

The test procedure shall be as specified in BS6755 Part

1 D8, for various types of valves.

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Note: Assemble the valve as illustrated in figure III or

other similar arrangement for Valve Seat
Pneumatic Test Arrangement.

6.0

SPECIAL REQUIREMENTS
6.1

7.0

During the entire Pneumatic & Hydrostatic testing period, the following
safety precaution should be considered :
6.1.1

A safety relief valve shall be set at pressure 10% higher than

the test pressure and a calibrated pressure gauge shall be
fitted on the pump discharge side.

6.1.2

Only authorized personnel involved in the testing shall be

allowed in the test area.

6.1.3

Barriers with safety sign shall be visible around the test area
during the entire test period.

6.1.4

Safety standards applied during the testing shall meet the

satisfaction of Client Representative prior to carrying out the
test.

RECORDS
Title

Responsibility

Retention Period

7.1

Request for Valve

Test

QC Inspector

Until completion
of project

7.2

Valve leak Test

Record

QC Inspector

At least one year

after completion
Of Project

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PRESSURE GAUGE

BLEED VALVE

SAFETY RELIEF VALVE

SIDE
B

PUMP
WATER
TANK
ISOLATION
VALVE

BLANK
FLANGE

BLANK
FLANGE

FIGURE I BODY (SHELL) HYDROSTATIC TEST ARRANGEMENT

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FIGURE II VALVE SEAT HYDROSTATIC TEST ARRANGEMENT

Notes : 1)

The valve seat is tested from side A first.

2)

The reverse seat test is conducted by reversing the water inlet to side B

3)

The valves to be tested in the open position with the exception of the valve
undergoing the seat test.

4)

Please refer to figure iv Valve Seat Leak Test Details for multiple valve
tests.

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FIGURE III VALVE SEAT PNEUMATIC TEST ARRANGEMENT

Notes : 1)

The valve seat is tested from side A first.

2)

The reverse seat test is conducted by reversing the air inlet to side B.

3)

The valves to be tested in the open position with the exception of the valve
undergoing the seat test.

4)

Please refer to Figure IV Valve Seat Leak Test Details for multiple valve
tests.

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FIGURE IV VALVE SEAT LEAK TEST DETAILS

APPENDICES

QCP-12 Rev-0
Appendix I

REQUEST FOR VALVE LEAK TEST

PROJECT NO

PROJECT TITTLE :
CLIENT

REQUEST NO.

DATE

(1) LIST OF VALVE TO BE TESTED

TYPE OF VALVE

TAG NO.

(2) DATE

P & ID/SYSTEM

TYPE OF LEAK TEST TO BE CONDUCTED

TIME

(3) LOCATION

ALL PREPARATORY WORK FOR THE ABOVE MENTIONED TEST HAVE BEEN/WILL BE COMPLETED PRIOR
TO THE DATE AND TIME INDICATED ABOVE.

ACKNOWLEDGED RECEIPT BY:

QC INSPECTOR

CLIENT'S REPRESENTATIVE

QCP-12 Rev-0
Appendix II

VALVE LEAK TEST RECORD

TYPE OF TEST

PROJEC

TEST PRESSURE

REPORT

TEST MEDIUM

DATE

ITEM
NO.

VALVE TYPE

TAG NO.

SERIAL NO.

P&ID / SYSTEM

TEST
LOCATION

REMARKS

NOTES & COMMENTS :

The above mentioned items, accepted / rejected by:

QC INSPECTOR
NAME
SIGNATURE
DATE

CLIENT'S REPRESENTATIVE