Leak testing of Valves

¶ American Petroleum Institute API

The API standard 598.. Valve Inspection and Testing, covers the testing and
inspection requirements for gate, globe, check, ball, plug and butterfly valves. It
has acceptable leakage rates for liquid as well as gas testing. All valves built to
the various API standards are required to meet API-598 leakage criteria prior to
shipment from the manufacturer or supplier.

API 598 states for shell and BACK SEAT tests, no visible leakage is permitted.
If the fluid is a liquid, there shall be no visible evidence of drops or wetting of the
external surfaces (no visible leakage through the body, body liner, if any, and
body-to-bonnet joint and no structural damage).

If the test fluid is air or gas, no leakage shall be revealed by the established
detection method. For both the low-pressure closure test and the high-pressure
closure test, visual evidence of leakage through the disk, behind the seat rings,
or past the shaft seals (of valves that have this feature) is not permitted (Plastic
deformation of resilient seats and seals is not considered structural damage).
The allowable rate for leakage of test fluid past the seats, for the duration of the
tests, is listed in the following table..

All Metal Seated Valves

All Resilient (except Check Valves)
Valve Size
Seated Liquid Test Gas Test
NPS
Valves (drops (bubbles
min.) min.)
<2 0 0 (1) 0 (1)
2-6 0 12 24
8 - 12 0 20 40
> 12 0 28 56
Metal Seated
All Resilient Check Valves
Valve Size
Seated Liquid Test Gas Test
NPS
Valves (drops (bubbles
min.) min.)
<2 0 (2) (3)
2-6 0 (2) (3)
8 - 12 0 (2) (3)
> 12 0 (2) (3)

General notes..
  1 milliliter is considered equivalent to 16 drops.
 For check valves larger than NPS 24, the allowable leakage rate
shall be per agreement between purchaser and manufacturer.

Notes..

1. There shall be no leakage for the minimum specified test duration. For
liquid test, 0 drop means no visible leakage per minimum specified test
duration. For gas test, 0 bubble means less then 1 bubble per minimum
specified test duration.
2. The maximum permissible leakage rate shall be 0.18 cubic inch (3 cubic
centimeters) per minute per inch of nominal pipe size.
3. The maximum permissible leakage rates shall be 1.5 standard cubic feet
(0.042 cubic meter) of gas per hour per inch of nominal pipe size.

¶ Manufacturer's Standardisation
Society MSS
The MSS standard MSS-SP-61.. Pressure Testing of Valves was originally
adopted in 1961. It was developed for the purpose of providing a uniform means
of testing valves commonly used in the "full open" and "full closed" type of
service. It is not intended for use with control valves. Refer to standard
ANSI/FCI 70-2 for Control Valves.

Section 5 of their Pressure Testing of Steel Valves, relates to seat closure tests,
and defines the following leakage rates..

 Gate, Globe, Ball valves..

10 cc/hr per inch of nominal pipe diameter. (Example.. A 6" globe valve is
allowed to leak 60 cc/hr in a test)
 Check valves..
40 cc/hr per inch of nominal pipe diameter

All shutoff or isolation valves specified to MSS-SP-61 must pass the above
standards. The seat closure test must be performed at a fluid (liquid or gas)
pressure no less than 1.1 times the 1000°F (380°C) rating rounded to the next 5
psi (0.5 bar).

¶ American National Standards

Institute ANSI
The ANSI standard FCI 70-2.. Control Valve Seat Leakage, establishes a series
of six seat leakage classes for control valves and defines the test procedures.

Class I. Is also know as dust tight and can refer to metal or resilient seated
valves.

Class II. This class establishes the maximum permissible leakage generally
associated with commercial double-seat control valves or balanced single-seat
control valves with a piston ring seal and metal-to-metal seats.

Class III. This class establishes the maximum permissible leakage generally
associated with Class II (4.2.2), but with a higher degree of seat and seal
tightness.

Class IV. This class establishes the maximum permissible leakage generally
associated with commercial unbalanced single-seat control valves and
balanced single-seat control valves with extra tight piston rings or other sealing
means and metal-to-metal seats.

Class V. This class is usually specified for critical applications where the control
valve may be required to be closed, without a blocking valve, for long periods of
time with high differential pressure across the seating surfaces. It requires
special manufacturing, assembly and testing techniques. This class is generally
associated with metal seat, unbalanced single-seat control valves or balanced
single-seat designs with exceptional seat and seal tightness.

CLASS VI. This class establishes the maximum permissible seat leakage
generally associated with resilient seating control valves either unbalanced or
balanced single-seat with "O" rings or similar gapless seals.

Leakage Maximum Leakage

Test Medium
Class Allowable
I
Air or water at 50-
II 0.5% of rated capacity
125°F (10-52°)
III 0.1% of rated capacity As above
IV 0.01% of rated capacity As above
0.0005 ml per minute of water per
Water at 50 to 125°F
V inch of port diameter per psi
(10 to 52°C)
differential
Not to exceed amounts shown in
Air or nitrogen at 50 to
VI following table based on port
125 F (10to52C)
diameter.
Leakage
Test Pressure Test Procedure
Class
I No test required,
 as long as purchaser and vendor both
agree.
45-60 psig or max. Pressure applied to valve inlet with outlet
operating open to atmosphere or connected to a low
II
differential head loss measuring device full normal
whichever is lower closing thrust provided by actuator.
III As above As above
IV As above As above
Pressure applied to valve inlet after filling
Max service
entire body cavity and connected piping
pressure drop
with water and stroking valve plug closed.
V across valve plug,
Use net specified max actuator thrust, but
not to exceed
no more, even if available during test.
ANSI body rating.
Allow time for leakage flow to stabilize.
50 psig or max Actuator should be adjusted to operating
rated differential conditions specified with full normal
VI pressure across closing thrust applied to valve plug seat.
valve plug Allow time for leakage flow to stabilize
whichever is lower. and use suitable measuring device.
CONTROL VALVE SEAT LEAKAGE CLASSIFICATIONS
Nominal Nominal
Leak Rate Leak Rate
Port Dia Port Dia
ml / min bubbles / min
Inches mm
3 76 0.9 6
4 102 1.7 11
6 152 4 27
8 203 6.75 45
10 250 11.1
12 300 16
14 350 21.6
16 400 28.4

Note..
Bubbles per minute as tabulated are a suggested alternative based on a
suitable calibrated measuring device, in this case a 0.25-inch OD X 0.032-inch
wall tube submerged in water to a depth of from 1/8 to 1/4 inch.
The tube end shall be cut square and smooth with no chamfers or burrs. The
tube axis shall be perpendicular to the surface of the water. Other measuring
devices may be constructed and the number of bubbles per minute may differ
from those shown as long as they correctly indicate the flow in milliliters per
minute.
¶ International organization for standardization ISO
The purpose of ISO standard 5208.. Industrial valves - Pressure testing of
metallic valves, is the establishment of basic requirements and practices for
pressure testing valves of various configurations that are used in general
purpose, power generation, petroleum, and petrochemical or allied industry
applications. The intent is to provide a consistent set of procedural requirements
and acceptance criteria that can be considered in conjunction with valve specific
standards appropriate for specific applications. Account has been taken of the
valve testing requirement needs of EN 12266 and API 598 with requirements
referenced for PN designated valves for the former and Class designated
valves for the latter.

Prescribed pressure tests

PN
GLOBE
TEST DN OR
VALVE
CLASS
SHELL TEST
ALL ALL REQ
LIQUID
SHELL TEST
ALL ALL OPT
GAS
BACK SEAT TEST
(B, C) ALL ALL OPT
LIQUID
CLASS ≤ 1500
AND OPT
PN ≤ 250
DN ≤ 100
CLASS > 1500
AND OPT
CLOSURE TEST PN > 250
GAS
LOW-PRESSURE CLASS ≤ 600
AND OPT
PN ≤ 100
DN > 100
CLASS > 600
AND OPT
PN > 100
CLOSURE TEST CLASS ≤ 1500
LIQUID AND REQ
HIGH-PRESSURE PN ≤ 250
DN ≤ 100
CLASS > 1500
AND REQ
PN > 250
DN > 100 CLASS ≤ 600 REQ
AND
PN ≤ 100
 CLASS > 600
AND REQ
PN > 100
Prescribed pressure tests
PN PLUG
TEST DN OR VALVE
CLASS (A)
SHELL TEST
ALL ALL REQ
LIQUID
SHELL TEST
ALL ALL OPT
GAS
BACK SEAT TEST
NOT
(B, C) ALL ALL
REQ
LIQUID
CLASS ≤ 1500
AND REQ
PN ≤ 250
DN ≤ 100
CLASS > 1500
AND OPT
CLOSURE TEST PN > 250
GAS
LOW-PRESSURE CLASS ≤ 600
AND OPT
PN ≤ 100
DN > 100
CLASS > 600
AND OPT
PN > 100
CLASS ≤ 1500
AND OPT
PN ≤ 250
DN ≤ 100
CLASS > 1500
AND REQ
CLOSURE TEST PN > 250
LIQUID
HIGH-PRESSURE CLASS ≤ 600
AND OPT
PN ≤ 100
DN > 100
CLASS > 600
AND REQ
PN > 100
Prescribed pressure tests
PN
CHECK
TEST DN OR
VALVE
CLASS
SHELL TEST
ALL ALL REQ
LIQUID
SHELL TEST
ALL ALL OPT
GAS
BACK SEAT TEST ALL ALL NOT
 (B, C)
REQ
LIQUID
CLASS ≤ 1500
AND OPT
PN ≤ 250
DN ≤ 100
CLASS > 1500
AND OPT
CLOSURE TEST PN > 250
GAS
LOW-PRESSURE CLASS ≤ 600
AND OPT
PN ≤ 100
DN > 100
CLASS > 600
AND OPT
PN > 100
CLASS ≤ 1500
AND REQ
PN ≤ 250
DN ≤ 100
CLASS > 1500
AND REQ
CLOSURE TEST PN > 250
LIQUID
HIGH-PRESSURE CLASS ≤ 600
AND REQ
PN ≤ 100
DN > 100
CLASS > 600
AND REQ
PN > 100
Prescribed pressure tests
FLOATING BALL
PN
OR
TEST DN OR
DIAPHRAGM
CLASS
VALVE
SHELL TEST
ALL ALL REQ
LIQUID
SHELL TEST
ALL ALL OPT
GAS
BACK SEAT TEST
NOT
(B, C) ALL ALL
REQ
LIQUID
CLOSURE TEST CLASS ≤ 1500
GAS AND REQ
LOW-PRESSURE PN ≤ 250
DN ≤ 100
CLASS > 1500
AND REQ
PN > 250
DN > 100 CLASS ≤ 600 REQ
AND
PN ≤ 100
 CLASS > 600
AND REQ
PN > 100
CLASS ≤ 1500
AND OPT
PN ≤ 250
DN ≤ 100
CLASS > 1500
AND OPT
CLOSURE TEST PN > 250
LIQUID
HIGH-PRESSURE CLASS ≤ 600
AND OPT
PN ≤ 100
DN > 100
CLASS > 600
AND OPT
PN > 100
Prescribed pressure tests
BUTTERFLY OR
PN
TRUNNION
TEST DN OR
MOUNTED
CLASS
BALL VALVE
SHELL TEST
ALL ALL REQ
LIQUID
SHELL TEST
ALL ALL OPT
GAS
BACK SEAT TEST
NOT
(B, C) ALL ALL
REQ
LIQUID
CLASS ≤ 1500
AND REQ
PN ≤ 250
DN ≤ 100
CLASS > 1500
AND OPT
CLOSURE TEST PN > 250
GAS
LOW-PRESSURE CLASS ≤ 600
AND REQ
PN ≤ 100
DN > 100
CLASS > 600
AND OPT
PN > 100
CLOSURE TEST CLASS ≤ 1500
LIQUID AND OPT
HIGH-PRESSURE PN ≤ 250
DN ≤ 100
CLASS > 1500
AND REQ
PN > 250
DN > 100 CLASS ≤ 600 OPT
AND
PN ≤ 100
 CLASS > 600
AND REQ
PN > 100

Notes..

1. REQ - REQUIRED, OPT - OPTIONAL

2. Successful completion of an optional test does not relieve the
manufacturer from also successfully completing the required test.
3. In the case of resilient seated valves, a high-pressure closure test may
°rade subsequent closure sealing performance in low-pressure
applications.

 (A) Plug valves that rely on a sealing compound to effect a closure seal
may be closure tested with the compound installed.
 (B) Successful completion of a BACK SEAT test should not be
interpreted as a recommendation by the valve manufacturer that, while
an installed valve is pressurized, the stem seal may be altered, repaired
or replaced when BACK SEATed.
 (C) In the case of bellows stem sealed valves, a BACK SEAT test is not
required.

Maximum allowable closure test leakage rate

UNIT
TEST RATE RATE
LEAKAGE
FLUID A AA
RATES
0.006
MM3/S X
DN
LIQUID (1)
0.0001
DROPS/S X
DN
0.18
MM3/S X
DN
GAS (1)
0.003
BUBBLES/S X
DN
Maximum allowable closure test leakage rate
UNIT
TEST RATE RATE
LEAKAGE
FLUID B C
RATES
0.01 0.03
MM3/S X X
DN DN
LIQUID
0.00016 0.0005
DROPS/S X X
DN DN
 0.3 3
MM3/S X X
DN DN
GAS
0.0046 0.0458
BUBBLES/S X X
DN DN
Maximum allowable closure test leakage rate
UNIT
TEST RATE RATE
LEAKAGE
FLUID CC D
RATES
0.08 0.1
MM3/S X X
DN DN
LIQUID
0.0013 0.0016
DROPS/S X X
DN DN
22.3 30
MM3/S X X
DN DN
GAS
0.3407 0.4584
BUBBLES/S X X
DN DN
Maximum allowable closure test leakage rate
UNIT
TEST RATE RATE
LEAKAGE
FLUID E EE
RATES
0.3 0.39
MM3/S X X
DN DN
LIQUID
0.0048 0.0062
DROPS/S X X
DN DN
300 470
MM3/S X X
DN DN
GAS
4.5837 7.1293
BUBBLES/S X X
DN DN
Maximum allowable closure test leakage rate
UNIT
TEST RATE RATE
LEAKAGE
FLUID F G
RATES
LIQUID 1 2
MM3/S X X
DN DN
DROPS/S 0.016 0.032
X X
 DN DN
3000 6000
MM3/S X X
DN DN
GAS
45.837 91.673
BUBBLES/S X X
DN DN
Maximum allowable closure test leakage rate
UNIT
TEST RATE RATE
LEAKAGE
FLUID F G
RATES
1 2
MM3/S X X
DN DN
LIQUID
0.016 0.032
DROPS/S X X
DN DN
3000 6000
MM3/S X X
DN DN
GAS
45.837 91.673
BUBBLES/S X X
DN DN

Notes..
(1) No visually detectable leakage for the duration of the test

1. The leakage rates only apply when discharging test fluid to the
atmosphere.
2. The closure leakage rate that applies is either that identified in a valve
product standard or a leakage rate identified in a purchaser's valve
procurement purchase order that is more stringent than that specified in
the product standard.
3. The meaning of "No visually detectable leakage" is that there is no visible
weeping or leakage in the form of drops or bubbles.
4. There is a loosely defined correspondence between the leakage rate
acceptance values of API 598 and the leakage values Rate A as applied
to DN ≤50, Rate AA-Gas and Rate CC-Liquid for other than metal seated
check valves and for check valves Rate EE-Gas and Rate G-Liquid.
Rates A, B, C, D E, F and G correspond to values in EN 12266-1.

Remark(s) of the Author...

Types of Leakage

There are two types of leakage from a valve, namely; fugitive emissions from
the valve to atmosphere, and leakage through the valve but contained within the
piping system.
Fugitive emissions can both be detrimental to the environment and a potential
safety hazard. Valves are considered to be the major contributors to fugitive
emission losses.

Leakage through the valve can also be a safety hazard, and can be detrimental
to the process.

Reasons that Valves leak

Common causes of leakage through the valve include..

 Valve is not fully closed. This can be due to various reasons, including;
 Valve seat is prevented from closing fully due to dirt, rust, or line debris
 Insufficient actuator travel
 The seat is damaged, e.g. scored
 The seal is damaged

Common causes of leakage to atmosphere..

 Gasket between valve-body and valve-bonnet is damaged

 Stem Pakking is worn, loose or damaged

Both of them can have several causes