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PROCEDURE

FOR

LEAK TESTING OF VALVES

CONTRACT No. 04262-2545 SAREF ULSD BALANCE OF PLANT SAUDI ARAMCO SHELL REFINERY Jubail, Saudi Arabia

MS-L-001
0 Rev. 21 May 08 Date

Signature Print Name W. V. Fontanilla Prepared by MMG E. V. Lucero Checked by MMG H. S. Lorenzo Approved by MMG Approved by CB&I

1.

PURPOSE:
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To establish series of pressure testing required for body and seats of metallic valves in the field. 2. SCOPE: The scope of this procedure covers the project requirement for field test of valves shall be conducted for the following: a. 1% of all new Valves shall receive a body hydrostatic test prior to installation in the line. b. Isolating Valves- such as gate valve, ball valve, angle valve, plug valve, butterfly valve, etc, shall be subjected to a high pressure hydrostatic seat test prior to installation. Excluded from this scope are control valve, safety relief valve, surge relief valve, pilot valve, solenoid valve, globe valve, check valve and other valves. 3. REFERENCES: - API 598 - API 6D-1994 : : Valve Inspection and Testing Pipeline Valves (Gate, Plug, Ball and check valves) Valves Flanged, threaded and welding end.

- ASME B16.34-1996 : 4. TOOLS & EQUIPMENT: a) b) c) d) e) f) g) h) i) j)

Pressure pumps (Manual & Motor Driven). Air Compressor. Test manifold with block valves and hoses. (Calibration frequency; 6 months) Pressure gauges. (Calibration frequency; 1 month) Safety Relief Valves (Calibration frequency; 1 week) Thermometers. (Calibration frequency; 1 month) Air Filters. Hand Tool sets / Spanners / Torque Wrench etc. Pressure Recorder / Temperature Recorder. (Calibration frequency; 1 month) Miscellaneous tools.
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5.

WORK SEQUENCE / PROCEDURE: 5.1 General Requirements for Testing 5.1.1 Time, pressure and acceptance criteria are all listed in API 598 5.1.2 All valves to be tested at site shall be subject to hydrostatic shell test as per API 598 refer to paragraph 3.3.3 & 3.3.4 of API 598. 5.1.3 Testing media shall be water complying with SASREF/ CBI Specification. 5.1.4 Valves specified for flare system isolation service shall receive low pressure pneumatic seat test at 5 psig. This test shall be performed in lieu of the high pressure closure test. 5.1.5 For Steel Valves 2 and below, the shell hydrostatic test shall be maintained for one (1) minute. All other sizes the test duration shall be maintained for five (5) minutes. 5.2 Testing Preparation: 5.2.1 Before employing the pressure testing manifold, it shall be separately pressure tested to at least 1.2 times the system pressure. 5.2.2 The relief valve of adequate capacity set to relieve at 5% above the hydrotest pressure shall be installed. The relief valve shall be tested, dated, and tagged within one week prior to the hydrotest. 5.2.3 Pressure gauges and pressure recorders are calibrated before the tests. The calibration interval shall not exceed one (1) month. Sticker shall be applied indicating the latest calibration date. 5.2.4 All gauges have a range, such that the test pressure is within 30 to 80% of the full range. 5.2.5 A minimum of two pressure gauges are available for the test system. Their accuracy is within 5% of one another. 5.2.6 Do not use the water for hydrotesting if its pH value is less than 6 and/or its sulphate reducing bacteria (SRB) counts are greater than 10 sq per ml. If water from more than one source is to be used ensure mixing them will not cause scaling.

5.3 Testing Procedures for Shell Test

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5.3.1 Both sides of the valve should be closed with blinds with corresponding thickness designed for the testing pressure. Valves to be tested shall be in partial open position. For valves size up to 8 test can be coupled into 5 or more valve per test, provided they are of the same valve size and test pressure. Bigger valves (10 and above) shall be tested individually. 5.3.2 Ensure that all air is expelled through high point bleed.

5.3.3 The shell test pressure shall not be less than 1.5 times the pressure rating at 100F (38C) rounded off to the next higher 25 psi increment. 5.3.4 Make sure that the external surfaces of the valve are completely dry. 5.3.5 The test pressure shall be applied for the test duration specified in the applicable standard. For other valves refer to table No. 2 of API 598 5.3.6 The valve shall be acceptable, if leakage or loss of pressure is not observed. 5.3.7 After completing the test and draining the test media, dry valve internals thoroughly.

5.3.8 Test status shall be identified on each valve. 5.4 Testing Procedure for Seat Test: 5.4.1 High Pressure Closure Test of Gate Valves (Note for Double block & bleed type valves, refer to para. 5.4.3 below. 5.4.1.1 Blind one side, put the seat in closed position and start filling with test water. All air should be expelled. It can be bled through the stuffing box by loosening the gland packing and tighten after all air is expelled. 5.4.1.2 The pressure of high pressure closure test (API 598 table 3) shall not be less than 110 % of the pressure rating at 1000F (380 deg. C). 5.4.1.3 The test pressure shall be applied for the test duration specified in the applicable standard. 5.4.1.4 Observe leakage from the open side, the acceptance criteria for leakage shall be as per API 598, table No. 5.
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5.4.2

5 psig Low Pressure Closure Test for Flare Isolation Service Valve (if theres any) 5.4.2.1 The same procedure of the high pressure closure test is to be applied except that the test medium is air and the test pressure is 5 psig. For Acceptance criteria refer to table No. 5 of API 598. Method of testing shall be by blinding open end and attaching a inch plastic tubing which will be immersed 1/8 - 1/4 inches below water surface to determine the leakage rate by bubble count as per the table.

5.4.3 Seat Testing of double-block and bleed valve such as parallel slab gate valve, ball valve and plug valve. 5.4.3.1 Valve shall be in close position ensuring the removal of air. 5.4.3.2 Drain plugs provided in the cavity shall be opened or removed. 5.4.3.3 Pressurize one side of the valve seat through the flange and check for leakage through the drain opening. 5.4.3.4 Performed test procedure as in item 5.4.1. 5.4.4 Method to be used for leak detection: Test medium Water, Air or Nitrogen 5.4.4.1 For Gas and liquid test the maximum allowable leakage rate for closure test shall be as shown in API STD 598 Table 5. 5.4.4.2 For liquid test, this can be measured using graduated syringe. 5.4.4.3 For gas test, a bubble means less than 1 bubble per minimum specified test duration. 6. SAFETY PRECAUTIONS: 6alve shall not be kept under pressure without person in attendance. Barricade the working area and provide warning board. Ensure that working permit is available. Review / check safety test requirement. List of Valve to be tested.

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7.

ATTACHMENT: a. Pipe Test Manifold Diagram (2 sheets) b. Sample Valve Test Arrangement (2 sheets)

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END

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