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API 6D contain separate leakage rate requirements. API 6D makes reference to ISO 5208, but in practice API 6D valves are often in Europe specified with allowable leakage rates as per EN 12266-1. In the following it is seen that the conditions for tests are quite similar for the two leakage / test standards as the high pressure liquid test will be performed
at 110% of the valve design pressure and the low pressure gas test is carried out at approximately 5 barg pressure.
Valves: NPS 4 & ASME class 1500; NPS > 4 & ASME class 600
Test description Valve type Gate Globe Plug Check Floating ball Required Optional Butterfly and trunnion mounted ball Required Optional
or control valves allowable seat leakage rates are given by ANSI FCI 70-2 and are not further elaborated
Low-pressure gas
Required
Optional Required
Required Optional
Optional Required
here. The leakage rates listed in the following are the acceptance rates for new valves, i.e. the acceptance levels during the leak testing in the factory. Valves in operation are not covered by the stated leakage rates.
Valves: NPS 4 & ASME class > 1500; NPS > 4 & ASME class > 600
Valve type Test description Gate Globe Plug Check Floating ball Required Optional Butterfly and trunnion mounted ball Optional Required
Low-pressure gas
Optional
Optional Required
Optional Required
Optional Required
Standards
Classification of allowable leakage rates as well as the test procedures and conditions are stated in several standards, but two of the most often references from oil companies and consulting engineers are: API 598, Valve Inspection and Testing EN 12266-1, Industrial valves - Testing of valves. Part 1: Pressure tests, test procedures and acceptance criteria. Mandatory requirements. These standards covers both strength test (shell pressure test) and seat leakage test. It shall be noted that some valve design standards, such as BS 5351 and
Test pressures:
Test description Low-preesure gas High-pressure liq. Pressure 4 - 7 barg 110% (*)
Table 3, API 598 test conditions (*) 110% of max. allowable pressure at 38 C in acc. with the purchase specification.
2 2 - 6 8 - 12 14
Abbreviations
DN: Nominal Diameter (in mm) ESDV: Emergency Shutdown Valve PN: Nominal pressure (in bar) rating as per EN-standards NPS: Nominal Pipe Size (nominal diameter in inches)
Table 4:API 598 test acceptance criteria (**): For valves NPS 14, the max. permissible leakage rate shall be 2 drops per minute per in. NPS (***): For valves NPS 14, the max. permissible leakage rate shall be 4 bubbles per minute per in. NPS (#): The maximum permissible leakage rate shall be 3 cm3 per minute per in. NPS. (##): The maximum permissible leakage rate shall be 0.042 m3 per minute per in. NPS. September 2010 29
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M at e r i a l s & M a n u fa c t u r i n g
Fig. 1: Offshore metal-to-metal seated, trunnion type riser valve (24 NPS) to API 598. Leakage rate EN 12266-1, rate D.
Fig. 2: 1 NPS class 150, soft seated floating ball valve. This valve will require a leakage rate A according to EN 12266-1.
the valves in service, i.e. after they have been in use for some time. Therefore it is appropriate to apply a requirement not stronger than the rate D for new valves. This is also in line with the recommended leakage rates in ISO 14313.
It shall be mentioned that leakage rates of safety critical valves in service cannot be evaluated against the above mentioned leakage rates. An approach including risk analysis on a case-by-case basis must be applied for valves in service.
Maximum allowable seat leakage for each leakage rate in cubic millimetres per second:
Test fluid Liquid Gas Rate A 0 0 Rate B 0,01 x DN 0,3 x DN Rate C 0,03 x DN 3,0 x DN Rate D 0,1 x DN 30 x DN Rate E 0,3 x DN 300 x DN Rate F 1,0 x DN 3000 x DN Rate G 2,0 x DN 6000 x DN
Test pressures:
Test description Low-preesure gas High-pressure liq. Pressure 5 - 7 barg(**) 110% (*)
Table 5: EN 12266-1 test conditions. (*) 110% of max. allowable differential pressure at room temperature. (**) Applicable for valves sizes up to DN 80 for all pressure ratings sizes > DN 80 - DN 200 for pressure ratings up to PN40 / class 300.
The rate A is here normally the class specified for soft seated valves, especially those for ESD use including riser ESDVs.
Conclusion
For riser valves and emergency shutdown valves with metal-to-metal seats a rate D would often be specified in the oil/gas industry. However, for riser ESDVs, leakage rates B or C are also in some cases specified. In general there seems to be no correlation between the allowable leakage rates specified for new valves and that of
30 September 2010 Fig. 3: 8 NPS, class 150 wafer check valve, metalto-metal seated. Check valves are normally not considered to be tight and a leakage rate E, F or G would be sufficient for most check valves.
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