TESTING PROCEDURE

FOR BALL VALVE

API 6D
Document No : 003/RRP/SOP/III/21
Date : 24 March 2021

TESTING PROCEDURE FOR BALL VALVE API 6D 1

Table of Contents
TESTING PROCEDURE ............................................................................................................................................. 1
FOR BALL VALVE ....................................................................................................................................................... 1
API 6D .......................................................................................................................................................................... 1
APPROVAL SHEET ..................................................................................................................................................... 4
A. PURPOSE............................................................................................................................................................... 5
B. SCOPE .................................................................................................................................................................... 5
C. DEFINITIONS ......................................................................................................................................................... 5
1. Product ............................................................................................................................................................. 5
2. Record Document ............................................................................................................................................. 5
3. Inspection ......................................................................................................................................................... 5
4. Bidirectional Valve............................................................................................................................................. 5
5. Block Valve ....................................................................................................................................................... 5
6. Double-Block & Bleed ....................................................................................................................................... 5
7. Obturator / Closure Member .............................................................................................................................. 5
8. Pressure Containing Parts ................................................................................................................................. 5
9. Test Pressure ................................................................................................................................................... 5
10. Test Fluid.......................................................................................................................................................... 5
11. Liquid................................................................................................................................................................ 5
12. Gas .................................................................................................................................................................. 5
D. REFERENCES DOCUMENTS .............................................................................................................................. 6
E. SAFETY AND ENVIRONMENTAL REQUIREMENTS ......................................................................................... 6
F. RESPONSIBILITIES ............................................................................................................................................... 6
G. PRESSURE TEST GENERAL REQUIREMENTS ................................................................................................ 7
1. General............................................................................................................................................................. 7
2. Test Location .................................................................................................................................................... 7
3. Test Equipment ................................................................................................................................................. 7
4. Test Required for Ball Valves ............................................................................................................................ 8
H. PRESSURE TEST PROCEDURES ...................................................................................................................... 8
1. General............................................................................................................................................................. 8
2. Hydrostatic Shell Test ....................................................................................................................................... 8
3. Hydrostatic Seat Test ........................................................................................................................................ 9
4. Air Seat Test ..................................................................................................................................................... 9
5. Supplementary pressure test requirements ...................................................................................................... 10
6. Test Pressure Steps ........................................................................................................................................ 10
I. ANNEX A - SUPPLEMENTARY PRESSURE TEST REQUIREMENTS ........................................................... 11
1. General........................................................................................................................................................... 11
2. Low-pressure gas seat testing ......................................................................................................................... 11

TESTING PROCEDURE FOR BALL VALVE API 6D 2

 3. High-pressure gas seat testing ........................................................................................................................ 12
5. Twin-seat, both seat bi-directional ball valves................................................................................................... 13
6. Twin-seat, one seat uni-directional and one seat bi-directional .......................................................................... 13
J. APPENDIXES ....................................................................................................................................................... 14
1. API 6D Testing Requirements.......................................................................................................................... 14
2. Test Duration .................................................................................................................................................. 15
3. Allowable Leakage .......................................................................................................................................... 15

TESTING PROCEDURE FOR BALL VALVE API 6D 3

 APPROVAL SHEET

PREP’D REV’D CUST.

REV DATE ISSUE TYPE APP’D BY
BY BY APP’D

ISSUED FOR NEW

1 24/03/21 AS TW PSP __
PROCEDURE

TESTING PROCEDURE FOR BALL VALVE API 6D 4

A. PURPOSE

The purpose of this procedure is to maintain a system which identifies and plans the method, acceptance
criteria and responsibilities to perform Pressure Testing of Valves required by PT. Rame Rekaguna
Prakarsa and/or the contracts.

B. SCOPE

This procedure covers Pressure Testing of Ball Valve. Every valve is to be hydrostatic shell pressure
tested to ensure the pressure integrity of valve body. The valve seat is also checked to verify that leakage
pass the API Specification 6D and customer requirements.

C. DEFINITIONS

1. Product
Result of a set interrelated or interacting activities which transforms inputs into outputs.
2. Record Document
Stating results achieved or providing evidence of activities performed.
3. Inspection
Conformity evaluation by observation and judgment accompanied as appropriate by measurement,
testing or gauging.
4. Bidirectional Valve
Valve designed for blocking the fluid in both downstream and upsteam directions.
5. Block Valve
Gate, plug or ball valve that blocks flow into the downstream conduit when in the closed position.
6. Double-Block & Bleed
Valve with two seating surfaces which, in the closed position, blocks flow from both valve ends when
the cavity between the seating surfaces is vented through a bleed connection provided on the body
cavity.
7. Obturator / Closure Member
Part of valve, such as a ball, clapper, disc, gate or plug, which is positioned in the flow stream to
permit or block flow.
8. Pressure Containing Parts
Parts, such as bodies, bonnets, glands, stems, gaskets and bolting, designed to contain the pipeline
fluid.
9. Test Pressure
Internal pressure, expressed in psi or Mpa or Kg/cm2, to which the valve under test is subjected.
10. Test Fluid
At the discretion of the manufacturer, either 3.11 or 3.12.
11. Liquid
Water which may contain a corrosion inhibitor, kerosene, or other suitable liquid having a viscosity
not greater than that of water.
12. Gas
Air or suitable gas.

TESTING PROCEDURE FOR BALL VALVE API 6D 5

D. REFERENCES DOCUMENTS

API Spec. 6D : Pipeline Valves

ISO 14313 : MOD, Petroleum and Natural Gas Industries-Pipeline Transportation Systems-Pipeline
Valves
ISO 5208 : Industrial Valves-Pressure testing of valves
ASME B16.34 : Valves - Flanged, Threaded, and Welding Ends
ASME B16.5 : Pipe Flanges and Flanged Fittings--NPS 1/2 through NPS 24
ASME B16.47 : Larger Diameter Steel Flanges--NPS 26 through NPS 60
ASME B1.20.1 : Pipe Threads, General Purpose (Inch)
ASME B16.11 : Forged Steel Fitting, Socket-Welding and Threaded
MSS SP-44 : Steel Pipelines Flanges
MSS SP-55 : Quality Standard for Steel Castings for Valves, Flanges and Fittings and other Piping
Components - Visual Method
MSS SP-91 : Guidelines for Manual Operation of Valves

E. SAFETY AND ENVIRONMENTAL REQUIREMENTS

1. The execution of the provisions of this procedure is entrusted to appropriately qualified and
experienced personnel because it calls for procedures that may be injurious to health if adequate
precautions are not taken.

2. It is responsibility of PT. Rame Rekaguna Prakarsa to verify that appropriate safety and health practice
and devices have established by the Health, Safety & Environmental responsible.

3. Water used for pressure tests shall not be released out of the re-cycling circuit of pressure testing
area.

F. RESPONSIBILITIES

1. Workshop Manager shall ensure all members of staff comply with the requirements of this procedure.
2. Client shall ensure no changes are to their specification during the project and advice PT. Rame
Rekaguna Prakarsa of any planned changes or amendments.
3. The health, safety & Environmental Department has the responsibility for the safety of the pressure
test equipments and for everything is relevant to the safety execution of all pressure test in testing
area.
4. The Workshop Supervisor has the responsibility for the execution of :
- All pressure test
- Functional test
- Availability of all testing equipments
- Handling and transportation of the tested valve.
5. The Quality Control Inspector is responsible for the operation of this procedure and ensure the

TESTING PROCEDURE FOR BALL VALVE API 6D 6

 necessary records and logs are kept such as :
- Verify for the current calibration and adequacy of the pressure gauges used
- Evaluate the result of all pressure tests carried out
- Verify that the requirements of this specification are correctly fulfilled
- Issue the pressure test report relevant to the pressure test carried out

G. PRESSURE TEST GENERAL REQUIREMENTS

1. General

a) During pressure testing of valves, if any leaks are detected is out of the specified or standard
acceptance criteria, Workshop Manager and Quality Control shall be notified of the Non
Conformance Products in accordance with Non Conforming Materials/ Products Procedure.

b) Prior to testing of valves, the pressure gauge shall be check for calibration dates and gauge
reading zero when test bench machine is idle.

c) Valves shall be visually inspected, if required washed and cleared of any foreign objects.

d) Testing shall be performed in the sequence used in this clause for specifying the test
requirements. Shell pressure testing shall be carried out before painting the valves. If the valve
has been previously shell tested prior to external painting, any additional test may be performed
with the valve externally painted.

e) Test fluid shall be fresh water which may contain a corrosion inhibitor and, by agreement,
antifreeze.

f) Valves shall be tested with the seating and sealing surfaces free from sealant except where the
sealant is the primary means of sealing.

g) Tests specified with the valve half-open may also be performed with the valve fully open
provided the body cavity is simultaneously filled and pressurized through a cavity connection.

h) Methods for monitoring pressures and/or leakage shall be adequate also when valve body
connections are not available for direct monitoring.

i) A sufficient stabilization period shall be allowed for all pressure tests.

2. Test Location

Pressure test performed by PT. Rame Rekaguna Prakarsa at the PT. Rame Rekaguna Prakarsa's
workshop.

3. Test Equipment

Test Equipment used by PT. Rame Rekaguna Prakarsa: Test Bench

TESTING PROCEDURE FOR BALL VALVE API 6D 7

 4. Test Required for Ball Valves

Ball valve pressure test shall include the following tests :

a. Hydrostatic Shell Test
b. Hydrostatic Seat Test
c. Air Seat Test

H. PRESSURE TEST PROCEDURES

1. General

a) Just before valve testing, perform three complete cycles without pressure in order to verify :
Proper functionality of the valve/operator, correct alignment of the valve.
b) Before starting with hydrostatic seat tests, especially for metal-seated ball valve, a plastic pipe
with internal diameter shall be matching when connected to the inspection port (cavity). leakage
will be detected through the verification of the water level different between the beginning and
the end of the holding period. The same plastic pipe shall be connected to a bubble counter
when a pneumatic seat test is performed.
2. Hydrostatic Shell Test

a) Hydrostatic shell test procedure :

Ball valve shall be closed off and the obturator placed in the partially open position during the
test. Where present, external relief valves shall be removed and their connections plugged.

b) Hydrostatic shell test pressure :

Hydrostatic shell test pressure shall be 1.5 or more times the valve pressure rating determined
in accordance with material groups in ASME B16.34 at 38 0C (100 0F). Detail pressure tests
are listed in Table.1 (see Appendixes).

c) Hydrostatic shell test duration :

Hydrostatic shell test duration shall not be less than specified in Table.2 (see Appendixes).

d) Hydrostatic shell test acceptance criteria :

After hydrostatic shell testing, external relief valves shall be (re) fitted to the ball valve. The
connection to the ball valve body shall be tested at 95% of the set pressure of the relief valve
for 2 minutes for ball valve sizes up to and including DN 100 (NPS 4), and 5 minutes for ball
valve ball valve sizes DN 150 (NPS 6) and larger. The relief valve connection shall be free of
visible leakage during this period.

e) Where provided, the external relief valve shall be set to relieve at the specified pressure and
tested. The set pressure shall be between 1.1 and 1.33 times the valve pressure rating
determined in accordance with material groups in ASME B16.34 at 38 0C (100 0F).

TESTING PROCEDURE FOR BALL VALVE API 6D 8

3. Hydrostatic Seat Test

a) Hydrostatic seat test preparation :

Lubricants shall be removed from seats and ball sealing surfaces except, by agreement, for
assembly lubricants for metal-to-metal contact surfaces.

b) Hydrostatic seat test pressure :

Hydrostatic seat test pressure shall be not less than 1.1 times the valve pressure rating
determined in accordance with material groups in ASME B16.34 at 38 0C (100 0F). Detail
pressure tests are listed in Table.1 (see Appendixes).

c) Hydrostatic seat test duration :

Hydrostatic shell test duration shall not be less than specified in Table.2 (see Appendixes).

d) Hydrostatic shell test acceptance criteria :

* Leakage for soft-seated ball valve shall not exceed (no visible leakage)

* Leakage for metal-seated ball valve shall not exceed, detail Obtuator tightness leak rate are
listed in Table.3 (see Appendixes).

Except that the leakage rate during the seat test for Double-block seat test shall not more than
two times ISO 5208 Rate D unless otherwise specified.

e) Hydrostatic seat test procedure :

With the ball valve half open, the valve and its cavity shall be completely filled with test fluid.
The ball valve shall than be closed and the test pressure applied successively to both ends of
the ball valve.

Seat leakage shall be monitored from each seat via the ball valve cavity vent or drain
connection. For valves without a body cavity vent or drain connection, seat leakage shall be
monitored from respective downstream end of the valve.

4. Air Seat Test

a) Air seat test pressure :

The seat test specified in 8.3 shall be repeated at the test pressure of 80.8 psig ± 10.3 psig(5.5
± 0.7 bar gauge) using air as the test medium.
Detail pressure tests are listed in Table.1 (see Appendixes).
b) Air Seat test acceptance criteria :
* Leakage for soft-seated ball valve shall not exceed ISO 5208 Rate A (no visible leakage)
* Leakage for metal-seated ball valve shall not exceed ISO 5208 Rate D
Detail Obtuator tightness leak rate are listed in Table.3 (see Appendixes).

TESTING PROCEDURE FOR BALL VALVE API 6D 9

5. Supplementary pressure test requirements

The requirements for supplementary ball valve testing, refer to Annex A.

6. Test Pressure Steps

a) Hydrostatic Shell Test

1. If possible, the ball valve shall be clamped securily to the Test Bench Machine and both
ends of the valve shall be blanked off. If not possible to clamp in the Test Bench, the Blind
Flanges shall be bolting securely to the both side of Tested Ball Valve by using Bolts and
Nuts.
2. Open ball valve and ball element is partially open.
3. Open the fluid inlet line.
4. Fill ball valve to the top with fluid thereafter closed the fluid inlet line.
5. Dry external of ball valve using air line.
6. Turn on pump and pressurized in accordance with specification (Refer to Table-1).
7. Hold the specified pressure for the duration specified (Refer to Table.2).
8. Check for any leakage and record results in Pressure Test Report Form (see Appendixes).
9. Acceptance criteria :
No visible leakage is permitted during the hydrostatic shell test.
10. Turn off pressure slowly (to avoid damage of gauge).
11. Open the outlet line.
12. Allow all fluid to drain out.
13. Completed the test results on Pressure Test Report Form.
14. Continue to Hydrostatic Seat Test.
b). Hydrostatic Seat Test

1. If possible, the ball valve shall be clamped securily to the Test Bench Machine and both
ends of the valve shall be blanked off. If not possible to clamp in the Test Bench, the Blind
Flanges shall be bolting securely to the both side of Tested Ball Valve by using Bolts and
Nuts.
2. Open ball valve and ball element is partially open.
3. For valve with a body cavity connection (normally trunnion type) :
Remove the plug of valve body cavity vent or drain and connected a test pipe to the
inspection port (cavity).
4. Open the fluid inlet line.
5. The ball valve and its cavity shall be completely filled with test fluid.
6. Shut the fluid inlet line.
7. Closed the ball valve.

TESTING PROCEDURE FOR BALL VALVE API 6D 10

 8. Removed the test closure on the downstream end of the ball valve.
9. Dry external of ball valve using air line.
Wash out the downstream end that vented to atmosphere and remove any excess of fluid
by using air line.
10. Turn on pump and pressurized in accordance with specification (Refer to Table-1).
11. Hold the specified pressure for the duration specified (Refer to Table.2).
12. Check for any fluids leakage.
Seat leakage shall be monitored from each seat via the valve body cavity vent or drain
connection.
For ball valve without a body cavity vent or drain connection (normally floating type) : Seat
leakage shall be monitored from the respective downstream end of the ball valve.
13. Acceptance criteria :
For Soft-Seated ball valve, in accordance with ISO 5208 Rate A (no visible leakage).
Detail Obtuator tightness leak rate are listed in Table.3 (see Appendixes).
14. Record results in Pressure Test Report Form (see Appendixes)
15. Release pressure slowly (to avoid damage to gauge).
16. Open the outlet line.
17. Open ball valve fully to allow fluid drain out.
18. Repeat instructions 1 - 16 to perform air seat test the opposite valve end.
19. Open the ball valve fully to allow all fluid to drain out.
20. Dry the internal and external of valve using air line.
21. Apply light oil on internal surfaces of the valve.
22. Put in "Final Inspection Area" with ball in the fully open position.

I. ANNEX A - SUPPLEMENTARY PRESSURE TEST REQUIREMENTS

1. General

This annex defines requirements for supplementary ball valve testing which shall be performed by
PT. Rame Rekaguna Prakarsa if specified by the purchaser. The frequency of testing shall also be
specified by the purchaser, if not defined in this annex.\

2. Low-pressure gas seat testing

a) Acceptance

The acceptance leakage rate for low-pressure gas seat test testing shall be :
- ISO 5208 Rate A (no visible leakage) for soft-seated ball valve.
- ISO 5208 Rate D for metal-seated ball valve.
Detail Obtuator tightness leak rate are listed in Table.3 (see Appendixes).

TESTING PROCEDURE FOR BALL VALVE API 6D 11

 b) Type I

The seat test specified in 8.3 shall be repeated at a test pressure between 7.3 psig and 14.7
psig (0.5 bar and 1.0 bar gauge) using air or nitrogen as the test medium.

c) Type II

The seat test specified in 8.3 shall be repeated at a test pressure of 80.8 psig ± 10.3 psig(5.5
± 0.7 bar gauge) using air or nitrogen as the test medium.

3. High-pressure gas seat testing

The seat test specified in 8.3 shall be replaced with a high-pressure seat test using an inert gas as
the test medium. The test pressure and duration shall be as specified in 8.3.

4. Cavity Relief Testing

a) General

Cavity relief testing is not required if protection of the cavity against over-pressure is ensured,
for both the open and the closed position, by a hole in the obturator or around the seat seal.

b) Frequency

Each Valve shall be tested.

c) Trunnion-mounted ball valves with internal-relieving seats

The procedure for cavity relief testing of trunnion-mounted ball valves with internal-relieving
seats shall be :

1. Fill the valve in the half-open position with water.

2. Close the valve and allow water to overflow from the test connection at each end of the
valve.

3. Apply pressure to the valve cavity until one seat relieves the cavity pressure into the valve
end and record this relief pressure.

4. For ball valve type with second-seat relief, continue to increase the pressure to the cavity
until the second seat relieves and record the relief pressure of the second seat.

Failure to relieve shall be cause for rejection.

d) Floating-ball valves with internal-relieving seats

The procedure for cavity relief testing of floating-ball valves shall be :

1) With the valve half-open, pressurize the valve to 1.33 times the valve pressure rating
determined in accordance with material groups in ASME B16.34 at 38 0C (100 0F)

TESTING PROCEDURE FOR BALL VALVE API 6D 12

 2) Close the valve and vent each end to atmospheric pressure.

3) Open the valve to the half-open position and monitor for the release of test medium
trapped in the cavity.

Evidence of trapped pressurizing medium in the cavity shall be cause for rejection.

5. Twin-seat, both seat bi-directional ball valves

Each seat shall be tested in both directions.

Cavity relief valves shall be removed if fitted. The valve and cavity shall be filled with test fluid, with
the valve half-open, until the test fluid overflows through the cavity relief connection.

To test for seat leakage in the direction of the cavity, the valve shall be closed. The test pressure
shall be applied successively to each valve end to test each seat separately from the upstream side.
Leakage shall be monitored via the valve cavity pressure relief connection.

Thereafter, each seat shall be tested as a downstream seat. Both ends of the valve shall be drained
and the valve cavity filled with test fluid. Pressure shall then be applied whilst monitoring leakage
through each seat at both ends of the valve.

6. Twin-seat, one seat uni-directional and one seat bi-directional

a) Uni-directional seat

With the valve half-open, the valve and the test cavity shall be completely filled with test fluid
until fluid overflows through the valve cavity vent connection. The valve shall than be closed
and the vent valve on the test closure opened to allow fluid to overflow, or the test closure on
the downstream end of the valve removed. The test pressure shall than be applied to the
upstream end (uni-directional seat end) and leakage monitored from the cavity connection. If
leakage is also occurring through the downstream seat, the upstream seat leakage shall be
taken as the sum of the leakage measured from the cavity and the downstream connections.

b) Bi-directional seat

The test in 9.6.1 shall be repeated to test the bi-directional seat in its upstream-sealing
direction. To test the bi-directional seat in its downstream sealing direction, both ends of the
valve shall be blanked off. With the valve half open the valve shall be completely filled with
test fluid and pressurized to the test pressure. The valve shall than be closed and test fluid
allowed to overflow from a connection on the test closure fitted to the end of the valve at the
bi-directional seat end (i.e., downstream of the bi directional seat). The test pressure shall be
maintained on the cavity connection whilst monitoring seat leakage of bi-directional seat at the
overflow connection on the downstream test closure.

TESTING PROCEDURE FOR BALL VALVE API 6D 13

 7. Double-block-and-bleed ball valves

a) Single-seat test

With the valve half-open, the valve and its cavity shall be completely filled with test fluid. The
valve shall than be closed and the valve body vent valve opened to allow excess test fluid to
overflow from the valve cavity test connection. The test pressure shall than be applied to one
end of the valve and the pressure released at the other end. This test shall be repeated for the
other valve end.

Seat tightness shall be monitored during each test via overflow from the valve cavity connection.

b) Double-block seat test

With the valve half-open, the valve and its cavity shall be completely filled with test fluid. The
valve shall than be closed and the valve body vent valve opened to allow excess test fluid to
overflow from the valve cavity test connection. The test pressure shall be applied simultaneously
from both valve ends.Seat tightness shall be monitored via overflow from the valve cavity
connection.

J. APPENDIXES

1. API 6D Testing Requirements

Table 2
Seat Closure
Valve Shell Seat Closure Air
Hydro
Class Psi Bar Psi Bar Psi Bar
150 425 29.3 300 20.6 80 5.5
300 1100 75.8 800 55.1 80 5.5
600 1450 100.0 1060 73.1 80 5.5
800 2175 150.0 1600 110.3 80 5.5
900 3375 232.7 2400 165.5 80 5.5
1500 5625 387.9 4000 275.8 80 5.5
2500 9000 620.6 6600 455.2 80 5.5

TESTING PROCEDURE FOR BALL VALVE API 6D 14

 2. Test Duration
Table 3

VALVE SIZE (INCH)/TIME (MINUTES)

TYPE OF TEST ND from ND from 12” to
ND from6” to 10” ND ≥ 20”
½” to 4” 18”

HYDROSTATIC
2 5 15 30
SHELL
HTDROSTATIC
SEAT/LOW
PRESSURE GAS 2 5 5 10
SEAT

3. Allowable Leakage
Table 4

Metal seated valves except

Valve size All Resilient Metal seated check valves
check
Seated
Liquid Test Gas Test Liquid Test Gas Test Gas Test
DN (mm) NPS (in.) Valves
(drops/min) (Bubbles/min) (cc/min) M3/h) (ft3/h)
≤ 50 ≤2 0 0b 0b 6 0.08 3
65 21/2 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

TESTING PROCEDURE FOR BALL VALVE API 6D 15

PT RAME REKAGUNA PRAKARSA

Head Office Kirana Two Tower Level 10A Kelapa Gading 14250, Indonesia

Operational Office JL. PLTGU No 08 Tarumajaya Bekasi 17218, Indonesia

(021) 2288 9091 info@ramevalve.com www.ramevalve.com

TESTING PROCEDURE FOR BALL VALVE API 6D 16