DOCUMENT No. TITLE REV.

DATE PAGES

MAP/007/001 TESTING PROCEDURE FOR BALL VALVE 00 08 Oct.’18 1 of 15

(API 598/6D)

TESTING
PROCEDURE FOR
BALL VALVE

APPROVAL SHEET

00 08 Oct. ‘18 ISSUED FOR NEW PROCEDURE MKAR RR FY ---

APP’D CUST.
REV. DATE ISSUE TYPE PREP’D BY REV’D BY
BY APP’D
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(API 598/6D)

REVISION CONTROL SHEET

Page Rev Date DESCRIPTION REMARKS

All 00 Oct. ‘18 ISSUE AS NEW PROCEDURES NEW PROCEDURE

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(API 598/6D)

CONTENTS
PAGE

CONTENTS 1
APPROVAL SHEET 1
REVISION HISTORY 2
1. PURPOSE 4
2. SCOPE 4
3. DEFINITIONS 4
4. REFERENCE DOCUMENTS 5
5. SAFETY AND ENVIRONMENT REQUIREMENTS 5
6. RESPONSIBILITIES 6
7. PRESSURE TEST GENERAL REQUIREMENTS 7
8. PRESSURE TEST PROCEDURES 7
8.1. GENERAL 7
8.2. HYDROSTATIC SHELL TEST 8
8.3. HYDROSTATIC SEAT TEST 9
8.4. AIR SEAT TEST 10
8.5. SUPLEMENTARY PRESSURE TEST REQUIREMENTS 10
8.6. TEST PRESSURE STEPS 10
9. ANNEX A – SUPLEMENTARY PRESSURE TEST SUPLEMENTS 12
10. APPENDIX 13
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1.0 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.MAP and/or the contracts.

2.0 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 598/6D and customer requirements.

3.0 Definitions

3.1 Product : Result of a set interrelated or interacting activities which

transforms inputs into outputs.
3.2 Record Document : Stating results achieved or providing evidence of activities
performed.
3.3 Inspection : Conformity evaluation by observation and judgment
accompanied as appropriate by measurement, testing or
gauging.
3.4 Bidirectional Valve : Valve designed for blocking the fluid in both downstream
and upsteam directions.
3.5 Block Valve : Gate, plug or ball valve that blocks flow into the
downstream conduit when in the closed position.
3.6 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.
3.7 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.
3.8 Pressure Containing Parts: Parts, such as bodies, bonnets, glands, stems, gaskets
and bolting, designed to contain the pipeline fluid.
3.9 Test Pressure : Internal pressure, expressed in psi or Mpa or Kg/cm2, to
which the valve under test is subjected.
3.10 Test Fluid : At the discretion of the manufacturer, either 3.11 or 3.12.
3.11 Liquid : Water which may contain a corrosion inhibitor, kerosene,
or other suitable liquid having a viscosity not greater than
that of water.
3.12 Gas : Air or suitable gas.
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4.0 References Documents

API 598 : Valve Inspection And Test

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

5.0 Safety and Environmental Requirements

5.1 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.

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

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

6.1 Workshop Manager shall ensure all members of staff comply with the requirements
of this procedure.
6.2 Client shall ensure no changes are to their specification during the project and advice
PT.MAP of any planned changes or amendments.
6.3 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.
6.4 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.
6.5 The Quality Control Inspector is responsible for the operation of this procedure and
ensure the 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

7.0 Pressure Test General Requirements

7.1 General
7.1.1 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.

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

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

7.1.4 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.
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7.1.5 Test fluid shall be fresh water which may contain a corrosion inhibitor and, by
agreement, antifreeze.

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

7.1.7 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.

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

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

7.2 Test Location

Pressure test performed PT.MAP at the PT.MAP workshop.

7.3 Test Equipment

Test Equipment used by PT.MAP: Test Bench

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

8.0 Pressure Test Procedures

8.1 General
8.1.1 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.

8.1.2 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.
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8.2 Hydrostatic Shell Test

8.2.1 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.

8.2.2 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&2 (see Appendixes).

8.2.3 Hydrostatic shell test duration :

Hydrostatic shell test duration shall not be less than specified in Table.3 (see
Appendixes).

8.2.4 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.

8.2.5 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).
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8.3 Hydrostatic Seat Test

8.3.1 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.

8.3.2 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 & 2 (see
Appendixes).

8.3.3 Hydrostatic seat test duration :

Hydrostatic shell test duration shall not be less than specified in Table.3 (see
Appendixes).

8.3.4 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.4 (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.

8.3.5 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.
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8.4 Air Seat Test

8.4.1 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 & 2(see Appendixes).

8.4.2 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.4 (see Appendixes).

8.5 Supplementary pressure test requirements

The requirements for supplementary ball valve testing, refer to ANNEX A

8.6 Test Pressure Steps

8.6.1 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 & 2).
7. Hold the specified pressure for the duration specified (Refer to Table.3).
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.
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13. Completed the test results on Pressure Test Report Form.

14. Continue to Hydrostatic Seat Test.

8.6.2 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.
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 & 2).
11. Hold the specified pressure for the duration specified (Refer to Table.3).
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.4 (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.
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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.

9.0 Annex A - Supplementary Pressure Test Requirements

9.1 General

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

9.2 Low-pressure gas seat testing

9.2.1 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.4 (see Appendixes).

9.2.2 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.

9.2.3 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.
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10.0 Appendixes

10.1 TEST PRESSURE

TABLE 1 - API 598 Testing Pressure Requirements

Seat Closure
Valve Shell Seat Closure Air Backseat
Hydro
Class Psi Bar Psi Bar Psi Bar Psi Bar
150 450 31.0 325 22.4 100 7.0 325 22.4
300 1125 77.6 825 56.9 100 7.0 825 56.9
600 2225 153.4 1650 113.8 100 7.0 1650 113.8
800 3000 206.8 2200 151.7 100 7.0 2200 151.7
900 3375 232.7 2475 170.6 100 7.0 2475 170.6
1500 5625 387.8 4125 284.4 100 7.0 4125 284.4
2500 9375 646.4 6875 473.9 100 7.0 6875 473.9

Table 2 - API 6D Testing Requirements

Seat Closure
Valve Shell Seat Closure Air Backseat
Hydro
Class Psi Bar Psi Bar Psi Bar Psi Bar
150 425 31.0 300 21.8 80 7.0 300 21.8
300 1100 77.6 800 56.2 80 7.0 800 56.2
600 1450 153.4 1100 112.4 80 7.0 1100 112.4
800 2175 201.5 1600 150.0 80 7.0 1600 150.0
900 3375 231.0 2475 168.0 80 7.0 2475 168.0
1500 5625 384.4 4125 281.3 80 7.0 4125 281.3
2500 9000 639.5 6600 468.2 80 7.0 6600 468.2
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10.2 TEST DURATION

TABLE 3
Duration of Required Test Pressure

VALVE SIZE (INCH)/TIME (MINUTES)

ND from ND from ND from ND ≥ 20”
TYPE OF TEST
½” to 4” 6” to 12” to 18”
10”
2’ 5’ 15’ 30’
HYDROSTATIC SHELL

HTDROSTATIC SEAT/LOW
2’ 5’ 5’ 10’
PRESSURE GAS SEAT
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10.3 ALLOWABLE LEAKAGE RATE

TABLE 4