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This document specifies the fugitive emission testing procedures for evaluation of external
leakage of valve stem seals and body joints of 1 ball valve supplied by Blaker Pumps.
Tested valve shall be certified for fugitive emissions when all steps of this procedure have
been satisfactory completed.
As per the clients instruction these valves shall be tested for following criteria:
i.
ii.
iii.
Endurance Class:
Tightness Class:
Test Temperature:
CO1
B
750C
2 References
This procedure is prepared based on following international standard.
ISO 15848-1 Classification system and qualification procedures for type testing of valve.
3 Safety Notes
A full JSA of the system shall be carried out before starting the test. All
potential hazards shall be identified and action shall be taken to eliminate
these hazards.
Hand gloves shall always be worn all times before handling the valve.
The body of the test valve must be hydro tested prior to any fugitive emissions
test as per the relevant standard.
4 Quality Notes
Only a fully assembled valve shall be used for the test.
The valve shall have been tested and accepted in accordance with ISO 5208 or any
other applicable standard and no subsequent protective coating shall have been
applied.
The test valve interior shall be dried and lubricants (if any) shall be removed. The
valve and test equipment shall be clean and free of water, oil and dust.
If a test valve is equipped with a manually adjustable stem (or shaft) seal(s), it shall
be initially adjusted according to the manufacturer instructions, and recorded in the
test report.
The test fluid shall be helium gas of 97 % minimum purity. The same test fluid shall
be used throughout the test.
The test temperature shall be recorded for each leakage measurement.
The temperature of the test valve shall be measured at three locations (X, Y, Z), as
shown in Figure 1, and recorded in a test report. All temperatures at location X, Y
and Z shall be stabilized before leakage is measured. Variation of temperature shall
be within +5%.
1. Location X:
2. Location Y:
3. Location Z:
Flow Path
Valve Body
Stuffing box
Temperature at location "Z" shall be stabilized for minimum 10 min prior to leakage
measurement.
5 Equipment
Source of 97% helium which can apply and maintain test pressure within +5% of the
nominal value.
Hand lever or actuator to mechanically cycle the valve.
Heating coil to heat the valve to the test temperature, and maintain it within +5% but
not exceeding 75C. Valve shall not be operated during temperature change.
Data recorder to record time, pressure, temperature, leakage and duration of a valve
mechanical cycle.
Torque wrench to measure the actuation torque of the valve.
Standard capillary leak for calibration of mass spectrometer.
6 Preparation of Test
The test valve shall be mounted on a test rig, according to the arrangement as shown
in Fig 2.
All sealing systems shall have been properly adjusted beforehand, according to the
manufacturer's instructions. For valves using packings as a stem seal, the tightening
torque of the gland boltings shall be measured and recorded after any stem seal
adjustment. Mechanical adjustments of stem (or shaft) sealing system during the
type test shall be permitted only once for class CO1, if stem (or shaft) leakage has
been measured in excess of the target tightness class B.
If a stem (or shaft) sealing arrangement fails to achieve the target tightness class, or
it is not possible to continue mechanical cycling, the test shall be considered
terminated, and the test valve shall be evaluated for qualification of lower tightness
and endurance classes, if applicable.
Leakage from the stem (or shaft) seal and from the body seals shall be separately
measured. If the valve does not allow such a separate measurement the total
leakage of both stem (or shaft) and body seals shall be measured at the same time
according to Section 8 of this procedure.
Actual methods of mechanical cycles shall be in accordance with the manufacturer's
instructions, and opening, closing and dwelling time shall be recorded in the test
report. Basically, they shall represent the intended operating conditions of a test
valve.
Valve opening and closing force (or torque) shall be measured and recorded at the
start and at the end of the test, following subsequent stem seal adjustments if
applicable.
Record the test results (nominal and max leakage measurements) in the test report.
7.13 Qualification
Tested valves shall be qualified when all
I.
steps of test procedures have been satisfactorily performed for the target
performance class;
II.
All leakage measurements are verified equal or lower than the values specified in
Annex-2 of this procedure.
Testing Procedure:
Before each test,
Sr. No.
Size
Class
Type
Test Fluid
1.
PN10
Ball
Helium
Test Pressure at
ambient temperature
(kPag)
1000
Test Pressure at
750C temperature
(kPag)
1000
Size Class
1
PN10
Type
Ball
16
Model
Serial No
Pressure
Body
Seat
Stem Diameter
Not Available
345-9/13
PN10
WCB
PTFE
16 mm
Actuator Model
AP085 G
Model
MS-60
Actuator Details
Actuator Make
Stroke Time
Vacuum Instrument
Corporation (VIC)
Portable Leak Detector
Test Details
Test Fluid
Tightness Class
Test Specification
Test Temp Range
Background Reading
Valve Condition
Date of Test
Helium
7/4/2014
Endurance Class
Class B
CO1
Test Method:
EN ISO 15848:1 2006
Flushing Method
Ambient to 75 Deg C
-5
Leakage rate lower than 0.0 x 10 mBar.L/s is not measurable using
sniffing method. Test is deemed to be failed when leakage higher than 0.0 x
-5
10 mBar.L/s.
- Valve is provided by client in brand new condition, no stem gland
adjustment performed.
- Test is carried out onto the valves as the condition we receive the valve.
- The valve has been hydro tested and passed the test prior to begin
Fugitive Emission Test.
Pre Test
Valve Torque Measurement Before Test: __10__Unit: __Nm_
-5
Zero Gas Level Reading: ______0.0 x 10 _____ Unit: __mBar.L/s__ / Response Time: _6 minutes_
Probe Gas Flow Rate: ____0.042____ Unit:__L/min__
Flush Gas (Nitrogen) Flow Rate: __0.253___ Unit:__L/min_
During Test
Measured Temperature (C)
at location
Test
Cycle
No
Temp
(deg C)
Test
Pressure
(kPag)
Unit: mBar.L/s_
X
(Flow
Path)
(Body)
(Stem)
(Test
Cell)
Nominal
Leakage
Max
Leakage
Test
Criteria
Static
Ambient
1000
24.9
25.6
24.6
24.9
0.0 x 10-5
0.0 x 10-5
Pass
150
Ambient
1000
28
28.5
29.1
25
0.0 x 10-5
0.3 x 10-5
Pass
Static
75
1000
78.4
76.9
77.3
66.3
0.0 x 10-5
0.0 x 10-5
Pass
100
75
1000
78.3
77.3
78
66.7
0.0 x 10-5
1.8 x 10-5
Pass
Static
Ambient
1000
22.3
22.4
22
22.3
2.2 x 10-5
9.9 x 10-1
Failed
Re-torque gland and test resumed from previous test, i.e. test 5
Static
Ambient
1000
24.6
25.4
24.7
25
5.2 x 10-5
5.2 x 10-1
Failed
150
Ambient
1000
24.6
25.4
24.7
25
9.9 x 10-2
9.9 x 10-2
Failed
Static
75
1000
100
75
1000
Static
Ambient
1000
Figure 9: Thermocouple