VALVE SEAT LEAK TEST PROCEDURE | METHOD STATEMENT

This article is about valve seat leak test procedure, Valve Backseat Test, Gas valve, Gate valve, Check valve and Ball valve Testing Procedure and method statement as per international standard and codes.

1. PURPOSE.
2. SCOPE.
3. APPLICABLE DOCUMENTS.
4. RESPONSIBILITY.
5. MANPOWER.
6. TOOLS & EQUIPMENT.
7. METHODS/PROCEDURES.
8. QUALITY CONTROL.
9. SAFETY PRECAUTION.
10. ATTACHMENTS.

VALVE SEAT LEAK TEST PROCEDURE | METHOD STATEMENT

1.0 PURPOSE

This method statement shall provide minimum guidelines to carry out the field valve leak testing activities, procedures for Buildings, plants and refinery. In accordance with contract scope of work and project specification.

2.0 SCOPE

2.1. This Method Statement covers the procedure of field valve leak testing for Buildings, plants and refinery.

3.0 APPLICABLE DOCUMENTS

3.1. Saudi Aramco Standard

3.1.1. SAES-L-350 Construction of Plant Piping.
3.1.2. SAES-L-108 Selection of Valves.
3.1.3. SAES-A-004 General Requirements for Pressure Testing.
3.1.4. SAES-A-007 Hydrostatic Testing Fluids and Lay-up Procedure.

3.2. Industry Codes Standard

3.2.1. ASME B31.3 Process Piping.
3.2.2. API 598 Valve Inspection and Testing.
3.2.3. 04-SAMSS-048 Valve Inspection and Testing Requirements.
3.2.4. Saudi ARAMCO Construction Safety Manual.

3.3. Applicable SATIP/SAIC/SATR

3.3.1. SATIP-L-108-01 Valve Inspection, Testing & Installation..
3.3.2. SAIC-L-2042 Field Hydrostatic Testing of Isolation Valves.
3.3.3. SAIC-A-2009 Verify Test Equipment (Safety Assessment).
3.3.4. SAIC-A-2015 Visual Inspection at Test Pressure.
3.3.5. SATR-A-2001-V Pressure Test Report (Valve Inspection & Field Testing).

4.0 RESPONSIBILITY

4.1. Construction Manager is responsible for implementing HSE and shall study, analyze and schedule all construction activities with his department to include manpower and equipment line up as well as other possible resources required for the successful implementation of the construction work activities. Study all aspects of work procedure as per JV Technical Scope of Work.

4.2. Piping Superintendent shall assist Construction Manager in the overall construction activities. Receives and carries out directives and strategies of Construction Manager in various phases of duties assigned by this immediate Supervisor.
4.3. Piping Supervisor shall be directly reporting to the Piping Superintendent and
responsible in the implementation and control of all site activities per Technical Scope of Work and latest approved construction drawings.
4.4. QC Inspector shall be responsible in inspection and monitoring of the work and ensure that the work is performed and properly documented in accordance with Project requirements.
4.5. Safety Supervisor shall be responsible in monitoring safety aspects and ensuring that the work is done in accordance with JGC/DAEWOO Safety Standard Procedure. He shall discuss to the Supervisor’s the characteristics of related materials and status of work area giving reminders as an additional point to work safely.

5.0 MANPOWER

5.1. The Piping Superintendent shall control the overall activity of Bolt torquing and tensioning Works. The basic manpower under him shall consist but not limited to the following:

5.1.1. Piping Supervisor.
5.1.2. Piping Foreman.
5.1.3. Hydro Test Crew.
5.2. Safety Engineer/Officer.
5.3. QC Inspector.

6.0 TOOLS AND EQUIPMENT

6.1. Tools and equipment needed should be in good condition and must be checked by Technician/Piping Supervisor/ Safety Officer prior to use. These includes but not limited to:

1. Tools & Equipment.
2. Test Pump.
3. Test Manifold.
4. Pressure Gauges.
5. Pressure Relief Valves.
6. Hand Tools.

7.0 FIELD VALVE LEAK TESTING PROCEDURE | METHOD STATEMENT

7.1. General Requirements

7.1.1. Valve Field Testing

1. Field Testing locations shall be approved by Saudi Aramco, including Project Inspection.
2. General Instruction Gl-0002.102 “Pressure Testing Safely” shall be followed during pressure testing.
3. Consider prevailing winds and fouling.
4. If requested by the proponent, all new valves designated for isolation service (as specified by the Proponent) shall be subjected to a high pressure hydrostatic seat test prior to installation in the line.
5. A low pressure pneumatic seat test at 35 kPa (5 psig) shall be substituted for the high pressure hydrostatic seat test for flare system valves.
6. Buttweld and socketweld end valves in nominal pipe size (NPS) 2 inches and smaller are exempt from the above field testing requirements.
7. Test procedures, pressures, durations, and leakage acceptance criteria shall be equal to those that the valves were originally purchased to. All resilient (soft) seated isolation valves shall have zero leakage.

7.1.2. Handling and Hauling

1. Special cares and consideration shall be taken during handling and transporting of valves against mechanical.
2. Critical points of the valves such as the valve end ports and stem shall be protected.
3. All valves shall comply with 04-SAMSS-035 shipment preparation requirement during transportation, handling and field storing at all times.
4. Valves shall be restrained from movements during transportation to avoid any damages to the main valve and its accessories.
5. Small size valves shall be positioned carefully to prevent any damage.
6. Transportation, lifting and handling of valves shall be carried out safely by appropriate equipment and trained personnel.
7. Handwheels, stems, gears, actuators or any other accessories shall never be used as lifting points.

7.1.3. Receiving Inspection

1. Receiving inspection shall be performed prior to transfer of custody to insure no damage has occurred during transportation and handling. A standard inspection checklist SAIC-L-2040 can be used for full check of valves integrity.
2. Use SAIC-L-2040 Checklist & SATR-A-2001V for Receiving Inspection.
3. Use SAIC-L-2041 Checklist & SATR-A-2001V for Storage & Preservation.

7.1.4. Hydrostatic Requirement

Hydrostatic tests shall be carried as per below requirements and against the standard inspection checklist SAIC-L-2042 Field Hydrostatic Testing of Isolation Valves.

7.1.4.2 Test Location & test requirement

The following requirements shall be available in the test locations:

1. The location/shop: It shall not introduce any foreign materials that could intervene with the valve functions such as dirt/sand or other hard particles. The location should have means of protections.
2. Valves fixtures: Valves should be supported off the ground and restrained from any free movement.
3. Floor profile: Flooring shall be hard such as concrete floor, paving or any sort tiling.

7.1.4.3 Testing Equipment Capability

1. Blinds: they shall be matching with the same rating and type of the valve ends. Both blinds shall be provided with pressure/vent connections.
2. Blind/bolts conditions. They must be clean and shall not have signs of corrosion.
3. Pressure gauges: the test pressure shall not be less than 30% no greater than 80% of the full scale range of the pressure gauge. All instruments shall have the calibration certificates.
4. All connections must have the proper pressure ratings.
5. The pressure reliefs and setting must comply with SAES-A-004.

7.1.4.4 Test Fluid

7.1.4.4.1 The fluid quality shall be within the acceptable criteria of API STD 6D, API STD 598 or BS 6755 Part 2.
7.1.4.4.2 For shell, high-pressure backseat, and high pressure closure test, the test fluid shall be air, inert gas, kerosene, water, or a non corrosive liquid with a viscosity not higher than that of water.
7.1.4.4.3 For the low-pressure closure and low-pressure backseat test, the test fluid shall air or inert gas.
7.1.4.4.4 When air or gas is used for closure, shell, or backseat tests, the valve manufacturer shall be capable of demonstrating the adequacy of the method of leakage detection.
7.1.4.4.5 Water used for any test may contain water-soluble oil or a rust inhibitor. When specified by the purchaser, a wetting agent shall be included in the water. For testing of austenitic stainless steel valves, water with chloride content not exceeding 100 parts per million shall be used. The valve manufacturer shall be able to document the chloride content.

7.1.4.5 Test required

1. All flanged valve except check valve to be tested at field.
2. High pressure hydrostatic seat test.
3. Reference industrial standard for field valve test to identify test pressure, acceptance criteria etc.

7.1.5. Testing Procedure

Manufacturer instructions and guidelines shall be taken into consideration.

7.1.5.2 Valve Backseat Test

7.1.5.2.1 The backseat test is required for all valves, except for bellows seal valves, that have the backseat feature and shall be performed by applying pressure inside the assembled valve with the valve ends closed, the valve fully open, and the packing gland loose. The backseat test may be performed immediately after the shell test, and all packing glands shall be retightened after the backseat test.

7.1.5.3 Low Pressure Closure

The low-pressure closure test shall be performed with the sealing surfaces clean and free from oil, grease, and sealant, if necessary to prevent galling, the sealing surfaces may be coated with a film of oil that is not heavier than kerosene. This requirement does not apply to a valve that uses a lubricant as its primary seal (for example, lubricated plug valves)

7.1.5.4 High Pressure Closure

The procedure for the high-pressure closure test shall be the same as the procedure for the low­ pressure closure test except that, in the case of a liquid test, leakage shall be detected when drops.

7.1.6. VALVE SEAT LEAK TEST PROCEDURE TECHNICAL REQUIREMENT

1. Valve Test shall be conducted at Valve Testing Location, located at Work Shop area.
2. Only personnel involved on testing shall be allowed to enter the test area.
3. Prepare all necessary tools prior for testing.
4. Fill with approved test fluid through the filling point.
5. When system is already filled with test fluid, close all vents and start pressuring. Pressurization shall be gradual and under control to allow time for material to strain, temperature to equalize, and time for personnel to check for leaks and weaknesses.
6. When pressure reaches 50% of the test pressure, stop pressurization and proceed checking for leaks and weaknesses. If gauge drops, it indicates a leak.
7. If any leak has been noticed, de-pressurize and drain the test fluid, of necessary before repairing the leaks. Before draining, make sure that vents are opened before opening the drain valves. After the cause of the leak has been rectified, again re-fill and pressurize up to 50% of the test pressure.
8. After satisfactory preliminary checks for leak at 50% of strength test pressure, increase the pressure gradually by 20% and if no leak occurred during this stage, pressurization shall continue until the required test is attained.
9. Upon reaching 100% of test pressure, the test pressure shall be maintained for a sufficient time according to required duration specified and inspection is to be conducted, to determine that there are no leaks and the test pump will be disconnected. Complete visual inspection.
10. After the test is completed and accepted, secure acceptance signature  and Saudi Aramco Inspection representative according to the approved forms for documentation.
11. Valve shall be completely dry by using any method such as blowing of hot or dried compressed air, controlled dew point, inert gas or other methods to remove all test medium residuals.
12. Corrosion prevention, upon completion of drying process, means of corrosion inhibition and lubrication shall be applied as applicable.
13. Upon completion of the testing, valves shall be restored to the original packing condition if installation time is not immediately after the testing as per 04-SAMSS-035 and/or SAIC-L-2041.

8.0 QUALITY CONTROL

1. QC personnel shall be assigned to ensure the quality control and assurance requirement of the project.
2. QC Inspector shall coordinate with other inspector to conduct inspection as required in SATIP.
3. QC Inspector shall be responsible to conduct all required inspections/documentations and to ensure that all applicable requirements, codes, and standards are complied with.
4. QC to utilize the applicable SAIC for every activity.
5. Calibration shall be done as required for all machines and tools going to be used in the work in accordance with schedule Q.

9.0 SAFETY PRECAUTION

Obtain the approval of the work permit from the concerned Representative before starting any work.

1. Prior to starting any work, all requirement of Gl-0002.102 is fulfilled.
2. Personnel involved with the testing and inspection shall be adequately trained.
3. Use only designated lift lugs for lifting.
4. Tools must be inspected to be fit for service, including sling wires and tie connection.
5. Never try to open or make repairs to any pressurized part of the valve before depressurizing and verifying no trapped pressure exists.
6. Work area must be prepared; accessibility must be fully provided and inspected.
7. Warning signs with “DANGER HIGH PRESSURE TESTING” in English and Arabic shall be posted at strategic locations.
8. Provide sufficient barricade on working area and only assigned personnel will be allowed in the area.
9. All necessary personal protective equipment (PPE) shall be provided and to be worn at all times.
10. Housekeeping shall be maintained and working area shall be kept in a clean and tidy manner.
11. Job Hazard and Risk Assessment (JHRA) of this method statement shall be disseminated and explained to workers prior to start of work.

10.0 ATTACHMENT

Attachment 1 – Job Hazard and Risk Assessment (JHRA)

PRESSURE LEAK TEST OF CONTROL IMPULSE LINES, INSTRUMENT AIRLINES & PNEUMATIC LINE

LEAK TEST PROCEDURE FOR UNDERGROUND FIRE WATER PIPING

FIELD PRESSURE TESTING OF VALVES PROCEDURE | METHOD STATEMENT