Valve Testing Requirements by Standard

Seat Tightness of Pressure Relief Valves

• -Seat tightness test at 90% of set pressure
• -Bubble count or drop count per API 527 acceptance table
• -Test conducted before shipment and after maintenance

Valve Inspection and Testing

• -Shell test: 1.5× rated CWP, minimum duration per table
• -High-pressure seat: 1.1× rated CWP, liquid, duration per table
• -Low-pressure seat: 80–100 kPa, gas (air/N₂), duration per table
• -Backseat test where specified

Fire Test for Quarter-Turn Valves and Valves Equipped with Nonmetallic Seats

• -Fire test per API 607: 750–1100°C for 30 minutes
• -Post-fire leakage test: seats ≤200 mL/min, stem ≤50 mL/min
• -Post-fire operational test: full open/close cycle
• -Certificate of qualification (CoQ) from accredited test facility

API 622 - Type Testing of Process Valve Packing for Fugitive Emissions

• -1,500 thermal cycle helium leak test
• -Witnessed by independent third party

API 624 - Type Testing of Rising and Setting Stem Valves Equipped with Graphite Packing for Fugitive Emissions

• -1,500 thermal cycle helium leak test on complete valve assembly
• -ISO 21049 or ASME B16.34 dimensional compliance verification

Qualification Testing of Quarter-Turn Valves for Fugitive Emissions

• -310 mechanical operating cycles at ambient temperature per API 641 procedure
• -Thermal cycling from −29°C to +200°C (3 cycles minimum)
• -Stem and body-bonnet leak measurement per EPA Method 21 at every stage
• -Leak rate result reported as ppm methane-equivalent
• -Final test pressure: 10% of rated pressure for leak measurement

Specification for Fire Testing of Valves

• -Fire test: 750–1000°C for 30 minutes in gas-fired or propane furnace
• -Post-fire leakage: seats ≤200 mL/min, stem/body ≤200 mL/min
• -Post-fire operation: full open/close cycle
• -Certificate of qualification (CoQ) required from third-party test facility

Testing of Valves - Production Pressure Testing and Fire Type Testing Requirements

• -Shell hydrostatic test at 1.5× pressure rating (production test on every valve)
• -High-pressure closure test at 1.1× pressure rating
• -Low-pressure air seat test at 0.6 bar ± 0.1 bar
• -Duration per BS 6755 Table 1 (varies by valve size, NPS 1/2" through NPS 60")
• -Temperature: ambient (10–40°C) for production tests

Industrial Valves - Testing of Metallic Valves (Parts 1 and 2)

• -EN 12266-1 shell and seat test with documented FAT report
• -CE marking attestation if PED-relevant

Testing of Valves - Fire Type-Testing Requirements

• -Fire test: 750–1100°C for 30 minutes in certified test facility
• -Post-fire leakage: ≤200 mL/min through seats and body
• -Post-fire operation: full open/close cycle

Measurement, Test, and Qualification Procedures for Fugitive Emissions - Industrial Valves

• -Type test per ISO 15848-1 (qualification)
• -Production test per ISO 15848-2 (100% or AQL sampling)
• -Helium or methane tracer gas
• -ISO-accredited test facility certificate

Industrial Valves - Measurement, Test and Qualification Procedures for Fugitive Emissions - Part 1

• -Helium leak test at rated class temperature and pressure
• -Minimum 210 mechanical cycles (CO1) or 2,500 cycles (CO2) before qualification
• -Tightness measurement using mass spectrometry or equivalent helium leak detector

Industrial Valves - Pressure Testing of Metallic Valves

• -Shell test: 1.5× rated pressure, per duration table
• -Seat test: 1.1× rated pressure, per leakage rate
• -Pneumatic test option: 6 bar air or nitrogen for gas valves

Design and Operation of Subsea Production Systems - Subsea Wellhead and Tree Equipment

• -Factory acceptance test (FAT): full hydrostatic test at 1.5× rated working pressure
• -Seat test at rated working pressure from both upstream and downstream
• -Low-pressure gas test at 50–100 psi for seat integrity check
• -Full functional cycling under rated pressure (minimum cycle count per PSL level)
• -System integration test (SIT): assembled tree tested with running tools and ROV override

Flanged Steel Pressure-Relief Valves

• -Set pressure test: valve must open at ± tolerance of set pressure
• -Blowdown test: valve must reseat within 7–10% of set pressure
• -Seat leakage test: per API 527
• -Cold-differential test pressure (CDTP) accounting for back pressure and temperature correction

Check Valves: Flanged, Lug, Wafer, and Butt-Welding

• -Shell test: 1.5× rated pressure
• -Seat leakage test: 1.1× rated pressure per API 598
• -Low-pressure seat test: 6 bar air

Metal Plug Valves - Flanged, Threaded and Welding End

• -Shell hydrostatic test: 1.5× rated pressure, zero external leakage
• -Seat leakage test: 1.1× rated pressure per API 598 Class IV or VI

Specification for Steel Gate Valves - Flanged and Butt-Welding Ends, Bolted and Pressure-Seal Bonnets

• -Shell test: 1.5× rated pressure for minimum 60 seconds
• -Seat leakage test: 1.1× rated pressure per API 598 Class VI
• -Back seat test: 1.1× rated pressure with packing loose
• -Dimensional inspection per API 600 Table 1 face-to-face dimensions

Gate, Globe, and Check Valves for Sizes DN 100 and Smaller for the Petroleum and Natural Gas Industries

• -Shell test: 1.5× cold working pressure
• -Seat leakage test: 1.1× cold working pressure
• -Back seat test per API 598

Butterfly Valves: Double-Flanged, Lug- and Wafer-Type

• -Shell test: 1.5× rated pressure
• -Seat leakage test: 1.1× rated pressure, Class A or D per API 598
• -Torque measurement at rated differential pressure
• -Fire test per API 607 if fire-safe designation

Steel Globe Valves - Flanged and Butt-Welding Ends, Bolted Bonnet

• -Shell test: 1.5× rated pressure, 15 minutes, zero leakage through body or bonnet joint
• -Seat leakage test: 1.1× rated pressure per API 598 acceptance classes
• -Backseat test when backseat is provided: 1.1× rated pressure, zero leakage

Specification for Wellhead and Christmas Tree Equipment

• -Hydrostatic body (shell) test at 1.5× rated working pressure
• -Seat (gate/seat interface) test at rated working pressure, both upstream and downstream seats
• -Low-pressure gas seat test at 100–200 psi for PSL 3G/4
• -Functional test: full open-to-close-to-open cycle under rated pressure
• -Extended cyclic pressure test for PSL 3G and 4 qualification

Specification for Pipeline and Piping Valves

• -Shell test: 1.5× rated pressure, 15 minutes minimum, zero leakage
• -Seat leakage test: 1.1× rated pressure, per API 598 leak class
• -Back seat test (if applicable): 1.1× rated pressure
• -Anti-static device test: <10 ohm resistance
• -Torque measurement at maximum differential pressure
• -Hydrostatic test certificate required for all valves

Face-to-Face and End-to-End Dimensions of Valves

• -Dimensional inspection: face-to-face measurement within B16.10 tolerance

Buttwelding Ends

• -Dimensional verification of bore diameter and bevel angle
• -Visual inspection of end preparation

Valves - Flanged, Threaded, and Welding End

• -Shell/body hydrostatic test: 1.5× rated pressure at 20°C
• -Seat/closure test: 1.1× rated pressure
• -Backseat test (where applicable)
• -Shell test duration proportional to NPS

Large Diameter Steel Flanges NPS 26 Through NPS 60 Metric/Inch Standard

• -Dimensional inspection per ASME B16.47 Series A or B tables
• -Hydrostatic shell test at 1.5× rated pressure for flanged valves
• -PMI verification for alloy steel and stainless steel flanges

Pipe Flanges and Flanged Fittings NPS 1/2 through NPS 24 Metric/Inch Standard

• -Shell hydrostatic test: 1.5× rated pressure per class and material group
• -Flange facing dimensional inspection to B16.5 tolerances
• -Positive material identification (PMI) for alloy and stainless steel flanges

Hydrogen Piping and Pipelines

• -Hydrostatic shell test: 1.5× design pressure, per ASME B16.34
• -Seat leakage test: per API 598 (Class A bubble-tight preferred for hydrogen)
• -Fugitive emission test: ISO 15848-1 Type Testing Class A (≤50 ppm methane equivalent)
• -Fire-safe type test: API 607 or API 6FA qualification
• -Low-temperature testing if cryogenic hydrogen (LH2) service

Rubber-Seated Butterfly Valves, 3 In. Through 72 In. (76 mm through 1,800 mm)

• -Hydrostatic shell test: 1.5× rated working pressure, 2 minutes, zero visible leakage
• -Disc seat test: 1.1× rated pressure each direction, 2 minutes, zero visible leakage
• -Actuator torque test: torque measured at maximum differential pressure before seal test

Steel Globe and Globe Stop and Check Valves (Flanged and Butt-Welding Ends) for the Petroleum, Petrochemical and Allied Industries

• -Shell test: 1.5× rated pressure, minimum 15 minutes, zero leakage
• -Seat leakage test: 1.1× rated pressure, acceptance per API 598 or ISO 5208
• -Backseat test: 1.1× rated pressure when backseat is provided

Steel Ball Valves for Petroleum, Petrochemical and Allied Industries

• -Shell test: 1.5× rated pressure, 15 minutes minimum, zero leakage
• -Seat leakage test: 1.1× rated pressure per API 598 or ISO 5208 acceptance criteria
• -Anti-static continuity test: electrical resistance ≤10 ohms across stem-ball-body
• -Fire-safe test per BS 6755 Part 2 / ISO 10497 when specified

BS 6364 - Specification for Valves for Cryogenic Service

• -Cold-shock test at -196°C
• -Seat leakage test at cryogenic temperature
• -Low-temperature Charpy impact test

Flanges and Their Joints - Circular Flanges for Pipes, Valves, Fittings and Accessories, PN Designated - Part 1: Steel Flanges

• -Dimensional inspection of flange face, bolt circle, and outer diameter per EN 1092-1 tables
• -Shell hydrostatic test per manufacturer standard or PED requirements
• -Material verification: PMI or 3.1 MTR for alloy and stainless steel flanges

Industrial Valves - Shell Design Strength

• -Shell pressure test per EN 12266-1 (industrial valve testing standard): 1.5× rated pressure, 2 minutes minimum
• -Seat leakage test per EN 12266-1, leak rate class A/B/C/D per EN 1267
• -Prototype pressure test to burst (EN 12516-3) if calculation method not applied

EN 558 - Face-to-Face and Centre-to-Face Dimensions of Metal Valves for Use in Flanged Pipe Systems

• -Dimensional inspection per EN 558 table at time of manufacture

Industrial Valves - Metallic Butterfly Valves

• -Shell test per EN 12266 Part 1: 1.5× PN rating
• -Seat leakage test per EN 12266 Part 1: 1.1× PN rating
• -Leakage rate A, B, C, or D as specified

Petroleum and Natural Gas Industries - Pipeline Transportation Systems - Pipeline Valves

• -Shell test: 1.5× rated pressure, 15 minutes minimum, zero leakage
• -Seat leakage test: 1.1× rated pressure, acceptance per ISO 5208 rate A or B
• -Anti-static continuity test: ≤10 ohms across stem-ball/disc-body
• -Functional test: open-close-open cycle under rated pressure

ISO 17292 - Metal Ball Valves for Petroleum, Petrochemical and Allied Industries

• -Shell hydrostatic test 1.5× rated pressure
• -Seat test at rated pressure bidirectional
• -Optional fire test to ISO 10497

Quality Management Systems - Requirements

• -Calibrated test equipment for hydrostatic and pneumatic testing (traceable to national measurement standards)
• -Dimensional inspection records using calibrated gauges, micrometers, and CMM
• -Material verification records matching mill certificates to physical products
• -Non-conforming product identification, segregation, and disposition records

Specification for High-Test Wrought Butt-Welding Fittings

• -Hydrostatic test of fitting body per ASME B16.9 (for shaped fittings) or per manufacturer's procedure
• -Radiographic examination of girth welds in fittings
• -Impact testing per ASTM A420 for low-temperature fittings (Charpy V-notch at -46°C for WPL6)
• -Hardness testing for sour-service NACE MR0175 compliance where applicable

Bronze Gate, Globe, Angle and Check Valves

• -Shell test: 2× working pressure, all valves, no leakage through body
• -Seat test: 1× working pressure, acceptable bubble rate per test criteria
• -Dimensional checks per MSS SP-80 tables for each valve type and size

Quality Standard for Steel Castings and Forgings for Valves, Flanges, Fittings and Other Piping Components

• -Visual inspection against MSS SP-55 photographic reference chart
• -100% visual inspection of all critical areas (flow path, seating surfaces)

Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refinery Environments

• -Brinell or Rockwell hardness testing of body, bonnet, and trim
• -PWHT verification by hardness test
• -Traceability to heat treatment records

Petroleum and Natural Gas Industries - Materials for Use in H₂S-Containing Environments (Sour Service)

• -Hardness testing: all valve bodies, bonnets, stems - per NACE MR0175 limits
• -Charpy impact testing (where required by NACE MR0175)
• -Weld hardness survey for hard-faced seats
• -PWHT verification (where required)

Material Data Sheets and Element Requirements for Piping

• -Charpy impact testing at −46°C (or lower for Arctic service) per MDS requirements
• -Corrosion testing per applicable MDS (ASTM A262, ASTM G48, or ASTM A923)
• -Ferrite content measurement for duplex/super-duplex stainless valves
• -Pitting resistance equivalent number (PREN) verification for stainless alloys

Power Piping

• -Hydrostatic test of each valve per ASME B16.34 / API 598 before installation
• -System hydrostatic or pneumatic test after installation per B31.1 test requirements
• -NDE examination of welds (RT or UT) for Class 1 and critical piping

Process Piping

• -Hydrostatic leak test of piping system after installation
• -Individual valve test certificates per API 598 / ISO 5208

Pipeline Transportation Systems for Liquids and Slurries

• -Valve shell test: per applicable valve standard (API 598, ISO 5208)
• -Pipeline hydrostatic test: 1.25× MAOP, 4-hour minimum hold at pressure
• -Leak test after pressure test: visual inspection of all joints and valve bodies

Gas Transmission and Distribution Piping Systems

• -Valve testing per API 598 or ISO 5208 required at manufacture
• -Field hydrostatic test of new pipeline: 1.25–1.5× MAOP depending on location class
• -Leak survey by walking or aerial survey required after commissioning