SPE77-312微泄露试验规范

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MESC ADDITIONAL REQUIREMENT Revision: 22-03-2001.

SPE 77/312

1.

1.1

1.1.1

(ISA-1.2),

(ISA-1.5)

(FCI-3)

1.1.2 (ISA-1)

(ISOp1-1)

(ISOp2-1)

(ISOp3-1)

1.1.3

1.1.4

1.1.5 (ISA-2)

1.1.6

2. (ISOp1-2)

(ISOp2-2)

Page 1 of 21.

FUGITIVE EMISSION LEAK DETECTION OF VALVES.

INTRODUCTION

SCOPE

This specification shall apply to the test and evaluation of fugitive emission

suppressing performance level of on/off valves, control valves (including valves for

vacuum services).

In this specification a distinction is made between the classification system,

qualification procedures tests and methods used for fugitive emission leakage,

emitted through valve stem seal, body and bonnet flange seals and plug

connections for:

- prototype approval test of valve assemblies,

- production acceptance testing of valve assemblies,

- methods for in-situ (on site) valve fugitive emission measurement.

A fugitive emission is defined as any chemical or mixture of chemicals which

represents an unanticipated or spurious leak.

This specification is an amendment / supplement to working draft standards

ISO/WD 15848-1.9, ISO/WD 15848-2.1, ISO/WD 15848-3, and standards

ANSI / ISA-S 93.00.01 and ANSI / FCI 91-1 and shall be considered to be part of

the valve buying description, when referred to in a MESC description and / or

requisition.

The specification describes the type of detection method and test medium to be

used and specify the acceptance and rejection criteria.

The numbers in brackets at the section headings refer to the relevant section in

the standards as follows:

ISA-a = ANSI / ISA-S 93.00.01,

ISOp1-b = ISO / WD-15848-1.9,

ISOp2-c = ISO / WD-15848-2.1,

ISOp3-d = ISO / WD-15848-3,

FCI-e = ANSI / FCI 91-1 and

EDF = EDF document HT-21/00/032/A.

REFERENCES

In this specification, reference is made to the following publications:

NOTE: Unless specifically designated by date, the latest edition of each publication shall be used,

together with any amendments/supplements/revisions thereto.

ASME B 16.34 Valves, flanged, threaded and welding end.

ASME section V Boiler and pressure vessel code; non destructive

examination Appendix IV: Helium mass spectrometer

test - detector probe technique, Appendix V: tracer probe

and hood techniques.

Clean Air Act List of air pollutants and their regulating program.

Amendments:

updated strategies

MESC ADDITIONAL REQUIREMENT Revision: 22-03-2001.

SPE 77/312

3. (ISA-3)

3.1

(ISOp1-3)

(ISOp2-3)

Page 2 of 21.

Environmental Determination of volatile organic compound leaks, title

Protection Agency 40, appendix A, method 21, type 1.

EN 1779 Non destructive testing – Leak testing – Criteria for

(8-1999) method and technique selection.

EPA 453 / R 95-017 Protocol for equipment leak emission estimates,

(Release 11-1995) section 2 and appendix B, pages B7 and B18.

RW - TUV: Technische Anleitung zur reinhaltung der Luft:

Die neue TA Luft Aktuelle Emmissionsschutzrechtliche Anforderungen an

(12-1997) den Anlagenbetreiber (chapters 2.3 and 3.2)

ANSI / FCI 91-1 Standard for qualification of control valve stem seals.

(6-6-1997)

IEC 600534-4 Industrial control valves,

Part 4: inspection and routine testing.

ANSI/ISA-S 93.00.01

Standard method for the evaluation of external leakage of

(15-1-2000).

manual and automated on-off valves.

ISO / WD -15848-1.9

Industrial valves - fugitive emissions - measurement, test

(ISO-TC153/SC1/

and qualification procedures; part 1: Classification system

WG10-N106)

and qualification procedures for type tests of valve

Release: 22-12-2000.

assembles (proof of design, type testing).

ISO / WD-15848-2.1

Industrial valves - fugitive emissions - measurement, test

(ISO-TC153/SC1/

and qualification procedures; part 2: Production

WG10-N72)

acceptance test of valve assemblies (quality control).

Release 15-5-2000.

ISO / WD-15848-3 Industrial valves - fugitive emissions - measurement, test

(ISO-TC153/SC1/ and qualification procedures; part 3: Methods for on site

WG10-N17) valve fugitive emissions measurement (in plant tests).

(not yet released)

MSS SP project 93-17Valve fugitive emission measurement and classification.

Release: 8-7-1997.

MSS SP 117 Bellows seals for globe and gate valves.

Electricite De France

Corrosion test (hot and cold) on valve packing.

document

HT-21/00/032/A

(17-7-2000)

SPE 77/200 Valves in service below minus 50 degrees Celsius.

SPE 77/209 Valves in services between zero and minus 50 degrees

Celsius.

DEFINITIONS

The definitions are in accordance with standards ANSI / ISA- S 93.00.01,

ISO / WD -15848-1.9 and ANSI / FCI 91-1 with the following alterations:

MESC ADDITIONAL REQUIREMENT Revision: 22-03-2001.

SPE 77/312

3.2 (ISOp1-3.14)

3.2.1 (ISOp1-5)

3.2.2 (ISOp1-5.1)

3.2.3

(ISOp1-5.1.2)

3.2.4

(ISOp1-table 4)

(ISOp1-5.1.3)

(ISA -table 1)

Page 3 of 21.

Leakage (ISA-3.5) For stem seal and body/bonnet seal(s) the test medium

(ISOp1-3.13) being emitted under defined test conditions.

(FCI-2.6):

Leak rate category Allowable limits of leakage in ppm (volume) or (mbar.l/s), as

(ISA-3.6), defined in this specification.

(FCI-table 1)

Stem seals A pressure containing seal/packing to prevent leakage of

(ISA-3.13) the media to the atmosphere through the interfaces of the

(ISOp1-3.5) valve stem in contact with the valve bodies and adjacent

(FCI-2.6)

parts.

Test media

- Helium (He) with a purity exceeding 97% for indoor

(ISA-3.5)

type testing and production testing or,

(ISA-6.1.5)

- Methane (CH4) for in-situ testing and production testing,

(ISOp1-4.1.2)

but only if specified by the Principal.

Test pressure

For prototype testing:

(ISA-3.9 )

the rated valve body pressure at the test temperatures, as

(ISA-4.1)

defined in ASME B16.34 and section 3.2.4.

(ISOp1-3.10)

For production acceptance testing:

the valve body pressures at the test temperatures as

specified in section 10.3.3 and 3.2.4.

Performance classes

The selected performance class for a valve qualification shall be agreed between

the manufacturer and the Principal.

The performance class is defined by the:

- tightness class

- endurance class and

- temperature class

For each endurance class are the total number of cycles for both prototype

testing and production testing defined in section 3.2.5.

The applicable temperature class and number of thermal cycles at test

temperatures shall be selected from the following piping class categories:

MESC ADDITIONAL REQUIREMENT

SPE 77/312

Revision: 22-03-2001.

Page 4 of 21.

maximum piping class

design temperature

range: [º C]

-196 to +200

(&<-100)

Temp.

class:

Number of thermal cycles

at test temperatures [º C] for

prototype testing

Number of thermal cycles at

test temperatures [º C] for

production testing

T1

3

1

(at lower, ambient and

(at lower design temperature

upper design temperature)

and ambient temp.)

2

(at lower and upper design

temperature).

1

(at lower design temperature

and ambient temp.)

-100 to +60 T2

- 80 to +150

(&>+60)

T3 2

1

(at lower and upper design

(at lower design temperature

temperature).

and ambient temp.)

T4 2

1

(at lower and upper design

(at lower design temperature

temperature).

and ambient temp.)

T5 3

1

(at lower, 100 º C and upper

(at lower design temperature

design temperature).

and ambient temp.)

T6 4

1

(at lower, 250 º C and upper

(at lower design temperature

design temperature).

and ambient temp.)

T7 1

1

(at lower design

(at lower design temperature

temperature and ambient

and ambient temp.)

temperature).

T8 1

(at ambient and upper

design temperature).

0

(at ambient temperature).

- 50 to +125

(&>+38)

- 50 to +200

(& >125)

- 50 to +400

(& >200)

- 46 to +38

- 35 to +80

- 29 to +150

(& >80)

T9 2

0

(at ambient, 100 º C and

(at ambient temperature).

upper design temperature).

T10 3

0

(at ambient, 150 º C and

(at ambient temperature).

upper design temperature).

T11 4

1

(at ambient, 200 º C and

(at ambient and upper

upper design temperature).

design temperature).

T12 5

1

(at ambient temperature,

(at ambient temperature,

+250 º C and +550 º C)

+550 º C )

T13 5

1

(at ambient temperature,

(at ambient temperature

+350 º C and +650 º C)

and +650 º C)

- 29 to +250

(&>150)

-29 to +450

(&>250)

Zero to +538

(& >450)

zero to +650

(&> 538)

MESC ADDITIONAL REQUIREMENT

SPE 77/312

3.2.5

Revision: 22-03-2001.

Page 5 of 21.

(ISA-fig.1& 3.15)

Total number of cycles (includes both mechanical and thermal) for prototype

(ISOp1-fig1 & 2)

testing and production testing at prescribed test pressure (unless otherwise

(FCI-table1)

specified by the Principal):

Total number of cycles

(see notes 1 u/I 5)

Valve type Endurance

For

For

class:

prototype

production

(ISO-figure 1)

testing

testing

Check valves, plug, or swing type (without

counter weight)

Check valves, plug, or swing type (with

counter weight)

on/off rising stem (manual) valves, bellows

sealed

(note 6)

on/off rising stem (manual) valves, bellows

sealed

(note 6)

on/off rising stem valves (manual) with

advanced stuffing box

on/off rising stem valves (manual) with

standard stuffing box

on/off rising stem valves (manual) with

standard stuffing box

on/off quarter turn valves (manual) with

standard stuffing box

on/off quarter turn valves (automated) with

standard stuffing box

CO-1c N.A. N.A.

CO-2b 100 25

CO-B-1m

500 25

CO-B-2m

500 50

CO-1-ma 200 50

CO-1-ms 100

50

CO-2-ms 200

100

CO-3-ms 250 125

CO-1-as 500

50

on/off (automated) CO-2a 1.500

100

on/off (automated)

CO-3a 2.500 200

control valve

(note 5) CC-1

5.000 125

control valve

(note 5) CC-2

10.000 250

MESC ADDITIONAL REQUIREMENT

SPE 77/312

Revision: 22-03-2001.

Page 6 of 21.

(ISOp1-fig. 1)

(ISOp1-fig. 2)

(ISA 6.5.3.1)

(ISA 6.3.5.2)

(FCI table 1)

NOTES:

1. Leak measurement at start and completion of each temperature increment.

2. When conducting the cycle test, cycling shall be carried out in the following sequence:

- cycle the valve at room temperature,

- change to the specified test temperature and

- follow by valve cycling at that test temperature.

The distribution of the thermal cycles shall be equally divided over the total number of

cycles.

3. The test cycle for on/off valves is a full stroke travel.

For (linear and rotary) control valves test cycle shall be performed at 50% of stroke / angle

with an amplitude of +/- 10% of full stroke / angle.

4. During the temperature transition period mechanical cycling is not allowed. Mechanical

cycling shall be performed at the selected test temperature only.

5. Rotary and linear motion control valves shall be tested in accordance with ANSI / FCI 91-1

requirements, unless otherwise specified.

6. To check the stuffing box performance, bellows sealed valves shall be tested without a

bellow or a leak bellow.

4. (ISA-1.4)

VALVE CLASSIFICATION

4.1 (ISA-4.3) On completion of testing the valve is assigned a classification comprising a test

(ISOp1-5.2) temperature, pressure rating, number of completed mechanical and thermal

cycles, number of stem seal adjustments and actual emission leakage.

For typical examples see appendix C.

5.

TYPE OF LEAK DETECTION METHOD AND TEST MEDIUM TO BE USED

5.1 (ISOp1-annex A

For prototype emission testing, production emission testing and in-situ

and B),

emission measurement the EPA-21 open air direct sniffing leak detection

method shall be used.

(ISOp2-6.3)

(ISOp1-annex

Emissions shall be measured at the:

B)

- valve stem/stuffing box ,

- body/bonnet flange seals:

- inlet pressure connection, drain and flange plug(s) and grease injector

(if installed).

Remarks:

1. The maximum allowable stem leakage rate for “Shell” tightness class A deviates from the

maximum allowable ISO/WD 15848-1.9 tightness class A (see appendix B)

2. Valves with a ISO/WD 15848-1.9 tightness class D shall not be used.

5.2

(ISA-6.1.4)

(ISA-6.1.5)

(FCI-6.2.2, 6.2.3)

(ISOp1-3.15)

(ISOp1-4)

(ISA-6.1.4, 6.1.4)

(ISA-6.2.1)

(FCI-6.2.2, 6.2.3)

(ISOp2-6.1, p3)

(ISOp1-3.16),

(ISOp1-3.17)

For prototype emission testing the leak detection medium shall be helium gas

with 97% minimum purity (see also sections 10.1 and 10.2), unless otherwise

specified by the Principal.

5.3

Production acceptance testing and in-situ emission measurement:

The leak detection medium shall be

- helium gas with 97% minimum purity (preferred for production emission testing) or

- methane (but only if accepted by the Principal).

(see also sections 10.1, 10.3 and 10.4).

MESC ADDITIONAL REQUIREMENT

SPE 77/312

Revision: 22-03-2001.

Page 7 of 21.

6.

6.1

(ISOp1-table 2)

(ISOp1-table 3)

ACCEPTANCE CRITERIA

Tightness class for proto type and production acceptance testing:

The helium leakage rate Qact ,

by local measurement with the EPA 21 open air

direct sniffing leak detection method, shall not exceed for:

stem seals:

[cm³ /s]

(ISOp2-table 1)

“Shell”

(ISOp2-tabel 2)

tightness class:

body and bonnet

seals: [cm³ /s]

NOTES:

6.2

(ISOp1-table 2)

(ISOp1-table 3)

(see note 7)

(see notes 1, 5, 8)

(see notes 2, 8)

Class A

(note 6) 1.76 * 10-7

1.76 * 10-8

Class B 1.76 * 10-6

1.76 * 10-7

Class C 1.76* 10-5

1.76 * 10-6

1. Stem seal leakage is per mm stem diameter.

2. Body and bonnet seal leakage is per mm body / bonnet flange circumference.

3. The developed gasket length is π x outside flange diameter.

4. The developed packing length is π x stuffing box outside diameter.

5. See also appendix B

6. Class A for carcinogene, toxic and aggressive media.

Use rising stem, bellows sealed valves for sizes up to DN 50 and valves with

special gland packing for sizes DN50 and larger.

7. Valves with an ISO/WD 15848-1.9 tightness class D shall not be used.

8. For leakage rates conversion factors see EN 1779 annex B.

In-situ emission measurement (EPA-21 method)

The following maximum emission limits (= leak tightness classification) shall be

adhered to:

Valve service application Maximum emission

Maximum emission

(note 1): limit, correlated to

limit, correlated to

helium (He): (note 4) methane (CH4) (note 4)

Class A for:

10 ppm volume 20 ppm volume

- Suspected mutagene and

carcinogen media

- Volatile Hazardous Air

Pollutants (VHAP);

- Aggressive, toxic, carcinogen

media and

- Media with corrosion risk.

(see notes 2, 3 and 4)

Class B for: 50 ppm volume 100 ppm volume

Hydro carbons and steam.

Class C for:

250 ppm volume 500 ppm volume

volatile media not covered

under class A and B.

MESC ADDITIONAL REQUIREMENT Revision: 22-03-2001.

SPE 77/312

7.

(ISA-1.4)

(ISOp1-7)

(FCI-5.8)

8.

(ISOp1-4.2.2)

8.1

8.2

8.3

(ISA-6.2.4)

8.4

(ISA-6.2.1)

(ISOp2-6.2)

Page 8 of 21.

NOTES:

1. The manufacturer shall quote the applied detector type (see sections 8.4 and 8.5).

2. Volatile Hazardous Air Pollutants are listed in the clean air act amendments.

3. In case of linear stroke (gate and globe) valves, rising stem, bellows sealed, valves shall be

applied for sizes up to DN 50 and valves with special gland packing for sizes DN50 and

larger. For both linear stroke and quarter turn valves the manufacturer shall prove compliance

with tightness class A (see section 6.1)

4. See appendix D for methane - helium correlation factors.

VALVE QUALIFICATION OF UNTESTED VALVE SIZES

When compared with the tested valve, untested extension of valve classification is

acceptable for valves with identical design, geometry and material and loading

characteristics ( i.e. number and dimensions of packing rings, packing friction

and transfer factor, stem and stuffing box roughness, radial packing ring

stress, gasket sealing stress and packing gland torque) with:

- body gasket circumference’s which are smaller or up to 100% larger than the

tested valve and

- stem seal (packing) outside diameters which are smaller or up to 20% larger than

those of the test valve and

- equal or lower pressure class rating and

- smaller design temperature range (temperature class) than that of the qualified

valve and

- lower ISO/WD-15848-1.9 endurance class category (see section 10.2.7.2) and

- the tightness class required is equal to, or less severe than that of the

qualified valve.

When comparing the maximum nominal sizes resulting from stem seal and body

gasket circumference qualification requirements, the untested valve qualification shall

be the one with the lowest nominal size.

The qualification may also be extended to an automated valve of the same

manufacture and design and vice versa providing the above-mentioned creteria

are met and stem operating torque’s are unchanged.

The use of a gearbox or other actuator doesn’t require a separate qualification.

INSTRUMENTS SENSITIVITY AND CALIBRATION

For the calibration of instruments see ASME V chapters IV-1030 and IV-1060.

The range of the test pressure gauges shall not be more than twice the test pressure.

Thermocouples shall be used to measure the temperatures of the body, the flow line

as well as stem and body / bonnet seals.

For prototype, production and in-situ emission testing a suitable (portable)

helium mass spectrometer leak detector and sample probes shall be used, e.g.:

MESC ADDITIONAL REQUIREMENT Revision: 22-03-2001.

SPE 77/312

Leybold,

Leybold,

Varian,

8.5

(ISA-6.2.1)

8.6

8.7

8.8

Page 9 of 21.

Brand and type

Sensitivity (minimum detectable

Suitable for “Shell”

of helium mass

helium leakage rate): [Pa*m3/s]

tightness class(es):

spectrometer

(see notes B and C)

leak detector

(note A).

Alcatel ASM 142

Sniffing (technique B.4): <1* 10-7 A, B and C

BOC Edwards: Sniffing (technique B.4): 4* 10-9 A, B and C

Spectron 300E

Leybold, type: Vacuum (technique A.2): <2 * 10-10

A, B and C

UL 100 Plus Sniffing (technique B.4): <2* 10-7

type:

Vacuum (technique A.2): <5 * 10-10

A, B and C

UL 200

Sniffing (technique B.4): <1* 10-7

type:

Vacuum

-10

A, B and C

UL 200-dry

(technique A.2): <3 * 10Sniffing (technique B.4): <1* 10-7

Leybold

Sniffing (technique B.4): < 1 * 10-7 A, B and C

sample probe

type: QT-100

model:

Sniffing (technique B.4): <5* 10-7 C

979

Notes:

A) Other measuring instruments are subject to approval of the Principal.

B) Minimum detectable leakages are as listed in EN 1779 annex A table A.1.

C) For conversion factors for leakage rates see EN 1779 annex B.

For in-situ emission testing a methane sniffer from Foxboro types OVA-108 or

TVA 1000 may be used. Any other measuring instrument shall be subject to an

approval of the Principal.

The manufacturer shall confirm that the sensitivities of the:

- mass emission spectrometer (including sniffing probe),

- calibrated leak standard for mass spectrometer calibration

- calibrated leak standard for detector sniffer probe calibration

are suitable to correctly measure the actual leakage rate against the specified

tightness class requirements (see section 6.1).

The EPA-21 instrument calibration shall be done at a distance of at least 1

meter from the valve to be measured.

Gauges of the mass spectrometers are in class 1 with an adequate bottom scale.

MESC ADDITIONAL REQUIREMENT Revision: 22-03-2001.

SPE 77/312

8.9

8.10

9.

9.1 (EDF)

9.2

(ISA-6.1.1)

(ISA-6.3.1)

9.3 (FCI-6.3)

9.4

9.5

9.6

9.6.1

9.6.2

9.7

(ISOp1-4.2.1)

9.8

Page 10 of 21.

The mass spectrometer and sniffing probe correlation factors shall be registered as

follows:

Qa

= value of the calibrated capillary leak standard leakage

Qar

= measured value

F=QaQ= correlation factor

arNote: Instrument correlation factors are depending on detectors, their sampling flow rates and the

different media used.

All measuring equipment and instruments shall have valid calibration certificates.

PREPARATION PRIOR TO TESTING

Tightness of valve packing is important. The corrosion hazard, that may occur

on the valve stem and stuffing box, shall be taken into account and the valve

and test equipment shall be clean and free of water, oil and dust.

The valve assembly and bolt tightening prior to the test shall be in accordance to

manufacturers specifications.

Prior to the valve assembly the valve parts shall be visually inspected for any

damage, defects. The valve stem shall be checked for any damage or

degradation of surface finish.

Valves prototype tested at manufacturers works shall not have any protective

painting or coating on the valve body and internals. Surface treatments of pressure

containing valve components to prevent corrosion during storage prior to and

during manufacture with a single base primer coat (maximum 25 micron

thickness) or phosphate treatment is acceptable, provided these preservations

do not hide any porosity.

It is allowed to paint the valve prior to an emission production test.

Depending on the nominal size the valve may be assembled with an actuator or a

manual gear.

Sealing components (gaskets):

For valves with flanged ends the gaskets for the end flanges shall be spiral wound

with ASTM A240 type 316(L) windings, inner ring and centring ring and graphite filler,

to allow a perfect flange sealing.

For valves with a wafer/ lug design, butt welded ends, socket welded ends and

screwed ends the sealing connectors shall be modified (by the manufacturer)

accordingly to accommodate this type of valve.

Approval of the Principal is required prior start of fugitive emission testing.

As illustrated in appendix A, one valve end must be connected to the bottle(s) with the

test medium. The other valve end must be connected to a vent valve, to discharge the

test medium outside the room of the test rig, avoiding any increase in the test medium

concentration in the atmosphere around the valve tested.

Brackets to support the valve in the test rig shall be fixed to the end covers or

clamped to the body. No support shall mounted on the valve bonnet or cover.

MESC ADDITIONAL REQUIREMENT

SPE 77/312

Revision: 22-03-2001.

Page 11 of 21.

9.9

(ISA-6.3.2) VALVE ORIENTATION:

(ISOp1-4.2.4.1b)

Valves, except check valves, shall be tested with the stem in the horizontal position.

Changes in the test position of the valve (e.g. for low temperature and

cryogenic valves) shall be agreed with the Principal

(see also SPE 77/200 section 3.2.6 and SPE 77/209, section 3.2.2).

SEAL ADJUSTMENT

(ISA-6.1.3)

(FCI-6.1.2,

6.1.3)

The bolting of the valve end flanges and/or stuffing box gland shall be re-tightened in case during a thermal cycle the valve bonnet flanges and/or valve

end flanges starts to leak. This is to avoid impact on the measurement test

results. In the test report shall be shown of which valve part(s) the bolts were

re-tightened and at which stage of the test this was done. In case during the

test a second failure of the bonnet flanges, end flanges and/or stuffing box area

occurs, the test shall be stopped.

9.10

9.10.1

9.10.2

(ISOp1-4.1.1.d)

The packing load shall ensure that the valve will not be difficult to operate.

(ISOp1-4.2.4.1d)

The valve opening and closing torque’s shall be measured and shall be below the

maximum value specified by the Principal.

(ISA-6.2.1) The area of the test rig shall be in still air, isolated from wind, fans or drafts

(see ASME V chapter IV-1071).

TESTING OF VALVE ASSEMBLIES

9.11

10.

(ISA-6)

(ISOp1-4.2)

(FCI-6.2)

10.1

10.1.1

GENERAL REQUIREMENTS

(ISOp1-4.1.4) The thermocouples shall be placed on the:

- body of the valve at the thinnest wall thickness adjacent to the seating

(to show an accurate reproduction of service conditions during the

thermal cycling) and,

- bonnet (at the stuffing box area).

Note: where possible it is preferred to mount the thermocouple on the inside of the valve body.

10.1.2 Since the retainer less dual plate check valve design eliminates potential

leak paths there is no need to perform fugitive emission production testing

on these valves.

For on/off valves the movement of the valve stem shall be from fully open to full

close and back to full open constitute one cycle.

For on / off valves with both rotary and linear stem motion, the closure element

shall be fully engaged with the seat, to ensure that during cycling the pressure

loads on the stem shall reproduce the bending load in the stem that the valve

would encounter in service.

10.1.3

10.1.4

(ISA-6.3.7)

(ISOp2-7.1b)

(ISA-6.3.3)

(ISOp2-7.1c)

10.1.5 (FCI 5.11)

The mechanical test cycles for (linear and rotary) control valves shall be

(ISOp1-performed at 50% of stroke / angle with an amplitude of +/- 10% of full

4.2.43.b)

stroke / angle.

10.1.6

10.1.7

(ISOp2-7.1a)

(ISOp2-7.2a)

(ISOp1-4.2.4.2)

Set the valve closure member in the half open position.

Introduce inside the valve a pressure of 2 bar test medium.

MESC ADDITIONAL REQUIREMENT

SPE 77/312

Revision: 22-03-2001.

Page 12 of 21.

10.1.8

10.1.9

10.1.10

10.1.10.1

(ISA-6.3.5)

Discharge the pressure to vent any traces of air contained inside the valve.

Close the vent valve (see appendix A).

Leakage detection

General.

Increase the pressure to the specified test pressure (see 10.2.5 or 10.3.5). 10.1.10.1.1

(ISA-6.3.7)

10.1.10.1.2

10.1.10.1.3

10.1.10.1.4

10.1.10.1.5

10.1.10.1.6

10.1.10.1.7

10.1.10.2

10.1.10.2.1

10.1.10.2.2

10.1.10.2.3

(ISOp1-4.2.2a)

(ISOp1-4.2.2c)

(ISA-6.3.6)

(ISA-6.2.2)

(ISA-6.2.2)

(ISA-6.2.3)

(ISA-6.3.8)

(ISOp2-7.1)

(ISOp2-7.1)

The pressure shall remain stable throughout the test duration, within 3% in line

with the normal accuracy of the pressure gauges.

If, due to temperature changes, the applied pressure changes excessively the

test duration shall begin after the pressure in the system has been stabilised.

Measure the leakage not before 5 minutes after having pressurised the valve at

the specified test temperature.

After completion of the mechanical cycling the valve shall be set in half open

position.

The leakage shall be measured both in static and dynamic (stem movement)

valve conditions.

The actual leakage Qact will be equal to:

Qact =

Qr x F, where:

Qr = instrument measured value

F = Correlation factor (see section 8.9)

Sniffing method.

Leakage’s to the outside of the entire valve shall be detected at both the

beginning and end of the thermal and mechanical cycles, especially:

- stem seal(s) / stuffing box leakage along the interface between shaft and

gland flange.

- body seal(s) leakage along the interface between the body, bonnet and/or

cover joints closures and,

- Inlet pressure connection, drain and flange plug(s) and grease injector

(if installed).

The distance between the check points shall be for the:

- stem seal: every 90 degrees (4 locations)

- body seals and flange joints: every location between the flange bolts.

Wherever practical (i.e. for a testing temperature range of –200 degrees C

up to +450 degrees C ) body seals and flange joints shall be sealed with an

adhesive aluminium foil tape, 40 micron thickness, having a single pierced

hole to ensure that the sniffer picks up any leakage.

The detector probe shall be kept at:

- the edge of the body/bonnet flange circumference and

- a scanning distance as close as possible (say 5 mm) to the stem seal, if the

valve design allows such a close access (ref. ASME V chapter IV - 1074)

MESC ADDITIONAL REQUIREMENT Revision: 22-03-2001.

SPE 77/312

10.1.10.2.4

(ISOp2-7.1)

10.2

10.2.1

(ISA-6.1.2)

(ISOp1-4.1.1c)

10.2.2

(ISOp1-4.1.1)

(FCI-6.1.1)

10.2.3

10.2.4

(ISA-6.2.1)

10.2.5

(ISOp1-4.1.2)

10.2.6

(ISA-table 1)

(ISOp1 table 4)

(ISA-6.3.5)

10.2.7

(ISA-figure 1)

(ISA-3.15)

10.2.8

ISO-p1-4.2.4.9

Page 13 of 21.

For each point the probe must be maintained in position for a duration of

approximately 15 seconds. The scanning rate shall comply with ASME V chapter

IV-1062.2 requirements.

PROTO TYPE TESTING

The valve shall be a standard off-the-shelf valve and built to normal production

tolerances.

The valves to be prototype emission tested are:

- at random selected

- maximum 3 pieces per valve type

- selected using the following table:

Nominal valve Number of valves

size range: to be tested:

DN <= 50 1 piece

50<= DN<= 300 1 piece

DN > 300 1 piece

In case above listed and tested nominal valve size(s) cannot provide

sufficient qualification range for larger valves the nearest valve size shall be

prototype tested to cover the complete production range (see also section 7).

Testing shall be done at manufacturers works or third party testing institute

and under controlled (laboratory) conditions (see also section 10.1).

The pneumatic test pressure shall be the rated valve body pressure at the

selected test temperature, as defined in ASME B.16.34.

The number of thermal cycles and test temperatures shall be selected from

section 3.2.4 and accepted by the Principal.

The temperature class shall cover the range for which the valve is designed.

The total number of cycles (includes both mechanical and thermal) for

prototype testing is specified in section 3.2.5.

VALVE DISASSEMBLY AND INSPECTION

The valve shall be disassembled after the prototype test and all

components shall be inspected for notable wear and other significant

defects that would influence any test results.

In case soft seals and seat materials are applied, special attention is

required for any distortion and/or damage of these components.

Detailed pictures of the disassembled valve parts shall be taken and

included in the report.

Measurements shall be taken of key component dimensions and compared

with drawing tolerances and finishes to insure they conform to the

specifications and are within the drawing specifications.

MESC ADDITIONAL REQUIREMENT Revision: 22-03-2001.

SPE 77/312

10.3

10.3.1

(ISA-6.1.2)

(ISOp2-5.1)

(FCI-6.1.1)

10.3.2

10.3.3

(ISOp2-6.5)

10.3.4

(ISA-figure 1)

(ISA-3.15)

10.3.5 (ISOp1-3.10)

(ISOp2-6.4)

10.4

(ISOp3)

(ISOp1-3.17)

10.4.1

10.4.2

11.

11.1 (FCI-6.3)

ISOp1-4.2.4.10

11.2 ISOp1-4.2.4.10

Page 14 of 21.

PRODUCTION ACCEPTANCE TESTING

For production testing the sampling percentage is 3 % (at random selected) with

a minimum of 1 piece per stem diameter and per valve type.

The number of thermal cycles and test temperatures shall be in accordance

with the table in section 3.2.4.

Production emission measurement may be carried out at ambient temperature if

accepted by the Principal (see sections 3.2.4).

The total number of cycles (includes both mechanical and thermal) for

production testing is specified in section 3.2.5.

The pneumatic test pressure at the test temperature shall be:

- the rated valve body pressure for PN10 and PN16 valves,

- 20 barg for class 150 valves,

- 30 barg for class 300 valves,

- 40 barg for class 600 valves,

- 25 % of the rated valve body pressure for valves in class 900 and above,

- not exceeding 150 barg,

unless otherwise specified by the Principal.

FIELD (IN-SITU) FUGITIVE EMISSION MEASUREMENT

The EPA-21 leak measurement method shall be used.

Use an organic vapour analyser (OVA) previously calibrated from methane

(CH4), or other reference media, specified by the Principal, as a basis for the

evaluation.

The measuring principle is a reading of the difference between the concentration

level measured at a distance of at least 1 metre from the source and the level

measured as close as possible to the potential leak source.

If the value measured exceeds the limits imposed by the regulations, the

component is deemed to be ‘off-spec’.

This method shall be used for statistical evaluation of emissions only and not for

individual leak measurement.

The weather condition (wind speed) shall be monitored during in-situ

fugitive emission measurement to check the impact on the actual

measured emissions.

Note/remark: The definition and scope of work covering field (in-situ)

measurement is currently being prepared by CEN-TC-264-WG17.

REJECTION CRITERIA FOR PROTO TYPE AND PRODUCTION EMISSION

TESTING

If the reading for the stem and body seals is over the allowable limit repeat the

reading twice with at least 2 minutes between the two readings. If one of the

additional readings is still over the limit the test has failed and the tested

valve(s) shall be post test examined.

If one valve of the lot fails to meet the test requirements the total lot shall be

rejected. Recorded data and findings shall be submitted to the Principal for

review.

MESC ADDITIONAL REQUIREMENT

SPE 77/312

Revision: 22-03-2001.

Page 15 of 21.

12.

(ISA-7)

(ISA-annex B)

(ISA-6.3.6)

(ISA-4.2)

(ISA-5.3)

(ISOp1-6)

(ISOp2-9)

(FCI-7)

TEST REPORT REQUIREMENTS

In addition to the specified requirements the following shall be recorded and

reported:

- installed gaskets and packing makes and styles,

- control valve dead band hysteresis (if applicable),

- packing compression (i.e. the position of gland follower),

- torque of the gland bolting (packing tightening),

to ensure leakage requirements are met and the valve can be closed and

opened satisfactory.

MESC ADDITIONAL REQUIREMENT

SPE 77/312

Appendix A: Schematic arrangement of test rig.

Revision: 22-03-2001.

Page 16 of 21.

MESC ADDITIONAL REQUIREMENT

SPE 77/312

Appendix B:

Revision: 22-03-2001.

Page 17 of 21.

Stem seal helium leakage rate comparison for fugitive emission testing

ISO (Class A)

Allowable Leak Rate

Shell (Class A)

Allowable Leak Rate

ISO / Shell (Class B) ISO / Shell (Class C)

Allowable Leak Rate Allowable Leak Rate

RWTUV

Allowable Leak Rate

1.76E-08 [cm3/s/mm dia.] 1.76E-07 [cm3/s/mm dia.] 1.76E-06 [cm3/s/mm dia.] 1.76E-05 [cm3/s/mm dia.] 3.1E-07 [cm3/s/mm dia.]

Leakage Stem Leakage Stem Leakage Stem Leakage Stem Leakage Stem

rate per diameter rate per diameter rate per diameter rate per diameter rate per diameter

stem diam. stem diam. stem diam. stem diam. stem diam.

[cm3/s] [mm] [cm3/s] [mm] [cm3/s] [mm] [cm3/s] [mm] [cm3/s] [mm]

1.8E-07 10 1.8E-06 10 1.8E-05 10 1.8E-04 10 3.1E-06 10

2.6E-07 15 2.6E-06 15 2.6E-05 15 2.6E-04 15 4.7E-06 15

3.5E-07 20 3.5E-06 20 3.5E-05 20 3.5E-04 20 6.2E-06 20

4.4E-07 25 4.4E-06 25 4.4E-05 25 4.4E-04 25 7.8E-06 25

5.3E-07 30 5.3E-06 30 5.3E-05 30 5.3E-04 30 9.3E-06 30

6.2E-07 35 6.2E-06 35 6.2E-05 35 6.2E-04 35 1.1E-05 35

7.0E-07 40 7.0E-06 40 7.0E-05 40 7.0E-04 40 1.2E-05 40

8.8E-07 50 8.8E-06 50 8.8E-05 50 8.8E-04 50 1.6E-05 50

1.1E-06 60 1.1E-05 60 1.1E-04 60 1.1E-03 60 1.9E-05 60

1.2E-06 70 1.2E-05 70 1.2E-04 70 1.2E-03 70 2.2E-05 70

1.4E-06 80 1.4E-05 80 1.4E-04 80 1.4E-03 80 2.5E-05 80

The above listed stem leakage rates are measured at the selected:

•

•

test pressure (i.e. for prototype testing the rated valve body pressure (see section 10.2.5) and

for production acceptance testing the pressure listed in section 10.3.5.

test temperatures (see section 3.2.4).

MESC ADDITIONAL REQUIREMENT

SPE 77/312

Revision: 22-03-2001.

Page 18 of 21.

1.0E-01

Stem Diameter (mm)

10

15

20

25

30

35

40

50

60

70

80

Leakage

Rate

(cm3/s)

1.0E-02

1.0E-03

1.0E-04

1.0E-05

1.0E-06

1.0E-07

ISO (Class A)

ISO / Shell (Class C)

Shell (Class A)

ISO / Shell (Class B)

RWTUV

Helium leakage rate per stem diameter.

Tightness class

A

Allowable stem seal helium leakage rate:

[mg/s/m circ]

10.

-6

ISO / WD-15848-1.9, 2.1

and 3

Shell SPE 77/312:

=

[cm/s/mm dia.]

1.76x10

-83B

10

-3-4=

=

1.76x10

1.76x10

-5-6C 10

Tightness class

A

B

Allowable stem seal helium leakage rate:

[mg/s/m circ]

10.

10

-3-4-5

=

=

=

[cm/s/mm dia.]

1.76x10

1.76x10

1.76x10

-5-6-73

RWTUV:

C 10

Temperature

0range [C]

<= 250

> 250

Allowable stem seal helium leakage rate:

[mbarl/s/m circ.]

-4 [cm/s/mm dia.]

-7310. =

10. =

-23.1 x10

3.1 x10

-5

MESC ADDITIONAL REQUIREMENT

SPE 77/312

APPENDIX C

(ISA-4.4)

Valve classification - typical examples:

(ISA-5.4)

(ISA-table 2)

(ISA-table 3)

(ISA-annex B)

(ISOp1-5.2.1)

Test

temp.

[ºC]

Maximum

pressure

rating [barg]

Stem

diameter(mm)

Revision: 22-03-2001.

Page 19 of 21.

Actual number of

number of

Total

stem seal

maximum

number of

completed

thermal

adjustments

emission

completed

cycles:

at cycle no.:

leakage

cycles:

(see appendix

B & D)

On/off rising stem valves (manual), bellows sealed and stuffing box with square section graphite packing.

Ambient

& +400

< 1 ppmv

Helium

50 2 0

On/off rising stem valves (manual) with advanced stuffing box (graphite cup and cone packing).

Ambient

& +500

< 20 ppmv

Helium

200 2 0

On/off rising stem valves and standard stuffing box (square section graphite packing).

Ambient

&+400

204

(class 800)

11.1 <= 1.76*10

mbar.l/s He

(Shell class A)

-61500 1 1

Ambient

&+350

50. (8” class

<= 100 ppm

-4300 gate

5.8*10

3valve) /s He

(Shell class B)

2000 2 0

Ambient 51.7 6”-class

100 ppm

300 WC6

dynamic CH4

gate vlv (Shell class C)

3500 0 0

On/off quarter turn valve (automated) with PTFE or graphite packing in the stuffing box:

Ambient

& -196

105

(class 600)

65

16” valve

< 1*10

mbar*l/s He

(ISO-class A)

< 2*10

mbar*l/s He

(Shell-class C)

-5-640.000 4 0

Ambient

& -196

18.5

(class 150)

24” valve

2 0

(ISA-table 2)

(ISA-table 3)

(ISA-annex B)

(ISOp1-5.2.1)

Test

temp.

[ºC]

Maximum

pressure

rating [barg]

Stem

diameter(mm)

Actual number of

number of

Total

stem seal

maximum

number of

completed

thermal

adjustments

emission

completed

cycles:

at cycle no.:

leakage

cycles:

(see appendix

B & D)

MESC ADDITIONAL REQUIREMENT

SPE 77/312

Revision: 22-03-2001.

Page 20 of 21.

On/off quarter turn (soft seated) ball valve (manual) with PTFE seats and packing:

Ambient,

+100 &

+150

Ambient,

+100 &

+150

50

(class 300)

14.3

1” valve

3*10 cm/s He

(Shell class A)

-63-732500 3 0

50

(class 300)

25.6

4” valve

4*10 cm/s He

(Shell class A)

200 3 0

Ambient 8.6 1” full

5 ppm CH4

port style

(Shell class A)

5SB-150

50000 0 0

APPENDIX D

(ISA-annex C)

METHANE - HELIUM CORRELATION FACTORS.

D.1

The modes of leakage, which may result from the factors which influence

gaseous flow through leaks, are: molecular, transitional and viscous (both

laminar and turbulent).

For the measuring media methane (CH4) versus helium (He) the following

correlation factors shall be adhered to:

Sniffing new valves and in situ testing with molecular flow with leakage less

than

-710 mbar.l/s: Q(CH4) to Q (He) = 1 to 2

Leakage’s from valve glands and body/bonnet connections are generally

of the small viscous laminar flow type (i.e. a free flow route):

Q(CH4) to Q (He) = 1.8 to 1 (at 10 bar and 300K)

Q(CH4) to Q (He) = 1.9 to 1 (at 50 bar and 300K)

Q(CH4) to Q (He) = 1.96 to 1 (at 100 bar and 300K)

Q(CH4) to Q (He) = 2 to 1 (rounded off)

MESC ADDITIONAL REQUIREMENT

SPE 77/312

APPENDIX D

Revision: 22-03-2001.

Page 21 of 21.

The correlation between the methane screening value (ppmv) and the

methane leak rate (kg/hour) for valves used in the Synthetic Organic

Chemical Manufacturing Industry (SOCMI) and the Petroleum Industry

(ref. EPA 453/R-95-017 publication, section 2 and appendix B, pages B7

and B18) can be calculated.

The protocol for equipment leak emission estimates states:

ß0ß1Methane leak rate [kg/hr] = SBCF * 10 * (screening value [ppmv]) where:

31 kg/hr methane = 386 mbar.l/s (Q=0.72 kg/m) and

Petroleum industry correlation for valves:

SBCF = 3.27 (Scale Bias Correction factor),

ß0 = -6.154 (intercept of regression line) and

ß1 = 0.746 (slope of regression line),

SOCMI correlation for gas valves:

SBCF = 6.315 (Scale Bias Correction factor),

ß0 = -6.529 (intercept of regression line) and

ß1 = 0.873 (slope of regression line),

SOCMI correlation for light liquid valves:

SBCF = 7.52 (Scale Bias Correction factor),

ß0 = -6.069 (intercept of regression line) and

ß1 = 0.797 (slope of regression line),

For the comparison of local measurements (ppmv) and global

measurements (mg/s) for Petroleum Industry valves and SOCMI valves

are the following methane screening value – leak rate correlations

applicable:

D.2

Methane

screening

value

[ppmv]

2.8

10

25

50

100

250

500

Average

methane leak

rate for valves

[mbar.l/s]

3.1 * 10

8.6 * 10

2.1 * 10

3.1 * 10

5.5 * 10

1.2 * 10

2.0 * 10

-1-1-2-2-2-3-3 Methane leak rate

for Petroleum

Industry valves

[mbar.l/s]

1.9 * 10

4.9 * 10

1.0 * 10

1.6 * 10

2.8 * 10

0.6 * 10

0.9 * 10

-1-1-2-2-2-3-3Methane leak rate

for SOCMI gas

valves

[mbar.l/s]

1.8 * 10

5.4 * 10

1.2 * 10

2.2 * 10

4.0 * 10

0.9 * 10

1.6 * 10

-1-1-2-2-2-3-3Methane leak rate

for SOCMI light

liquid valves

[mbar.l/s]

5.6 * 10

15.5 * 10

3.2 * 10

5.6 * 10

9.7 * 10

2.0 * 10

3.5 * 10

-1-1-2-2-2-3-3

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