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Knowledge

1. Standards

1. API 598 – Valve Inspection and Testing

API 598 is a widely recognized standard for inspection and pressure testing of valves, covering gate, globe, check, ball, and plug valves.

Testing Requirements:

  • Shell Test: Hydrostatic pressure test at 1.5 times the rated pressure to check for leaks.
  • Seat Leakage Test: Tests valve closure under pressure (0.6 times rated pressure for hydrostatic and full-rated pressure for air/gas).
  • Backseat Test: Applies to gate and globe valves to check stem sealing capability.
  • Visual Inspection: Ensures proper assembly and workmanship.
2. API 6D – Pipeline Valve Testing

API 6D is the standard for pipeline valves, including ball, check, plug, and gate valves used in oil and gas transmission.

Testing Requirements:

  • Shell Test: Hydrostatic test at 1.5 times the valve pressure rating.
  • Seat Test: Performed with both low-pressure air and high-pressure hydrostatic tests to check internal leakage.
  • Double Block & Bleed (DBB) Test: For ball and plug valves to confirm independent sealing on both sides.
  • Operational Testing: Ensures proper valve movement and sealing under real-world conditions.
3. BS EN 12266 – Industrial Valves Testing

BS EN 12266 is the European standard for industrial valve pressure testing, providing a classification for valve tightness and leak rates.

Testing Requirements:

  • Pressure Shell Test: Similar to API 598, ensuring valve body integrity under pressure.
  • Leakage Classifications: Defines allowable leakage limits, with EN 12266-1 for hydrostatic testing and EN 12266-2 for supplementary air/gas testing.
  • High-Temperature and Cryogenic Testing: For valves used in extreme conditions.
  • Actuator Performance Tests: Ensures proper operation of automated valves.
4. FCA 70-2 – Fire Safe Testing for Valves

FCA 70-2 is a fire-safe testing standard for industrial valves, ensuring they can maintain integrity and functionality under extreme fire conditions.

Testing Requirements:

  • Fire Exposure Test: The valve is subjected to direct flame exposure for a specific duration to assess sealing performance.
  • Post-Fire Leakage Test: After fire exposure, the valve is checked for external and internal leakage under pressure.
  • Operational Test After Fire: Ensures the valve remains operable after exposure to fire conditions.
  • Seat & Shell Integrity: Assesses the resilience of seals, packing, and body materials under extreme heat.
5. BS 6364 – Cryogenic Valve Testing

BS 6364 is the British Standard for cryogenic valves, ensuring their functionality at extremely low temperatures, typically for liquefied gases such as LNG, liquid oxygen, and liquid nitrogen.

Testing Requirements:

  • Cryogenic Shell Test: The valve body is tested at cryogenic temperatures (as low as -196°C) to check material durability.
  • Low-Temperature Seat Leakage Test: Performed using liquid nitrogen or helium to ensure tight shut-off at cryogenic conditions.
  • Operational Test at Low Temperatures: The valve must open and close smoothly under extreme cold.
  • Gland Packing and Stem Seal Integrity: Ensures minimal leakage from the stem and packing area.
Ensuring Compliance with Hydroflow Systems

Hydroflow Systems specializes in designing and manufacturing advanced test benches that help industries meet the above global testing requirements. Our test systems ensure:

  • Accurate and repeatable testing in compliance with international standards
  • Custom-built solutions for specific valve types and testing needs
  • Reliable results that enhance product safety and quality

By adhering to these stringent standards, we help industries maintain operational safety, reliability, and efficiency in critical applications.

2. Sealing Types

1. Flange Sealing

Concept: Flange sealing involves clamping the valve flanges between sealing plates using high-pressure hydraulic clamping or bolted connections. The test bench applies pressure to check for leaks in the valve body and seat.

Application:

  • Suitable for Gate Valves, Globe Valves, Ball Valves, and Butterfly Valves with flanged ends.
  • Used when the valve has flat-faced or raised-face flanges.
2. Bore Sealing

Concept: Bore sealing uses expandable seals or O-rings inside the valve bore to create a pressure-tight seal. This method eliminates the need for external clamping.

Application:

  • Suitable for Ball Valves, Plug Valves, and Check Valves with a smooth bore.
  • Ideal for valves without flanges or valves with integrated welding ends.
3. Compression Sealing

Concept: Compression sealing uses hydraulic pistons or mechanical clamps to apply force to the valve ends, compressing soft seals (like rubber or PTFE) to create a pressure-tight connection.

Application:

  • Used for Pressure Relief Valves, Safety Valves, and Actuated Valves.
  • Suitable for valves with threaded or socket-weld ends.
Conclusion

At Hydroflow Systems, we provide valve test stands equipped with all these sealing methods to accommodate a wide range of valve types. Our advanced sealing technology ensures:

  • Accurate testing results with minimal leakage
  • Customizable solutions for different valve designs
  • User-friendly test benches for quick and efficient testing

Our team can help select the best sealing method based on your valve type and testing needs. Let us assist you in achieving safe, efficient, and compliant valve testing.

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