WINGS CORPORATION Doc. No. : WD14-001E Japan Rev. No. : E0wingshome.co.jp/introduction/section8_e.pdf · 2018. 10. 16. · Also, low temperature tests at temperatures below -196 °

The copyright is in Takashi Yagisawa

Translation Start Date: August 8th, 2018

http://wingshome.co.jp/introduction_e.html

WINGS CORPORATION

Japan

Doc. No. : WD14-001E

Sheet 116 of 138

Rev. No. : E0

Title: Introduction of the inspection and testing for the

industrial valves

8. Function test (PERFORMANCE INSPECTION)

This commentary for mainly operating tests and actual temperature of the actuator with the valve (low

temperature and high temperature) test.

Others, Fire Test etc are also available but I will omit it.

8.1 Operation test of valve with actuator

Actuators are mainly classified as electric, pneumatic, and hydraulic by operating methods. In the selection

(sizing) of the actuator, it is general that the maximum design differential pressure is used as a reference.

Pressure inspection (PRESSURE INSPECTION) will be implemented in accordance with paragraph 5 of this

article. However, the High-Pressure Closure Test uses a test pressure (API 598, JPI-7S-39, etc.) 1.1 times the

maximum design differential pressure and operates with the actuator.

For the valves with actuators, perform the following function tests according to the operation method. (refer

to JPI-7R-68.)

8.1.1 Motor Operated Actuator

(1) Operation inspection: It is electrically operated fully open and fully closed, operation is smooth, limit

switch, torque switch, etc. are functioning. Also, the opening indication must be accurate when fully open or

fully closed.

In addition, measure the current at startup and running, and be within the range of specifications.

(2) Opening and Closing Time Test: Full opening / closing within the prescribed time.

(3) Manual operation inspection: If equipped with manual operation function, switch to manual operation

and operate smoothly.

(4) Withstand voltage: Test voltage (motor rated voltage × 2 + 1,000 V) is applied for 1 minute between the

stator winding of the motor (motor) and earth and there is no abnormality. However, in principle, it is not

carried out when the actuator manufacturer carries out the certificate. Which may cause deterioration.

(5) Insulation resistance test: Set to 100 MΩ or more at DC 500 V between each terminal of the motor and

the electrical components and the earth.





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Note:

An explosion-proof standard is set for valves with actuators installed in the plant when they are used in an

atmosphere of flammable gas. Attach the actuator with the structure specified in the explosion-proof grade

of the purchase specification (regulation of IEC 60079). These grades are listed on the nameplate of the

actuator and it is necessary to check whether there is any difference from the certificate.

The following is a reference example of explosion proof symbol.

For reference, Name Plate indication





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8.1.2 Pneumatic Operated Actuator

(1) Operation inspection: It is fully open and fully closed by pneumatic pressure, operation is smooth, limit


fully closed.

In addition, in the case of a single operation by a combination with a spring, the air is stopped and the state

of air pressure disappears, and a fully closed or full open test by a spring return is performed.




(4) Cylinder leakage inspection: Pressurize the cylinder part to the specified air pressure and have no leakage

from each part of the cylinder.

8.1.3 Hydraulic Operated Actuator

(1) Operation inspection: It is fully open and fully closed by pneumatic pressure, operation is smooth, limit


fully closed.




(4) Leakage inspection: The specified pressure is applied to the hydraulic part, and there is no leakage from

each part such as hydraulic piping.





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For reference only: The following is an example of formula for calculating actuator sizing.





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8.2 Low- and High-Temperature Testings

A test to confirm the function in a low temperature or high temperature environment close to the actual use

condition of the valve is called a real temperature test. The actual temperature test must be carried out by

presenting to the valve maker the test procedure including application status, quantity to be purchased and

amount of leakage in purchase specifications. In the absence of these requirements, the valve manufacturer

does not normally perform real temperature test.

8.2.1 Low temperature test

For the low temperature test, the minimum design temperature of the valve is from -50 ° C to -196 ° C for

BS 6364: Valve for cryogenic service, from -30 ° C to -196 ° C for Shell MESC SPE 77/200: 2007 VALVE

IN LOW TEMPERATURE AND CRYOGENIC SERVICES . Also, low temperature tests at temperatures

below -196 ° C are not common as they require special testing equipment.

(1) Test facility (Test Rig Arrangement)

Reference examples of test equipment are shown below.

· The line on the pressurizing side needs to be approved in Japan as a high pressure gas production facility.

· All piping must be designed to have sufficient strength under low temperature environment by using

stainless steel pipe, fitting, flange, high pressure connecting jig. In addition, it is necessary to confirm that

leakage of piping system is less than allowable leakage amount by helium pressure applied pressure before





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testing.

· For temperature measurement, measure the temperature of the test site, the vicinity of Disc inside the valve,

the body surface and Stuffing Box portion.

· The test pressure shall be measured at two places, the pressurizing side and the exit side, and at least the

test pressure at the pressurizing side must be recorded continuously. Please calibrate the pressure gauge and

use range according to applicable standards.

· Check the valve leakage amount with a flow meter provided on the outlet side or a small amount of leakage

with a measuring cylinder in water.

· It is recommended that test data (pressure, temperature, flow meter leakage, helium detector leakage etc.)

be recorded over time. It is now easier to digitally record using a data logger.

Example in which recording was observed using a data logger (values shown in the example when high temperature test was performed)

· Place a safety valve on the pressurizing side and miss the pressure when abnormal pressurization occurs.





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· Stainless steel plate is used for the low temperature tank and it is structured to withstand the load of the

target valve, and it is enclosed by the insulation material.

Secure the height at which the coolant is immersed to the border with Bonnet's Extension section or to the

tip of Bonnet Bolt.

Sample of cold bath for large diameter valve Sample of cold bath for small caliber valve

(2) Coolant (Coolant)

· When carrying out at -196 ° C, use liquefied nitrogen.

· When carrying out at less than -196 ° C, it is common to use gas vaporized liquefied nitrogen, industrial

alcohol + liquefied nitrogen or industrial alcohol + dry ice, but a large amount of alcohol is dangerous,

compliance with laws and regulations , It is necessary to fully consider safety assurance.

(3) Test fluid (Test Fluid)

It is recommended to use helium gas regardless of test temperature. However, with Shell MESC SPE 77/200,

100% nitrogen gas or 99% nitrogen gas + 1% helium gas is allowed for the test temperature of -110 ° C or

higher.

(4) Test Temperature (Test Temperature)

Depending on the design temperature, it will not test below the impact test temperature specified by Body /

Bonnet / Cover material standard (ASTM, JIS etc.).





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Note:

1) Main liquefied gas types and boiling points (° C)

Ammonia - 33.4, Propane - 42.1, Propylene - 47.7, Hydrogen Sulfide - 61, Acetylene - 84, Ethane - 88.6,

Ethylene - 103.5, Methane - 165.5, Oxygen - 183, Argon - 185.8, Nitrogen - 195.8, Hydrogen - -268.9.

It should be noted that a liquefied gas which is a liquefied gas whose pressure exceeds 0.2 megapascals at a

normal temperature and has a pressure of 0.2 megapascals or more at present or a temperature of 35 ° C. or

less when the pressure becomes 0.2 megapascals , Under the High Pressure Gas Safety Act. in Japan.

2) Main specifications of low temperature materials and impact test temperature:

Material Standards Impact Test Temp.℃ Material Standards Impact Test Temp.℃

ASTM A352 LCB -46 ASTM A350 LF2 CL.1 -46

ASTM A352 LCC -46 ASTM A350 LF2 CL.2 -18

ASTM A352 LC1 -59 ASTM A350 LF3 -101

ASTM A352 LC2 -73 ASTM A350 LF5 -59

ASTM A352 LC3 -101 ASTM A350 LF6 CL.1 -51

ASTM A352 LC9 -196 ASTM A350 LF9 -73

3) Main low temperature characteristics of austenitic stainless steel

It is known that when austenitic stainless steel is held at -100 ° C. or lower for a long time, a part of the

structure undergoes martensitic transformation. These austenitic stainless steel (mainly ASTM A351 Gr.

CF8M / ASTM A182 Gr. F316) are often used for body material of cryogenic valve is deformed due to the

martensitic transformation, is the cause of the seat leakage There. However, the influence of thermal

deformation is also significant, and it is required to design in consideration of these phenomena.

As for the martensitic transformation, treatment may be carried out in which transformation occurs in advance

in liquefied nitrogen (-196 ° C.) at the stage of material or semi-processing to partially alleviate the risk of

deformation. These processes are called sub-zero processing (SUB-ZERO TREATMENT), the valve

manufacturer decides the processing standard and decides which part range to execute.

(5) Test method

1) Prior to testing

Before conducting the low temperature test, perform the above-mentioned pressure test at the room

temperature at the target valve and proceed the low-temperature test to the accepted valve. It is recommended

to use nitrogen gas or helium gas as the test fluid in this case.

When confirmed by water pressure, it is necessary to thoroughly dry the inside of the valve. In particular, it

is difficult to remove water that has penetrated into packing and gaskets.

Eliminate dust, dirt, oil and other foreign matter, and install the test fixture in a clean environment.

Also, make sure that all bolts / nuts (Bonnet Bolting / Gland Bolting) are tightened with the prescribed torque

before the low temperature test. The specified torque must be calculated and presented by the valve maker.





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2) Immersion in liquefied nitrogen (Cooling Down)

- After installing the test fixture and moving to the low temperature bath, purge the piping system with helium

and remove the internal moisture. For large valves, measure the dew point as necessary and confirm that no

dew condensation occurs at low temperature.

· Next, pressurize the piping system with helium of 0.2 MPa, and use a helium detector to check leakage

from the connection. In this case, the amount of leakage shall be less than the allowable leakage amount

described in the purchasing specifications.

· When it is confirmed that there is no moisture and leakage, inject liquefied nitrogen into the low

temperature bath.

Note:

Since liquefied nitrogen boils until the cold bath and the valve cools down, oxygen in the low temperature

tank and around it becomes oxygen deficient. Prepare an oxygen concentration meter, measure the oxygen

concentration in the surroundings, ventilate so as not to suffocate, and take safety measures.

3) Cryogenic Test Method

Described with reference to BS 6364:

· When liquefied nitrogen is filled up to the specified height, hold for at least 1 hour until measurement

temperature stabilizes.

* Shell In MESC SPE 77 / 300-2007, test can be started if it is kept for 5 minutes until it becomes stable and

the temperature inside the valve becomes -190 ℃ or lower (test temperature is -196 ℃). For other test

temperatures, it can be started when the temperature difference is 5% of the specified test temperature or 5 °

C, whichever is higher.

· Valve seat test pressure stage (Increment Test Pressure)

BS 6364 pressurizes to the maximum pressure of 20 ° C of the Rating Pressure (Max. Allowable Working

Pressure / MAWP) of each pressure (Nominal Pressure) at the following pressure stage.

Nominal Pressure Class (PN) Increment Pressure (MPa)

Class 150 (PN 20) 0.35

Class 300 (PN 50) 0.75

Class 600 (PN 100) 2.00

For example, the rating press of ASME B 16.34 at 20 ° C of Body material CF 8 M,

Class 150: 1.90 MPa, Class 300: 4.96 MPa, Class 600: 9.93 MPa.

unit: MPa

Class 1st. Step 2nd. Step 3rd. Step 4th. Step 5th. Step 6th. Step

150 0.35 0.70 1.05 1.40 1.75 1.90

300 0.75 1.50 2.25 3.00 3.75 4.96

600 2.00 4.00 6.00 8.00 9.93 N/A





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Shell MESC SPE 77/300-2007 では、(CF8M) unit: MPa

Class LP seat 1st. 35%

MAWP

2nd. 70%

MAWP

3rd. 110%

MAWP HP seat 100%

150 0.2 / 0.7 0.665 1.33 2.09 1.90

300 0.2 / 0.7 1.736 3.472 5.456 4.96

600 0.2 / 0.7 3.476 6.951 10.923 9.93

· Operation test

In BS 6364, Open / Close is performed 20 times at each stage, and the operation torque of Open / Close is

measured at the beginning and the end. The upper limit value of the operation torque is converted to 350 N

in terms of the steering wheel operating force.

In Shell MESC SPE 77 / 300-2007, perform opening / closing 90% at LP seat and 15 times at HP seat and

measure the torque the first time at the first time. The upper limit value of the operation torque is converted

to 350 N in terms of the steering wheel operating force.

Operational tests exclude Check Valve.

· Valve seat leak test (Incremental Pressure Seat Leakage Tests)

At BS 6364, tests should be conducted at each pressure stage and below the allowable leakage below.

Gate & Globe Valves: 100 mm 3 / s × DN.

Check Valves: 200 mm 3 / s × DN.

(Except for Check Valve, tightening torque shall be not more than the value determined by the valve maker.)

Test Duration:

unit: Minutes, Minimum

Valve Sizes LP seat 3 Steps HP seat

DN 15 -- 400 5 5 5

DN 450 -- 600 5 5 10

＞DN 600 10 10 15

For Shell MESC SPE 77 / 300-2007, tests should be conducted at each pressure stage and below the allowable

leakage below.

Gate & Globe Valves: 80 mm 3 / s × DN.

Check Valves: 160 mm 3 / s × DN.

(Except for Check Valve, tightening torque shall be not more than the value determined by the valve maker.)





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· Pressure resistance test (Shell Test)

In BS 6364, there is no visual leakage from Gland part and Body / Bonnet Joint at each pressure stage, but

there is no specific method and regulation of allowable leakage amount.

For Shell MESC SPE 77 / 300-2007, conduct and check the leakage FE test from the Gland part and Body /

Bonnet Joint at 100% MAWP pressure. The test method is also described in the leak test in Section 4.5.

Test Duration:

unit: Minutes, Minimum

Valve Sizes Class 150 Class 300 Class 600

DN 15 -- 40 10 10 10

DN 50 -- 150 10 10 15

DN 200 – 400 10 10 15

DN 450 -- 600 10 10 15

＞DN 600 15 15 20

Allowable Leakage Rate:

Stem Seal Area;

Class A (HS): ≦ 1.78 × 10 -8 × Stem Diameter (mm) Pa · m 3 / s

Class B: ≦ 1.78 × 10 -7 × Stem Diameter (mm) Pa · m 3 / s

Gasket Seal Area;

Class A (HS): ≦ 1.78 × 10 -9 × Perimeter of the Gasket (mm) Pa · m 3 / s

Class B: ≦ 1.78 × 10 -8 × Perimeter of the Gasket (mm) Pa · m 3 / s

Note:

1) After the low-temperature test, open the valve halfway, seal the pressure within about 0.2 MPa, leave it to

room temperature naturally. If the valve is opened immediately after the cold test, dew condensation will

occur due to the difference with room temperature, and it will contain moisture inside.

In addition, there is a case where the valve seat leakage test and the pressure resistance test are performed

again after returning to room temperature. In the Prototype Test, disassemble and check for damage of parts

etc.





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2) Difference in polishing of Disc Seat face;

The left side shows the general valve and the right shows the seat side of the low temperature valve. Surface

roughness depends on production standard of each valve manufacturer.

3) Precautions for Pressure Relief Hole of Cryogenic Valve:

In the disc of Gate Valve for Cryogenic, a hole is drilled as shown in the left figure for preventing abnormal pressure rise.

Therefore, when pressure is applied from the opposite side of the hole as shown in the left figure, it leaks to the primary side through a hole (Pressure Relief Hole). Normally, "High

Pressure Side" or "Vent Hole Side" is displayed on the hole side of the valve.

Even when piping, care must be taken in the sealing direction when fully closed.





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4) Location of “BackSeat” for Cryogenic Valves

Fig. 1

Normally, the position of BackSeat is the position shown in Fig.1, but Shell specifies Fig.2 or Fig.3. The reason is that liquefied gas enters the Cavity of Long Bonnet, and when using BackSeat it is the purpose of

preventing the risk of abnormal boost. The disadvantage is that manufacturing precision is required, and if BackSeat leaks, repair becomes difficult. We will judge that the case of using BackSeat of valve after piping installation is extremely limited. In addition, since packing exchange during pressurization is prohibited, the

author recommends the position in Fig.

Length for

Non Cold Box

Rev. 1B

Length for

Cold Box

Rev. 1B





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5) Long Bonnet length of cold valve

The minimum length is specified as follows according to each standard and regulation.

* BS 6364:

The length below is the length from the center line of the valve diameter in the upper figure Fig.1.

Note:

The above Table 1 is the length when the valve body is installed in the Cold Box, and in the case of the Non

Cold Box, it is stipulated as Min. 250 mm. (See Fig.1)

＊SHELL MESC SPE 77/200-2007：

Note:

In order to maintain the effect of the Vapor Space, the cold valve is a horizontal piping and the Stem is

generally in a vertical attitude. With respect to the Stem vertical, the BS6364 is ± 15 degrees, the MESC SPE

77/200 is ± 30 degrees Of the maximum allowable range.





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＊MSS SP-134-2006a Valves for Cryogenic Service Including Requirements for Body/Bonnet Extensions：

Note:

The standard of the length is the Top of the Stuffing Box from the valve centerline line.

It differs from BS and MESC.

* Other

Although it seems that there is no regulation about the temperature of Stuffing Box when fluid of Cryogenic

Service is flowed, in general, the temperature at which Packing section does not freeze is a standard.

Regarding the verification of the temperature of the Stuffing Box, it is possible to perform temperature

analysis using a method to obtain by experiment such as aeration method and recently using finite element

method (FEM).

FEM analysis example:





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8.2.2 High Temperature Test

For the method of high temperature testing, there are a method of passing a heated steam or a high temperature

gas through the inside of the valve and a method of winding and heating the outside of the valve with an

electric heating coil or the like.

Except for blowing out tests of safety valves, general valves are less frequently implemented except when

specially requested for Prototype Test. Twenty years ago, we held a boiler test site at the Japan Valve

Manufacturers Association, and there were cases in which function tests of high temperature / high pressure

valves etc. of each company were carried out.

In the above picture, a coil for local heating is wound around the bulb and a heat insulating material is attached.

As for the test method, generally, when the temperature inside the valve falls within the specified temperature

range, the operation, the valve seat leakage, and the withstanding pressure are checked as in the low

temperature test. It is necessary to clarify each test method and specified leakage amount in the order

specifications.





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For reference:

Reference example of approximate calorie calculation

(Class 150 - 6 "Calculation example in the case of Gate Valve CF8. The value varies depending on the

manufacturer.)

Condition: heating temperature 200 ° C., fluid: helium

① The amount of heat required for heating Helium in the valve:

W 1 = 1.16 × C 1 × d 1 × V 1 × Δt

C1: Helium specific heat = 1.25 kg * cal / (kg * ° C)

d 1: Helium density = 0.178 kg / m 3

V1: Valve volume roughly 0.006 m3

⊿t: Heating from 0 ° C to 200 ° C

∴ W1 about 0.31 W

② Heat quantity required for heating the valve body:

W 2 = 1.16 × C 2 × d 2 × V 2 × Δt

C2: Specific heat of stainless steel = 0.118 kg * cal / (kg * ° C)

d 2 × V 2 = 110 kg (Body & Bonnet material weight)

⊿t: Heating from 0 ° C to 200 ° C

∴ W 2 about 3010 W

③ Heat radiation of valve surface:

W 2 = A × Q

A: Valve surface area about 0.68 m 3

Q: Heat dissipation loss coefficient Without heat retention: 3400 W / m 3

∴ W3 about 2312 W

Total power: The amount of electricity required for heating up to 200 ° C in 1 hour is about 5.3 kW

Class 150 - 6 "For Gate Valve CF8:

Under heating conditions up to 200 ° C in 5 hours, winding a heater of about 1.06 kW is a measure of the

test.

Documents

WINGS CORPORATION Doc. No. : WD14-001E Japan Rev. No. : E0wingshome.co.jp/introduction/section8_e.pdf · 2018. 10. 16. · Also, low temperature tests at temperatures below -196 °