77 -312

MESC ADDITIONAL REQUIREMENT SPE 77/312

Revision: 18 – 06 - 2004. Page 1 of 25.

INDUSTRIAL VALVES: FUGITIVE EMISSIONS (FE) MEASUREMENT, CLASSIFICSATION SYSTEM, QUALIFICATION PROCEDURES AND FE-PROTOTYPE AND FE-PRODUCTION TESTS OF VALVES.

INTRODUCTION

1

(ISO-p1introduction)

The risk associated with Fugitive Emissions (FE) from equipment in facilities that use, manufacture or transport media have created laws and Health, Safety and Environment (HSE) regulations with the objective to minimize fugitive emission leakage emitted through equipment, valves and piping systems to a level that is as Low As Reasonably Practicable (LARP).

(ISOp1-1)

SCOPE

1.1

This specification shall apply to the test and evaluation of fugitive emission suppressing performance level of on/off valves and control valves.

1.2

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: - FE-proto-type test of manual-, gear- and actuator operated valves - FE-production testing of manual-, gear-and actuator operated valves.

(ISOp1-1) (ISOp2-1) 1.3

A fugitive emission is defined as a leak from a fluid (e.g. hydrocarbons, chemical or mixture of chemicals).

1.4

This specification gives amendments / supplements to standards: - ISO/DIS 15848-1 (30 October 2003), - ISO/CD 15848-2 (doc’s. N598 & N601 of 12-06-2003) with the purpose of compliance with Shell Group requirements.

1.5

This specification shall be considered to be part of the valve buying description, when referred to in a MESC description and / or requisition.

1.6

The specification describes the type of detection method and test medium to be used and specify the acceptance and rejection criteria.

1.7

The numbers in brackets at the section headings refer to the relevant section in the standards as follows: ISOp1 = ISO / DIS-15848-1, ISOp2 = ISO / CD-15848-2.

MESC ADDITIONAL REQUIREMENT

Revision: 18 – 06 - 2004.

SPE 77/312

2.

(ISOp1-2) (ISOp2-2)

Page 2 of 25.

NORMATIVE 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.

ANSI / FCI 91-1 (6-6-1997)

Standard for qualification of control valve stem seals.

ASME B 16.34a, 1998 addenda

Valves, flanged, threaded and welding end.

Clean Air Act Amendments: updated strategies

List of air pollutants and their regulating program.

BS-EN 473 (2000)

Non destructive testing – Qualification and certification of NDT personnel – General Principles.

EN 1779 (8-1999)

Non destructive testing – Leak testing – Criteria for method and technique selection.

EN 13445-2

Unfired pressure vessels, Part 2 Materials.

EPA method 21 (issue: June 1990)

Determination of volatile organic compound leak. Code of Federal Regulations.

IEC 61514 year 2000

Industrial process control systems - Methods of evaluating the performance of valve positioners with pneumatic outputs.

ISO 5208

Industrial valves: Pressure testing of valves.

ISO-10434

Bolted bonnet steel gate valves for petroleum and natural gas industries.

ISO / DIS -15848-1 (ISO-TC153/SC1) Release: 30-10-2003.

Industrial valves - Fugitive emissions - Measurement, test and qualification procedures; Part 1: Classification system and qualification procedures for type tests of valves (proof of design, type testing).

ISO / CD-15848-2 (ISO-TC153/SC1) Document N598 of 12-06-2003.

Industrial valves - Fugitive emissions - Measurement, test and qualification procedures; Part 2: FE-production test of valves.

2nd issue February 2002

Shell Group HSE Management system.

2nd issue April 1999

Shell HSE Risk Assessment Matrix.

SPE 77/200

Valves in service below minus 50 degrees Celsius.

SPE 77/209

Valves in services between zero and minus 50 degrees Celsius.

MESC ADDITIONAL REQUIREMENT

Revision: 18 – 06 - 2004.

SPE 77/312

3. 3.1

4.

Page 3 of 25.

TERMS AND DEFINITIONS (ISOp1-3) (ISOp2-3)

(ISOp1-4)

The definitions are in accordance with standards ISO/DIS-15848-1 and ISO/CD-15848-2 with the following alterations: Identical

Equivalent (same configuration, form and function, but not exactly the same dimensions).

Same

Equal. Without any difference.

Leakage (ISOp1-3.6)

For stem seal and body/bonnet seal(s) the test medium being emitted under defined test conditions.

Leak rate (ISOp1-3.7)

The rate of leakage to atmosphere.

Principal

The principal is the owner of the production facility, (who ultimately pays for the purchased equipment).

Stem seals (ISOp1-3.17)

A pressure containing seal/packing to prevent leakage of the media to the atmosphere through the interfaces of the valve stem in contact with the valve bodies and adjacent parts.

Test pressures (ISOp1-3.19)

For FE prototype testing the rated valve body pressures at the selected test temperatures, as defined in section 4.6.1. For FE-production testing the valve body pressures at the test temperatures as defined in section 4.6.2.

Test temperature (ISOp1-3.20)

The stabilized valve test temperature (adjacent to the seating area) selected for the FE- test. The test temperature shall be measured at the thinnest valve wall body (outside). Ref. ISO/DIS 15848-1 figure 1 location X.

TYPE TEST CONDITIONS.

4.1

General requirements and valve preparation prior to testing

4.1.1

Testing shall be done at manufacturer’s works, end-user’s facilities or third party testing institutes and shall be executed under controlled (laboratory) conditions.

4.1.2

(ISOp1-4.1.1)

Only a fully assembled valve shall be used for FE-testing. Test fixtures in lieu of an assembled valve shall not be used.

4.1.3

In order to ensure a clear reference point with respect to the condition of the valve, the manufacturer shall confirm prior to commencing any FE prototype testing and FE production testing that the valve is in perfect condition.

4.1.4

Valves FE-tested 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, are acceptable provided these preservations do not hide any porosity.

4.1.5

The valve and bolt tightening prior to the test shall be in accordance to manufacturer’s specifications. If a test valve is equipped with a manually adjustable stem (or shaft) seal(s) it shall be initially adjusted according to the manufacturers instructions and recorded in the test report (Ref.: section 10).

MESC ADDITIONAL REQUIREMENT

Revision: 18 – 06 - 2004.

SPE 77/312

4.1.6

(ISOp1-4.1.1)

Page 4 of 25.

The valve and test equipment shall be clean and free of water, oil and dust. The test valve interior shall be completely dried prior to the test.

4.1.7

The required qualification/competent levels for FE testing operators are NDT method leak testing levels LT1, LT2 and LT3, complying to BS-EN 473.

4.2

PROTO TYPE TESTING

4.2.1

(ISOp1-4.1.1b)

A valve for FE prototype testing shall be selected from standard production, built to normal production tolerances.

4.2.2

It is not necessary to conduct an individual test of valves with all combinations of sizes and wall thickness’. A successful proof test on representative valves represent others to the extent described in sections 4.2.3 and 7.

4.2.3.

Number of valves to be tested and valve qualification

4.2.3.1

(ISOp1-4.1.1) (ISOp1-7)

If a valve successfully has been FE-prototype tested it shall qualify nominal valve sizes 1 size smaller and 2 sizes bigger, e.g. a successful FE-test of a DN 20 valve size qualifies DN15, DN 20, DN 25 and DN40 nominal valve sizes. Valve nominal sizes with designation (T) shall be FE prototype tested. Note: The test valve selection tables provide the optimum nominal sizes that shall be tested to qualify a maximum valve range.

Ball, gate, globe, check, butterfly (>DN80) and plug valves: NOM SIZES INCHES

DN

1/2

15

3/4

20

1

25

1.1/2

40

2

50

PRESSURE CLASS: 150

T = Valve selected for testing.

300

600

800

900 1500 2500

T

T

T

T

MESC ADDITIONAL REQUIREMENT

Revision: 18 – 06 - 2004.

SPE 77/312

Page 5 of 25.

NOM SIZES INCHES

DN

3

80

4

100

6

150

8

200

10

250

12

300

14

350

16

400

18

450

20

500

24

600

PRESSURE CLASS: 150

300

600

900 1500 2500

T

T

T

T

T

T

T

T

T

T = Valve selected for testing. 4.2.3.2

(ISOp1-7)

With respect to the tables in section 4.2.3.1: The following class qualification valve groupings are established: Group 1: Class 600 qualify also classes 150 and 300, Group 2: Class 1500 qualify also class 900, Group 3: Class 800 is unique for valves with threaded ends, SW ends and extended-weld-ends and qualifies class 800 only. Group 4: Class 2500 qualify only class 2500. These groupings assume valve designs are identical in terms of construction, form and function. Certain valve types and production ranges may not be produced in the above class qualification groupings. In such cases the following rules apply: Group 1: Where class 600 is not produced then class 300 qualifies class 150. Group 2: Where class 1500 is not made then class 900 qualifies only class 900.

4.2.3.3

(ISOp1-7)

In case these tested nominal valve size(s) cannot provide sufficient qualification range for larger valves, the nearest valve size shall be FE prototype tested to cover the complete production range.

MESC ADDITIONAL REQUIREMENT

Revision: 18 – 06 - 2004.

SPE 77/312

Page 6 of 25.

4.3 4.3.1

PRODUCTION TESTING (ISOp2-4.1)

For FE-production testing the sampling percentage shall be 3 % of the lot (at random selected) with a minimum of 1 piece per: - stem diameter and per valve type, and - valve diameter for check valves. The lot is defined as being the ordered quantity.

4.3.2 4.3.3

(ISOp2-4.2)

Pre-condition to grant a waiver for FE-production testing:

4.3.3.1

(ISOp2-4.2)

FE-production testing on subsequent valve orders is not required provided the manufacturer shall confirm that: - Product(s) successfully passed FE-prototype testing (ref. 4.2), - Provides the client FE-prototype and (were applicable) production acceptance test report(s) of random selected valve(s) (see also section 7) which successfully passed these tests and are used for the same temperature class, endurance class and tightness class. - The accepted FE-prototype and FE-production test report(s) shall be: - not older than 2 years and - in compliance with section 7. - Documentary evidence shall be included in the technical dossier and remain with the manufacturer.

4.4

Sealing components:

4.4.1

For valves with flanged, butt welded, socket welded or screwed ends.

4.4.1.1

For valves with flanged ends the gaskets for the end flanges shall be spiral wound with ASTM A240 type 316(L) or 304(L) windings, inner ring and centring ring and graphite filler.

4.4.1.2

The manufacturer shall ensure that suitable test clamp connectors shall be used for valves with a wafer/lug design, butt welded (BW) ends, socket welded (SW) ends or screwed ends (to seal the valve ends).

MESC ADDITIONAL REQUIREMENT SPE 77/312

Revision: 18 – 06 - 2004. Page 7 of 25.

4.4.2

(ISOp1-4.2.3.1) (ISOp2-4.3)

Seal adjustment.

4.4.2.1

(ISOp1-4.2.3.1)

The bolting of the valve: - end flanges, - (or test clamp connections in case of valves with a wafer/ lug design, BW ends, SW ends or screwed ends ), - bonnet flanges and/or - stuffing box gland may be re-tightened only once in the event these connections 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. Failure of the valve end flanges or test clamp connections and/or auxiliary piping connection(s) (pressure inlet), i.e. exceeding the applicable tightness class leakage specified in section 6.1, will not lead to a valve rejection but shall result in a retest of the valve. In case during the FE-test a second failure of the bonnet flanges and/or stuffing box gland occurs, the FE-test shall be stopped.

4.4.2.2

(ISOp14.2.4.1g) (ISOp2-4.3)

To ensure the valve is within its design limits and as a pre set-up test requirement the following actual torque value’s shall be verified prior to the execution of the fugitive emission testing: BTO = Break To Open, RTO = Running Torque to Open, ETO = End To Open, BTC = Break To Close, RTC = Running Torque to Close, ETC = End To Close. The manufacturer shall provide thrust and torque value design limits. Note: Torque and thrust tests shall be carried out in accordance with the testing requirements laid down in the applicable MESC buying description and prevailing MESC additional requirements.

4.4.2.3

The valve opening, running and closing torques shall be below the values specified by the Principal in the purchase order or data requisition sheets.

4.5

Test pressures:

4.5.1

(ISOp1-3.19)

For FE-prototype testing the gas test pressure shall be the rated valve body pressure at the selected test temperatures (ref. note 1), as defined in ISO-10434 and ASME B.16.34 - table 2 (pressure-temperature ratings for the various material groups). Note 1: Be aware of reduced design (P/T) limits for soft-seated valves (with elastomeric seats and seals). For soft-seated valves the manufacturer shall provide P/T seat ratings for the proposed soft seat materials in accordance with BS5351 section 6, table 3. The allowable P/T soft seat rating shall be determined by calculations in accordance with a recognised international standard, e.g. ASME VIII div.1/2 or EN 13445-2.

MESC ADDITIONAL REQUIREMENT SPE 77/312

4.5.2

Revision: 18 – 06 - 2004. Page 8 of 25.

(ISOp2-5.3)

For FE-production testing the gas test pressure for the test temperatures listed in section 5.3 - table 4 shall be:

(ref. 4.5.1)

- 6 barg for PN10 and PN16 valves, - 10 barg for class 150 (PN 20) valves, - 20 barg for class 300 (PN 50) valves, - 25 barg for class 600 (PN 100) valves, - 20 % of the rated valve body pressure at ambient temperature for valves in class 900 (PN 150) and above. 4.5.3

(ISOp1-4.2.2a)

The internal pressure applied to a test valve shall be maintained at the test temperature to a uniform level during the test. A temporary variation of the test pressure, within a range of +/- 5% of the nominal value as well as a momentary pressure drop, which is restored immediately, shall not invalidate the test results.

4.5.4

(ISOp1-4.2.2c)

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

4.6 4.6.1

Number of mechanical and thermal cycles and test temperature: (ISOp1-4.1.3) (ISOp2-6.1.b)

Mechanical cycling (valve stroking) shall be carried out at temperatures specified in sections 5.2.1 and 5.3 - table 4.

(ISOp1-3.10)

On/off valves: For FE prototype testing of on/off valves (except check valves) the mechanical test cycles shall move the valve stem from the fully closed position to 90% of the open position and back to fully closed position and constitute one 90% stroke cycle.

4.6.2

4.6.3

(ISOp2-6.1b)

For FE-production testing of on/off valves the mechanical test cycles shall move the valve stem from the fully closed position to 75% of the open position and back to fully closed position and constitute one 75% stroke cycle.

(ISOp1-3.9

Control valves: For both FE-prototype testing and FE-production testing of (linear and rotary) control valves the mechanical test cycles shall move the valve stem from the fully closed position to 20% of the open position and back to fully closed position and constitute one 20% of the stroke cycle (ref. ISO 15848-1 sections 3.9 and 4.2.4.3 and IEC 61514-2000 section 6.10.3).

4.6.4.

(ISOp1-4.1.3 & fig. 2) (ISOp2-5.4)

The temperature class shall cover the range for which the valve is designed. A temporary temperature variation: - within a range of +/- 5% and/or, - not exceeding +/- 15oC of the test temperature shall not invalidate the fugitive emission test result.

MESC ADDITIONAL REQUIREMENT

Revision: 18 – 06 - 2004.

SPE 77/312

Page 9 of 25.

4.7 4.7.1

Leakage detection and measurement. (ISOp1-annex A and B),

For FE prototype emission testing and production emission testing preferably the EPA method 21 direct sniffing leak detection method shall be used.

(ISOp2-5.2)

Note: Selecting the EPA method 21 sniffing technique or vacuum technique is depending on the sensitivity of the helium mass spectrometer leak detector equipment available (Ref.4.9.4). Fugitive emissions shall be measured at the: - valve stem/stuffing box, - body seals (i.e. body/bonnet, split body and body/cover flange seals), - valve end flanges (or test clamp connections in case of valves with a wafer/ lug design, BW ends, SW ends or screwed ends ), - inlet pressure connection, and for valves to ISO 14313 /API 6D the drain and vent plug(s) and grease injector (if installed).

4.7.2 (ISOp1-4.2.4.5 & 4.2.4.7)

4.7.3 (ISOp1-4.1.4) (ISOp2-5.4) 4.7.4

(ISOp2-5.2) (ISOp1- Annex B.1.6.2, item 3)

After completion of the mechanical cycling: - the valve shall be set in half open position, however, - soft seated ball valves shall be set in the fully open position (to prevent possible damage of the soft seats). Measure the leakage not before 10 minutes after having pressurised the valve at the specified test temperature.

The leakage shall be measured in both the static and dynamic valve stem conditions. Note: Precaution shall be taken not to touch the moving stem during dynamic testing.

4.7.5

The dynamic valve stem reading shall be taken when the stem moves from the closed position to the open position.

4.8

Test procedures, test equipment, test method and fixture.

4.8.1

The area of the test rig shall be in still air, isolated from wind, fans or drafts (see ASME V chapter IV-1071).

4.8.2

(ISOp1-4.2.1) (ISOp2-6)

As illustrated in ISO/DIS 15848-1annex B, figure B.2, one valve end shall be connected to the test medium bottles. To discharge the test medium outside the testing room, avoiding any increase in the test medium concentration in the atmosphere around the test rig and valve tested, the other valve end shall be connected to a vent valve outside the testing room.

4.8.3 4.8.3.1

Valve fixture and orientation: (ISOp1-4.2.4.1b)

Valves, except check valves and gate- and globe valves used in low temperature and cryogenic applications, shall be tested with the stem in the horizontal position (Ref.: SPE 77/312 section 3.1, SPE 77/200 section 3.2.6 and SPE 77/209, section 3.2.2).

MESC ADDITIONAL REQUIREMENT

Revision: 18 – 06 - 2004.

SPE 77/312

4.8.3.2

Page 10 of 25.

(ISOp1-4.2.4.1a)

The test fixture shall be designed taking into consideration all HSE, risk and safety precautions that ensure robustness of the test fixture, safety to personnel and environment. This is particularly critical when testing at cryogenic and/or high pressures/temperatures. Brackets to support the valve in the test rig shall be fixed to the end covers or clamped to the body. No support shall be mounted on the valve bonnet or cover.

4.8.3.3

The execution of the stuffing box shall be one of the following: - without a helium detection connection, - with single seal and test connection in the gland, as shown in Figure 1.

Figure1. Test rig with single seal and test connection in the gland 4.8.4

Test fluid / leak detection medium.

4.8.4.1

(ISOp1-4.1.2) (ISOp2-5.1)

For both FE prototype emission testing and FE production testing the leak detection medium shall be helium gas with 97% minimum purity. Helium is a non-toxic gas and does not react chemically with any other element, making it intrinsically safe. Due to its small molecules helium allows detection of the smallest leaks with little background interference.

4.9

(ISOp1-4.2.2)

Test equipment and instruments: sensitivity and calibration

4.9.1

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

4.9.2

The range of the test pressure gauges shall comply to ASME V requirements.

4.9.3

(ISOp1-fig.1)

The thermocouples shall be placed on the: - flow line, - body/bonnet (for body/bonnet gasket seal). - 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 (gland temperature). Note: If there is sufficient access the thermocouple shall be mounted on the inside of the valve body.

4.9.4

(ISOp1 annex B1.2) (ISOp2-5.2)

For FE prototype and production emission testing a suitable (portable) helium mass spectrometer leak detector and sample probes shall be used, e.g.:

MESC ADDITIONAL REQUIREMENT

Revision: 18 – 06 - 2004.

SPE 77/312

Page 11 of 25.

Suitable for “Shell” tightness classes: (Ref. Section 6.1)

Brand and type of helium mass spectrometer leak detector (note 1).

Sensitivity (minimum detectable helium leakage rate): [Pa*m3 *s-1]

Alcatel ASM-142 &

Stem seals.

Body- & bonnetseals.

Vacuum (technique A.2): 1* 10-12

A, B & C

A, B & C

ASM-142D

Sniffing (technique B.4): 1* 10-8

A, B & C

B&C

Alcatel ASM-182T &

Vacuum (technique A.2): 5* 10-13

A, B & C

A, B & C

ASM-182TD+

Sniffing (technique B.4): 1* 10-8

A, B & C

B&C

Alcatel ASM-192T,

Vacuum (technique A.2): 5* 10-13

A, B & C

A, B & C

192T2, 192TD+ & 192T2D+

Sniffing (technique B.4): 1* 10-8

A, B & C

B&C

Alcatel ASM-122D

Vacuum (technique A.2): 5* 10-13

A, B & C

A, B & C

Sniffing (technique B.4): 1* 10-8

A, B & C

B&C

Vacuum (technique A.2): 8*10-11

A, B & C

A, B & C

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

C

Not suitable

BOC Edwards: Spectron 300E

Sniffing (technique B.4): 4* 10-9

A, B & C

B&C

Kyky ZhP-30

Vacuum (technique A.2): 5*10-11

A, B & C

A, B & C

Vacuum (technique A.2):