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09 Testing Procedures HP - EN
09 Testing Procedures HP - EN
09 Testing Procedures HP - EN
Content
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Cold differential test pressure
CDTP page 2
1 What is CDTP?
Cold differential test pressure (CDTP) is defined in standard
CDTP is used if correction of set pressure of safety valves according to deviation of service
conditions is necessary.
2 What is CDTP-correction?
The CDTP-correction is the correction of set pressure at test bench condition to achieve the correct
set pressure at service condition.
3 Which influences on safety valves are covered with the setting at CDTP ?
The set pressure on test bench deviating from service condition is influence by:
- temperature
- superimposed back pressure
The CDTP covers only influences of superimposed back pressure and/or temperature.
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Cold differential test pressure
CDTP page 3
p cdtp = ( p set − p a ) * k T
pset: set pressure at service conditions [psig or barg]
pa: superimposed back pressure, constant or variable [psig or barg]. If variable and
conventional design, the max. superimposed back pressure should be used. If balanced
bellows design is used pa is set to 0 bar or 0 psig.
kT: correction factor for CDTP [-], this is depending on valve design/conventional
design/balanced bellows design/open or closed bonnet
T: temperature in [°C]
Calculation-formulas:
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Cold differential test pressure
CDTP page 4
paf/p * 100 [%] d0 = 9 [mm] d0= 17,5 [mm] paf/p * 100 [%] d0 = 9 [mm] d0= 17,5 [mm]
5 How does LESER set the safety valves depending on different service condition
with temperature and back pressure?
LESER has made steam tests on LESER test laboratory. These measurements have been
monitored, evaluated and processed into a correction curve. This curve was approved by German
TÜV Nord to be a adequate practible procedure to correct set pressure to cold differential test
pressure concerning deviation of service conditions. The original confirmation of TÜV Nord and a
englisch translation is attached in chapter 9.
Please note, that for gas service the setting is defined as “first audible discharge”. For full opening
of valve pls. add another 10%.
1,120
1,080
Approved correction curve by
German TÜV Nord
1,060
Correction factor kT
1,020
1,000
-300 -200 -100 0 100 200 300 400 500
0,980
Temperature T [°C]
0,960
-508 -308 -108 92 292 492 692 892
Temperature T [°F]
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Cold differential test pressure
CDTP page 6
Correction factor kT for conventional design open bonnet to correct adjusting on cold air
for service conditions of high temperature - cold differential test pressure -
1,120
1,080
Approved correction
curve by German TÜV
Nord
1,060
correction factor kT
1,020
1,000
-300 -200 -100 0 100 200 300 400 500
Temperatur (°C)
0,980
0,960
-508 -308 -108 92 292 492 692 892
Temperature (°F)
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Cold differential test pressure
CDTP page 7
Correction factor kT, stainless steel bellows design, open or closed bonnet,
to correct adjusting on cold air for service conditions of high temperature
- cold differential test pressure -
1,120
1,060
Correction factor kT
1,020
1,000
-300 -200 -100 0 100 200 300 400 500
Temperature T [°C]
0,980
0,960
-508 -308 -108 92 292 492 692 892
Temperature T [°F]
figure 3: correction factor kT for open or closed bonnet balanced bellows design
Note 1: LESER set safety valves in the range of 0 – 3% set pressure tolerance.
Note 2: The CDTP is not the popping point. It is according to LESER definition the set pressure with definition
“audible discharge” for gases/steam and “first steady stream” for liquids. The pening pressure is 10 %
higher than CDTP.
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Cold differential test pressure
CDTP page 8
Figure 3: Figure 4:
6.2 How is the influence of balanced bellows in case of type 459 / 462 safety valves?
For these two types the different discharge diameter do= 9, 13 and 17,5 mm have influence to the
correction of CDTP. This is based on the design of balanced bellows. The same stainless steel
bellows is implemented in all three do´s. The effective area of do = 13mm design is equal to the
balancing area of stainless steel bellows. A correction for differing effective areas (do = 9 mm and
do = 17,5 mm) of seat area and balancing area have to be considered with the additional correction
factor kaf .
Please refer to LWN 037.07 for detailed information.
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Cold differential test pressure
CDTP page 9
1,30
kaf
kaf (d0=9 mm) = 1,1575E-4*(paf /p*100%)²+1,899E-3*(paf /p*100%)+0,9987
1,20
1,10
1,00
0,90
diagram 1: correction factor kaf for balanced bellows design for type 459 / 462
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Cold differential test pressure
CDTP page 10
Closed Design:
Figure 5: Figure 6:
Open design is recommended for application which are not harmfull for environment. Closed
design is recommended for application with higher safety aspects. This has to be preselected by
customer.
The open bonnet design allows higher temperature of medium because of cooling effect with free
circulation of air. The temperature increase in comparison to closed bonnet design is smaller. The
correction factor is listed in table 1.
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Cold differential test pressure
CDTP page 11
If these limits are exceeded the spring characteristics are no more valid. The influence on
relaxation is stated in DIN EN 13906-1 or DIN 2089 (old not valid version).
The effect on CDTP-correction is covered with the stated correction factor in chapter 3. The spring
material has no significant effect on the test results.
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Cold differential test pressure
CDTP page 12
Nameplate ASME:
LESER-TAG:
11 EXAMPLE
11.1 Example: Temperature influence
Design: Type 441, open bonnet
Service condition: pset = 10barg (145 psig), pa = 0barg, t = 320°C ( 608°F), Steam
pcdtp = ( p set − p a ) * kT
kT: according to equation (3) in chapter 3:
kT = 1,025
pa = 0, because of no backpressure
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Cold differential test pressure
CDTP page 13
pcdtpmin = 10,25 barg +0,00*10,25 barg = 10,25 barg (148,66 psig)
pcdtpmin = 10,25 barg +0,03*10,25 barg = 10,56 barg (153,16 psig)
pcdtp = ( pset * k af − pa ) * kT
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Cold differential test pressure
CDTP page 14
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Cold differential test pressure
CDTP page 15
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Cold differential test pressure
CDTP page 16
Translation by LESER:
Dear Mr. Stremme,
We think it is a realistic way to consider the temperature at the Cold Differential Test Pressure of safety
valves according to the enclosed diagram.
The multiplication factor for the Cold Differential Test Pressure at the operating temperature is given by the
enclosed diagram.
This procedure will be applied only if the customer states it explicitly and annotated this on the column
“further manufacturers’ instructions”.
Sincerely yours
Schwenn
TÜV Inspector
End of LWN
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Tightness Test
Testing Procedure at LESER Page 1
Contents
1 Scope and Applicability.............................................................................................................. 3
2 Definition.................................................................................................................................... 3
3 Test description for LESER Safety Valves ................................................................................ 3
3.1 Seat tightness test procedure, Test P12 ........................................................................ 3
3.1.1 Definition ................................................................................................................... 3
3.1.2 Requirements of LESER ........................................................................................... 3
3.1.3 Scope ........................................................................................................................ 3
3.1.4 Test media................................................................................................................. 3
3.1.5 Test pressure ............................................................................................................ 3
3.1.6 Test duration ............................................................................................................. 3
3.1.7 Test method for the seat tightness test ..................................................................... 3
3.1.7.1 Testing of seat tightness with air, bubbles emission test procedure ............ 3
3.1.7.1.1 Applicability........................................................................................................ 3
3.1.7.1.2 Test Equipment (Kellog-Test)............................................................................ 3
3.1.7.1.3 Test duration...................................................................................................... 3
3.1.7.1.4 Test pressure..................................................................................................... 3
3.1.7.1.5 Test description ................................................................................................. 3
3.1.7.1.6 Acceptance criteria, Option Code...................................................................... 3
3.1.7.1.7 Certification........................................................................................................ 3
3.1.7.2 Seat tightness test procedure with air, another method ................................. 3
3.1.7.2.1 Applicability........................................................................................................ 3
3.1.7.2.2 Test equipment.................................................................................................. 3
3.1.7.2.3 Test description ................................................................................................. 3
3.1.7.3 Seat tightness test procedure with helium ....................................................... 3
3.1.7.3.1 Applicability........................................................................................................ 3
3.1.7.3.2 Test equipment.................................................................................................. 3
3.1.7.3.3 Test method....................................................................................................... 3
3.1.7.3.4 Test pressure..................................................................................................... 3
3.1.7.3.5 Test duration...................................................................................................... 3
3.1.7.3.7 Test description ................................................................................................. 3
3.1.7.3.8 Acceptance criteria, Option Code...................................................................... 3
3.1.7.3.9 Certification........................................................................................................ 3
3.1.7.4 Seat tightness test procedure with water ......................................................... 3
3.1.7.4.1 Applicability........................................................................................................ 3
3.1.7.4.2 Test description ................................................................................................. 3
3.1.7.4.3 Acceptance criteria, Option Code...................................................................... 3
3.1.7.4.4 Certification........................................................................................................ 3
3.1.7.5 Seat tightness test procedure with steam ........................................................ 3
3.1.7.5.1 Applicability........................................................................................................ 3
3.1.7.5.2 Test equipment.................................................................................................. 3
3.1.7.5.3 Test pressure..................................................................................................... 3
3.1.7.5.4 Test duration...................................................................................................... 3
3.1.7.5.5 Test description ................................................................................................. 3
3.1.7.5.6 Acceptance criteria, Option Code...................................................................... 3
3.1.7.5.7 Certification........................................................................................................ 3
3.2 Shell Tightness test procedure P11................................................................................ 3
3.2.1 Applicability ............................................................................................................... 3
3.2.2 General, Definition..................................................................................................... 3
3.2.3 Test procedure at LESER ......................................................................................... 3
3.2.3.1 Applicability............................................................................................................ 3
3.2.3.2 Test equipment...................................................................................................... 3
3.2.3.3 Test medium.......................................................................................................... 3
Fortsetzung Bl. 2
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Tightness Test
Testing Procedure at LESER Page 2
3.2.3.4 Test pressure......................................................................................................... 3
3.2.3.5 Test duration.......................................................................................................... 3
3.2.3.6 Test description ..................................................................................................... 3
3.2.3.7 Certification, Option Code ..................................................................................... 3
3.3 Back seat tightness, test P21 (tightness outwards)...................................................... 3
3.3.1 Scope ........................................................................................................................ 3
3.3.2 Definition ................................................................................................................... 3
3.3.3 Test procedure at LESER’s ....................................................................................... 3
3.3.3.1 Applicability............................................................................................................ 3
3.3.3.2 Test equipment...................................................................................................... 3
3.3.3.3 Test medium.......................................................................................................... 3
3.3.3.4 Test pressure......................................................................................................... 3
3.3.3.5 Test duration.......................................................................................................... 3
3.3.3.6 Test description ..................................................................................................... 3
3.3.3.6.1 Operation with application of the test fluids (DIN EN 1593)............................... 3
This test procedure will be used for safety valves when the dipping is impractical................ 3
3.3.3.6.2 Dipping procedure (DIN EN 1593)..................................................................... 3
3.3.3.6.3 Helium test......................................................................................................... 3
3.3.3.7 Certification, Option Code ..................................................................................... 3
4 Qualifications of the staff ........................................................................................................... 3
5 Certification................................................................................................................................ 3
6 Demands of standards............................................................................................................... 3
7 References to further standards ................................................................................................ 3
8 Appendix 1: Seat tightness requirements acc. to API 527......................................................... 3
9 Appendix 2: Seat tightness LESER Standard tightness requirements ...................................... 3
10 Appendix 3: Seat tightness LESER increased tightness requirements.................................. 3
Fortsetzung Bl. 3
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Tightness Test
Testing Procedure at LESER Page 3
All LESER safety valves have to be tested on tightness except SKD Kits Compact Performance-
Valves (ref. to LWN 704.41).
2 Definition
The tightness test is a production test and is practised at LESER standardly.
Fortsetzung Bl. 4
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Tightness Test
Testing Procedure at LESER Page 4
3.1.3 Scope
The testing procedure of seat tightness for each safety valve occurs after setting and
checking of cold differential set pressure on test bench in accordance with operation chart,
which is deposited in SAP System.
At LESER the performance of pressure range and test pressure requirements acc. to API
527 is as follows (table 1):
Fortsetzung Bl. 5
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Tightness Test
Testing Procedure at LESER Page 5
3.1.7.1 Testing of seat tightness with air, bubbles emission test procedure
3.1.7.1.1 Applicability
This procedure of seat leakage test with air, counting number of bubbles, is practised
in case of safety valves with gastight design (lifting device H4, cap H2, closed
bonnet).
Fig. 1
Fortsetzung Bl. 6
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Tightness Test
Testing Procedure at LESER Page 6
The leakage rate shall not exceed the limited leakage rates depending on the flow
area d0 and valve design as mentioned in appendix 2 and 3.
Option
Text Remark
Code
Grinding: For increased The Option Code N50 is not used any
N50 tightness acc. to LWN 220.01 longer
(intern)
Table 2
3.1.7.1.7 Certification
The testing of seat tightness with air (bubble emission procedure) is documented in
the SAP system and confirmed by inspection test certificate acc. to DIN EN 10204.
If test report for seat leakage test is required, it has to be accessed with option code
M66.
Fortsetzung Bl. 7
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Tightness Test
Testing Procedure at LESER Page 7
3.1.7.2.1 Applicability
In case of non-gas tight safety valve design (lifting device H3, open bonnet), the seat
leakage test is carried out with procedure of applying test fluid (acc. to DIN EN 1593).
The application of test fluid is a qualitative test procedure, because the quantitative
procedure of bubble counting (leakage rate) is not possible.
As test fluid a foamy lotion acc. to DIN EN 14291, leakage finder, is used. The test
fluid shall be non-volatile (it shall not dry at test temperature during test period) and
viscous.
Fig. 2
Austritt
outlet
Eintritt
inlet
Prüftisch
test bench
Fortsetzung Bl. 8
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Tightness Test
Testing Procedure at LESER Page 8
3.1.7.2.4 Certification, Option Code
The testing of seat tightness with air, applying of test liquid procedure, is documented
in the SAP system and confirmed by an inspection certificate according to DIN EN
10204.
If inspection certificate for seat tightness test is required, it has to be accessed with
option code M22.
Fortsetzung Bl. 9
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Tightness Test
Testing Procedure at LESER Page 9
Following option codes shall be used for seat leakage test with helium:
- Option Code N62, for sniffing method
- Option Code M86, for vacuum method
3.1.7.3.9 Certification
The testing of seat tightness with helium is documented in the SAP system and
confirmed by inspection test certificate acc. to DIN EN 10204 / test report.
Following information are to be considered:
- Test subject
- Requirements of Standard
- Reference terms / Main technical characteristics
Test medium, Helium
Test equipment: helium leakage detector, Alcatel Type ASM 120H
Helium calibrated leaks, leakage rate 1,5x10-7 mbar l/s
- Test results
- Test method for each test result
- Relevant Units, mbar l/s, for each test result.
If inspection certificate for seat tightness test with helium is required, it has to be
accessed with following option code:
- M 77 for seat tightness, overpressure procedure (sniffing method)
- M 81 for seat tightness, procedure of leakage detection in vacuum
3.1.7.4.1 Applicability
This test procedure is only carried out on customer demand and relevant rules and
regulations. Terms of test conditions and tightness requirements are listed in
Appendix 2 resp. 3.
3
cm /min 0,166 0,166 0,166 4 5 6 8 11 13 17 25 33 42 50 66
Table 3: Leakage volume depending on nominal size acc. to API 527 (App. 1)
Fortsetzung Bl. 10
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Tightness Test
Testing Procedure at LESER Page 10
3.1.7.4.4 Certification
The testing of seat tightness with water is documented in the SAP system and
confirmed by inspection test certificate acc. to DIN EN 10204.
3.1.7.5.1 Applicability
Testing of seat tightness with steam is practised for safety valves which are setted on
cold-differential set pressure with steam.
3.1.7.5.7 Certification
The seat leakage test with steam is documented in the SAP system and confirmed by
inspection test certificate acc. to DIN EN 10204.
Fortsetzung Bl. 11
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Tightness Test
Testing Procedure at LESER Page 11
DIN EN 12266-1, Edition June 2003 replaces DIN 3230-1: 1974-04, DIN 3230-2:1974-04,
and DIN EN 12266-2:2003-05 replaces DIN 3230-3.
The former designation is: BF, BQ, BW acc. to DIN 3230-3.
3.2.3.1 Applicability
Acc. to work schedule the shell tightness test procedure is deposited in SAP system for
every safety valve in gastight design. LESER has integrated this test procedure into
production process standardly.
Fortsetzung Bl. 12
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Tightness Test
Testing Procedure at LESER Page 12
Remark!
During test period the test pressure shall be kept constant.
Afterwards the valve has to be blown dry with compressed air.
If inspection certificate for shell tightness test with air is required, it has to be accessed
with option code M18.
Fortsetzung Bl. 13
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Tightness Test
Testing Procedure at LESER Page 13
3.3.2 Definition
The test is a pre-expediting pressure test for certification that the determined leakage rate
of the back sealing is kept to the moment of the manufacture.
The tightness outwards has reference to the test of the tightness at the connections
body/bonnet, bonnet/lifting device H4 (cap H2) as well as the outlet of the body.
Marking in accordance with DIN EN 12266-2, edition 2003
Tightness of back seal, test P21-EN 12266.2
The tightness of the back seal, test P21, is in accordance with the task schedule which is
deposited in the data base of the SAP-system for every safety valve in gastight design. At
LESER’s, this test is standard which is integrated in the production process.
1
“Built-up back pressure For the LESER safety valve, 15 % of the set pressure minus superimposed back pressure
(if applicable) is generally permissible. “ Complete catalogue 21/30
Fortsetzung Bl. 14
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Tightness Test
Testing Procedure at LESER Page 14
- Test pressures outside of the scope of the standard must be coordinated between the
customer and LESER (VK/TB).
The test pressure must be maintained at least for the test period determined in table 5 (in
accordance with DIN E 12266-2).
Table 5: Minimum test period for testing of the tightness of the back seal
Nominal size Minimum test period
s
> DN 50 15
from DN 65 to DN 200 15
DN 250 to DN 450 30
Remark! During the test period the test pressure has to be kept constantly.
The safety vale should be blistered dry with compressed air.
With the leak detector used by LESER (Alcatel – ASM 120H), the tightness test with the
vacuum-method is realized.
The safety valve will be sealed (at the inlet) with a sealing cap. Afterwards the safety valve
will be clamped (at the outlet) on the leak detector. When the evacuation process is finished
(in the safety valve is now a vacuum) helium will be sprayed with an air gun on every
connection for 3 – 4 sec. The test result will be read if the LED display is stabled.
Fortsetzung Bl. 15
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Tightness Test
Testing Procedure at LESER Page 15
As a standard test with air, the tightness test of the back sealing, tightness outwards, will
follow without option code.
The tightness test of the back sealing, tightness outwards, with Helium will be regulated
with option code N64.
If inspection certificate for back seat test tightness outwards is required, it has to be
accessed with following Option Codes:
- M 28 Back seat tightness test outwards, application of test fluids
- M 78 Back seat tightness test outwards, dipping procedure
- M 82 Back seat tightness test outwards with helium, overpressure method (sniffing
method)
5 Certification
Test results are reported standardly in the SAP system and are proved by an inspection certificate
according to 3.1 of DIN EN 10204.
Following information has to be included in APZ 3.1:
- Test subject
- Requirements of Standard
- Used procedures
- Reference terms / technical characteristics
Test medium, test liquid, test device
- Test results
- Test method for each test result
- Relevant units, mbar l/s, for each test result.
6 Demands of standards
Following standards are considered for the tightness tests at LESER’s:
DIN EN ISO 4126-1, Safety devices for protection against excessive pressure Part 1: Safety
valves, chapter. 6 Production testing, 6.6 Seat leakage test:
„The seat leakage test of a safety valve shall be carried out. The test procedure and leakage rate
shall be agreed between the manufacturer and the purchaser”
ASME Code Section VIII Rules for Construction of Pressure Vessels, Edition 2006
Part UG-136(d) Production Testing by Manufacturers and Assemblers
UG- 136 (d) (3) The secondary pressure zone of each closed bonnet pressure relief valve
exceeding NPS 1 (DN 25) inlet size when such pressure relief valves are designed for discharge to
a closed system shall be tested with air or other gas at a pressure of at least 30 psi (200kPa).
There shall not be visible sign of leakage.”
UG- 136(d) (5) After completion of the tests required by (d) (4) above, a seat tightness test shall be
conducted. Unless otherwise designated by a Manufacturer’s published pressure relief valve
specification or another specification agreed to by the user, the seat tightness test and acceptance
criteria shall be in accordance with API 527.”
Fortsetzung Bl. 16
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Tightness Test
Testing Procedure at LESER Page 16
DIN EN 12266-1 Industrial valves: Testing of valves, part 1: Pressure tests, test procedures
and acceptance criteria- Mandatory requirements, edition 2003, chapter.4 Test requirements:
4.2 „Every valve shall be subjected to the shell tightness test, reference P11, listed in Table 1.“
DIN EN 12266-2 Industrial valves – Testing of valves, part 2: Tests, test procedures and
acceptance criteria, edition 2003, A.3 Back seat tightness, test P21
ASME Code Section VIII Rules for Construction of Pressure Vessels, Edition 2006
Fortsetzung Bl. 17
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Tightness test
Testing at LESER Page 17
Set pressure Blow down up o PZ = Test Time (related to 16°C; bubble volume (related to 16°C; bubble volume
3 3,
po VB= 0,295 cm , tube ∅ = 6,12mm) VB= 0,295 cm tube ∅ = 6,12mm)
(relating to 16°C) Test pressure Min
DN DN DN
≤50 65...100 >100 Number of Leakage Leakage Number of Leakage Leakage
≤2“ 21/2...4“ >4“ bubbles volume rate bubbles volume rate
3 3
bar MPa bubble/ min cm / min Mbar l/s Bubble/ min cm / min Mbar l/s
BZ PZ BZ PZ BZ PZ
-1 -2
1,03-68,9 0,103-6,896 40 11,80 1,9x10 20 5,90 9,4x10
103 10,3 po ≤ 3,45 bar 60 17,70 2,8x10
-1
30 8,85 1,4x10
-1
Metal-to-metal
-1 -1
Air (Gases)
-3
- - 1 1 2 1 5 1 0 0 <4,7x10 0 0
Metal-to-metal
Soft sealing
Steam
sealing
p0 >3,45 bar
(0,345 MPa)
NW≥1“ (DN25)
Metal-to-metal
3
Leakage volume ≤10cm /h x Inlet nominal size /
sealing
LWN 220-01
pPrüf.= 0,9*po 3
leakage volume ≤10cm /h*
test
- - No leakage
Soft
Fortsetzung Bl. 18
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LESER-WORKS STANDARD LWN 220-01-EN
Tightness test
Testing at LESER Page 18
3 3
(related to 20°C) BZ-damping time (related to 20°C; bubble volume VB= 0,295 cm (related to 20°C; bubble volume VB= 0,295 cm
After testing of set
PZ-Test time tube ∅ = 6,12mm) tube ∅ = 6,12mm)
pressure po
Blow down up to...
Test pressure
Pressure stages acc. to Number of Leakage volume Leakage Number of Leakage volume Leakage
Blow-down of...
LWN 220.03 bubbles rate bubbles rate
Test pressure 3 3
bar MPa s / min bubble/min cm /min mm³/sec mbarl/s bubble/min cm /min mm³/sec mbarl/s
Metal-to-metal
-1 -2
0,1- 66 0,01- 6,6 0,1< po < 0,7 (bar) 40 11,80 196,66 1,9x10 20 5,90 98,33 9,4x10
BZ = 10s
sealing
-1 -1
>66-165 >6,6-16,5 PZ = 10s 60 17,70 295,00 2,8x10 30 8,85 147,50 1,4x10
-1 -1
>165- 700 >16,5- 70,0 80 23,60 393,33 3,8x10 40 11,80 196,66 1,8x10
Pprüf = 0,5*p0
Air (Gases)
Soft sealing
-2 -2
- - PZ = 10s 20 5,90 98,33 9,4x10 10 2,95 49,16 4,7x10
soft sealing
BZ =10s
-5 -5
- - PZ = 10s 0 0 0 ≤9x10 0 0 0 ≤9x10
pPrü f= p0 - 0,35bar
test (0,035 Mpa)
Steam
BZ = 3 min
sealing
LWN 220-01
No recognized or visible leakage
- - p0 > 3,5 bar PZ = 1 min
No indication of pressure drop at the pressure gauge
po >0,35 (MPa)
Soft sealing
Water
BZ =10s
sealing
metal
- -
pPrüf. = 0,9*po PZ = 10s
No recognized or visible leakage
test
Fortsetzung Bl. 19
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Tightness test
Testing at LESER Page 19
3 3
(related to 20°C; Bubble volume VB= 0,295 cm (related to 20°C; Bubble volume VB= 0,295 cm
(related to 20°C) After testing of set BZ=damping time
Pz = test time tube ∅ = 6,12mm) tube ∅ = 6,12mm)
pressure po
Blow down up to ...
Test pressure
Pressure stage acc. to Blow-down of... Number of Leakage Number of Leakage
Leakage volume Lekage volume
LWN 220.03 Test pressure bubbles rate bubbles rate
3
bar MPa cm /min mm³/sec cm³/min mm³/sec
bubble/min mbarl/s bubble/min (mbarl/s)
Soft sealing Metal-to-metal
-2 -2
LESER - increased tightness
Pprüf = 0,5*p0
- - test - Increased tightness not possible, ref. to App. 2: Standard tightness requirements
BZ =3 min
sealing
metal
-
Metal-to- Soft sealing
pPrü f= p0 - 0,35bar
- test (0,035 Mpa) - Increased tightness not possible, ref. to App. 2: Standard tightness requirements
metal sealing
LWN 220-01
- - PZ = 10s
Water
Soft sealing
pPrüf. = 0,9*po
- - test - Increased tightness not possible, ref. to App. 2: Standard tightness requirements
Table of contents
Summary ........................................................................................................................................................... 2
1 General and definitions......................................................................................................................... 2
2 Purpose and area of application........................................................................................................... 2
3 Derivation of standard specifications on LESER safety valves............................................................ 3
4 Testing depth at LESER, practical application of the set pressure tolerances .................................... 3
5 Assembly and test equipment .............................................................................................................. 3
6 Pressure measuring devices ................................................................................................................ 4
7 Test media ............................................................................................................................................ 4
8 Test procedure at LESER..................................................................................................................... 5
8.1 Setting and testing of the cold differential test pressure with air .............................................. 5
8.1.1 Testing depth, option code ............................................................................................................................ 5
8.1.2 Test bench ..................................................................................................................................................... 5
8.1.3 Testing procedure ......................................................................................................................................... 6
8.1.4 Acceptance criteria ..................................................................................................................................... 10
8.2 Setting and testing of the cold differential test pressure with water ....................................... 10
8.2.1 Testing depth, option code .......................................................................................................................... 10
8.2.2 Test bed....................................................................................................................................................... 10
8.2.3 Testing procedure ....................................................................................................................................... 10
8.2.4 Acceptance criteria ..................................................................................................................................... 10
8.3 Setting and testing of the cold differential test pressure with steam ...................................... 10
8.3.1 Standards applied ....................................................................................................................................... 10
8.3.2 Testing depth, option code .......................................................................................................................... 10
8.3.3 Test media................................................................................................................................................... 10
8.3.4 Test bed....................................................................................................................................................... 11
8.3.5 Testing procedure ....................................................................................................................................... 11
8.3.6 Acceptance criteria ..................................................................................................................................... 11
8.3.7 Testing on capacity test bench of National Board (USA) ........................................................................... 12
9 Qualifications of the test personnel .................................................................................................... 12
10 Documentation and option code......................................................................................................... 12
11 Standards applied............................................................................................................................... 12
12 Normative instructions ........................................................................................................................ 14
13 Terms and abbreviations .................................................................................................................... 14
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Procedures for the testing of cold differential
test pressure page 2
Summary
This LWN lists the standard requirements and will describe the procedure during the setting and
testing of the cold differential test pressure of safety valves at LESER and its documentation.
The Procedure is valid for all safety valves to be set with steam, water or air at the LESER
production sites Hamburg, Hohenwestedt and at the authorised LESER service partners, In case
they act on behalf of LESER.
The testing of the cold differential test pressure shall not be applied for safety valves carrying out:
The issuing of an inspection certificate about the testing carried out can be order with the following
option codes.
Option code Acceptance test certificate Comments
LESER CGA (Certificate for Global Application) – Inspection
H03
certificate 3.1 according to DIN EN 10204
Inspection certificate 3.1 acc. to DIN EN 10204: Testing of optional
N05
cold differential test pressure with air
The cold set pressure (DIN EN ISO 4126-1, chapter 3.2.5) is the static pressure on the inlet side,
at which a safety valve will start opening on the test bed. This pressure includes corrections for
operational conditions, e.g. counter pressure and/or temperature.
The cold set pressure will be used, if a correction of set pressure is necessary due to deviations to
the operating conditions.
The evaluation of cold differential test pressure (CDTP) under consideration of influencing factors
can be taken from LWN 001-69.
The definition of the cold set pressure of LESER safety valves is:
The pressure, the safety valve is adjusted at LESER on the test bed and the first audible noise in
case of steams/air/gases and/or the first continuous flow of liquid.
The set pressure (EN ISO 4126-1 chapter 3.2.1) is the preset pressure, a safety valve starts
opening under operational conditions (DIN EN ISO 4126-1). It is the excess pressure on the valve
inlet side, where the forces that open the valve under the specific operational conditions, will be
equal to the forces that keep the valve disc in position.
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Procedures for the testing of cold differential
test pressure page 3
From 300 psi (20,7 bar) the specifications in accordance with ASME Section I, Rules for
Construction of Power Valves, PG 72.2 General Requirements for all Methods of Construction,
Safety Valves and Safety Relief Valves will be ignored as at present none of such products are
being manufactured. Should this situation change, this will be regulated in this LWN.
Summary: The specifications regarding the set pressure tolerance for all named standards
have been listed in table 1.
1,65 bar ( 23,9 psi) ... 3,96 bar ( 58 psi) plus 0,1 bar ( 1,45 psi)
When adjusting the safety valves three important influencing factors have to be principally
considered:
• Preciseness of the measuring equipment
• Reading exactness of the technician and/or tester (analogue display)
• Repetitive setting exactness of the valves
All three factors have to be covered by the set pressure tolerance, whereby only during the setting
a person can take direct influence.
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Procedures for the testing of cold differential
test pressure page 4
Table 2: LESER preferential series for pressure measuring devices (in accordance with ASME-
Code and DIN EN 837-1)
Comment:
The LESER preferential series in accordance with ASME starts with manometer 0 - 2,5 bar.
The controlled areas in accordance with ASME-Code start from > 15 psi (1,03 bar). The
controlled areas in accordance with the European pressure appliances guideline (from >
0,5 bar) and the pressure vessel regulation (from > 0,1 bar) have been included.
All mechanical class 0.6 pressure measuring devices with operational error limit ± 0,6% of
the LESER preferential series have to be regularly gauged and/or adjusted in accordance
with LWN 615.07 at a minimum of every 12 months.
The use of pressure measuring devices at the assembly sites is regulated in LWN 220.03.
7 Test media
Safety valve set pressure is normally set with air on a test bed and the valve is then operated with
different media types, steam, gases or liquids.
As a standard air is used for setting and testing of the cold-set pressures of safety valves.
Still, if it is required to adjust the safety valve with the medium water or steam on the test bed, this
has to be specified in the order.
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Procedures for the testing of cold differential
test pressure page 5
8.1 Setting and testing of the cold differential test pressure with air
8.1.1 Testing depth, option code
As a standard safety valves for air or other gases have to be set and tested with air at room
temperature. This is carried out in accordance with work schedule recorded in the SAP
System for each safety valve. The control is carried out without option code.
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Procedures for the testing of cold differential
test pressure page 6
After assembly the safety valve will be pressurized and adjusted via adjusting screw to the given
set pressure acc. to SAP demand (flag Q-feature). Safety valves with lever will be setted up per
positioning the weight.
The set pressure is reached when the discharge of air is audible. A saturated opening with clear
clicking noise or crack shall be reached. Stealthy setting is not allowed.
The procedure of setting and testing of cold differential test pressure with air is described exactly
for each valve type in the working instructions (assembly / installation documentation).
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Procedures for the testing of cold differential
test pressure page 7
The following work stages have to be adhered to (Example for a threaded valve):
Work stage 1
Tools
Software system
Testing equipment
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Procedures for the testing of cold differential
test pressure page 8
Work stage 2
Tools
Equipment
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Procedures for the testing of cold differential
test pressure page 9
Work stage 3
Tools
• Splint mandrel, open-end wrench
• Software Visual Manometer
• SAP Transaction ZAKL / tab Q-
characteristics
Equipment
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Procedures for the testing of cold differential
test pressure page 10
8.1.4 Acceptance criteria
The safety valve has to open within the preset pressure tolerance.
Escaping air has to be audible. Full opening has to be achieved with a clear bang. A
creeping response is not admissible.
8.2 Setting and testing of the cold differential test pressure with water
8.2.1 Testing depth, option code
The safety valves to set and tested using water are controlled in accordance with SAP
System recorded work schedule, using option code M09.
8.3 Setting and testing of the cold differential test pressure with steam
8.3.1 Standards applied
This testing is valid for safety valves with UV-Stamp (LWN 001.26, LWN 619.12) and for
safety valves that are set by steam. The ASME Code Sec. VIII Div.1 specifies under UG
136(d)(4) that safety valves for steam applications have to be set using steam, whereby
safety valves that due nominal width and response pressure are beyond the possibilities of
the steam test bed, can be tested using air.
• Each safety valve has to respond several times (if necessary also pop) to warm up the valve
seat and valve disk.
• After several responses (if necessary also pop) of the test valve the set pressure in accordance
with specifications has to be set and checked.
The set pressure of the valves has been reached, when the escaping steam is clearly audible.
You have to achieve a full opening with a clearly audible cracking and/or bang. A creeping
response is not admissible.
• For evaluation of actual set pressure 3 single serial values have to be within a repeat accuracy
of 1%. The average value of this 3 single values is the determined actual set pressure, which
has to be within an allowable tolerance of +3% of set point. The determined actual set pressure
is definded as set pressure and builds the basis for further testings.
• After cooling of safety valves the tightness test with air acc. to LWN 220.01 will be carried out.
The steel safety valves will be protected against corrosion. Blowing space and sealing strip will be
treated with a silicon-free corrosion oil and then cleaned.
Please note! After that the valve has to be blown dry with pressurised air.
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Procedures for the testing of cold differential
test pressure page 12
The escaping steam has to be audible. A full opening with a bang has to be achieved. A creeping
response is not admissible.
Depending on demanded capacity of the valve different values will be gathered (six or eight). The
smaller the capacity of valve the more measured values will be gathered and the more longer
takes the measuring process. Exactly one value per minute will be recorded. Reason for this
procedure is the precision of measuring of condensate steam using a water tank on a balance.
The steam will be condensated behind the valve and the water will be pumped in a second
metering box. This quantity of emerged water will be scaled. It will be pumped into two tanks (three
minutes each tank). During measurement of capacity the actual overpressure (10% over set
pressure) as well as the steam temperature will be read off and documented per each single value.
These values will be averaged and build the basis for the required capacity of valve.
The issuing of a certification about the testing of the cold differential test pressures can be ordered
using the following option codes:
Option code Acceptance test certificate Comments
LESER CGA (Certificate for Global Application) – Inspection
H03
certificate 3.1 according to DIN EN 10204
Inspection certificate 3.1 acc. to DIN EN 10204: Testing of optional
N05
cold differential test pressure with air
11 Standards applied
• DIN EN ISO 4126-1 Safety appliances against non-permissible excess pressure, Part 1:
safety valves (edition May 2004), chapter 7- component tests
7.2 Tests for the determination of operational characteristics
“7.2.1 General requirements
.......The permissible tolerances and/or limits for the operational characteristics areas follows:
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Procedures for the testing of cold differential
test pressure page 13
≤ 70 (0,5) 2 psi
> 70 (0,5) and ≤ 300 (2,1) 3 % of set pressure
> 300 (2,1) and ≤ 1000 (7,0) 10 psi
> 1000 (7,0) 1 % of set pressure
• ASME Code, Section VIII, Rules for Construction of Pressure Vessels, Division 1,
(Edition 2007)
Part UG General Requirements for All Methods of Construction and All Materials
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Procedures for the testing of cold differential
test pressure page 14
12 Normative instructions
LWN 001.26 Safety valves with ASME certification
LWN 001.69 Cold differential test pressure (CDTP)
LWN 001.78 Set pressure, tightness, operation
LWN 220.01 Tightness test, testing procedure at LESER
LWN 220.03 Use of pressure measuring devices at the test beds (DIN EN- / ASME)
LWN 615.07 Gauging intervals (test media)
LWN 619.12 ASME/National Board- approval for LESER Safety valves (Stamp-
attainment)
LWN 205.80 Operation, maintenance and maintenance steam machine, softening plant,
steam setting table HOW
End of LWN
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Performing
Leak Tests
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
1 General
This LWN describes professional application of the test procedures. It summarises
the user information in a target-group-oriented manner.
Information:
Always keep the test manual
at the assembly test bench.
The manual must always be immediately available.
2 Contents
1 General....................................................................................................................................2
2 Contents..................................................................................................................................2
3 Scope ......................................................................................................................................3
3.1 Purpose of the document .................................................................................................3
3.2 Improper use ....................................................................................................................3
3.3 Informal measures............................................................................................................3
4 References to standards .......................................................................................................4
4.1 Operational materials and supplies ..................................................................................5
5 Distinguishing features of valve designs ............................................................................7
5.1 Safety valves in a gas-tight design...................................................................................7
5.2 Safety valves in a non-gas-tight design............................................................................7
6 Test description .....................................................................................................................8
6.1 Safety valves in a gas-tight design...................................................................................8
6.1.1 Flanged valves .........................................................................................................8
6.1.2 Threaded valves .....................................................................................................19
6.2 Safety valves in a non-gas-tight design:.........................................................................33
6.2.1 Flanged valves .......................................................................................................33
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Set-up of Equipment in Warehouses
3 Scope
This manual is valid for the execution of leak tests on safety valves in domestic and
foreign agencies of LESER GmbH & Co. KG.
The leak test is a production test, and must be performed as a standard procedure.
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Set-up of Equipment in Warehouses
4 References to standards
The standards that are taken into consideration and applied by LESER for testing for
leaks are established in LWN 220-01.
It also contains the
• standard requirements for functional seal tightness (seat seal tightness) as well as
• increased seal tightness requirements of the functional seal tightness (seat seal
tightness) for
• gas-tight and non-gas-tight valves.
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Set-up of Equipment in Warehouses
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Set-up of Equipment in Warehouses
Fig. 5: Accessories
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Set-up of Equipment in Warehouses
Flanged valves
Open Open
bonnet lever (H3)
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Set-up of Equipment in Warehouses
6 Test description
6.1 Safety valves in a gas-tight design
6.1.1 Flanged valves
Valve assembly:
The safety valve is assembled and adjusted to the set pressure
(see assembly documentation)
• LWN 369.30
1. • LWN 369.32
• LWN 369.33
3.
4.
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Set-up of Equipment in Warehouses
1. Valve assembly:
The valve must be assembled according to the assembly documentation.
• LWN 369.30
• LWN 369.32
• LWN 369.33
Fig. 7: API gas-tight
Test data for testing the functional seal tightness with air:
The following test data must be observed when testing the functional seal tightness with
gas-tight valves.
Test data
Test characteristic Seal tightness between the seat and disc
Testing standard Number of bubbles per second, see LWN 220-01, Attachment 1-3
Testing depth Every safety valve, 100% testing
Test medium Air
Test pressure 90% of set pressure
Testing device Bubble counting unit
Length of test Settling time of at least 10 seconds + testing time of 10 seconds
Test data for testing the functional seal tightness with water:
The following test data must be observed when testing the functional seal tightness with
gas-tight valves.
Test data
Test characteristic Seal tightness between the seat and disc
Leak volume [cm³/min.] depending on the nominal diameter, see
Testing standard
LWN 220-01, TABLE 3
Testing depth Only at the request of the customer
Test medium Water
Test pressure 90% of set pressure
Testing device Water expansion kit, LWN 369.55
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Auxiliary materials:
The following auxiliary materials must be available when testing the functional seal tight-
ness.
Note:
Tests with water are only permissible if the functional operation of the safety valve will not be ad-
versely affected. A qualitative assessment of the leak volume as per LWN 220-01 Table 3 cannot
be conducted in a technically reasonable way.
If a quantitative statement is requested (leak rate) on the functional seal tightness for safety
valves that must be set with water, then the functional seal tightness of the valves will be tested
with air after finishing the adjustment of the set pressure.
Testing of the functional seal tightness with water can only represent a quantitative statement.
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Operations:
a) The inlet side of the safety valve must be vertically at-
tached to the chuck.
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Test passed:
If the number of bubbles is less than or equal to
the specification, then the test has been
passed.
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Set-up of Equipment in Warehouses
Operations:
a) The inlet side of the safety valve must be vertically at-
tached to the chuck.
-10%
d) After a settling time of 10 seconds, a qualitative as- Fig .16: Pressure reduction by 10%
sessment of the leak volume must be performed as
per LWN 220-01.
continues on page 14
processed: Kai Krohn edition: 2010-05-10
LESER
LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test data:
The following test data must be observed when testing the seal tightness of the pressure-bearing
body.
Test data
Test characteristic Testing the body seal tightness
Testing standard The valve must not have any visual signs of leaks
Every safety valve with a cast body and a rolled-in seat, 100%
Testing depth
testing
Test medium Air
Auxiliary materials:
The following auxiliary materials must be provided when testing the body seal tightness.
continues on page 15
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LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Operations:
a) The inlet side of the safety valve must be
vertically attached to the chuck.
6 bar
b) Apply test pressure of 6 bar (87.02) psi to the
safety valve.
Test passed:
If there is no foam formation on the body,
then the test has been passed.
continues on page 16
processed: Kai Krohn edition: 2010-05-10
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LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test data:
The following test data must be observed when testing the back seal.
Test data
Test characteristic Testing of the seal tightness of the valve on the outlet side
Testing standard The valve must not have any visual signs of leaks
Testing depth Every safety valve with a gas-tight design, 100% testing
Test medium Air
Test pressure 6 bar (87.02 psi)
Testing device Application of test liquid
Auxiliary materials:
The following auxiliary materials must be provided when testing the back seal.
continues on page 17
processed: Kai Krohn edition: 2010-05-10
LESER
LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Operations:
a) The outlet side of the safety valve must be
attached to the chuck.
6 bar
continues on page 18
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LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test passed:
If there is no foam formation on the surface of the valve,
then the test has been passed.
continues on page 19
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LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Valve assembly:
The safety valve is assembled and adjusted to the set pressure
(see assembly documentation)
• LWN 369.31
1.
2.
3.
Figure 28
4.
continues on page 20
processed: Kai Krohn edition: 2010-05-10
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LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
1. Valve assembly:
The valve must be assembled according to the assembly documentation.
• LWN 369.31
Test data
Test characteristic Seal tightness between the seat and disc
Testing standard Number of bubbles per second, see LWN 220-01, Attachment 1-3
Testing depth Every safety valve, 100% testing
Test medium Air
Test pressure 90% of set pressure
Testing device Bubble counting unit
Length of test Settling time of at least 10 seconds + testing time of 10 seconds
Test data
Test characteristic Seal tightness between the seat and disc
Leak volume [cm³/min.] depending on the nominal diameter, see
Testing standard
LWN 220-01, TABLE 3
Testing depth Only at the request of the customer
Test medium Water
Test pressure 90% of set pressure
Testing device Water expansion kit, LWN 369.55
continues on page 21
processed: Kai Krohn edition: 2010-05-10
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LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Auxiliary materials:
The following auxiliary materials must be provided when testing the seal tightness of the
seat for threaded valves.
Note:
Tests with water are only permissible if the functional operation of the safety valve will not be ad-
versely affected. A quantitative assessment of the leak volume as per LWN 220-01 Table 3 can-
not be conducted in a technically reasonable way.
If a quantitative statement is requested (leak rate) on the functional seal tightness for safety
valves that must be set with water, then the functional seal tightness of the valves will be tested
with air after finishing the adjustment of the set pressure.
Testing of the functional seal tightness with water can only represent a quantitative statement.
continues on page 22
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LESER
LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Operations:
Figure 31
a) The inlet side of the safety valve must be verti-
cally attached to the clamping device (see LWN
0121.0001).
continues on page 23
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LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
-10%
d) Trigger the safety valve to trigger once. Then
lower the pressure by 10% of the set pressure, or
more precisely, by 0.35 bar (5.08 psi) for set
pressures ≤3.5 bar (50.76 psi).
continues on page 24
processed: Kai Krohn edition: 2010-05-10
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LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test passed:
If the number of bubbles is less than or equal
to the tolerance specification, the the test has
been passed.
continues on page 25
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LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Operations:
continues on page 26
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LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
-10%
e) Then lower the pressure by 10% of the set pres-
sure, or more precisely, by 0.35 bar (5.08 psi) for
set pressures ≤3.5 bar (50.76 psi).
continues on page 27
processed: Kai Krohn edition: 2010-05-10
LESER
LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test data:
The following test data must be observed when testing the body seal tightness.
Test data
Test characteristic Testing of the seal tightness of the pressure-bearing body
Testing standard The body must not have any visual signs of leaks
Every safety valve with a cast body and a rolled-in seat, 100%
Testing depth
testing
Test medium Air
Test pressure 6 bar (87.02 psi)
Testing device Application of test liquid
Auxiliary materials:
The following auxiliary materials must be provided when testing the seal tightness of the
pressure-bearing body for threaded valves.
continues on page 28
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LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Operations:
continues on page 29
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LESER
LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test passed:
If there is no foam formation on the body, then
the test has been passed.
continues on page 30
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LESER
LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test data:
The following test data must be observed when testing the back seal.
Test data
Test characteristic Testing of the seal tightness of the valve on the outlet side
Testing standard The valve must not have any visual signs of leaks
Testing depth Every safety valve with a gas-tight design, 100% testing
Test medium Air
Test pressure 6 bar (87.02 psi)
Testing device Application of test liquid
Auxiliary materials:
The following auxiliary materials must be provided when testing the back seal.
continues on page 31
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LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
continues on page 32
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LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test passed:
If there is no foam formation on the body,
then test has been passed.
continues on page 33
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LESER
LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Valve assembly:
The safety valve is assembled and adjusted to the set pressure
(see assembly documentation)
• LWN 369.30
1. • LWN 369.32
• LWN 369.33
2.
3.
continues on page 34
processed: Kai Krohn edition: 2010-05-10
LESER
LESER GmbH & Co. KG approved ECO 00465A replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
1. Valve assembly:
The valve must be assembled according to the assembly documentation.
• LWN 369.30
• LWN 369.32
• LWN 369.33
Fig. 58: API non-gas-tight
Test data:
The following test data must be observed when testing functional seal tightness with non-gas-tight
valves.
Test data
Test characteristic Seal tightness between the seat and disc
Testing standard The blow-hole at the outlet must not extend more than 5mm
Testing depth Every safety valve, 100% testing
Test medium Air
Test pressure 90% of set pressure
Testing device Application of test liquid
Length of test Settling time of at least 10 seconds + testing time of 5 seconds
Auxiliary materials:
The following auxiliary materials must be provided when testing the functional seal tight-
ness of non-gas-tight valves.
continues on page 35
processed: M. Lammers edition: 2009-11-04
LESER
LESER GmbH & Co. KG replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Operations:
a) The outlet side of the safety valve must be attached
to the chuck.
6 bar
continues on page 36
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LESER GmbH & Co. KG replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test passed:
If the blow-out remains as it is and does not
burst, then the test is considered to have
passed.
continues on page 37
processed: M. Lammers edition: 2009-11-04
LESER
LESER GmbH & Co. KG replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Test data:
The following test data must be observed when testing the body seal tightness.
Test data
Test characteristic Testing of the seal tightness of the pressure-bearing body
Testing standard The body must not have any visual signs of leaks
Every safety valve with a cast body and a rolled-in seat, 100%
Testing depth
testing
Test medium Air
A test pressure must be chosen that is slightly lower than the
Test pressure
set pressure.
Testing device Application of test liquid
Auxiliary materials:
The following auxiliary materials must be provided when testing body seal tightness for
non-gas-tight valves.
continues on page 38
processed: M. Lammers edition: 2009-11-04
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LESER GmbH & Co. KG replaces edition: ----
LESER WORKS STANDARD LWN 369-34 E
Set-up of Equipment in Warehouses
Operations:
a) The inlet side of the safety valve must be
vertically attached to the chuck.
Test passed:
If there is no foam formation on the body,
then the test has been passed.
End of LWN
processed: M. Lammers edition: 2009-11-04
LESER
LESER GmbH & Co. KG replaces edition: ----
LESER Global Standard LGS_1117
Final visual inspection of repaired valves Page 1/8
Contents
1 Purpose ............................................................................................................... 1
2 Scope .................................................................................................................. 1
3 Disclaimer............................................................................................................ 1
4 Qualified fitting personnel .................................................................................... 2
5 General Information............................................................................................. 2
6 Flow chart for the visual inspection (final inspection) .......................................... 2
7 Performing the final inspection ............................................................................ 3
7.1 General inspections...................................................................................... 3
7.2 Visual inspection of other items.................................................................... 4
7.3 Fault notification process.............................................................................. 8
1 Purpose
This LESER Global Standard (LGS) provides instruction on the visual final inspection
of LESER safety valves. The required work steps and materials are described.
2 Scope
protected
This document must be observed in the visual final inspection of safety valves in agencies
and subsidiaries of LESER GmbH & Co. KG.
3 Disclaimer
LESER puts in a great deal of effort into making up-to-date and correct
documentation available. Nevertheless, LESER GmbH & Co. KG gives no guarantee
that the recommended actions presented here are entirely correct and error free.
This document is to be applied exclusively to the specified type. LESER GmbH & Co.
KG declines any liability or responsibility for the correctness and completeness of the
content.
LESER GmbH & Co. KG reserves the right to change the information contained in
this document, which is for the products of LESER GmbH & Co. KG and is intended
for LESER subsidiaries, at any time and without prior announcement.
LESER GmbH & Co. KG is available to the users of this document to provide
additional information.
5 General Information
• Gloves must be worn during the final inspection of oil and
grease-free safety valves.
Perform the
ident. check
Fault
protected
notification
process
Inspecti
on OK
no
yes
Completion of
the final
inspection and
delivery
Figure 6-1
a) Compare the content of the valve inspection plan or repair order to the valve
model.
EXAMPLE /
protected
SPECIMEN
Figure 7.1-1
Figure 7.1-2: Check the type number against the Figure 7.1-3: Check the BT plate / customer ID
valve inspection plan / repair order plate data against the valve inspection plan /
repair order
protected
Figure 7.2.1-1
Figure 7.2.1-2
Figure 7.2.1-3
Figure 7.2.1-4
Figure 7.2.1-5
Figure 7.2.1-6
protected
OK specimen: Rejected specimen:
Figure 7.2.1-7
Figure 7.2.1-8
Figure 7.2.1-10
protected
Figure 7.2.1-9
Figure 7.2.2-1
Figure 7.2.2-2
protected
7.2.3 Inspection of the seal
Figure 7.2.3-1
If the result of the inspection is okay, then the safety valve is sent for packaging and
shipment.
• If the result of the inspection is not okay, then the fitting is sent to the fault
notification process that is to be determined.
• The final inspection is performed again after completion of the fault notification
process.
protected