Zero Leakage test criteria includes zero leakage of the packing box, ball/seat area and body gasket. Zero Leakage tests at Copeland are in addition to nationally recognized ball valve seat leakage test standards. Specific features to promote the lowest leakage rates go beyond bench tests and can be readily observed in our designs.

Copeland is committed to provide products that exceed globally recognized standards, testing procedures, acceptance criteria and performance standards. Test specifications include zero leakage during the test period and  API 598, “Valve Inspection and Test.”  

Zero leakage is defined as no detectable leakage of gas or a liquid for a period of three minutes and after multiple cycles and various pressure conditions. 

A witnessed test report is attached to every valve we ship.   

Most Common Testing Standards

• API 598, “Valve Inspection and Test” – The most widely used test specification. The document covers all types of valves in sizes through NPS 24. It also includes leakage rates and testing criteria for metal-seated and resilient-seated valves.
• API 527, “Seat Tightness of Pressure Relief Valves” – Includes allowable leakage rates for testing with steam, water and air.
• ASME B16.34, “Valves – Flanged, Threaded and Welding End” – The primary valve design document, it also contains charts for determining the working pressures of valves to be used in conjunction with other test standards, such as API 598. B16.34 contains a test procedure, but no seat leakage acceptance criteria.
• ASME PTC 25, “Pressure Relief Devices” –PTC 25 contains detailed procedures for testing relief valves with air or steam.
• FCI 70-2, “Control Valve Seat Leakage” – This document contains detailed test procedures and leakage rate classes for control valves. The leakage classes are also occasionally referenced by other documents and used as acceptance criteria.
• ISA-S75, “Hydrostatic Testing of Control Valves” – Provides a procedure for the hydrostatic shell testing of control valves. Closure testing and acceptance criteria are out of the scope of this document and usually are covered by referencing FCI 70-2.
• ISO 5208, “Industrial Valves, Pressure Testing of Valves” – ISO’s primary testing standard and similar to API598, this document covers all types of valves and has four levels of allowable closure test leakage.
• MSS SP61, “Hydrostatic Testing of Steel Valves” – Similar to API 598, this document has small differences in test holding times and leakage rates.
• MSS SP70, “Cast Iron Gate Valves, Flanged and Threaded Ends” – Design document that contains testing procedures and acceptance criteria.
• MSS SP71, “Cast Iron Swing Check Valves, Flanged and Threaded Ends” – Design document that contains testing procedures and acceptance criteria.
• MSS SP78, “Cast Iron Plug Valves, Flanged and Threaded End” – Design document that contains testing procedures and acceptance criteria.
• MSS SP80, “Bronze Gate, Globe, Angle and Check Valves” – Design document for commodity bronze valves that contains testing procedures and acceptance criteria.
• MSS SP85, “Cast Iron Globe & Angle Valves” – Design document that also contains testing procedures and acceptance criteria.

 Useful Web Sites

• American Petroleum Institute
• American Standards Association
• American Society of Mechanical Engineers
• British Standards Institution
• Fluid Controls Institute
• International Organization for Standardization
• ISA (Instrumentation, Systems and Automation Society of America) 
• Manufacturers Standardization Society of the Valve and Fittings Industry

More Resources

• Brown Book Shop, Houston, TX
• Global Engineering Documents, Englewood, CO. (obsolete and out-of-date specifications)
  
  

Advantages to Zero Leakage Testing

MIning:  Whether it is a slurry line in Mongolia, China or Chile to an autoclave in the USA, Australia or Asia, valve leakage will soon lead to erosion of the internal components and an expensive repair and  operational down-time. Design features suited to the service conditions is the key to a lower cost of valve ownership.

Power: Reducing leakage in high pressure steam applications can result in significant cost savings by improving the heat rate and saving energy. Copeland valves offer long term reliability and reduced valve maintance for additional savings in time and money. 

Petrochemical and Refining: Fugitive Emissions has become a hot topic in these industries. Besides tight shut-off of the ball and seat, Copeland can provide a truely Zero Leakage stem sealing package that can reduce emmissions to zero.

Small bore valves for steam are always tested to the Zero Leakage Criteria. There is an added level of confidence when a valve may be tested in a customers plant site with 100 psi plant air and not leak.