LESER Global Standard Tightness Test. Content

Transcription

1 LESER Global Stanar Page 1/29 Content 1 Purpose Scope References Introuction Test Proceures at LESER Test Equipment at LESER Seat tightness test proceure, Test P Shell Tightness test proceure P Back seat tightness, test P21 (tightness outwars) Tightness of Pressure Seals of POSVs Qualifications of the staff Certification Demans of stanars Appenix 1: Seat tightness requirements acc. to API Appenix 2: Seat tightness LESER Stanar tightness requirement for spring safety valve Appenix 3: Seat tightness LESER increase tightness requirements Appenix 4: Seat tightness LESER increase tightness requirements POSV, Type 810, Pop Action pilot Appenix 4: Seat tightness LESER increase tightness requirements POSV, Type 810, Moulate Action Pilot Back Seat tightness, LESER stanar requirements for POSVs Seat tightness acc. to PAS SV Purpose This LESER Global (LGS) compiles the requirements of stanars an escribes the proceure of tightness testing of safety valves an pilot operate safety valves an also their Certification. 2 Scope This LGS applies to all members of the LESER quality cluster, as well as at national an overseas representatives an approve LESER service repair shops, in case of service on LESER s account. 3 References LID_DE ,, LGS 0222, LDeS_ DIN EN ISO DIN EN ISO DIN EN ISO Safety evices for protection against excessive pressure Part 1: Safety valves, Safety evices for protection against excessive pressure Part 4: Pilot-operate safety valves Inustrial valves: Testing of valves, part 1: Pressure tests, test proceures an acceptance criteria Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

2 LESER Global Stanar Page 2/29 DIN EN ISO DIN EN 1593 DIN EN DIN EN Inustrial valves Testing of valves, part 2: Tests, test proceures an acceptance criteria, supplementary requirements Tightness test, bubble test Foam proucing solutions for leak etection on gas installations Metallic proucts- Types of inspection ocuments ASME Coe Section VIII Rules for Construction of Pressure Vessels API 527 American Petroleum Institute Seat Tightness of Pressure Relief Valves 4 Introuction All LESER safety valves have to be test on tightness except SKD Kits Compact Performance-Valves (ref. to LID_DE ). The tightness test is a prouction test an is set up to ensure that each safety valve fulfils the requirements for which they have been esign without suffering from leakage of pressurize parts or seals. The tightness test is stanar practise at LESER (100 %) after the set pressure was be emonstrate. The leakage rates shall be ocument. In case the observe leakage rate excees the efine specification limit, the valve must be subject to the LESER quality rework process. The test requirements an acceptance criteria shall be accoring to Appenix. 4.1 Test meia The following test meia are to be use at LESER: Air, helium, water an steam. The test meium for etermining the seat tightness, air, steam or water, shall be the same as that use for etermining the set pressure of the valve. For ual- service valves, the test meium, air, steam or water, shall be the same as the primary relieving meium. (API Stanar 527). Upon customer request, LESER can conuct the tightness test using Helium as test meium for higher accuracy. 4.2 Pressure range The set pressure range by safety valve is regulate as follows: - acc. to ASME Coe pressure range starts with 15 psi (1,03 bar) - acc. to DGRL 97/23 pressure range starts with 0,5 bar - acc. to DIN EN ISO pressure range starts with 0,1 bar. The test pressure for the leakage is applie accoring the set pressure range. Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

3 LESER Global Stanar Page 3/ Test pressure The test pressure is regulate accoring set pressure range an requirement by API527 for each test proceure an is fixe in Appenix 1 to Test uration The test uration is regulate accoring stanars requirement for each test proceure an is fixe in Appenix 1 to Temperature As a stanar technique, the minimum or maximum temperature shall not be bellow 5 C (40 F) nor above 50 C (125 F) uring the test. (ASME Coe Section V, Article 10). 4.6 Acceptance Criteria Leakage rates, measure uring the etermine test perio, shall not excee the fixe leakage rates efine for the relevant types/esigns. The leakages rates are fixe in Appenix. 5 Test Proceures at LESER Following test proceures for tightness are to be applie for LESER safety valves an POSVs: - Seat tightness test proceure, Test P12 - Shell tightness test proceure, Test P11 - Back seat Tightness test proceure, Test P21 - Tightness test proceure for pressure seals Test meium is water, gas (air or helium) an steam. 6 Test Equipment at LESER The LESER safety valves are assemble an teste on an assembly an test benches. The assembly an test benches consist of the following subunits: - fixture system (incl. aaptors) - pressure system (air) - pressure measurement system - bubble count evice (Kellog test) - valve submerge basin LESER POSVs are assemble an teste on assembly an test benches for POSVs. The benches consist of the following sub units: - pilot assembly an test bench where the pilots are assemble an set - assembly an test bench for fully assemble POSV: in this place the full POSV is assemble, set an teste. 7 Seat tightness test proceure, Test P Definition Seat tightness means tightness between seat an isc. A safety valve/posv is consiere to be tight between seat an isc, if all requirements of the relevant stanar are performe. Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

4 LESER Global Stanar Page 4/29 Following measures for etermination of seat tightness can be use: o Leakage Rate in mbar l/s, o Leakage Volume in cm³/min. an o Number of bubbles/min. Testing of seat tightness will be carrie out at ambient temperature. 7.2 Requirements of LESER Due to the fact that API 527 is the sole international approve stanar which regulates tightness requirements for safety valves in special, LESER in its function as global company refers to this stanar only. However, LESER consiers also tightness requirements acc. to DIN EN an EN ISO Appenix 1: Seat tightness API 527 Requirements Test conitions an requirements for seat tightness acc. to API 527 are subject of this Appenix. Appenix 2: Seat tightness, LESER stanar requirements for SVs, Test conitions an tightness requirements acc. to API 527 an DIN EN for seat tightness an general requirements are eviate in Appenix 2 to 4. Appenix 3: Seat tightness, LESER improve tightness requirements for SVs, Test conitions an requirements of tightness for increase tightness are summarize in this Appenix. The allowable leakage rate for metal- safety valves with increase tightness equals half of allowable leakage rate for general tightness. It has to be consiere that in case of tightness requirements which excee the stanar higher lapping effort an higher costs will arise. Appenix 4: Seat tightness, LESER stanar requirements for POSVs Test conitions an requirements for seat tightness acc. to API 527, EN ISO an DIN EN of POSVs (stanar requirements) are subject of this Appenix. 7.3 Scope The testing proceure of seat tightness for each valve occurs after setting an checking of col ifferential set pressure on test bench in accorance with operation chart, which is eposite in SAP System. 7.4 Test meia The following test meia are to be use at LESER: Air, helium, water an steam. 7.5 Test pressure The pressure range is regulate as follows: - Acc. to ASME Coe pressure range starts with 15 psi (1,03 bar) - Acc. to DGRL 97/23 pressure range starts with 0,5 bar - Acc. to DIN EN ISO pressure range starts with 0,1 bar. At LESER the performance of pressure range an test pressure requirements acc. to API 527 is as follows (table 1): Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

5 LESER Global Stanar Page 5/29 Set pressure / col ifferential set pressure, p0, bar Test pressure, ptest bar 0,1< p0 < 0,7 0,5* p0 0,7 p0 3,5 p0-0,35 p0 > 3,5 Table 1: Test pressures for seat tightness testing 0,9* p0 7.6 Test uration After a short amping time, the test pressure has to be retaine over the entire etermine test perio (ref. to App. 2 an 4). 7.7 Test metho for the seat tightness test Consiering a.m. requirements of LESER, following test proceures are utilize for seat leakage test: - Seat tightness test proceure with air, proceure of bubble counting - Seat tightness test proceure acc. to PAS Seat tightness test proceure with air, application of test flui - Seat tightness test proceure with helium - Seat tightness test proceure with water - Seat tightness test proceure with steam 7.8 Testing of seat tightness with air, bubbles emission test proceure Applicability This proceure of seat leakage test with air, counting number of bubbles, is practise in case of safety valves with gastight esign (lifting evice H4, cap H2, close bonnet). For POSVs this test is first carrie out on the pilot, afterwars the full system (POSV) is teste Test Equipment for SVs (Kellog-Test) Testing of seat tightness with air, counting number of bubbles is practise at assembler working place. Following parts are components of the assembly work place: Clamp station (with aapter iscs) Pressure system (air) Pressure gauge system Bubble counting instrument Following features of bubble counting instrument, shown in fig. 1, correspon to API 527: Inner tube iameter Ø = 6,12 mm Water hea t =12,7 mm Bubble volume = 0,295 cm³ Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

6 LESER Global Stanar Page 6/29 Fig Test Equipment for POSVs The test of seat tightness of the pilot is teste on the pilot assembly bench. For this purpose a bubble test evice fulfilling the requirements of API 527 is installe. The full POSV the test is carrie out on the PSV assembly bench, which is also equippe with a bubble test evice. A sketch of the bubble test evice is given by graph 1. This evice is fulfilling the API527 requirements with the following parameters: Test uration After a short amping time, the test pressure has to be retaine over the entire etermine test perio (ref. to App. 2 an 4) Test pressure After setting an checking of col ifferential set pressure p0 a blow own up to test pressure ptest has to be carrie out. The test pressure ptest is efine in table 1. Attention: For POSV with a set pressure greater than 30 bar, the seat tightness is aitionally checke at 30% of the set pressure after the functional tightness test Test escription Spring Safety Valves Angle type flange safety valves are mounte via clamping jaw vertically at the inlet 0flange on the test bench. For the a rubber pa is lai own uner the inlet flange of safety valve. For safety valves with screwe connection, a clamping evice with screwe connection is neee. After valve setting the leakage test is carrie out. Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

7 LESER Global Stanar Page 7/29 The pressure will be reuce by 10% resp. in case of set pressures 3,5 bar by 0,35 bar. After 10 secons of slowown the leakage rate will be etermine (test time 10 s). The amount of air leakage escaping from the inlet via the seal between seat an isc causes a low excess pressure in the close outlet chamber. This excess pressure will be ecompose in the water tank in form of escaping bubbles. The escaping bubbles are counte in etermine test time (ref. to appenix 2 an 3). The volume of bubbles is efine by resp. epens on the water hea an inner with of ipping tube. The leakage rate shall not excee the limite leakage rates epening on the flow area 0 an valve esign as mentione in appenix 2 an 3. POSV The testing of POSVs correspons to a two sets sequence: 1/ The pilot is fixe on the PILOT assembly bench, set an teste for tightness. Pilot boies along with the manifol block are attache to the pilot assembly bench with four screws. Sealing is achieve using suitable o-rings. After assembly an pressure setting of the pilot the seat tightness test is carrie out. The inlet pressure is increase to meet the test pressure an after a efine amping perio the leakage rate is etermine. The bubble test evice is hooke up to the outlet an the bubbles create within the test perio are counte. The testing proceures are implemente as part of the overall assembly an testing proceure of the control program. 2/ Every complete POSV is teste for its respective CDTP. Usually this is achieve by setting the PILOT an therefore no aitional setting is require. Consequently tightness of the seat is teste. For the fully assemble POSV the tightness of the seat is efine as the tightness between seat an isk of the main valve. For the test the inlet of the POSV is clampe (perpenicular) to the test bench. The pressure in the inlet is increase to the respective test pressure an after a suitable amping perio the leakage rate is etermine. The observable bubbles within the testing perio are then counte Acceptance criteria Leakage rates, measure uring the etermine test perio, shall not excee the fixe leakage rates efine for the relevant types/esigns. The leakages rates are fixe in Appenix 2 an 4. The seat tightness stanar - requirements of spring safety valve mae in Works- Hohenwestet are efine at LDeS Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

8 LESER Global Stanar Page 8/ Certification The testing of seat tightness with air (bubble emission proceure) is ocumente in the SAP system an confirme by inspection test certificate 3.1 acc. to DIN EN (LESER CGA) If test report for seat leakage test is require, it has to be accesse with option coe M Testing of seat tightness of safety valve with plate isc This requirements shall be applie to spring loae safety valve with configuration plate iscs at PTFE, Kel - F or VESPEL materials only. For all spring loae safety valves with seal plate configuration, test pressure is efine as escribe in 15 Appenix 2: ptest = p0 x (formula, please fin in column Test pressure uner 15 Appenix 2) ptest = test pressure p0 = col ifferential test pressure The test uration shall be applie accoring with the Appenix 2 an 3. Leakage Test 1. Before starting the seat tightness test, the set pressure shall be emonstrate accoring at LGS The safety valve shall than waiting for 48 hours. 3. After 48 Hours the seat tightness test as escribe above shall be eterminate again. 4. In case the valve has opene/lifte any time after the 48hour perio, the proceure has to be repeate beginning with step acc. to PAS 1085: Scope The seat tightness test accoring to PAS 1085 is only applie to spring loae safety valves. The seat tightness test is only applie to safety valves in gas tight configurations (lifting ai H4, cap H2 an close bonnet) Test Pressure, Stabilizing Time an Inspection Time The test pressure an stabilizing time epen on the CDTP an the nominal size, respectively. The inspection time is 1 minute for all safety valves. The efine stabilizing times an test pressures are liste in tables 2 an 3. Set pressure, p0 bar Test pressure, ptestf bar >= 1,0 0,97 x p0 < 1,0 0,9 x p0 Table 2: Test pressure for seat tightness test, acc. to PAS 1085 Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

9 LESER Global Stanar Page 9/29 Nominal size Stabilizing time Inspection Time Allowe leakage (Bubbles/Minute) Up to DN min. 1 min. 3 Over DN min. 1 min. 3 Table 3: Stabilizing Time, Inspection Time an leakage rates acc. to PAS Test Proceure - Fix safety valve on test bench in upright position - Ajust set pressure of safety valves acc. to LGS Release pressure an attach inspection tube to outlet, then increase pressure to test pressure accoring to table 2. - Determination of leakage rate starts after the stabilizing time efine in table 3 or latest after the release of the first bubble from the tube opening. - The etermination of the leakage rate is one over a perio of one minute. Relevant are only those bubbles, which were release from the tube uring this inspection time. - The observe number of relevant bubbles is recore. If this number excees the allowe number of bubbles as efine in table 3, the valve must be subject to the LESER quality rework process Acceptance Criteria The test parameters an the acceptance criteria are liste in the table of appenix (seat tightness acc. PAS 1085 for safety valves) Seat tightness test proceure with air, another metho Applicability In case of non-gas tight safety valve esign (lifting evice H3, open bonnet), the seat leakage test is carrie out with proceure of applying test flui (acc. to DIN EN 1593). The application of test flui is a qualitative test proceure, because the quantitative proceure of bubble counting (leakage rate) is not possible Test equipment The seat leakage test by using air, proceure of test flui application, can be carrie out at the assembly working place. Following parts are components of the assembly working place: Clamp station (with aapter iscs) Pressure system (air) Pressure gauge system Bubble counting instrument As test flui a foamy lotion acc. to DIN EN 14291, leakage finer, is use. The test flui shall be non-volatile (it shall not ry at test temperature uring test perio) an viscous. Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

10 LESER Global Stanar Page 10/ Test escription Angle type flange safety valves are mounte via clamping jaw vertically at the inlet flange on the test bench. For the a rubber pa is lai own uner the inlet flange of safety valve (fig. 2). After setting of safety valve the seat leakage test is carrie out. A foamy lotion is rawn over the outlet orifice. The extension uner pressure impact an the accumulate leakage volume can be observe at the outlet. Test time amounts 5 secons. The between seat an isc fulfils the tightness requirements of this stanar, if arises bubble extens not more than 5 mm uring test time. In case of nominal sizes DNA DN100 an opening reucing rubber plug is aopte, because only for nominal sizes up to DN 80 bubbles can be rawn reliable. Fig Certification, Option Coe The testing of seat tightness with air, applying of test liqui proceure, is ocumente in the SAP system an confirme by an inspection certificate accoring to DIN EN If inspection certificate for seat tightness test is require, it has to be accesse with option coe M22. Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

11 LESER Global Stanar Page 11/ Seat tightness test proceure with helium Applicability The testing of seat tightness with helium is a special case of testing an is practise on customer eman only. This test can be carrie out for all safety valve types, even though the helium test is very extensive for open valves Test equipment LESER uses a helium leak etector for the helium test proceure: Technical Characteristic: Max. Pressure 15 mbar Minimum etectable Helium. Leakage rate: - Vacuum metho 5* mbar l/sec - sniffing metho < 1* 10-7 mbar l/sec Maximum inicate Helium- Leakage rate 0,1 mbar l/sec Measuring range 12 ecae Test metho With this helium leak etector ifferent test proceures for seat tightness can be practise. LESER uses following test methos: Proceure of overpressure (sniffing metho) Proceure of leakage etector in vacuum.(spraying metho) Test pressure The test pressure has to correspon to the pressure values at ambient temperature mentione in App. 2 an Test uration The test pressure has to hol up at least 5 min Test escription Overpressure proceure (sniffing metho): After setting the relevant safety valve with air on col-ifferential set pressure, it will be carrie to the helium test lab. After safety valve is mounte via clamping jaw at the inlet flange on the test bench, it will be pressurize with helium. After reaching the test pressure leakage rate is etermine via probe at the outlet. Proceure of leakage etection in vacuum: After setting the relevant safety valve with air on col- ifferential set pressure, it will be carrie to the helium test lab. Via aapter the valve is connecte airproof with the helium leakage etector at the inlet. After evacuation (vacuum occurs in the fitting) an airgun is injection helium between isc an in the outlet. The test result is metere after 5 min. Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

12 LESER Global Stanar Page 12/ Acceptance criteria Leakage rates, measure uring the etermine test perio, shall not excee the fixe leakage rates efine for the relevant types/esigns. In case of metal-to-metal seale safety valves leakage rates up to 10-3 mbar l/s are possible. Depenent on the test proceure leakage rates up to 10-9 mbar l/s can be reache in case of soft-seale safety valves. The stanar test value for seat tightness of LESER safety valves with soft seal amounts < 1x10-5 mbar l/s. Following option coes shall be use for seat leakage test with helium: - Option Coe N62, for sniffing metho - Option Coe M86, for vacuum metho Certification The testing of seat tightness with helium is ocumente in the SAP system an confirme by inspection test certificate acc. to DIN EN / test report. Following information are to be consiere: - Test subject - Requirements of Stanar - Reference terms / Main technical characteristics Test meium, Helium Test equipment: helium leakage etector - Test results - Test metho for each test result - Relevant Units, mbar l/s, for each test result. If inspection certificate for seat tightness test with helium is require, it has to be accesse with following option coe: - M 77 for seat tightness, overpressure proceure (sniffing metho) - M 81 for seat tightness, proceure of leakage etection in vacuum 7.13 Seat tightness test proceure with water Scope All valves, which are set with meium water, must be seat tightness teste. The seat tightness test is carrie out with the meium water after setting up the set pressure. The test conitions, test pressure, test time an allowe leakage are efine in Appenix 2 resp Test escription The valve shall be mounting vertically on the water test stan. Before the leakage test, the set pressure must be etermine. After a successful set pressure test with water, the seat tightness test follows. The pressure shall be lowere to zero. Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

13 LESER Global Stanar Page 13/29 Wait until no more water rains/flows off the outlet area. It is not allowe to wipe ry the moistene outlet area (or the use testing evice (stream etector)) of the valve. Steaily the inlet pressure shall than be increase to the test pressure. When reach the test pressure the valve outlet area shall be observe for 1 minute. The leakage of the seat is etermine by counting of raining off water rops in outlet area of the valve or in the testing evice Acceptance criteria The leakage rate shall not excee the acceptance criteria efine in Appenix 2.1. Photo 4: Falling water rop at the ege of stream etector Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

14 LESER Global Stanar Page 14/ Seat tightness test proceure with steam Applicability Testing of seat tightness with steam is practise for safety valves, which are set on col-ifferential set pressure with steam Test equipment The test is carrie out at the steam test lab in Hohenwestet site Test pressure The test pressure has to be in accorance with test values etermine in Appenices 2 an Test uration The test pressure has to be retaine acc. to the etermine test perio in Appenices 2 an Test escription After setting the relevant valve on col-ifferential test pressure an testing, the seat leakage test is carrie out with steam. The pressure is to be roppe to test pressure an after a short amping time the qualitative statement can be etermine Acceptance criteria, Option Coe The valve obtains to be tight, if the qualitative estimation criteria acc. to App. 2 resp. 3 are fulfille: no noticeable or visible leakage, no pressure rop at the pressure gauge is recognize Certification The seat leakage test with steam is ocumente in the SAP system an confirme by inspection test certificate acc. to DIN EN Shell Tightness test proceure P Applicability The shell tightness test proceure, at LESER calle boy tightness, is carrie out for all LESER safety valves, Pilot Operate Safety Valves an Change Over Valves. For Safety Valves with a heating jacket the shell tightness test proceure is carrie out at the heating jacket itself incluing all connections. 8.2 General, Definition The shell tightness test proceure is a collateral prouction pressure test to prove the tightness of pressure retaining boy an is carrie out at LESER as a stanar test. Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

15 LESER Global Stanar Page 15/29 Designation acc. to DIN EN : Shell Tightness, test proceure P11-EN Test proceure at LESER For shell tightness test proceure the test flui is coate onto boy surface at the inlet area. During the shell tightness test the test object is subjecte to the test meium air up to a certain test pressure. The surface of the test object incluing all connections is than wette with a test liqui an subjecte to a visual inspection. 8.4 Depth of inspection The shell tightness test is conucte for each valve in gas tight esign. 8.5 Test equipment The shell tightness test proceure is carrie out on assembly test benches. As test flui a foamy lotion acc. to DIN EN 14291, leakage finer, is use. The test flui shall be non-volatile an viscous. 8.6 Test meium In General this test is carrie out with air at ambient temperature. 8.7 Test pressure The shell tightness test proceure is carrie out with a test pressure of 6 bar (±1). 8.8 Test uration The test pressure has to be retaine acc. to the etermine test perio in table 4. Table 4: Minimum test time for testing of pressure retaining boy Nominal size Minimum test time [s] Up to DN From DN 65 up to DN From DN 200 up to DN DN 350 an higher Test escription The valve is clampe on the inlet sie on the test bench an then pressurize to a test pressure of 6 bar (±1). The valve is then wette on the surface with the test liqui an subjecte to a visual inspection. For valves with a heating jacket esign, the heating jacket incluing connections must be also pressurize to a test pressure of 6 bar (±1) an the surfaces must be wette with the test liqui. Subsequently, a visual inspection of the surfaces an connections is carrie out. Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

16 LESER Global Stanar Page 16/ Acceptance criteria There shall be no continuous bubble formation which coul inicate a leak in the wall or at the connections Certification, Option Coe The shell tightness test with air is confirme by inspection test certificate acc. to DIN EN As stanar testing the leakage test of pressure retaining boy effects without access of option coe. The certification of the test is controlle by option coe M18 9 Back seat tightness, test P21 (tightness outwars) 9.1 Scope The tightness test of the back, LESER name it tightness outwars, is carrie out at all LESER s safety valves in gastight esign an at all POSV. 9.2 Definition The test is a pre-expeiting pressure test for certification that the etermine leakage rate of the back is kept to the moment of the manufacture. The tightness outwars has reference to the test of the tightness at the connections boy/bonnet, bonnet/lifting evice H4 (cap H2) as well as the outlet of the boy. POSV at the connections: Top plat an boy with spray, manifol block an top plate with spray an at backflow preventer with the Kellog test metho. Marking in accorance with DIN EN , Tightness of back seal, test P21-EN Applicability The tightness of the back seal, test P21, is in accorance with the task scheule which is eposite in the ata base of the SAP-system for every safety valve in gastight esign. At LESERs, this test is stanar which is integrate in the prouction process. 9.4 Test equipment At LESER s the test of the tightness of the back seal takes place at the test benches. 9.5 Test meium At LESERS s, this test is carrie out stanar with air in room temperature. The back seat tightness can be realize with helium test proceure if the customer requests. Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

17 LESER Global Stanar Page 17/ Test pressure The test pressure for tightness of back seal, test P21, tightness outwars, shall be a minimum of 1,1 times the allowable pressure or (6±1) bar whereby the lower value counts (in accorance with DIN EN ). Stanar LESER carries out this test with a test pressure of 6 bar with the exception of: - Safety valves beginning with a nominal size DN 200 will be teste with a test pressure of 2,5 bar/air 36 psig. - For safety valves with PTFE - or elastomer components the pressure must be limite as follows: for initial pressures / set pressures p 0 < 3 bar to 0,15 x p 0 bar an for initial pressures / set pressures p 0 3 bar to 2 bar (28 PSIG) to avoi amages Test pressures outsie of the scope of the stanar must be coorinate between the customer an LESER (VK/TB). 9.7 Test uration The test pressure must be maintaine at least for the test perio etermine in table 5 (in accorance with DIN E ). Table 5: Minimum test perio for testing of the tightness of the back seal Nominal size Minimum test perio s > DN from DN 65 to DN DN 250 to DN Test requirements for POSV Appenix 5: Back Seat tightness, LESER stanar requirements for POSVs Test conitions an requirements for back seat tightness acc. DIN EN of POSVs (stanar requirements) are subject of this Appenix. 9.9 Test escription Operation with application of the test fluis (DIN EN 1593) This test proceure will be use for safety valves when the ipping is impractical. The testing of the tightness of back seal, tightness outwars, will be controlle in stanar cases. After testing of the seat leakage an the test pressure the safety valve will be tightene (outlet) on the test bench an amitte with pressure. Reaching the test pressure, the safety valves will be spraye at the connections an the outlet area with a non- volatile an viscous test flui. If there is no frothing formation recognizable the teste areas are all right. Dipping proceure (DIN EN 1593) This test proceure is applicable for compact performance safety valves. The safety valve will be seale (inlet) with an unscrewe cap. After that the safety valve will be clampe (outlet) in the test bench an ippe into the iving basin (water) Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

18 LESER Global Stanar Page 18/29 The specifie test pressure 6 bar / air will start. If there are no bubbles on the outsie surface of the safety valve the teste safety valve is all right. The test pressure will blow off an the safety valve will be etache from the test control unit. Remark! During the test perio the test pressure has to be kept constantly. The safety vale shoul be blistere ry with compresse air Helium test This testing metho, tightness of the back seal with helium, will be realize if customer requires. Apart from testing with air the test can also be realize with Helium. The etermine leakage rate will be >10-5 mbar l / s in stanar cases With the leak etector use by LESER, the tightness test with the vacuum-metho is realize. The safety valve will be seale (at the inlet) with a cap. Afterwars the safety valve will be clampe (at the outlet) on the leak etector. When the evacuation process is finishe (in the safety valve is now a vacuum) helium will be spraye with an air gun on every connection for 3 4 sec. The test result will be rea if the LED isplay is stable Certification, Option Coe The back seat tightness test tightness outwars, will be mentione in the SAP system an confirme with the inspection certificate in accorance with DIN EN As a stanar test with air, the tightness test of the back, tightness outwars, will follow without option coe. The tightness test of the back, tightness outwars, with Helium will be regulate with option coe N64. If inspection certificate for back seat test tightness outwars is require, it has to be accesse with following Option Coes: - M 28 Back seat tightness test outwars, application of test fluis - M 78 Back seat tightness test outwars, ipping proceure - M 82 Back seat tightness test outwars with helium, overpressure metho (sniffing metho) 10 Tightness of Pressure Seals of POSVs 10.1 Scope The tightness test of pressure seals is carrie out on all LESER POSV Definition The tightness of pressure seals refers to the tightness verification of the valve, the loaing an unloaing tubes (pilot, manifol block, main valve), pilot an tubing (pilot, tubing, pilot tube). Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

19 LESER Global Stanar Page 19/ Test Proceure The tightness test of the pressure is carrie out using the bubble count proceure an/or with the application of a leakage etection agent (foaming test) Applicability The tightness test of pressure seals is performe accoring to the work plan efine in the SAP system for every POSV. At LESER this test is a stanar test integrate into the assembly proceures, 10.5 Test Equipment The tightness test of pressure seals is carrie out on the assembly benches for POSV: The pilot is teste at the pilot assembly bench an the complete POSV is then testes on the POSV assembly bench. For the Kellogg test the bubble count evice at the assembly bench is use. For the foaming test an foaming flui accoring to DIN is use. This flui must be non-volatile (it may not ry within the testing perio at the test temperature) an viscous Test Meia At LESER these tests are performe using air at ambient temperatures Test Pressure The test is carrie out at 10% or 0.35bar whichever is greater below set pressure Test Duration The test pressure must be applie for one minute Test Proceure The tightness test of pressure seals is carrie out uring an after assembly of the complete POSV. A etaile escription of the testing proceure is ocumente within the assembly instructions for POSVs. The following seals/connections are teste for tightness: Pilot: - The connection between ajusting screw an boy is teste uring assembly - bubble count metho. - After setting of CDTP an test of the seat tightness: - Connection between manifol block an boy leakage finer - Tightness at BFP (set to position forwar ) bubble count metho. POSV: After testing of the set pressure the tightness test of the pressurize seals is carrie out on the seals Acceptance Criteria No leakage of the pressure seals may occur. Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

20 LESER Global Stanar Page 20/ Certification The tightness testing of pressure seals is always ocumente within the SAP system an is certifie by a 3.1 inspection certificate accoring to DIN EN Qualifications of the staff The test staffs are in the situation, because of their professional knowlege as well as physical qualifications to carry out the a. m. test proceures correctly. 12 Certification Test results are reporte stanarly in the SAP system an are prove by an inspection certificate accoring to 3.1 of DIN EN Following information has to be inclue in the inspection certificate 3.1: - Test subject - Requirements of Stanar - Use proceures - Reference terms / technical characteristics Test meium, test liqui, test evice - Test results - Test metho for each test result - Relevant units, mbar l/s, for each test result. 13 Demans of stanars Following stanars are consiere for the tightness tests at LESER s: DIN EN ISO , Safety evices for protection against excessive pressure Part 1: Safety valves, chapter. 6 Prouction testing, 6.6 Seat leakage test: The seat leakage test of a safety valve shall be carrie out. The test proceure an leakage rate shall be agree between the manufacturer an the purchaser DIN EN ISO , Safety evices for protection against excessive pressure Part 4: Pilotoperate safety valves, Chapter 6 Prouction Testing, 6.6 Seat leakage test: The seat leakage test of the pilot operate safety valve shall be carrie out after the ajustment of the set or the col ifferential test pressure. The test proceure an the leakage rate shall be agree between the manufacturer an the purchaser. When it is not the case, the values in an shall be use. 6.7 Pressure Seals All pressure seals between valve, loaing/unloaing line an sensing line shall be leak teste. If appropriate, hol for 1 min at 10% or 0.35 bar whichever is the greater below set pressure, using air or nitrogen. Leakage is not acceptable. ASME Coe Section VIII Rules for Construction of Pressure Vessels, Part UG-136() Prouction Testing by Manufacturers an Assemblers UG- 136 () (3) The seconary pressure zone of each close bonnet pressure relief valve exceeing NPS 1 (DN 25) inlet size when such pressure relief valves are esigne for ischarge to a close system shall be teste with air or other gas at a pressure of at least 30 psi (200kPa). There shall not be visible sign of leakage. Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

21 LESER Global Stanar Page 21/29 UG- 136() (5) After completion of the tests require by () (4) above, a seat tightness test shall be conucte. Unless otherwise esignate by a Manufacturer s publishe pressure relief valve specification or another specification agree to by the user, the seat tightness test an acceptance criteria shall be in accorance with API 527. DIN EN Inustrial valves: Testing of valves, part 1: Pressure tests, test proceures an acceptance criteria- Manatory requirements, eition 2003, chapter.4 Test requirements: 4.2 Every valve shall be subjecte to the shell tightness test, reference P11, liste in Table 1. DIN EN Inustrial valves Testing of valves, part 2: Tests, test proceures an acceptance criteria, eition 2003, A.3 Back seat tightness, test P21 Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

22 LESER Global Stanar Page 22/29 API 527 Test meium Air (Gases) 14 Appenix 1: Seat tightness requirements acc. to API 527 Metal-to-metal Soft Set pressure p o (relating to 16 C) bar 1,03-68, MPa 0,103-6,896 10,3 13,0 17,2 20,7 27,6 38,5 41,4 Test conitions After testing of set pressure p o / Blow own up o Test pressure if po 3,45 bar (0,345 MPa) then pprüf = p0-0,345 bar test (0,0345 MPa) DN 50 2 Test Time BZ = amping time PZ = Test Time Min DN /2...4 DN >100 >4 BZ PZ BZ PZ BZ PZ Tightness requirements 0 18mm 0 > 18mm Leakage rate Leakage rate (relate to 16 C; bubble volume V B= 0,295 cm 3, tube = 6,12mm) Number of bubbles bubble/ min Leakage volume cm 3 / min Leakage rate Mbar l/s (relate to 16 C; bubble volume V B= 0,295 cm 3, tube = 6,12mm) Number of bubbles Bubble/ min Leakage volume cm 3 / min Leakage rate Mbar l/s <4,7x <4,7x ,80 17,70 23,60 29,50 29,50 1,9x10-1 2,8x10-1 3,8x10-1 4,7x10-1 4,7x ,90 8,85 11,80 14,75 17,70 23,60 29,50 29,50 9,4x10-2 1,4x10-1 1,8x10-1 2,3x10-1 2,8x10-1 3,8x10-1 4,7x10-1 4,7x10-1 Steam Water Metal-tometal Soft Metal-to-metal if p0 >3,45 bar (0,345 MPa) then pprüf.= 0,9*po test BZ= amping time = 3 min TZ= test time = 1 min TZ- test time = 1 min No recognize or visible leakage NW 1 (DN25) Leakage volume 10cm 3 /h x Inlet nominal size / inch (Leakage volume 0,166cm 3 /min x Inlet nominal size /inch) NW<1 (DN25) leakage volume 10cm 3 /h* Soft - - TZ- test time = 1 min No leakage 2) Note: see Appenix 6 Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

23 LESER Global Stanar Page 23/29 15 Appenix 2: Seat tightness LESER Stanar tightness requirement for spring safety valve Test meium Set pressure p o (relate to 16 C) Pressure stages acc. to LGS 0222 bar MPa Test conitions Test pressure p test After testing of set pressure p o Blow own up to... Test pressure Blow-own of... Test pressure Test time BZ-amping time TZ-Test time s / min 0 18mm Leakage rate (relate to 16 C; bubble volume V B= 0,295 cm 3 tube = 6,12mm) Number of bubbles bubble/min Tightness requirements 0 > 18mm Leakage rate (relate to 16 C; bubble volume V B= 0,295 cm 3 tube = 6,12mm) Leakage volume Leakage rate Number of bubbles Leakage volume cm 3 /min mm³/sec mbarl/s bubble/min cm 3 /min mm³/sec Leakage rate mbarl/s LESER-Stanar Air (Gases) Metal-to-metal Soft plate Soft O-Ring or isc With vulcanize soft 0,1-66 > > ,01-6,6 >6,6-16,5 >16,5-70, if 0,1< p o < 0,7 (bar) 0,01 < p o < 0,07 (MPa) then Ptest = 0,5*p0 if 0,7 p o 3,5 (bar) 0,07 po 0,35 (MPa) then ptest= p0-0,35bar BZ = 10s TZ = 10s ,80 17,70 23,60 196,66 295,00 393,33 1,9x10-1 2,8x10-1 3,8x ,90 8,85 11,80 98,33 147,50 196,66 9,4x10-2 1,4x10-1 1,8x10-1 BZ= 10s TZ = 10s 20 5,90 98,33 9,4x ,95 49,16 4,7x10-2 BZ =10s TZ = 10s x x10-5 Steam Water Metal-tometal Soft Metal-tometal Soft if p 0 > 3,5 bar po >0,35 (MPa) then ptest = 0,9*po BZ = 3 min PZ = 1 min TZ = 1 min No recognize or visible leakage No inication of pressure rop at the pressure gauge See Appenix 2.1 Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

24 LESER Global Stanar Page 24/29 Appenix 2.1: Seat tightness LESER Stanar tightness requirement, testing with water Test Meium Seat Nominal size Leakage volume Tightness requirements Leakage Water Drops (relate to 16 C; Drop volume VT = 0,1 cm 3) Water Metalseate Soft - seate DN inch cm³/h cm³/h cm³/min rop / min rop / min exakt Abgerunet Nominal size >= 1 (DN25) Leakage volume 10cm 3 /h x nominal size in inch ) (Leakage 0,166 cm 3 /min x nominal size in inch) x , , /2 10 x 1 1/2 15 0,25 2, x , , x , x , , x , , x x , , x , , x x , , Nominal size < 1 (DN25) Leakage volume 10cm 3 /h ( 0,166cm 3 min) 10 0, , No visible leakage Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

25 LESER Global Stanar Page 25/29 16 Appenix 3: Seat tightness LESER increase tightness requirements LESER - increase tightness Test meium Air (Gases) Steam Metal-tometal Soft Metal-tometal Soft Set pressure p o (relate to 16 C) Pressure stage acc. to LGS 0222 bar 0,1-66 > > Test conitions MPa 0,01-6,6 >6,6-16,5 >16,5-70,0 Test pressure p prüf After testing of set pressure p o Blow own up to... Test pressure Blow-own of... Test pressure if 0,1< p o < 0,7 (bar) 0,01 < p o < 0,07 (MPa) then Ptest = 0,5*p0 If 0,7 p o 3,5 (bar) 0,07 po 0,35 (MPa) Then ptest= p0-0,35bar (0,035 Mpa) Test time BZ=amping time TZ = test time BZ- =10s TZ = 10s 0 18mm Leakage rate (relate to 16 C; Bubble volume V B= 0,295 cm 3 tube = 6,12mm) Number of bubbles bubble/min Leakage volume Test requirements Leakage rate 0 > 18mm Leakage rate (relate to 16 C; Bubble volume V B= 0,295 cm 3 tube = 6,12mm) Number of bubbles Lekage volume cm 3 /min mm³/sec cm³/min mm³/sec mbarl/s bubble/min Increase tightness not possible, ref. to App. 2: Stanar tightness requirements BZ =3 min TZ- = 1 min 5,90 8,85 11,80 98,33 147,5 196,66 9,4x10-2 1,4x10-1 1,8x ,95 4,42 5,90 No recognize or visible leakage No inication of pressure rop at the pressure gauge 49,16 73,66 98,33 - Increase tightness not possible, ref. to App. 2: Stanar tightness requirements Leakage rate (mbarl/s) 4,7x10-2 7,0x10-2 9,4x10-2 Water Metal-tometal Soft - - if p 0 > 3,5 bar po >0,35 (MPa) then TZ = 1 min No recognize or visible leakage ptest = 0,9*po Increase tightness not possible, ref. to App. 2: Stanar tightness requirements Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention

26 LESER Global Stanar Page 26/29 17 Appenix 4: Seat tightness LESER increase tightness requirements POSV, Type 810, Pop Action pilot Seat Type Pouns per Square Inch Gauge (psig) Set pressure po bar Mega -Pascals, MPa Test pressure, ptest f bar Test time BZ=amping time Pz = test time Number of bubbles bubble/min Leakage rate (Maximum) Leakage volume cm 3 / min Leakage rate mbar* l/s ,03-68,9 0,103-6, ,9 9,4x10-2 Type 811- Pop Action Pilot Metal-to-metal (Main Valve) an Metallic or soft Or soft (Pilot) Soft (O-ring or plate at main valve) An > > 68,9-130 > 6,896-10,3 30 8,85 1,4x10-1 > > > 10, ,8 1,8x10-1 > > > > > 13-17,2 > 17,2-20,7 testing for than: POSV with ptest = p0-0,345 if: DN < =50 BZ = 1 po 3,45 Aitional (<= 2 ) PZ = ,75 17,7 2,3x10-1 2,8x10-1 DN BZ = 2 p0 >30 bar > > > 20,7-27,6 (21/2...4 ) PZ = ,6 3,8x10-1 If : > > > 27,6-42,5 p0 >3,45 than Than: ptest.= 0,3 *po DN > 100 BZ = ,5 4,7x10-1 Ptest.= 0,9*po (> 4 ) PZ = , ,103-42,5 No recognize or visible leakage - <4,7x10-3 Metalic or soft (Pilot) Disclosure cat.: II proofrea by: Ku publish ate: 05/01/18 effect.ate: 05/18 author: Mi release by: Win replaces: status: Publishe resp. epart.: QM ate of release: 05/01/18 revision No.: 13 oc. type: LGS change rep. No.: NA retention