MNT en 4.9 Testing Procedures

LESER WORKS STANDARD
Cold differential test pressure

CDTP
LWN 001-69-EN
page 1
Content
1
What is CDTP? ......................................................................................................................... 2
2
What is CDTP-correction? ........................................................................................................ 2
3
Which influences on safety valves are covered with the setting at CDTP ? ............................. 2
4
How is the CDTP-correction calculated? .................................................................................. 2
5
How does LESER set the safety valves depending on different service condition with
temperature and back pressure? ...................................................................................................... 5
6
How is the influence of balanced bellows? .............................................................................. 8
6.1
How is the influence of balanced bellows in general for safety valve?............................. 8
6.2
How is the influence of balanced bellows in case of type 459 / 462 safety valves?......... 8
7
How does an open/closed bonnet influences the CDTP?....................................................... 10
8
How does the spring material influences the CDTP?.............................................................. 11
9
How does the medium influences the CDTP? ........................................................................ 11
10
In which documents you will find the CDTP- value? ........................................................... 11
11
EXAMPLE ........................................................................................................................... 12
11.1 Example: Temperature influence ................................................................................... 12
11.2 Example: Temperature and constant backpressure influence ....................................... 13
11.3 Example: Temperature and variable backpressure influence ........................................ 13
12
Original confirmation of German TV Nord ........................................................................ 14
continues on page 2
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processed: Cal
approved: refer to M 132000
edition: 27.02.08
replaces edition: 05.02.08

CDTP
1
LWN 001-69-EN
page 2
What is CDTP?
Cold differential test pressure (CDTP) is defined in standard

-
DIN EN ISO 4126-1 Edition 2004, Chapter 3.2.5

ASME Sec. VIII, Div. 1, Edition 2007, UG 136 (d) 4
API 520-1 Seventh Edition 2000, Chapter 3.4.1
ASME PTC 25 - 2001 Chapter 2.7
CDTP is used if correction of set pressure of safety valves according to deviation of service
conditions is necessary.
Extract of ASME Sec. VIII, Div. 1, UG 136 (d) 4:
When a valve is adjusted to correct for service conditions of superimposed back pressure, temperature, or the differential
in popping pressure between steam and air, the actual test pressure (cold differential test pressure) shall be marked on
the valve per 129
Extract of DIN EN ISO 4126-1 Chapter 3.2.5:

The inlet static pressure at which a safety valve is set to commence to open on the test bench
NOTE This test pressure includes corrections for service conditions, e.g. back pressure and/or temperature.
Extract of API 520 Chapter 3.4.1:

The actual service conditions under which a pressure relief valve is required to open, may be different form the
conditions at which the pressure relief valve is set to operate on a test stand. To compensate for this effect, a CDTP is
specified for adjusting the set pressure of the valve on the test stand. The CDTP may include a correction for actual
service conditions of back pressure and/or temperature.
Extract of ASME PTC 25-2001 Chapter 2.7:

the inlet static pressure at which a pressure relief valve is adjusted to open on the test stand. This test pressure includes
corrections for service conditions of superimposed back pressure and/ or temperature.
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.
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
Basically effects at the setting by:
- set pressure tolerance
- medium
The CDTP covers only influences of superimposed back pressure and/or temperature.
How is the CDTP-correction calculated?
The CDTP-correction is provided by the manufacturer. LESER has done measurements on steam
test laboratory at high temperature service conditions. These measurements have been monitored
and ploted as curve which was approved by German TV Nord.
In case of superimposed back pressure and temperature the corrected set pressure is calculated
with formula. This formula is valid for conventional or balanced bellows design.
The term ( pset pa ) considers influences of superimposed backpressure.
The factor kT covers influences of temperature.
continues on page 3
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CDTP
Design
Superimposed
Superimposed
backpressure variable
backpressure constant
(0 T) [bar g]
y [bar g]
Conventional pa = T
pa = y
Bellows
pa = 0
pa = 0
Table 1: backpressure according to different safety valve design
LWN 001-69-EN
page 3
Built-up backpressure
[bar g]
Not valid for calculation
Not valid for calculation
p cdtp = ( p set p a ) * k T
pset:
pa:
kT:
T:
set pressure at service conditions [psig or barg]

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.
correction factor for CDTP [-], this is depending on valve design/conventional
design/balanced bellows design/open or closed bonnet
temperature in [C]
Calculation-formulas:
Open or close bonnet with kT=0,97339+0,00039(T-200)balanced bellows
0,0000015477(T200)+0,0000000029977(T-200)
equation (1)
Closed bonnet conventional kT=0,97339+0,00039Tdesign

0,0000015477T+0,0000000029977T equation (2)
Open bonnet conventional kT=0,97339+0,00039(T-50)design
0,0000015477(T50)+0,0000000029977(T-50)
equation (3)
Table 2: Formulas of kT calculation
continues on page 4
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CDTP
LWN 001-69-EN
page 4
LESER datasheet of CDTP (Cold differential test pressure)
pcdtp = ( pset pa ) * kT
pcdtp = ( pset * k af pa ) * kT (Type 459/462 only)
pcdtp: cold differential test pressure [psig or barg]

pset: set pressure at service conditions [psig or barg]
pa: superimposed back pressure, constant (pa is equal paf) [psig or barg]
kT : correction factor for CDTP , temperature influence [-]
kaf: correction factor for type 459 / 462, deviating effective area influence [-]
C
Open bonnet
conventional
Closed bonnet
conventional
Open bonnet
balanced bellows
Closed bonnet
balanced bellows
550
1022
1,049
Limitation at 427C
Limitation at 350C
(only with balanced
500
932
1,032
(only with balanced
bellows)
450
842
1,021
bellows)
400
752
1,049
1,013
350
662
1,032
1,049
1,007
300
572
1,021
1,032
250
482
1,013
1,021
1,000
200
392
1,007
1,013
150
302
1,000
1,007
100
212
50
122
0
32
-50
-58
No influence of service condition on CDTP,
correction factor: 1,000
-100 -148
-150 -238
-200 -328
-250 -418
Table 3: correction factor kT depending ond safety valve design
1,049
1,032
1,021
1,013
1,007
1,000
LESER diagram kaf for for type 459 / 462

paf/p * 100 [%]
d0 = 9 [mm]
d0= 17,5 [mm] paf/p * 100 [%]
d0 = 9 [mm]
d0= 17,5 [mm]
0,0
0,999
0,998
20,0
1,083
0,872
1,0
1,001
0,990
22,0
1,097
0,863
2,0
1,003
0,983
24,0
1,111
0,855
3,0
1,005
0,975
26,0
1,126
0,847
4,0
1,008
0,968
28,0
1,143
0,840
5,0
1,011
0,961
30,0
1,160
0,833
6,0
1,014
0,954
32,0
1,178
0,827
7,0
1,018
0,947
34,0
1,197
0,822
8,0
1,021
0,940
35,0
1,207
0,819
9,0
1,025
0,934
10,0
1,029
0,927
12,0
1,038
0,915
14,0
1,048
0,904
16,0
1,059
0,893
18,0
1,070
0,882
Note: Types 459/462 with do = 13mm is not influenced by correction factor kaf. It is in all case = 1.
continues on page 5
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CDTP
5
LWN 001-69-EN
page 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
TV 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 TV 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%.
Correction factor kT for conventional design, closed bonnet,
to correct adjusting on cold air for service conditions of high temperature
- cold differential test pressure -
1,120
upward setpressure (+3%) of allowable tolerances

(3%) according to EN ISO 4126-1 2003-09
1,100
1,080
Approved correction curve by

German TV Nord
Correction factor kT
1,060
1,040
downward setpressure (-3%) of allowable

tolarance (3) according to EN ISO 4126-1
2003-09
1,020
1,000
-300
-200
-100
0,980
100
200
300
400
500
Temperature T [C]
0,960
-508
-308
-108
92
292
492
692
892
Temperature T [F]
figure 1:
Note 1:
Note 2:
correction factor kT for closed bonnet conventional design

LESER set safety valves in the range of 0 3% set pressure tolerance.
The CDTP is not the popping point. It is to LESER definition the set pressure with definition audible
discharge for gases/steam and first steady stream for liquids. The opening pressure is 10 % higher
than CDTP.
continues on page 6
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CDTP
LWN 001-69-EN
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
upward setpressure (+3%) of

allowable tolerances (3%)
according to EN ISO 4126-1
2003-09
1,100
1,080
Approved correction
curve by German TV
Nord
correction factor kT
1,060
1,040
downward setpressure (-3%) of

allowable tolarance (3)
according to EN ISO 4126-1
2003-09
1,020
1,000
-300
-200
-100
100
200
300
400
500
Temperatur (C)
0,980
0,960
-508
-308
-108
92
292
492
692
892
Temperature (F)
figure 2:
Note 1:
Note 2:
correction factor kT for open bonnet conventional design

The CDTP is not the popping point. It is to LESER definition the set pressure with definition audible
discharge for gases/steam and first steady stream for liquids. The opening pressure is 10 % higher
than CDTP.
continues on page 7
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CDTP
LWN 001-69-EN
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
upward setpressure (+3%) of

allowed tolarances (3%) according
to EN ISO 4126-1 2003-09
1,100
Approved correction curve

by German TV Nord
1,080
Correction factor kT
1,060
1,040
downward setpressure (-3%) of

allowed tolarances (3%) according
to EN ISO 4126-1 2003-09
1,020
1,000
-300
-200
-100
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:
Note 1:
Note 2:
correction factor kT for open or closed bonnet balanced bellows design

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.
continues on page 8
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CDTP
6
6.1
LWN 001-69-EN
page 8
How is the influence of balanced bellows?

How is the influence of balanced bellows in general for safety valve?
The stainless steel bellows protects the upper area of safety valve against temperature and
compensates backpressure. The medium could not be in contact with the spring. This avoids
changes of mechanical properties of spring material and influences on the setting. This effect is
valid until limits of spring material.
Conventional design:
Balanced bellows design:
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 dos. 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.
continues on page 9
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CDTP
LWN 001-69-EN
page 9
1,30
kaf
kaf (d0=9 mm) = 1,1575E-4*(paf /p*100%)+1,899E-3*(paf /p*100%)+0,9987
1,20
1,10
1,00
0,90
kaf (d0=17.5 mm) = 7,78E-5*(paf /p*100%)-7,8332E-3*(paf /p*100%)+0,998

0,80
0
10
15
20
25
30
35
paf/p [%]
diagram 1: correction factor kaf for balanced bellows design for type 459 / 462
continues on page 10
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CDTP
7
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page 10
How does an open/closed bonnet influences the CDTP?
The bonnet design could be open or closed design.

Open Design:
Closed Design:
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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CDTP
8
LWN 001-69-EN
page 11
How does the spring material influences the CDTP?
The spring material limits the maximum temperature at spring. These limits are documented by
spring purchaser or in LWN 001.52
Spring material
DIN designation
ASME
designation
Carbon
1.1200 / Sort SH
Maximum
medium
temperature
200C (392F)
Creep resistant
1.8159 / 51CrV4
1.7102 / 54SiCr6
1.4310 / X10CrNi18-8
ASTM A322
550C (1022F)
Stainless steel
Inconel
2.4669 / NiCr15Fe7TiAl
Hastelloy C4
2.4610 / NiMo16Cr16Ti
Tungsten BH12 1.2605 / X35CrWMoV5
Grade 6150
ASTM A313
550C (1022F)
Grade 302
ASTM B 637-98
700C (1292F)
ASTM B 574-99 550C (1022F)

EN ISO 4957 550C (1022F)
(12/1999)
Temperature range,
temperature
measured at spring
-30C - 100 C
(-22F - 212F)
-60C - 220 C
(-76F - 428F)
-200C - 280 C
(-328F - 536F)
-200C - 500 C
(-328F - 932F)
Max. 450C (842F)
Max. 500C (932F)
table 1: material and temperature limits

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.
How does the medium influences the CDTP?
The medium has no significant influence on CDTP.
10 In which documents you will find the CDTP- value?

CGA:
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CDTP
LWN 001-69-EN
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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 = 320C ( 608F), Steam
pcdtp = ( p set p a ) * kT
kT: according to equation (3) in chapter 3:
kT = 1,025
pa = 0, because of no backpressure
pcdtp = 10 barg * 1,025 = 10,25 barg (148,66 psig)
Set pressure tolerance: 03%
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CDTP
LWN 001-69-EN
page 13
pcdtpmin = 10,25 barg +0,00*10,25 barg = 10,25 barg (148,66 psig)

11.2 Example: Temperature and constant backpressure influence

Design: Type 459 do = 9mm, closed bonnet, balanced bellows
Service condition: pset = 50barg (725 psig), pa = 5barg (72,5 psig), t = 400C ( 752F), Air
pcdtp = ( pset * k af pa ) * kT

kT = 1,013
kaf: According to diagram 1 in chapter 5.1:
kaf = 1,029
pa = 0, because of balanced bellows
pcdtp = 50 barg * 1,029 * 1,013= 52,12 barg (755,74 psig)

11.3 Example: Temperature and variable backpressure influence

Design: Type 441, closed bonnet,
Service condition: pset = 10barg (145 psig), pa = 0 1,5 barg, t = 320C ( 608F), air
kT = 1,038
pa = 1,5 barg, because of conventional design and worst case situation
pcdtp = (10 barg 1,5barg) * 1,038 = 8,82 barg (127,93 psig)

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CDTP
LWN 001-69-EN
page 14
12 Original confirmation of German TV Nord
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CDTP
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CDTP
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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
TV Inspector
End of LWN
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Tightness Test
Testing Procedure at LESER
LWN 220-01-EN
Page 1
Contents
1
2
3
Scope and Applicability.............................................................................................................. 3

Definition.................................................................................................................................... 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
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
3.1.7.3.8
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
3.1.7.4.3
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
3.1.7.5.6
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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Ersatz f. Ausgabe: 25.07.07

Tightness Test
LWN 220-01-EN
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 LESERs ....................................................................................... 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
1
LWN 220-01-EN
Page 3
Scope and Applicability
This LWN compiles the requirements of standards and describes the procedure of tightness testing
of safety valves at the LESER sites Hamburg and Hohenwestedt as well as at national and
overseas representatives and approved LESER service repair shops, in case of service on
LESERs account and also their Certification.
All LESER safety valves have to be tested on tightness except SKD Kits Compact PerformanceValves (ref. to LWN 704.41).
Definition
The tightness test is a production test and is practised at LESER standardly.
Test description for LESER Safety Valves
Following test procedures for tightness are to be applied for LESER safety valves:
- Seat tightness test procedure, Test P12
- Shell tightness test procedure, Test P11
- Back seat Tightness test procedure, Test P21
Test medium is water, gas (air or helium) and steam.
3.1
3.1.1
Seat tightness test procedure, Test P12

Definition
Seat tightness means tightness between seat and disc. A safety valve is deemed to be tight
between seat and disc, if all requirements of the relevant standard are performed.
Following measures for determination of seat tightness can be used:
o Leakage Rate in mbar l/s,
o Leakage Volume in cm/min. and
o Number of bubbles/min.
Testing of seat tightness will be carried out at ambient temperature.
3.1.2
Requirements of LESER
Due to the fact that API 527 is the sole international approved standard which regulates
tightness requirements for safety valves in special, LESER in its function as global
company refers to this standard only. However, LESER considers also tightness
requirements acc. to DIN EN 12266.
Appendix 1: Seat tightness API 527 Requirements
Test conditions and requirements of tightness for seat tightness acc. to API 527 are subject
of this Appendix.
Appendix 2: Seat tightness, LESER standard requirements,
Test conditions and tightness requirements acc. to API 527 and DIN EN 12266 for seat
tightness and general requirements are deviated in this Appendix.
Appendix 3: Seat tightness, LESER improved tightness requirements,
Test conditions and requirements of tightness for increased tightness are summarized in
this Appendix. The allowable leakage rate for metal-sealing safety valves with increased
tightness equals half of allowable leakage rate for general tightness. It has to be
considered that in case of tightness requirements which exceed the standard higher lapping
effort and higher costs will arise.
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3.1.3
LWN 220-01-EN
Page 4
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.
3.1.4
Test media
The following test media are to be used at LESER: Air, helium, water and steam.
3.1.5
Test pressure
The pressure range is regulated as follows:
- Acc. to ASME Code 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 4126-1 pressure range starts with 0,1 bar.
At LESER the performance of pressure range and test pressure requirements acc. to API
527 is as follows (table 1):
Set pressure / cold differential 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
0,9* p0
Table 1
3.1.6
Test duration
After a short damping time, the test pressure has to be retained over the entire determined
test period (ref. to App. 2 and 3).
3.1.7
Test method for the seat tightness test

Considering a.m. requirements of LESER, following test procedures are utilized for seat
leakage test:
- Seat tightness test procedure with air, procedure of bubble counting
- Seat tightness test procedure with air, application of test fluid
- Seat tightness test procedure with helium
- Seat tightness test procedure with water
- Seat tightness test procedure with steam
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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).
3.1.7.1.2 Test Equipment (Kellog-Test)
Testing of seat tightness with air, counting number of bubbles is practised at
assembler working place. Following parts are components of the assembly work
place:
Clamp station (with adapter discs)
Pressure system (air)
Pressure gauge system
Bubble counting instrument
Following features of bubble counting instrument, shown in fig. 1, correspond to
API 527:
Inner tube diameter = 6,12 mm
Water head t =12,7 mm
Bubble volume = 0,295 cm
Fig. 1
3.1.7.1.3 Test duration

After a short damping time, the test pressure has to be retained over the entire
determined test period (ref. to App. 2 and 3).
3.1.7.1.4 Test pressure
After setting and checking of cold differential set pressure p0 a blow down up to test
pressure ptest has to be carried out. The test pressure ptest is defined in table 1.
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3.1.7.1.5 Test description

Angle typed flanged safety valves are mounted via clamping jaw vertically at the inlet
0flange on the test bench. For the sealing a rubber pad is laid down under the inlet
flange of safety valve. For safety valves with screwed connection, a clamping device
with screwed connection is needed. After valve setting the leakage test is carried out.
The pressure will be reduced by 10% resp. in case of set pressures 3,5 bar by 0,35
bar. After 10 seconds of slowdown the leakage rate will be determined (test time 10
s). The amount of air leakage escaping from the inlet via the seal between seat and
disc causes a low excess pressure in the closed outlet chamber. This excess
pressure will be decomposed in the water tank in form of escaping bubbles. The
escaping bubbles are counted in determined test time (ref. to appendix 2 and 3). The
volume of bubbles is defined by resp. depends on the water head and inner width of
dipping tube.
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.
3.1.7.1.6 Acceptance criteria, Option Code
Leakage rates, measured during the determined test period, shall not exceed the
fixed leakage rates defined for the relevant types/designs. The leakages rates are
fixed in Appendix 2 and 3.
The general tightness of LESER safety valves is carried out without option code
controlling (App. 2).
For increased tightness requirements, following option codes are used (App. 3):
Option
Code
Text
Remark
J86
Grinding: For increased

tightness acc. to LWN 220.01
Cp. LWN 220.01 App. 3

Standard for Type 455-458
N50
Grinding: For increased

tightness acc. to LWN 220.01
(intern)
The Option Code N50 is not used any

longer
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.
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Page 7
3.1.7.2 Seat tightness test procedure with air, another method

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.
3.1.7.2.2 Test equipment
The seat leakage test by using air, procedure of test fluid application, can be carried
out at the assembly working place. Following parts are components of the assembly
working place:
Clamp station (with adapter discs)
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.
Angle typed flanged safety valves are mounted via clamping jaw vertically at the inlet
flange on the test bench. For the sealing a rubber pad is laid down under the inlet
flange of safety valve (fig. 2).
After setting of safety valve the seat leakage test is carried out. A foamy lotion is
drawn over the outlet orifice. The extension under pressure impact and the
accumulate leakage volume can be observed at the outlet.
Test time amounts 5 seconds. The sealing between seat and disc fulfils the tightness
requirements of this standard, if arises bubble extends not more than 5 mm during
test time.
In case of nominal sizes DNA DN100 an opening reducing rubber plug is adopted,
because only for nominal sizes up to DN 80 bubbles can be drawn reliable.
Fig. 2
Austritt
outlet
Eintritt
inlet
Prftisch
test bench
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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.
3.1.7.3 Seat tightness test procedure with helium
The testing of seat tightness with helium is a special case of testing and is practised
on customer demand only. This test can be carried out for all safety valve types, even
though the helium test is very extensive for open valves.
LESER uses a helium leak detector (Alcatel ASM 120H) for the helium test
procedure, which has a helium gauged leakage of 1,5x10-7 mbar l/s.
The ASM 120H detector is a complete leak detection unit, comprising a Helium gas
analyser with its pumping unit: molecular drag pump, and vane rotary vacuum pump,
the letter also being used as roughing pump.
Accessories: Spraying pistol ( helio probe type) and Helium calibrated leaks
The ASM 120H test range is between 10-9 to 1 mbar l/s.
3.1.7.3.3 Test method
With this helium leak detector different test procedures for seat tightness can be
practised. LESER uses following test methods:
Procedure of overpressure (sniffing method)
Procedure of leakage detector in vacuum.(spraying method)
The test pressure has to correspond to the pressure values at ambient temperature
mentioned in App. 2 and 3.
The test pressure has to hold up at least 5 min.
Overpressure procedure (sniffing method):
After setting the relevant safety valve with air on cold-differential set pressure, it will
be carried to the helium test lab. After safety valve is mounted via clamping jaw at the
inlet flange on the test bench, it will be pressurized with helium. After reaching the test
pressure leakage rate is determined via probe at the outlet.
Procedure of leakage detection in vacuum:
After setting the relevant safety valve with air on cold-differential set pressure, it will
be carried to the helium test lab.
Via adapter the valve is connected airproof with the helium leakage detector at the
inlet.
After evacuation (vacuum occurs in the fitting) an airgun is injection helium between
disc and sealing n the outlet. The test result is metered after 5 min.
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Page 9

Leakage rates, measured during the determined test period, shall not exceed the
fixed leakage rates defined for the relevant types/designs.
In case of metal-to-metal sealed safety valves leakage rates up to 10-3 mbar l/s are
possible. Dependent on the test procedure leakage rates up to 10-9 mbar l/s can be
reached in case of soft-sealed safety valves.
The standard test value for seat tightness of LESER safety valves with soft seal
amounts < 1x10-5 mbar l/s.
Following option codes shall be used for seat leakage test with helium:
Option Code N62, for sniffing method
Option Code M86, for vacuum method
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 Seat tightness test procedure with water
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.
Testing with water is permitted only, if the functional behaviour of the safety valve is
not influenced unfavourably. A quantitative estimation of the leakage volume acc. to
table 3 is technical not practicable.
DN
3
cm /min
10
15
20
0,166 0,166 0,166
25
32
40
50
65
80
100
150
200
250
300
400
11
13
17
25
33
42
50
66
Table 3: Leakage volume depending on nominal size acc. to API 527 (App. 1)
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If quantitative information (leakage rate) regarding seat tightness is required for

safety valves which are setted with water, the seat leakage test is carried out with air
(Kellog-Test) after setting and checking of cold-differential set pressure. The seat
leakage test with water can correspond only to a qualitative information.
The valve obtains to be tight, if the qualitative estimation criteria acc. to App. 2 resp. 3
are fulfilled: no noticeable or visible leakage, no pressure drop at the pressure gauge
is recognized.
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 Seat tightness test procedure with steam
Testing of seat tightness with steam is practised for safety valves which are setted on
cold-differential set pressure with steam.
The test is carried out at the steam test lab in Hohenwestedt site.
The test pressure has to be in accordance with test values determined in Appendices
2 and 3.
The test pressure has to be retained acc. to the determined test period in Appendices
2 and 3.
After setting the relevant valve on cold-differential test pressure and testing, the seat
leakage test is carried out with steam. The pressure is to be dropped to test pressure
and after a short damping time the qualitative statement can be determined.
The valve obtains to be tight, if the qualitative estimation criteria acc. to App. 2 resp. 3
are fulfilled: no noticeable or visible leakage, no pressure drop at the pressure gauge
is recognized.
The seat leakage test with steam is documented in the SAP system and confirmed by
inspection test certificate acc. to DIN EN 10204.
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3.2
3.2.1
LWN 220-01-EN
Page 11
Shell Tightness test procedure P11

Applicability
The shell tightness test procedure, at LESER called body tightness, is carried out for all
LESER safety valves generally.
3.2.2
General, Definition
The shell tightness test procedure is a collateral production pressure test to prove the
tightness of pressure retaining body incl. sealing of operational subject against internal
pressure.
Designation acc. to DIN EN 12266-1, Edition 2003:
Shell Tightness, test procedure P11-EN 12266-1
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
Test procedure at LESER

For shell tightness test procedure the test fluid is coated onto body surface at the inlet area.
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.
3.2.3.2 Test equipment
The shell tightness test procedure is carried out on assembly test benches. The assembly
and test work place contains following parts:
Clamp station
Pressure system
Dipping basin
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.
3.2.3.3 Test medium
At LESER this test is carried out standardly with air at ambient temperature.
3.2.3.4 Test pressure
The shell tightness test procedure is carried out with test pressure which corresponds to
set pressure / cold-differential set pressure.
3.2.3.5 Test duration
The test pressure has to be retained acc. to the determined test period in table 4 (acc. to
DIN EN 12266-1).
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Table 4: Minimum test time for testing of pressure retaining body

Nominal size
Minimum test time
s
Up to DN 50
15
From DN 65 up to DN 200
60
DN 250 and larger
180
3.2.3.6 Test description

Application with test fluid:
In standard cases the shell tightness is carried out at mounted safety valves using test
fluid application procedure.
The safety valve is clamped on the test bench sidewards the inlet and then pressurized.
After setting and testing of required set pressure / cold-differential set pressure the body is
spraid with leakage detector solution at the inlet socket. The tested inlet area is found
correct, when no foam appears.
Remark!
During test period the test pressure shall be kept constant.
Afterwards the valve has to be blown dry with compressed air.
3.2.3.7 Certification, Option Code
The shell tightness test procedure with air is documented in the SAP system and
confirmed by inspection test certificate acc. to DIN EN 10204. As standard testing the
leakage test of pressure retaining body effects without access of option code.
If inspection certificate for shell tightness test with air is required, it has to be accessed
with option code M18.
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3.3
3.3.1
LWN 220-01-EN
Page 13
Back seat tightness, test P21 (tightness outwards)

Scope
The tightness test of the back sealing, LESER named it tightness outwards, is carried out at
all LESERs safety valves in gastight design.
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
3.3.3
Test procedure at LESERs
3.3.3.1 Applicability
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
LESERs, this test is standard which is integrated in the production process.
3.3.3.2 Test equipment
At LESERs the test of the tightness of the back seal takes place at the test benches.
A test bench work station consists of following parts:
o A fixing mechanism of the valve to be testing
o A pressure control system / source of fluid under pressure
o Pressure measurement system upstream the valve to be tested
o Bubble test instrument
o Water basin
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.
3.3.3.3 Test medium
At LESERSs, this test is carried out standardly with air in room temperature. The back seat
tightness can be realized with helium test procedure if the customer requests.
3.3.3.4 Test pressure
The test pressure for tightness of back seal, test P21, tightness outwards, shall be a
minimum of 1,1 times the allowable pressure or (61) bar whereby the lower value counts
(in accordance with DIN EN 12266-2).
Standardly 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 tested with a test pressure
of 2,5 bar/air 36 psig .
- For safety valves with PTFE - or elastomer components the pressure must be limited as
follows:
for initial pressures / set pressures p0 < 3 bar to 0,15 x p0 bar1 and
for initial pressures / set pressures p0 3 bar to 2 bar (28 PSIG) to avoid damages
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
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-
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Page 14
Test pressures outside of the scope of the standard must be coordinated between the
customer and LESER (VK/TB).
3.3.3.5 Test duration

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
3.3.3.6 Test description
3.3.3.6.1 Operation with application of the test fluids (DIN EN 1593)
This test procedure will be used for safety valves when the dipping is impractical.
The testing of the tightness of back seal, tightness outwards, will be controlled in
standard cases. After testing of the seat leakage and the test pressure the safety
valve will be tightened (outlet) on the test bench and admitted with pressure.
Reaching the test pressure, the safety valves will be sprayed at the connections and
the outlet area with a diluation which seeks leaks. If there is no frothing formation
recognizable the tested areas are all right.
3.3.3.6.2 Dipping procedure (DIN EN 1593)
This test procedure is applicable for compact performance safety valves.
The safety valve will be sealed (inlet) with an unscrewed sealing cap. After that the safety
valve will be clamped (outlet) in the test bench and dipped into the diving basin (water)
The specified test pressure 6 bar/air will start. If there are no bubbles on the outside surface
of the safety valve the tested safety valve is all right.
The test pressure will be blowed off and the safety valve will be detached from the test
control unit.
Remark! During the test period the test pressure has to be kept constantly.
The safety vale should be blistered dry with compressed air.
3.3.3.6.3 Helium test
This testing method, tightness of the back seal with helium, will be realized if customer
requires. Apart from testing with air the test can also be realized with Helium. The
determined leakage rate will be >10-5 mbar l / s.in standard cases
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.
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Page 15
3.3.3.7 Certification, Option Code

The back seat tightness test tightness outwards, will be mentioned in the SAP system and
confirmed with the inspection certificate in accordance with DIN EN 10204
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)
Qualifications of the staff
The test staffs are in the situation, because of their professional knowledge as well as physical
qualifications to carry out the a. m. test procedures correctly.
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.
Demands of standards
Following standards are considered for the tightness tests at LESERs:

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 Manufacturers 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.
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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
References to further standards
DIN EN ISO 4126-1
DIN EN 1593
DIN EN 14291
DIN EN 10204
Safety devices for protection against excessive pressure

Part 1: Safety valves,
Industrial valves: Testing of valves, part 1: Pressure tests, test
procedures and acceptance criteria
Industrial valves Testing of valves, part 2: Tests, test procedures
and acceptance criteria, supplementary requirements
Tightness test, bubble test, Edition 1999
Foam producing solutions for leak detection on gas installations
Metallic products- Types of inspection documents
ASME Code Section VIII
Rules for Construction of Pressure Vessels, Edition 2006
API 527
American Petroleum Institute

Seat Tightness of Pressure Relief Valves
DIN EN ISO 12266-1

DIN EN ISO 12266-2
Fortsetzung Bl. 17
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LESER-WORKS STANDARD
Tightness test
Testing at LESER
8
LWN
220-01-EN
Page
17
Appendix 1: Seat tightness requirements acc. to API 527

Test conditions
Tightness requirements
d0 15,88mm1)
d0 > 15,88mm1)
Leakage rate
Leakage rate
(related to 16C; bubble volume

3
VB= 0,295 cm , tube = 6,12mm)
(related to 16C; bubble volume

3,
VB= 0,295 cm tube = 6,12mm)
bar
MPa
1,03-68,9
103
130
172
207
276
385
414
0,103-6,896
10,3
13,0
17,2
20,7
27,6
38,5
41,4
BZ = damping time
PZ = Test Time
Test pressure
Min
DN
50
2
BZ
DN
65...100
21/2...4
PZ
BZ
PZ
DN
>100
>4
BZ
PZ
po 3,45 bar
(0,345 MPa)
1
Number of
bubbles
bubble/ min
Leakage
volume
3
cm / min
Leakage
rate
Mbar l/s
40
60
80
100
11,80
17,70
23,60
29,50
1,9x10
-1
2,8x10
-1
3,8x10
-1
4,7x10
100
29,50
4,7x10
Number of
bubbles
Bubble/ min
Leakage
volume
3
cm / min
Leakage
rate
Mbar l/s
20
30
40
50
60
80
100
100
5,90
8,85
11,80
14,75
17,70
23,60
29,50
29,50
9,4x10
-1
1,4x10
-1
1,8x10
-1
2,3x10
-1
2,8x10
-1
3,8x10
-1
4,7x10
-1
4,7x10
-1
pPrf = p0 - 0,345 bar

(0,0345 MPa)
test
-1
-2
Soft
sealing
<4,7x10
-
Metal-to-metal
sealing
Soft sealing
Metal-to-metal
sealing
(relating to 16C)
BZ= damping time = 3 min

PZ= test time = 1 min
Metal-to-metal
sealing
p0 >3,45 bar
(0,345 MPa)
-
Soft
sealing
Air (Gases)
Set pressure
po
After testing of set pressure

po /
Blow down up o
BZ- damping time = 1 min
pPrf.= 0,9*po
<4,7x10
-3
-3
No recognized or visible leakage
NW1 (DN25)
3
Leakage volume 10cm /h x Inlet nominal size /
3
(Leakage volume 0,166cm /min x Inlet nominal size)
NW<1 (DN25)
3
leakage volume 10cm /h*
LWN 220-01
Water
Steam
API 527
Test medium
Test Time
test
BZ- damping time = 1 min
No leakage
Fortsetzung Bl. 18
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24.10.07
Tightness test
Testing at LESER
9
LWN
220-01-EN
Page
18
Appendix 2: Seat tightness LESER Standard tightness requirements

Test conditions
Tightness requirements
Test medium
d 0 16 mm ( DN10, G1/2; DN15, G3/4)
Set pressure
po
Test pressure
ptest
(related to 20C)
After testing of set

pressure po
Blow down up to...
Test pressure
Metal-to-metal
sealing
Metal-to- Metal-to-metal Soft sealing
Soft sealing
metal
sealing
O-Ring or disc
plate
sealing
Soft sealing With vulcanized
Soft sealing
soft sealing
Air (Gases)
Water
0,1- 66
0,01- 6,6
>66-165
>6,6-16,5
>165- 700
>16,5- 70,0
Blow-down of...
Test pressure
0,1< po < 0,7 (bar)
0,01 < po < 0,07 (MPa)
( DN20, G1 and bigger)
Leakage rate
BZ-damping time
PZ-Test time
Leakage rate
3
(related to 20C; bubble volume VB= 0,295 cm

tube = 6,12mm)
Leakage volume
(related to 20C; bubble volume VB= 0,295 cm

tube = 6,12mm)
Number of
bubbles
bubble/min
cm /min
mm/sec
Leakage
rate
mbarl/s
40
11,80
196,66
1,9x10
60
17,70
295,00
2,8x10
80
23,60
393,33
3,8x10
BZ= 10s
PZ = 10s
20
5,90
98,33
9,4x10
BZ =10s
PZ = 10s
9x10
s / min
BZ = 10s
PZ = 10s
Leakage volume
Number of
bubbles
bubble/min
cm /min
mm/sec
Leakage
rate
mbarl/s
-1
20
5,90
98,33
9,4x10
-2
-1
30
8,85
147,50
1,4x10
-1
-1
40
11,80
196,66
1,8x10
-1
-2
10
2,95
49,16
4,7x10
-2
-5
9x10
Pprf = 0,5*p0
test
0,7 po 3,5 (bar)

0,07 po 0,35 (MPa)
-5
pPr f= p0 - 0,35bar
test
(0,035 Mpa)
p0 > 3,5 bar

po >0,35 (MPa)
pPrf. = 0,9*po
test
BZ = 3 min
PZ = 1 min
BZ =10s
PZ = 10s
LWN 220-01
Steam
LESER-Standard
Pressure stages acc. to

LWN 220.03
bar
MPa
d 0 > 16 mm
Test time

No indication of pressure drop at the pressure gauge
Fortsetzung Bl. 19
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Tightness test
Testing at LESER
LWN
220-01-EN
Page
19
10 Appendix 3: Seat tightness LESER increased tightness requirements

Test conditions
Test requirements
d0 16 mm ( DN10, G1/2; DN15, G3/4)
Test medium
Set pressure
po
(related to 20C)
Pressure stage acc. to

LWN 220.03
Soft sealing Metal-to-metal

sealing
Metal-tometal
sealing
Metal-to- Soft sealing
metal sealing
Soft sealing
Air (Gases)
Steam
0,1-66
After testing of set

pressure po
Blow down up to ...
Test pressure
Test time
BZ=damping time
Pz = test time
Blow-down of...
Test pressure
>66-165
>6,6-16,5
>165-700
>16,5-70,0
Number of
bubbles
Leakage volume
3
bubble/min
0,1< po < 0,7 (bar)
0,01 < po < 0,07 (MPa)
BZ- =10s
PZ = 10s
cm /min
( DN20, G1 and bigger)
Leakage rate
(related to 20C; Bubble volume VB= 0,295 cm

tube = 6,12mm)
MPa
0,01-6,6
d0 > 16mm
Leakage rate
mm/sec
(related to 20C; Bubble volume VB= 0,295 cm

tube = 6,12mm)
Leakage
rate
Number of
bubbles
mbarl/s
bubble/min
Lekage volume
cm/min
mm/sec
Leakage
rate
(mbarl/s)
-2
10
2,95
49,16
4,7x10
-2
20
5,90
98,33
9,4x10
30
8,85
147,5
1,4x10
-1
15
4,42
73,66
7,0x10
40
11,80
196,66
1,8x10
-1
20
5,90
98,33
9,4x10
-2
-2
Pprf = 0,5*p0
0,7 po 3,5 (bar)

0,07 po 0,35 (MPa)
BZ =3 min
PZ- = 1 min
Increased tightness not possible, ref. to App. 2: Standard tightness requirements

No indication of pressure drop at the pressure gauge
pPr f= p0 - 0,35bar
test
test
(0,035 Mpa)
p0 > 3,5 bar

po >0,35 (MPa)
pPrf. = 0,9*po
test
BZ =10s
PZ = 10s
LWN 220-01
Water
LESER - increased tightness
bar
Test pressure
pprf
Ende der LWN
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Procedures for the testing of cold differential
test pressure
LWN 331-12-EN
page 1
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
8.3
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
8.3.7 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
continues on page 2
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LWN 331-12-EN
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:
LA Supply, Loosly Assembled
SKD Kits. Semi Knocked Down (Compact Performance)
The issuing of an inspection certificate about the testing carried out can be order with the following
option codes.
Option code
H03
N05
Acceptance test certificate

Comments
LESER CGA (Certificate for Global Application) Inspection
certificate 3.1 according to DIN EN 10204
Inspection certificate 3.1 acc. to DIN EN 10204: Testing of optional
cold differential test pressure with air
General and definitions
This LWN will put together the standard requirements and will describe the procedure during the
setting and testing of the cold set pressure of safety valves at LESER and its documentation.
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.
Purpose and area of application
The procedure is applicable for all safety valves that are set with steam, water or air at the LESER
production sites in Hamburg, Hohenwestedt and at the authorised LESER service partners, should
they act on behalf of LESER.
continues on page 3
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LWN 331-12-EN
page 3
Derivation of standard specifications on LESER safety valves
The following LESER specifications are derived from the in point 11 described standard
requirements:
In general tolerances of 3% from the specified set pressure are admissible, however in the
case LESER safety valves plus tolerances are admissible. The reason for this is that the plant
operator can then fully utilize the maximum operational parameters like pressure and
temperature.
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.
Set pressure (range)
Tolerance
1,65 bar ( 23,9 psi)
plus 0,05 bar ( 0,725 psi)
1,65 bar ( 23,9 psi) ... 3,96 bar ( 58 psi)
plus 0,1 bar ( 1,45 psi)
>3,96 bar (57,4 psi)
plus 3 %
Table 1: Summary set pressure tolerances at LESER
Testing depth at LESER, practical application of the set pressure tolerances
At LESER all safety valves apart from LA supply (Loosly Assembled) safety valves and SKD kits
for Compact Performance valves as a matter of standard are prepared and test on cold set
pressure in accordance with work schedule recorded in the SAP System.
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.
Assembly and test equipment
In general the safety valves at LESER will be assembled, set and checked at the assembly test
bed.
An assembly test bed consists of the following parts:
Loading station
Pressure system (air, water or steam)
Pressure measuring devices system
The setting and testing of the cold set pressures of safety valves with steam is carried out at the
steam test bed and with water at the water test bed in the HOW.
continues on page 4
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6
LWN 331-12-EN
page 4
Pressure measuring devices
LESER safety valves were set and tested using pressure measuring devices with bourdon tubes
that complied with the standard requirements in accordance with ASME Code Section VIII and EN
DIN 837-1.
To realise the ASME-Codes Section VIII, UG 102 (b) each test bed has to be equipped with (for
set pressures up to 396 bar) with 7 pressure measuring devices to cover the entire pressure range.
If higher pressures (> 396 bar) are set at LESER via a pressure transformer, optionally the
pressure measuring device 1000 bar should be used.
The number of manometers is determined by the operational error limit with regard to the full-scale
value. This resulted in the following LESER preferential series for pressure measuring devices of
the precision class 0,6 (Table 2):
Table 2: LESER preferential series for pressure measuring devices (in accordance with ASMECode and DIN EN 837-1)
Cold differential test
pressure
[bar]
Manometer scale (pressure stages)

[bar]
0,5 - 1,65
2,5
1,50 3,96
4,00 10,56
16
10,00 26,66
40
25,00 66,00
100
62,50 165,00
250
150,00 - 396,00
600
250 - 660
1000
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.
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.
continues on page 5
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8
LWN 331-12-EN
page 5
Test procedure at LESER
The following procedures are possible at LESER:

Cold differential test pressure with air (Standard, without option code)
Cold differential test pressure with steam
(option code M07)
Cold differential test pressure with water
(option code M09)
8.1
8.1.1
Setting and testing of the cold differential test pressure with air
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.
8.1.2
Test bench
The assembly, setting and testing of the cold differential test pressure with air is carried out
at the assembly test bench. An assembly and testing bed consists of the following parts:
Loading station
Pressure measuring devices system
continues on page 6
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test pressure
Fig. 1: Example for assembly test bench
Loading station
8.1.3
LWN 331-12-EN
page 6
Pressure measuring
device system
Pressure system
Testing procedure
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).
continues on page 7
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test pressure
LWN 331-12-EN
page 7
The following work stages have to be adhered to (Example for a threaded valve):
Work stage 1
Call up SAP tab Q characteristics and
read the pressure setting area.
The set pressure should also bet he

mean tolerance value (here 2,55 bar).
Tools
Software system
Testing equipment
Assembly test bench
continues on page 8
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test pressure
LWN 331-12-EN
page 8
Work stage 2
Set the scale of the pressure display

(selection window)
During the setting of the valves it

might be helpful to display both
displays on the screen
Tools
Software: Visual manometer
SAP Transaction ZAKL / tab Qcharacteristics
Equipment
Assembly test bench
continues on page 9
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test pressure
LWN 331-12-EN
page 9
Work stage 3
Secure the spindle with splint
mandrel against twisting when
setting the forcing screw.
Impinge valve with pressure and set
in accordance with specifications
(SAP tab Q-characteristics) using
the forcing screw to the level of the
response pressures.
Control whether the valve opens
during cold differential test pressure.
The set pressure of the valves has
been reached, when you can hear
the air escaping air. You have to
achieve a full cracking noise and/or
bang.
A creeping response is not
admissible.
Should the valve open outside the
preset pressure tolerance, the
forcing screw has to be re-adjusted.
a) Turning clockwise valve opens at higher
pressure
b) counter clockwise valve opens at lower pressure
By re-setting the forcing screw,

initially pressure will be released, the
forcing screw is being re-set and the
valve will again be impinged with
pressure.
Tools
Splint mandrel, open-end wrench
Software Visual Manometer
SAP Transaction ZAKL / tab Qcharacteristics
Equipment
Assembly test bench
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test pressure
8.1.4
LWN 331-12-EN
page 10
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
8.2.1
Setting and testing of the cold differential test pressure with water
The safety valves to set and tested using water are controlled in accordance with SAP
System recorded work schedule, using option code M09.
8.2.2
Test bed
The pressure setting on water and testing of the cold-set pressures is carried out on the
water test bed HOW. The water test bed consists of the following parts:
Loading station
Water pressure system
pressure measuring devices system
8.2.3
Testing procedure
The valves to be set with water are initially preset for air.
The assembly and pressure preset on air is carried out in the same way as with the safety
valves, preset for air, on the assembly test bed (see chapter 5.4.1).
After the test valve has responded, set and check the set pressure in accordance with
specifications. The set pressure of the valves has been reached, if you can see the initial
continuous flow (water).
8.2.4
Acceptance criteria
The safety valve has to open within the preset set pressure tolerance.
The set pressure of the valves has been reached, if the initial continuous flow (water) can
be seen.
8.3
8.3.1
Setting and testing of the cold differential test pressure with steam
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.
8.3.2

The setting and testing of the cold-set pressures with steam is carried out in accordance
with the SAP System recorded work schedule.
If a safety valve has to be set using air and will afterwards be operated using steam, the
cold differential test pressure has to be calculated by considering the correction factor for
an increased operational temperature.
If the setting of the safety valves on the test bed is required to be to medium steam, this has
to be controlled in the order with option code M07.
8.3.3
Test media
The setting of the cold differential test pressures of safety valves with steam is carried out
using the in Table 3 determined test temperature:
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test pressure
LWN 331-12-EN
page 11
Table 3: Test temperature for steam setting

Set pressure
bar
Test
temperature
C
<1
1,01 2
2,01 3
3,01 4
4,01 5
5,01 6
>105
>115
>138
>146
>154
>160
8.3.4
Set pressure
bar
6,01 7
7,01 8
8,01 9
9,01 10
10,01 11
11,01 12
12,01 13
Test
temperature.
C
>165
>170
>175
>180
>185
>187
>190
Set pressure
bar
13,01 14
14,01 15
15,01 16
16,01 17
17,01 18
18,01 19
19,01 20
Test
temperature
C
>193
>195
>197
>199
>202
>205
>207
Test bed
The setting and testing of the cold differential test pressures with steam will be carried out at
LESER on the steam test bed in the HOW. (LWN 205.80).
The steam test bed consists of the following parts:
Steam machine
Steam setting table
Pressure measuring devices/measuring appliances
There are three adapters at the setting table for different nominal inlet widths.
8.3.5
Testing procedure
The safety valves are initially preset and checked on air.

The assembly and pressure preset on air of safety valves with pressure setting to steam is carried
out the same way as the safety valves that were set to air.
The steam machine and the steam setting table are started up in accordance with the instruction
manual (LWN 220.80, 220.05). The test bed is warmed up via the warming up pipe at approx. 10
% below the set pressures until the test temperature in accordance with Table 3 has been reached.
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.
8.3.6
Acceptance criteria
The safety valve has to open within the preset pressure tolerance.
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test pressure
LWN 331-12-EN
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.
8.3.7
Testing on capacity test bench of National Board (USA)
8.3.7.1 Capacity test

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.
8.3.7.2 Blow Down
In case of valves with fixed blow down also the reseating pressure difference will be tested (target
max. minus 7% of set pressure). After testing of capacity it will be noted also, if the valve closed
correctly.
Qualifications of the test personnel
The setting and testing on the cold differential test pressure of safety valves is carried out exclusive
by qualified assemblers.
Qualifying personnel is part of the organisational process at LESER. Planning training
requirements and courses like the initial training, in-house training program will be carried out on a
regular basis.
10 Documentation and option code

The cold differential test pressure with air, water or steam will be printed for each safety valve on
the name plate and SAP System documented.
The issuing of a certification about the testing of the cold differential test pressures can be ordered
using the following option codes:
Option code
H03
N05
Acceptance test certificate

Comments
LESER CGA (Certificate for Global Application) Inspection
certificate 3.1 according to DIN EN 10204
Inspection certificate 3.1 acc. to DIN EN 10204: Testing of optional
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:
a) Response pressure: 3 % of the response pressures or 0,15 bar, the larger
value will apply.
LESER
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test pressure
LWN 331-12-EN
page 13
ASME Code, Section I, Rules for Construction of Power Boilers

(Edition 2007)
Part PG General Requirements for All Methods of Construction
PG-72
Operation
PG -72.2 the popping point tolerance plus or minus shall not exceed that specified
in the following table:
Set Pressure, psi (MPa)
Tolerance, plus or minus

from set pressure
70 (0,5)
> 70 (0,5) and 300 (2,1)
> 300 (2,1) and 1000 (7,0)
> 1000 (7,0)
2 psi
3 % of set pressure
10 psi
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
UG -134 Pressure Setting of Pressure Relief Devices
UG 134 (d ) (1) The set pressure tolerance for pressure relief valves shall not exceed 2 psi for
pressures up to and including 70 psi and 3% for pressures above 70 psi,
except as covered in(d)(2) below.
(2) The set pressure tolerance of the pressure relief valves which comply with
UG-125(c)(3) shall be within -0%, +10%.
TV Nord e.V
... Suggestion for setting tolerances during the setting of safety valves by TV Nord e.V.;
0% + 3% and/or for setting pressures 1,0 bar + 0,05 bar; >1,0 bar to 5,0 bar + 0,10 bar.
Do we do not allow a minus tolerance, since the availability of the plant cannot any longer
guaranteed considering the permissible operation excess pressure. ...
AD 2000 memorandum A2, chapter 11

API 526, API 527, API 576
DIN EN 837-1
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test pressure
LWN 331-12-EN
page 14
12 Normative instructions
LWN 001.26
LWN 001.69
LWN 001.78
LWN 220.01
LWN 220.03
LWN 615.07
LWN 619.12
Safety valves with ASME certification

Cold differential test pressure (CDTP)
Set pressure, tightness, operation
Tightness test, testing procedure at LESER
Use of pressure measuring devices at the test beds (DIN EN- / ASME)
Gauging intervals (test media)
ASME/National Board- approval for LESER Safety valves (Stampattainment)
Operation, maintenance and maintenance steam machine, softening plant,
steam setting table HOW
LWN 205.80
Pressure Equipment Directive 97/23/EC

DIN EN ISO 4126 I Safety appliances against impermissible excess pressure,
Part I: Safety valves
DIN EN 837-1
Pressure measuring devices
ASME Code Section I
Rules for Construction of Powers Boilers
Section VIII Rules for Construction of Pressure Vessels
API STANDARD 526
Flanged Steel Pressure
Relief Valves, Fifth Edition, June 2002
API STANDARD 527
Seat Tightness of Pressure, Relief Valves
Refining Department, Third Edition, July 1991
API STANDARD 576,
Inspection of Pressure Relieving Devices,
API Recommended Practice 576, Second Edition, December 2000
13
Terms and abbreviations
LA Supply
SKD Kits
Loosely assembled = pre-assembled delivery (LWN 704.43)

Semi Knocked Down (LWN 704.41 Compact Performance valves)
End of LWN
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Set-up of Equipment in Warehouses
Performing Leak Tests
LWN
369-34 E
Page 1
Performing
Leak Tests
continues on page 2
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Page 2
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
2
3
General....................................................................................................................................2
Contents..................................................................................................................................2
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
continues on page 3
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Page 3
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.
3.1 Purpose of the document

The instructions for leak testing presented here describe the leak tests that are used
for
safety valves in a gas-tight design and

safety valves in a non-gas-tight design
3.2 Improper use

Uses of the test equipment other than those given in this document are forbidden.
Improper use may have adverse effects on the operation and consequently lead to
inaccurate test results.
3.3 Informal measures

The operating manual must always be kept at the testing station and used in the
event of any unclarity in the test procedure.
continues on page 4
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Page 4
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.
continues on page 5
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Page 5
4.1 Operational materials and supplies

The operational materials and supplies given in the following must be ready for use in
testing safety valves in a gas-tight and non-gas-tight design.
Leak detection spray

Material no.: 0161.0000
Fig. 1: Leak detection
Valve-specific test caps

Material no.: not yet defined
Fig. 2: Test caps
Valve-specific test plugs

Fig. 3: Test plugs
continues on page 6
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Page 6
Bubble counting unit (Kellog Tester)

Fig. 4: Bubble counting

it
Accessories for threaded valves

Fig. 5: Accessories
Water expansion kit

Fig. 6: Water expansion kit
continues on page 7
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Page 7
5 Distinguishing features of valve designs

5.1 Safety valves in a gas-tight design
Flanged valves
Closed
bonnet
Closed
lever (H4)
Threaded valves
Closed
lever (H2)
5.2 Safety valves in a non-gas-tight design

Flanged valves
Open
bonnet
Open
lever (H3)
continues on page 8
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6 Test description
6.1 Safety valves in a gas-tight design
6.1.1 Flanged valves
1.
2.
Valve assembly:
The safety valve is assembled and adjusted to the set pressure
(see assembly documentation)
LWN 369.30
LWN 369.32
LWN 369.33
Testing of the functional seal tightness (seat seal tightness):

Testing of functional seal tightness with air
Testing of functional seal tightness with water
Testing of the body seal:

Testing of body seal tightness with air and application of a test
liquid
3.
Testing of the back seal:
Testing of the interconnection points and the entire outlet area
with the aid of air and by application of a test liquid.
4.
continues on page 9
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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
2. Testing of the functional seal tightness with air and water:

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 characteristic
Test data
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:
gas-tight valves.
Testing depth
Test data
Leak volume [cm/min.] depending on the nominal diameter, see
LWN 220-01, TABLE 3
Only at the request of the customer
Test medium
Water
Test pressure
90% of set pressure
Testing device
Water expansion kit, LWN 369.55
Test characteristic
Testing standard
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Auxiliary materials:
The following auxiliary materials must be available when testing the functional seal tightness.
Auxiliary material
Valve-specific test caps
Bubble counting unit (Kellog tester)
Water expansion kit
(on customer request)
Material no.
not yet defined
0172.0001
0172.0001
0171.0001
Note:
Tests with water are only permissible if the functional operation of the safety valve will not be adversely 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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Page 11
Testing of functional seal tightness with air

Operations:
a) The inlet side of the safety valve must be vertically attached to the chuck.
Clean sealing surfaces are a basic requirement

for accurate measurement results.
Fig. 8: Clamped on valve
b) Select the correct test cap and then install

the gas-tight test cap on the bonnet.
Tighten the test cap finger-tight.

No test air may escape.
Fig. 9: Select the test cap
c) Select a tapered end-plug to fit the outlet and insert

the test plug in the outlet flange of the safety valve.
Fig. 10: Install the test plug
d) Trigger the safety valve 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).
-10%
Fig. 11: Test pressure reduction
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Page 12
e) If the pressure has been set as described, then place

the hose of the bubble counting device on the already-installed end plug.
No test air may escape from the connection.
Fig. 12: Installation of the test hose
f) First, switch on the test lighting in the bubble counting device. Then count the bubbles per minute as
per LWN 220.01.
Allow a settling time of 10 seconds before

counting the bubbles.
The number of air bubbles that are determined
must be less than or equal to the tolerance
specification (LWN 220.01, Appendix 1-3).
Test passed:
If the number of bubbles is less than or equal to
the specification, then the test has been
passed.
Test not passed:

If the number of bubbles is greater than the
specification in LWN 220.01 Appendix 1-3, then
then test has not been passed. In this case,
the valve will be reworked
(see Reworking 369.37) and the test performed
again.
Fig. 13 Test setup
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Testing of functional seal tightness with water

Operations:
a) The inlet side of the safety valve must be vertically attached to the chuck.
Clean sealing surfaces are a basic requirement

for accurate measurement results.
Fig. 14: Clamping on the valve
b) Pressure must be applied to the safety valve with the

help of the water expansion kit (see LWN 369.55)
and caused to trigger one time.
-10%
c) 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).
d) After a settling time of 10 seconds, a qualitative assessment of the leak volume must be performed as
per LWN 220-01.
Fig .16: Pressure reduction by 10%
A quantitative assessment of the leak volume cannot

be conducted in a technically reasonable way.
An additional test of functional seal tightness with air
is necessary.
Fig .17: Functional seal tightness with water
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Page 14
3. Testing body seal tightness:
Test data:
The following test data must be observed when testing the seal tightness of the pressure-bearing
body.
Test characteristic
Test data
Testing the body seal tightness
Testing standard
The valve must not have any visual signs of leaks
Testing depth
Every safety valve with a cast body and a rolled-in seat, 100%
testing
Test medium
Air
Test pressure
The test pressure is 6 bar (87.02 psi)
Testing device
Application of test liquid
Length of test
Settling time of at least 10 seconds +

15 seconds up to DN 50
180 seconds above DN 200
The following auxiliary materials must be provided when testing the body seal tightness.
Auxiliary material
Material no.
0161.0000
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Page 15
Operations:
a) The inlet side of the safety valve must be
vertically attached to the chuck.
Clean sealing surfaces are the basic

requirement for accurate measurement results.
6 bar
b)
Apply test pressure of 6 bar (87.02) psi to the

safety valve.
c)
When the test pressure of 6 bar (87.02 psi) is

reached, spray the body with test liquid on the
inlet side between the markings (see Figure
19).
Fig. 19: Test pressure 6 bar

the test.
Test passed:
If there is no foam formation on the body,
then the test has been passed.
Test not passed:

If there is foam formation on the body,
then the test has not been passed.
If it is possible to repair the damage, then
the test must be conducted again.
Fig. 20: Testing zone
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Page 16
4. Testing of the back seal:

Test data:
The following test data must be observed when testing the back seal.
Test characteristic
Test data
Testing of the seal tightness of the valve on the outlet side
Testing standard
Testing depth
Every safety valve with a gas-tight design, 100% testing
Test medium
Air
Test pressure
6 bar (87.02 psi)
Testing device
Length of test

The following auxiliary materials must be provided when testing the back seal.
Auxiliary material
Material no.
0161.0000
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Page 17
Operations:
a) The outlet side of the safety valve must be
attached to the chuck.
Clean sealing surfaces are the

basic requirement for accurate
measurement results.
Fig.: 21: Clamping on the valve
6 bar
b)
Apply test pressure of 6 bar (87.02) psi to

the safety valve with the help of the handwheel needle valves.
c)
When the test pressure of 6 bar (87.02 psi)

is reached, spray the body with test liquid
on the outlet side between the markings
(see Figure 23).
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Page 18
Allow a settling time of 10 seconds

before testing.
Test passed:
If there is no foam formation on the surface of the valve,
Test not passed:

If there is foam formation on the surface of the valve,
then the test has not been passed.
If it is possible to repair the damage,
then the test must be conducted again.
Fig. 24: Foam formation
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Page 19
6.1.2 Threaded valves
1.
Valve assembly:
LWN 369.31
Testing of functional seal tightness (seat seal tightness):

Testing of the functional seal tightness with air
Testing of the functional seal tightness with water
2.
Testing body seal tightness:
Testing of the body seal tightness with air and application of
testing liquid
3.
Figure 28
Testing of the back seal:

Testing of the interconnection points and the entire outlet area
with the help of air and by applying test liquid.
4.
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Page 20
1. Valve assembly:
LWN 369.31
Fig. 30: CP valve
2. Testing of functional seal tightness with air and water:
Test data for testing functional seal tightness with air:

The following test data must be observed when testing the functional seal tightness
with gas-tight valves.
Test characteristic
Test data
Testing standard
Number of bubbles per second, see LWN 220-01, Attachment 1-3
Testing depth
Test medium
Air
Test pressure
90% of set pressure
Testing device
Bubble counting unit
Length of test
Test data for testing functional seal tightness with water:

gas-tight valves.
Testing depth
Test data
Leak volume [cm/min.] depending on the nominal diameter, see
LWN 220-01, TABLE 3
Only at the request of the customer
Test medium
Water
Test pressure
90% of set pressure
Testing device
Water expansion kit, LWN 369.55
Test characteristic
Testing standard
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Page 21
The following auxiliary materials must be provided when testing the seal tightness of the
seat for threaded valves.
Auxiliary material
Material no.
0172.0001
0151.0002
Bubble counting unit (Kellog tester)
0172.0001
Water expansion kit

(on customer request)
0171.0001
Note:
Tests with water are only permissible if the functional operation of the safety valve will not be adversely affected. A quantitative 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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Page 22
Testing of functional seal tightness with air:
Operations:
Figure 31
a)
The inlet side of the safety valve must be vertically attached to the clamping device (see LWN
0121.0001).
Clean sealing surfaces are a basic requirement for accurate measurement results.
Fig. 32: Clamping the valve in
the clamping device
b)
If the test is performed on the Manual Basic Test

Bench, then the valve must be attached to the
test bench with the help of the accessories for
threaded valves (material no.: 0151.0002) as
shown in Figure 33.
Fig. 33: Clamping on the

Manual Basic Test Bench
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c)
369-34 E
Page 23
Select a tapered end-plug to fit the outlet and insert the test plug in the outlet flange of the safety
valve.
Fig. 34: Inserting the test plug
-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).
Fig. 35: Pressure reduction by

10%
e)
If the pressure has been set as described, then

place the hose of the bubble counting device on
the already installed end-plug.
No test air may escape from the connection.

Fig. 36: Mounting the bubble hose
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Page 24
f) First, switch on the test lighting in the bubble counting device. Then count the bubbles per minute as
per LWN 220.01.

counting the bubbles.
The number of air bubbles that are determined must be less than or equal to the tolerance specification (LWN 220.01).
Test passed:
If the number of bubbles is less than or equal
to the tolerance specification, the the test has
been passed.
Test not passed:
If the number of bubbles is greater than the
tolerance specification, then the test has not
been passed. In this case, the valve will be
reworked (see LWN 369.37) and the test performed again.
Fig. 37: Counting

bubbles
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Page 25
Testing of the functional seal tightness with water:

Operations:
a) The inlet side of the safety valve must be attached

to the testing device with the help of the additional
screw connections (material no. 0151.0002). To do
this, the respective thread adapter must be first
screwed on.
Fig. 38: Thread adapter
b) In addition, the base unit of the accessories for

threaded valves (material no. 0151.0002) must be
attached to the test bench.
Fig. 39: Fixing the base unit in

position
c) The safety valve must be attached to the base unit

with the adapter.
Fig. 40: Screwing in the

valve
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Page 26
d) Pressure must be applied to the safety valve with

the help of the water expansion kit (see LWN
369.55) and caused to trigger one time.
-10%
e) 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).
Fig .44: Pressure reduction by 10%
f) After a settling time of 10 seconds, a qualitative

assessment of the leak volume must be performed
as per LWN 220-01.
A quantitative assessment of the leak volume cannot be conducted in a technically reasonable way.
An additional test of the functional seal tightness
with air is necessary.
Fig .45: Functional seal tightness with water
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Page 27
Test data:
The following test data must be observed when testing the body seal tightness.
Test characteristic
Test data
Testing of the seal tightness of the pressure-bearing body
Testing standard
The body must not have any visual signs of leaks
Testing depth
testing
Test medium
Air
Test pressure
6 bar (87.02 psi)
Testing device
Length of test
The following auxiliary materials must be provided when testing the seal tightness of the
pressure-bearing body for threaded valves.
Auxiliary material
Material no.
0161.0000
0151.0002
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Page 28
Operations:
a)
The inlet side of the safety valve must be vertically attached to the clamping device.
Fig. 46: Clamping the valve in

the clamping device
b)
If the test is performed on the Manual Basic Test

Bench, then the valve must be attached to the
test bench with the help of the accessories for
threaded valves (material no.: 0151.0002) as
shown in Figure 47.
Fig. 47: Clamping on the

Manual Basic Test Bench
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c)

safety valve.
LWN
369-34 E
Page 29
6 bar
d)

reached, spray the body with test liquid on the inlet
side between the markings (see Figure 49).
Allow a settling time of 10 seconds before the

test.
Test passed:
If there is no foam formation on the body, then
the test has been passed.
Test not passed:

If there is foam formation on the body, then the
test has not been passed.
Figure 50
If it is possible to repair the damage, then the
test must be conducted again.
Fig. 51: Bubble formation
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Page 30
4. Testing of the back seal:
Test data:
The following test data must be observed when testing the back seal.
Test characteristic
Test data
Testing of the seal tightness of the valve on the outlet side
Testing standard
Testing depth
Every safety valve with a gas-tight design, 100% testing
Test medium
Air
Test pressure
6 bar (87.02 psi)
Testing device
Length of test

The following auxiliary materials must be provided when testing the back seal.
Auxiliary material
Material no.
0161.0000
Thread adapter
(Only for the Manual Basic Test Bench)
0151.0002
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Page 31
a) The outlet side of the safety valve must be attached to the testing device with the help of the
additional screw connections. To do this, the
respective thread adapter must be screwed on
first.
Fig. 52: Screw in the thread

adapter
b) In addition, the base unit must be attached to

the test bench. The safety valve must be attached to the base unit with the adapter.
Fig. 53: Screw the valve into the
adapter
c) The testing zone is marked in colour (see Figure 54)
Fig. 54: marked testing zone
LESER
LESER GmbH & Co. KG

approved
ECO 00465A
edition:
replaces edition:
2010-05-10
----

LWN
369-34 E
Page 32
d) Test the marked zone with leak detection

spray.
Fig. 55: Applying the

leak detection spray
e) Count the bubbles per minute according to

LWN 220.01.
Allow a settling time of 10 seconds

before counting the bubbles.
Test passed:
then test has been passed.
Test not passed:

then test has not been passed.
If it is possible to repair the damage, then the test
must be conducted again.
Fig. 56: Foam formation
LESER
LESER GmbH & Co. KG

approved
ECO 00465A
edition:
replaces edition:
2010-05-10
----

LWN
369-34 E
Page 33
6.2 Safety valves in a non-gas-tight design:

6.2.1 Flanged valves
1.
Valve assembly:
LWN 369.30
LWN 369.32
LWN 369.33
Testing of the functional seal tightness:

Testing of the functional seal tightness with air and application
of testing liquid
2.
Testing the body seal tightness:
Testing of the body seal tightness with air and application of
testing liquid
3.
LESER
LESER GmbH & Co. KG

approved
ECO 00465A
edition:
replaces edition:
2010-05-10
----

LWN
369-34 E
Page 34
1. Valve assembly:
LWN 369.30
LWN 369.32
LWN 369.33
Fig. 58: API non-gas-tight
2. Testing of functional seal tightness:

Test data:
The following test data must be observed when testing functional seal tightness with non-gas-tight
valves.
Test characteristic
Test data
Testing standard
The blow-hole at the outlet must not extend more than 5mm
Testing depth
Test medium
Air
Test pressure
90% of set pressure
Testing device
Length of test
The following auxiliary materials must be provided when testing the functional seal tightness of non-gas-tight valves.
Auxiliary material
Material no.
0172.0001
0161.0000
LESER
LESER GmbH & Co. KG
processed: M. Lammers
edition: 2009-11-04
replaces edition:
----

LWN
369-34 E
Page 35
Operations:
a) The outlet side of the safety valve must be attached
to the chuck.
6 bar
b)

safety valve.
c)

reached, put the rubber test plug in the outlet
flange.
Fig. 61: Inserting the
test plug
LESER
LESER GmbH & Co. KG
edition: 2009-11-04
replaces edition:
----

d)
LWN
369-34 E
Page 36
The opening of the test plug must be

sprayed with leak detection liquid.
Fig.62: Application of the

leak detection liquid
The extension of the blow-out must be observed for 10 seconds.
Test passed:
If the blow-out remains as it is and does not
burst, then the test is considered to have
passed.
Test not passed:

If the blow-out projects more than 5 mm or
bursts, then the test is considered to have
failed. If it possible to repair the damage,
then the test must be conducted again.
Fig. 63: Blow-out extension
LESER
LESER GmbH & Co. KG
edition: 2009-11-04
replaces edition:
----

LWN
369-34 E
Page 37
Test data:
The following test data must be observed when testing the body seal tightness.
Test characteristic
Test data
Testing of the seal tightness of the pressure-bearing body
Testing standard
The body must not have any visual signs of leaks
Testing depth
testing
Test medium
Air
Test pressure
A test pressure must be chosen that is slightly lower than the

set pressure.
Testing device
Length of test

The following auxiliary materials must be provided when testing body seal tightness for
non-gas-tight valves.
Auxiliary material
Material no.
0161.0000
LESER
LESER GmbH & Co. KG
edition: 2009-11-04
replaces edition:
----

LWN
369-34 E
Page 38
Operations:
a) The inlet side of the safety valve must be
vertically attached to the chuck.
Clean sealing surfaces are the basic

requirement for accurate measurement results.
b)
c)

safety valve.

reached, spray the body with test liquid on the
inlet side between the markings (see Figure
65).
6 bar

the test.
Test passed:
Test not passed:
then the test has not been passed. If it is
possible to repair the damage, then the
test must be conducted again.
Fig. 48 Body with market

testing zone
End of LWN
LESER
LESER GmbH & Co. KG
edition: 2009-11-04
replaces edition:
----
LESER Global Standard

Final visual inspection of repaired valves
LGS_1117
Page 1/8
Contents
1
2
3
4
5
6
7
Purpose ............................................................................................................... 1
Scope .................................................................................................................. 1
Disclaimer............................................................................................................ 1
Qualified fitting personnel .................................................................................... 2
General Information............................................................................................. 2
Flow chart for the visual inspection (final inspection) .......................................... 2
Performing the final inspection ............................................................................ 3
7.1 General inspections...................................................................................... 3
7.2 Visual inspection of other items.................................................................... 4
7.3 Fault notification process.............................................................................. 8
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.
Scope
This document must be observed in the visual final inspection of safety valves in agencies
and subsidiaries of LESER GmbH & Co. KG.
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.
disclosure cat.:
author:
resp. depart.:
doc. type:
II
Niehus
PP
LGS
proofread:
released by:
date of release:
change rep. No.:
OR
KUW
8.11.10
00651A
published date:
replaces:
revision No.:
retention period:
17.11.10
initial
0
10y
effect. date:
status:
18.11.2010
valid
protected

4
LGS_1117
Page 2/8
Qualified fitting personnel
The visual final inspection of LESER safety valves may only be performed by trained
or qualified fitters. The qualifications must be obtained through the appropriate
training measures.
General Information
Gloves must be worn during the final inspection of oil and

grease-free safety valves.
Flow chart for the visual inspection (final inspection)
Perform the
ident. check
Inspecti
on OK
protected
Fault
notification
process
no
yes
Completion of
the final
inspection and
delivery
Figure 6-1
disclosure cat.:
author:
resp. depart.:
doc. type:
II
Niehus
PP
LGS
proofread:
released by:
date of release:
change rep. No.:
OR
KUW
8.11.10
00651A
published date:
replaces:
revision No.:
retention period:
17.11.10
initial
0
10y
effect. date:
status:
18.11.2010
valid

7
7.1
LGS_1117
Page 3/8
Performing the final inspection

General inspections
a) Compare the content of the valve inspection plan or repair order to the valve
model.
protected
EXAMPLE /
SPECIMEN
Figure 7.1-1
Figure 7.1-2: Check the type number against the

valve inspection plan / repair order
disclosure cat.:
author:
resp. depart.:
doc. type:
II
Niehus
PP
LGS
proofread:
released by:
date of release:
change rep. No.:
OR
KUW
8.11.10
00651A
Figure 7.1-3: Check the BT plate / customer ID

plate data against the valve inspection plan /
repair order
published date:
replaces:
revision No.:
retention period:
17.11.10
initial
0
10y
effect. date:
status:
18.11.2010
valid

7.2
LGS_1117
Page 4/8
Visual inspection of other items
7.2.1 Inspection of the paintwork

a) Valve is not completely painted
OK specimen:
Rejected specimen:
protected
Figure 7.2.1-1
Figure 7.2.1-2
b) Paint coat is cracked (too much paint)

OK specimen:
Rejected specimen:
Figure 7.2.1-3
Figure 7.2.1-4
disclosure cat.:
author:
resp. depart.:
doc. type:
II
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PP
LGS
proofread:
released by:
date of release:
change rep. No.:
OR
KUW
8.11.10
00651A
published date:
replaces:
revision No.:
retention period:
17.11.10
initial
0
10y
effect. date:
status:
18.11.2010
valid

LGS_1117
Page 5/8
c) Paint coat is not complete due to oil / grease

OK specimen:
Rejected specimen:
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
disclosure cat.:
author:
resp. depart.:
doc. type:
II
Niehus
PP
LGS
proofread:
released by:
date of release:
change rep. No.:
OR
KUW
8.11.10
00651A
published date:
replaces:
revision No.:
retention period:
17.11.10
initial
0
10y
effect. date:
status:
18.11.2010
valid

LGS_1117
Page 6/8
d) Paint on masked off areas

OK specimen:
Rejected specimen:
protected
Figure 7.2.1-10
Figure 7.2.1-9
OK specimen:
Rejected specimen:
Figure 7.2.1-11
Figure 7.2.1-12
Reason: The legibility of the plate is not guaranteed.
disclosure cat.:
author:
resp. depart.:
doc. type:
II
Niehus
PP
LGS
proofread:
released by:
date of release:
change rep. No.:
OR
KUW
8.11.10
00651A
published date:
replaces:
revision No.:
retention period:
17.11.10
initial
0
10y
effect. date:
status:
18.11.2010
valid

LGS_1117
Page 7/8
7.2.2 Inspection of the sealing surfaces

OK specimen:
Rejected specimen:
Figure 7.2.2-1
protected
Figure 7.2.2-2
7.2.3 Inspection of the seal

OK specimen:
Rejected specimen:
Seal is missing for sealed valves, or it is not
crimped.
Figure 7.2.3-1
If the result of the inspection is okay, then the safety valve is sent for packaging and
shipment.
disclosure cat.:
author:
resp. depart.:
doc. type:
II
Niehus
PP
LGS
proofread:
released by:
date of release:
change rep. No.:
OR
KUW
8.11.10
00651A
published date:
replaces:
revision No.:
retention period:
17.11.10
initial
0
10y
effect. date:
status:
18.11.2010
valid

7.3
LGS_1117
Page 8/8
Fault notification process
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
disclosure cat.:
author:
resp. depart.:
doc. type:
II
Niehus
PP
LGS
proofread:
released by:
date of release:
change rep. No.:
OR
KUW
8.11.10
00651A
published date:
replaces:
revision No.:
retention period:
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initial
0
10y
effect. date:
status:
18.11.2010
valid

MNT en 4.9 Testing Procedures

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LESER WORKS STANDARD

Cold differential test pressure

LESER WORKS STANDARD

Cold differential test pressure (CDTP) is defined in standard

DIN EN ISO 4126-1 Edition 2004, Chapter 3.2.5

Extract of DIN EN ISO 4126-1 Chapter 3.2.5:

Extract of API 520 Chapter 3.4.1:

Extract of ASME PTC 25-2001 Chapter 2.7:

How is the CDTP-correction calculated?

LESER WORKS STANDARD

set pressure at service conditions [psig or barg]

Closed bonnet conventional kT=0,97339+0,00039Tdesign

Table 2: Formulas of kT calculation

LESER WORKS STANDARD

LESER datasheet of CDTP (Cold differential test pressure)

pcdtp = ( pset * k af pa ) * kT (Type 459/462 only)

pcdtp: cold differential test pressure [psig or barg]

LESER diagram kaf for for type 459 / 462

d0= 17,5 [mm] paf/p * 100 [%]

d0= 17,5 [mm]

LESER WORKS STANDARD

upward setpressure (+3%) of allowable tolerances

Approved correction curve by

downward setpressure (-3%) of allowable

correction factor kT for closed bonnet conventional design

LESER WORKS STANDARD

upward setpressure (+3%) of

downward setpressure (-3%) of

correction factor kT for open bonnet conventional design

LESER WORKS STANDARD

upward setpressure (+3%) of

Approved correction curve

downward setpressure (-3%) of

correction factor kT for open or closed bonnet balanced bellows design

LESER WORKS STANDARD

How is the influence of balanced bellows?

Balanced bellows design:

LESER WORKS STANDARD

kaf (d0=17.5 mm) = 7,78E-5*(paf /p*100%)-7,8332E-3*(paf /p*100%)+0,998

LESER WORKS STANDARD

How does an open/closed bonnet influences the CDTP?

The bonnet design could be open or closed design.

LESER WORKS STANDARD

How does the spring material influences the CDTP?

ASTM B 574-99 550C (1022F)

table 1: material and temperature limits

How does the medium influences the CDTP?

The medium has no significant influence on CDTP.

10 In which documents you will find the CDTP- value?

LESER WORKS STANDARD

LESER WORKS STANDARD

pcdtpmin = 10,25 barg +0,00*10,25 barg = 10,25 barg (148,66 psig)

11.2 Example: Temperature and constant backpressure influence

kT: according to equation (1) in chapter 3:

pcdtpmin = 52,12 barg +0,00*52,12 barg = 52,12 barg (755,74 psig)

11.3 Example: Temperature and variable backpressure influence

pcdtpmin = 8,82 barg +0,00*8,82 barg = 8,82 barg (127,89 psig)

LESER WORKS STANDARD

12 Original confirmation of German TV Nord

LESER WORKS STANDARD

LESER WORKS STANDARD

LESER WORKS STANDARD

Scope and Applicability.............................................................................................................. 3

LESER WORKS STANDARD

kaf (d0=17.5 mm) = 7,78E-5(paf /p100%)-7,8332E-3(paf /p100%)+0,998