Best Practice

SABP-J-701 21 May 2015

Troubleshooting Control Valve Seat Leakage
Document Responsibility: Instrumentation Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Purpose.......................................................... 2
2 Scope............................................................. 2
3 Disclaimer....................................................... 2
4 Conflicts with Mandatory Standards............... 2
5 Definitions....................................................... 3
6 Safety Precautions......................................... 3
7 Troubleshooting.............................................. 4
8 Documentation.............................................. 12

Previous Issue: 30 December 2011 Next Planned Update: 21 May 2018

Revised paragraphs are indicated in the right margin Page 1 of 13
Primary contact: Nisar, Syed M (nisarsm) on 966-13-8801289

Copyright©Saudi Aramco 2015. All rights reserved.

Document Responsibility: Instrumentation Standards Committee SABP-J-701
Issue Date: 21 May 2015
Next Planned Update: 21 May 2018 Troubleshooting Control Valve Seat Leakage

1 Purpose

The purpose of this Practice is to establish guidelines and recommended procedures for
troubleshooting seat leakage for control valves installed at Saudi Aramco facilities.

2 Scope

The troubleshooting methodology, presented in this practice, addresses both sliding

stem and rotary valve designs. It employs the following strategies for seat leakage
diagnostics:

2.1 It starts by validating if the installed seat leakage rates meet the SA requirement
(per FCI 70-2).

2.2 If not, it suggest troubleshooting this problem using the following sequential
diagnostics approach:
i) Start with diagnosing air supply system (air supply, regulator/filter…etc);
ii) Then, diagnose the positioner;
iii) Then, diagnose the actuator;
iv) Last, diagnose valve internals.

This approach is highly recommended to minimize the need to take the valve out of
service to diagnose internals. For every check, it lists all possible causes with their
respective remedies. Finally, it concludes with how to document and log seat leakage
maintenance work.

3 Disclaimer

The material in this Best Practice document provides the most correct and accurate
troubleshooting guidelines available to Saudi Aramco which comply with international
industry practices. This material is being provided for the general guidance and benefit
of Maintenance and Engineering organizations. Saudi Aramco® is a registered
trademark of the Saudi Arabian Oil Company. Copyright, Saudi Aramco, 2011.

4 Conflicts with Mandatory Standards

In the event of a conflict between this Best Practice and other Mandatory Saudi Aramco
Engineering Requirement, the Mandatory Saudi Aramco Engineering Requirement shall
govern.

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Document Responsibility: Instrumentation Standards Committee SABP-J-701
Issue Date: 21 May 2015
Next Planned Update: 21 May 2018 Troubleshooting Control Valve Seat Leakage

5 Definitions

Balancing Rings: For pressure balanced linear valves, balancing rings are the sealing
assembly between the cage and outer rim of the plug.

Bench Test: The actuator pressure required to move the stem for a full stroke without
the valve assembly. It is a measure of the spring calibration.

Positioner Cross Over: A process by which the linear stem travel movement is
centered at the middle of the rotational movement of the positioner follower arm.

Seat Engagement: The profile that shows how the plug tip contacts and engages with
the seat.

Seat Load: The additional actuator force that is needed when the valve is at fully
closed position to maintain valve shutoff class.

Trunnion: For ball valves, the mechanism that holds the ball in vertical position and
guides its rotation.

Valve Signature: The relationship between actuator pressure versus valve travel in
graphical format (x-axis=valve travel, y-axis=actuator pressure).

6 Safety Precautions

Certain precautionary steps must be addressed clearly and adhered to prior to and
during the performance of maintenance and inspection of control valves such as, but not
limited to the following:
i) All required work permits shall be obtained prior to starting any work.
ii) Maintenance personnel shall be adequately trained accordingly.
iii) Tools must be inspected to be fit for the service.
iv) Work area must be prepared; accessibility must be fully provided and inspected,
especially where scaffolding erection is required.
v) Gas/H2S test must be performed prior to and during the job execution (for
potential toxic/hazardous services). In case venting or draining is required, a
procedure must be developed for isolation and safe venting and draining steps.
Make sure that all isolations, lockout and tags are performed in accordance with
the relative GI.
vi) A fire watch person shall be available for all auto-ignition services.
vii) Never try to open any pressurized part (such as plug, drain, vent, etc.) of the valve

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Document Responsibility: Instrumentation Standards Committee SABP-J-701
Issue Date: 21 May 2015
Next Planned Update: 21 May 2018 Troubleshooting Control Valve Seat Leakage

before verifying the valve is not subjected to line pressure.

viii) Trapped pressure is expected, hence, cautions must be taken when opening valve
plugs/drains/vents or fittings.
ix) For valves removal/in-situ repairs, engineering procedure must be developed to
include depressurizing, isolation, draining and venting. It also shall include
disconnecting from any electrical equipment and addressing all work location
preparation. Make sure that all safety related standards and requirements are well
addressed and followed.
x) Use adequate torque when trying to turn a seized valve or grease fitting. Excess
stem torque may cause the valve stem to bend or break.
xi) Valve ISS, drawing and manual shall be reviewed before performing any activity.
xii) Prior to any troubleshooting, valve history (i.e., valve PM record and/or valve
signature (if accessible)) shall be obtained and analyzed for any abnormalities.
xiii) If needed, consult the valve vendor for any technical requirement that need to be
included in the troubleshoot procedure.

7 Troubleshooting

7.1 Leakage Rate Verification

Nomenclature

Flow through the control valve

Differential pressure across the control valve
Valve flow coefficient
Upstream pressure
Upstream temperature
Specific gravity
Pressure drop ratio
Expansion factor
Molecular weight
Compressibility
Ratio of specific heats
Vapor pressure
Critical pressure

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Document Responsibility: Instrumentation Standards Committee SABP-J-701
Issue Date: 21 May 2015
Next Planned Update: 21 May 2018 Troubleshooting Control Valve Seat Leakage

Pressure recovery coefficient

Critical pressure ratio
SQRT Square root

To verify seat leakage rate for an existing valve, proceed with the following:
1. Obtain the actual flow rate when the valve is fully closed. This can be done by
simulation or acoustic measurement.
2. For the allowable test leakage rates, refer to FCI-70-2 table below.

ANSI
Maximum Leakage Medium Pressure and Temperature
Class
Lower of service P or 50 psid at
Class II 0.5% valve capacity at full travel Air or water
50 to 125°F
Lower of service P or 50 psid at
Class III 0.1% valve capacity at full travel Air or water
50 to 125°F
Lower of service P or 50 psid at
Class IV 0.01% valve capacity at full travel Air or water
50 to 125°F
5x10-4 mL/minute/psid/inch port diameter
Class V (5x10-12 m3/second/bar differential/mm Water Service P at 50 to 125°F
port diameter)
Bubbles mL
Port Diameter
per per
In mm minute minute
Class VI 1 25 1 0.15 Lower of service P or 50 psid at

1 1/2 38 2 0.30 50-125°F

2 51 3 0.45 Air

2 1/2 64 4 0.60
3 76 6 0.90
4 102 11 1.70
6 152 27 4.00
8 203 45 6.75
Extracted from American National Standard for Control Valve Seat Leakage, ANSI B16.104-1985 with the
permission of the publisher, Fluid Controls Institute, Inc.

3. Calculate Cv at shutoff from the table.

4. For non-compressible fluids, using actual values of DP shutoff and specific
gravity, calculate installed allowable leakage rate using the basic sizing equation.

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Document Responsibility: Instrumentation Standards Committee SABP-J-701
Issue Date: 21 May 2015
Next Planned Update: 21 May 2018 Troubleshooting Control Valve Seat Leakage

5. For compressible fluids, using actual values of DP, P1, MW, Z, T1, calculate
installed allowable leakage rate.

For volumetric flow:

For mass flow:

6. Compare the installed allowable leakage rate from step (4) or (5) with the actual
flow from step (1) to verify leakage rate.

Example 1

Given:
Actual leakage flow rate = 0.1 gpm
Valve rated Cv = 140
Port diameter = 2.5 IN
Actual DP = 100 psid
Fluid = crude oil (SG = 0.8)
Valve shutoff class = IV

Calculation:
1. Actual leakage flow rate = 0.1 gpm
2. According to FCI 70-2 table, the valve is class IV so allowable leakage is 0.01% of
140
3.

4.

5. (N/A)
6. Since actual leakage flow rate = 0.1 gpm < allowable leakage = 0.1565, then, the
valve meets the shutoff class.

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Document Responsibility: Instrumentation Standards Committee SABP-J-701
Issue Date: 21 May 2015
Next Planned Update: 21 May 2018 Troubleshooting Control Valve Seat Leakage

Example 2

Given:
Actual leakage flow rate = 0.001 scfm
Valve rated Cv = 25
Xt=0.75
Port diameter = 1 IN
P1= 500 psig
P2= 200 psig
Actual DP = 300 psid
Fluid = Natural Gas (MW = 20)
Valve shutoff class = V
Temperature = 212 F
Z=0.9
k=1.2

Calculation:
1. Actual leakage flow rate = 0.001 scfm
2. According to FCI 70-2 table, class V so allowable leakage is 0.0005 mL per minute
per psid per IN of port diameter.

3.

4. (N/A)

5.

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Document Responsibility: Instrumentation Standards Committee SABP-J-701
Issue Date: 21 May 2015
Next Planned Update: 21 May 2018 Troubleshooting Control Valve Seat Leakage

6. Since actual leakage flow rate = 0.001 scfm > allowable leakage = 0.0529 scfh =
0.0008816 scfm, then, the valve does not meet the shutoff class.

Note:

When performing seat leakage calculation for Class, II, III and IV, it is essential to
compare the actual DP to the valve critical DP. Valve critical DP equals FL 2x (P1-FF
x Pv). If the actual DP is larger than the valve critical DP, then the DP should be
substituted with FL 2x (P1-FF x Pv) where FF = 0.96 -0.28 x SQRT (Pv/Pc).

7.2 Leakage Diagnostics

7.2.1 Air Supply System

Check Possible Cause Remedy

Air regulator(s) For Air-to-Close ATC actuators, the Verify that the regulator pressure
regulator setting may fall below the setting is above the required pressure
minimum actuator pressure required to ensure enough seat loading. Use
to meet the desired shutoff class. caution not to exceed valve supplier
recommended air supply which could
damage valve, actuator, or
accessories.
Air filter(s) For Air-to-Close ATC actuators, the Inspect the air filter for blockage.
filter may have significant blockage to Clean or replace as needed.
cause actuator pressure degradation.
This may be common for facilities with
low quality instrument air.
Tubing & fittings For Air-to-Close ATC actuators, Verify that tubing/fitting are leakage
tubing or fitting air leak will cause free using soap test.
actuator pressure degradation.
This may be common for valves in
vibrating services.

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Document Responsibility: Instrumentation Standards Committee SABP-J-701
Issue Date: 21 May 2015
Next Planned Update: 21 May 2018 Troubleshooting Control Valve Seat Leakage

7.2.2 Positioner

Check Possible Cause Remedy

Feedback Misalignment, mis-calibration, missing Verify alignment, calibration and cross
mechanism cross-over, loose bolts…etc may over. Perform valve calibration
inaccurately be interpreted by the (automatic calibration if enabled) to
positioner as full closed position. The ensure accurate stem positioning.
positioner therefore, will not add
adequate air to the actuator to meet
the seat load requirement.
This may be common for valves in
vibrating services.
Positioner If the shutoff class is incorrectly Verify positioner configuration for the
configuration assigned to the positioner (in the shutoff class.
configuration tab), it will not add the
required seat load.
Positioner Some positioners have an add feature If this feature is available and the
configuration called “Tight-ShutOff (TSO)”. If the application requires TSO, then ensure
(optional features) valve is in a TSO application, this that this feature is enabled.
feature needs to be selected manually
during configuration to ensure that the
positioner applies the required seat
load for class V or VI valves.
Positioner Inadequate seat load. If possible, run valve diagnostics and
performance obtain valve signature to verify the
required seat loading and seat
engagement.

7.2.3 Actuator

Check Possible Cause Remedy

Actuator spring For single acting Air-to-Open ATO Verify spring range and test bench
actuators, the spring bench test may values. Alternatively, verify, using the
not be adequate to ensure that the valve signature, that the spring has
spring applies enough seat load when enough seat load.
the valve is fully closed.
Actuator casing For single acting Air-to-Close ATC Verify that the actuator is leakage free
leakage actuators, any air leak from tube using soap test.
connection will result in actuator
pressure loss.
This may be common for valves in
vibrating services.

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Document Responsibility: Instrumentation Standards Committee SABP-J-701
Issue Date: 21 May 2015
Next Planned Update: 21 May 2018 Troubleshooting Control Valve Seat Leakage

Check Possible Cause Remedy

Actuator O-ring For double acting actuators, leakage Using positioner diagnostics, verify
leakage from one side of the actuator to the actuator load. If possible, inspect
other side will cause pressure loss. O-ring for damage. Replace as
This may be common for valves in needed. Verify actuator piston
vibrating services or in frequently condition.
cyclic operation like refinery PSA
units.

7.2.4 Valve
a. Sliding Stem Valves

Check Possible Cause Remedy

Stem Misalignment of more than 0.0005” Verify stem alignment. Replace as
per inch of stem length or stem bent needed. Follow vendor torque
can cause improper seat recommendations for valve assembly
engagement. and disassembly.
This may be common for valves in
higher DPs than what they were
selected for. Misalignment can also
occur during improper torquing during
the disassembly or assembly of the
valve.
Connection If loose, can cause improper seat Verify connection arrangement
arrangement engagement. integrity and bolting. Replace as
(actuator stem to This may be common for valves in needed.
valve stem) vibrating services.
Plug tip If damaged, it will not seal against the Verify condition. Weld-repair or
seating arrangement. replace as needed.
This may be common for valves in
dirty (erosive) applications, or valves
in cavitation applications if their
shutoff class IV or less.
Balancing rings If damaged or improperly installed, Verify condition. Replace as needed.
they will cause leakage between the
cage and the plug.
This may be common for valves in
temperatures higher than the
temperature rating of the rings. This
also is common for applications with
significant clearance flow (between
the plug and cage).

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Document Responsibility: Instrumentation Standards Committee SABP-J-701
Issue Date: 21 May 2015
Next Planned Update: 21 May 2018 Troubleshooting Control Valve Seat Leakage

Check Possible Cause Remedy

Seating area If the seating area on the seat ring is Verify condition. Replace as needed.
damaged, it will not seal against the
plug tip.
This may be common for valves in
dirty (erosive) applications, or valves
in cavitation applications if their
shutoff is class IV or less.
Soft or metal seats If damaged, they will not seal against Verify condition. Replace as needed.
the plug tip.
This may be common for valves in
dirty (erosive) applications, or valves
in cavitation applications if their
shutoff is class IV or less.
Guiding or For cageless designs, if the guiding Verify condition. Replace as needed.
bushing on the stem or post is damaged, it will
cause stem mis-alignment that will
subsequently cause improper seat
engagement.
Plug/Seat If not properly done, it will cause seat Verify seat engagement profile using
Engagement leakage. positioner diagnostic (valve signature)
Stem Clamp If the stem clamp is binding on the Verify the stem clamp has sufficient
yoke and causing mis-alignment or clearance between clamp, yoke and
contacting the packing gland flange packing flange.
limiting seat load.
Plug/Seat area If enough dirt accumulation is present, Flush valve internals frequently for
it will prevent plug/seat engagement. services with considerable amount of
suspended particles and after plant
initial start-up.

b. Rotary Valves

Check Possible Cause Remedy

Seal If damaged, it will not seal against the Verify condition. Replace as needed.
disk.
This may be common for valves in
vibrating services, higher temperature
applications or in frequently cyclic
operation.
This can result from improper
installation by not observing preferred
flow direction.
Seal retainer If damaged or lost, it will not hold the Verify condition. Replace as needed.
seal in place.

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Document Responsibility: Instrumentation Standards Committee SABP-J-701
Issue Date: 21 May 2015
Next Planned Update: 21 May 2018 Troubleshooting Control Valve Seat Leakage

Check Possible Cause Remedy

Bearing or If its clearance to the shaft is beyond Verify condition. Replace as needed.
trunnion tolerance, it will cause the disk to set
away from the seal.
This may be common for valves in
vibrating services.
Mechanical If it introduces enough slippage, it will Verify condition. Replace as needed.
linkage (lever) cause lost motion and improper seal
engagement.
This may be common for valves in
vibrating services.
Seal/closure If enough dirt accumulation is present, Flush valve internals frequently for
member area it will prevent proper seal services with considerable amount of
engagement. suspended particles and after plant
initial start-up.

8 Documentation

Documenting the diagnostics and maintenance work is very essential. The documentation
needs to satisfy the following:

8.1 Information and data need to be entered in SAP system for better traceability
and accountability.

8.2 All valve data has to be entered as accurate as possible. Such data include (but
not limited to):
a) tag number
b) service and condition
c) valve/actuator/positioner type
d) valve/actuator/positioner make and model
e) guiding method
f) seat ring retention
g) seal type
h) valve shutoff class
i) actuator rating
j) required seat load
k) spring bench test
l) preferred flow direction (for rotary valves)
m) balanced ring design

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Document Responsibility: Instrumentation Standards Committee SABP-J-701
Issue Date: 21 May 2015
Next Planned Update: 21 May 2018 Troubleshooting Control Valve Seat Leakage

8.3 All information has to be entered as clear as possible. Such information include
(but not limited to):
a) The root cause(s) of the leakage
b) Work performed to rectify it
c) Application description (high vibration, cyclic, high temperature,…etc.)

8.4 Valve signature is recommended if the valve can undergo full stroke test.

8.5 Photographs of damaged parts are recommended to allow review of the damage
and to allow the valve vendor to make recommendations.

Revision Summary
30 January 2011 New Saudi Aramco Best Practice
21 May 2015 Editorial revision to change primary contact information

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