ANSI FCI 15-1-2015 Standard for Production Testing of Pressure Regulators.pdf

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1、 ANSI/FCI 15-1-2015 AMERICAN NATIONAL STANDARD STANDARD FOR PRODUCTION TESTING OF PRESSURE REGULATORS Fluid Controls Institute, Inc. Sponsor: Fluid Controls Institute, Inc. 1300 Sumner AveCleveland, Ohio 44115-2851 iiANSI/FCI 15-1-2015 AMERICAN NATIONAL STANDARD Standard for Production Testing of Pr

2、essure Regulators Sponsor Fluid Controls Institute, Inc. iiiCONTENTS PAGE Foreword iv 1. Purpose 1 2. Scope and Limitations .1 3. Definitions1 4. Test Requirements .3 5. Acceptance Standards . 5 Foreword (This foreword is included for information only and is not part of ANSI/FCI 15-1-2015, Standard

3、for Production Testing of Pressure Regulators.) This voluntary standard has been developed and issued in the public interest. It is intended to establish minimum guidelines for production testing of pressure regulators for use by manufacturers, specifiers, inspectors, and users. The standard was dev

4、eloped by the FCI Regulator Section in 2014 and approved in 2015. The existence of a Fluid Controls Institute (FCI) standard does not in any respect preclude any member or non-member from manufacturing or selling products not conforming to this standard nor is the FCI responsible for its use. FCI re

5、cognizes the need to periodically review and update this standard. Suggestions for improvement should be forwarded to the Fluid Controls Institute, Inc., 1300 Sumner Avenue, Cleveland, Ohio 44115-2851. All constructive suggestions for expansion and revision of this standard are welcome. Please go to

6、 the FCI web site for all of the latest technical articles and standards. ivANSI/FCI 15-1 PROPOSED AMERICAN NATIONAL STANDARD Standard for Production Testing of Pressure Regulators 1. PURPOSE This standard establishes minimum guidelines for production testing of pressure regulators for use by manufa

7、cturers, specifiers, inspectors, and users to ensure testing of atmospheric leak tightness and seat leakage are completed at the factory before shipment. 2. SCOPE and LIMITATIONS 2.1. This standard provides guidelines for documenting minimum production tests and determining pass/fail criteria for pr

8、essure regulators undergoing production tests in a manufacturing facility. It applies to most designs including self and pilot operated pressure reducing regulators, differential pressure regulators, pressure loaded regulators, and regulators with or without internal relief valves. 2.2. Certificatio

9、ns documenting the testing can be requested by the manufacturer upon ordering. 2.3. This standard includes pressure regulators which may have two static pressure ratings, one for the portion of the regulator subjected to the inlet pressure and the other for the portion subjected to the outlet pressu

10、re. 2.4. This standard does not cover capacity testing of pressure regulators which is covered in ANSI/FCI 99-2 and is not normally tested during a production test. 2.5. This standard does not cover testing for leakage through pressure boundary shells that would be identified during a production hyd

11、rotest. This hydrotest procedure is covered in ANSI/FCI 4-1. 2.6. Relief valves or backpressure regulators are not included in this standard. 2.7. This standard does not cover temperature regulators. 2.8. This standard is not intended to supersede existing standards for regulators in specific applic

12、ations such as those for gas appliance pressure regulators, for high pressure regulators for gas cylinders, or for fluid power regulators in machinery operations 3. DEFINITIONS 3.1. Controlled Variable. The variable which shall be monitored by the controlling process. This variable is either the out

13、let pressure or the differential pressure. 3.2. Diaphragm. A flexible element used to sense the outlet pressure (controlled variable.) The diaphragm also works to regulate the controlled variable in combination with the loading spring and valve plug linkage. Diaphragms are usually made from an elast

14、omeric or metallic material. 3.3. Differential Pressure Regulator. A pressure regulator that maintains a constant differential pressure between a reference pressure and the pressure of the controlled fluid. 13.4. Internal Relief Valve. An internal mechanism that relieves excessive outlet pressure th

15、rough the diaphragm and vent assembly. The internal relief set point is a function of the regulators set point and the maximum allowable build-up of downstream pressure allowed by the users application and is considered when the regulator is sized and selected. 3.5. Lockup (Dead End Shutoff). The de

16、viation of the controlled variable from set point obtained at a no flow position. 3.6. Pilot Operated Regulator. Pilot operated regulators are a combination of a primary (pilot valve or pilot) and secondary regulator (main valve). The primary regulator senses and amplifies the pressure signal of the

17、 controlled variable. The amplified signal is sensed by the secondary regulator, which adjusts to maintain the controlled variable at the set point value. The pilot may be internal or external. 3.7. Pressure Regulator. A pressure regulator as covered by this standard is a self contained and self pow

18、ered device that serves to automatically maintain a pressure at a controlled value (setpoint) over a specified flow. 3.8. Pressure Loaded Regulator. A regulator that relies on a reference pressure applied to the diaphragm in an enclosed chamber above the diaphragm by a suitable fluid from an externa

19、l source. This pressure may add to the force of the spring or be the only force determining the setpoint of the regulator. 3.9. Seat Leakage. The quantity of test fluid passing through an assembled regulator in the lockup position. Seat leakage classifications are covered in ANSI/FCI 70-3. 3.10. Sup

20、ply Pressure. The inlet pressure used for the pressure regulator under test. 3.11. Pulsation, hunting, or chattering. An unstable state in which there is oscillation of the regulator diaphragm, linkage and/or mechanisms that causes noise and/or t h e fluctuation of the controlled variable. 3.12. Rat

21、ed Capacity. The rate of flow obtainable through a regulator, for specified inlet and outlet conditions and fluid, at a specified offset or accuracy of regulation 3.13. Set Flow. The flow rate used to obtain the set point, typically 5 to 10% of rated capacity. 3.14. Set Point. The regulator adjustme

22、nt corresponding to the desired value of the controlled variable. 3.15. Spring Range. The usable pressure range for a spring. 3.16. Stability. The ability to hold a steady controlled variable. 3.17. Test Fluid. The fluid used as the pressure media for the assembly under test. 3.18. Vent. The opening

23、 to the atmospheric side of the diaphragm casing through which the regulator breathes. This may be the point of connection for a vent pipe or vent cap and could also be the opening for the relief of excess downstream pressure if equipped with an internal relief valve. 24. TEST REQUIREMENTS 4.1. Gene

24、ral 4.1.1. The vent shall not be blocked or inhibited during the production test. For regulators undergoing dunk testing a tube of equal diameter of the vent connection may be used to prevent fluid from entering the atmospheric side of the regulator under test or a leak tight vent plug during the sh

25、ell pressure test may be used. 4.1.2. The regulator under test should be oriented in the test fixture according to the manufacturers instructions. If there are no restrictions in orientation, any position is allowable. 4.1.3. Pressure measuring instruments shall be accurate within 5% at test pressur

26、e and analog types shall be used within 20% and 80% of their scale range. 4.2. Test Fluid 4.2.1. The testing fluid is air or water at 10-51C (50-125F). The test fluid may contain a corrosion inhibitor such that the mixtures viscosity is not greater than that of the water at a temperature not over 12

27、5 F or 51C. Make sure that the pressure regulator is dry after testing. 4.2.2. The test fluid shall be applied to the normal or specified valve body inlet. 4.3. Establish Set Point 4.3.1. If the customer order does not require a specific set point it can be set at the middle of the spring range or t

28、o a value determined by the manufacturer. 4.3.2. With the supply valve and downstream throttling valve closed, install the regulator to be tested into the test fixture. 4.3.3. Adjust the supply pressure of the fluid source to the pressure required for the production test. 4.3.4. Open the supply valv

29、e and assure there are no leaks in the setup. Verify the supply pressure is correct and maintained during the test. 4.3.5. Open the downstream throttling valve to obtain the set flow. Adjust the regulator to the desired setpoint. 4.3.6. For pilot operated regulators, set flow could be a pre-determin

30、ed pilot flow that would simulate the loading/unloading pressure to the main valve in order to stroke it to its minimal opening position. 4.3.7. Record the set point of the regulator under test. 4.4. Lock Up 4.4.1. Use section 4.3 above to establish the set point. While under flow at set point condi

31、tions, close the outlet valve at a constant speed over a period of five seconds. Ensure the test fluids pressure is present on both the inlet and outlet sides of the pressure regulator under test. If the pressure 3continues to rise, ensure seat leakage is within the stated leakage class. Refer to pa

32、ragraph 4.6. 4.4.2. Record this pressure as the lock up pressure. 4.5. Diaphragm Leakage Test 4.5.1. For regulators with atmospheric breather vents, the seal of the diaphragm and/or internal relief valve from the pressurized chamber to the atmospheric chamber shall be checked for leak tightness. 4.5

33、.2. While the unit is in a locked up position in a non flowing state, check for leakage from the atmospheric vent of the regulator under test. There are several ways of testing for leakage. The following are suggested methods of implementing this leak test: 4.5.2.1. Applying a leak detection fluid a

34、t the regulator vent to look for any visible leakage. No leakage is allowed for a period of at least 15 seconds. 4.5.2.2. Placing the vent discharge into a maximum water seal of 1” w.c. (0.25 kPa) and to look for any bubbles over a period of no less than 15 seconds. No visible bubbles shall be obser

35、ved. 4.6. Test for Leakage Class 4.6.1. The test fluid should be applied to the unit under test according to the leakage class being tested. Reference ANSI/FCI 70-3 for testing procedure. 4.6.2. During this test, it should be noted that adequate overpressure protection may be required if the inlet p

36、ressure is higher than the rated outlet pressure for the device under test. 4.6.3. Record results and verify that unit under tests meets leakage class as advertised in the manufacturers sales literature. 4.7. Shell Pressure Test 4.7.1. While the unit under test is in its locked up position, check fo

37、r atmospheric leakage from any joint such as diaphragm, body to actuator, or any other joint where atmospheric leakage could occur. Test duration should be no less than 15 seconds. The following are suggested methods of implementing this leak test. 4.7.1.1. A leak detection fluid applied to all pres

38、sure retaining joints with no visible leakage. 4.7.1.2. A dunk test in a fluid such as water with no visible bubbles over the test period. Care must be taken to avoid fluid entry into the atmospheric side of the regulator vent. 4.7.1.3. A measurable decay test where the test fluid is locked into the

39、 chambers and there is no measureable decay of pressure during the test period. 4.7.2. For pressure loaded and differential regulators, a test fluid will pressurize the chamber as determined by the manufacturer and all joints shall be tested for tightness using the criteria in 4.7.1. 454.7.3. For pi

40、lot operated regulators, the main valve actuator should be tested for leak tightness between chambers. One suggested method for testing is the following: 4.7.3.1. Apply a test pressure to one side of the main valve actuator leaving the other side open to atmosphere. The minimum test pressure should

41、be at least the minimum pressure required to fully stroke the actuator. Allow time for the diaphragm to fully travel to the open position before checking for leaks as trapped fluid will escape during the actuation of the diaphragm. 4.7.3.2. On the other side of the actuator, check for any leakage th

42、rough the main actuator diaphragm and seals. Test duration should be for a minimum of 15 seconds and the following are suggested methods of implementing this leak test. 4.7.3.2.1. Applying a leak detection fluid at the regulator vent to look for any visible leakage. No leakage is allowed for a perio

43、d of at least 15 seconds. 4.7.3.2.2. Placing the vent discharge into a maximum water seal of 1” w.c. (0.25 kPa) and to look for any bubbles over a period of no less than 15 seconds. No visible bubbles shall be observed 4.8. Internal Relief Valves (IRV) 4.8.1. If a pressure regulator has an internal

44、relief valve (IRV), this shall be tested to ensure proper operation. The start to discharge (STD) of the regulators IRV shall be determined in the production test. The testing shall consist of the following: 4.8.1.1. Place the vent discharge into a maximum water seal of 1” w.c. (0.25 kPa) or use a l

45、iquid leak detection fluid applied to the vent. 4.8.1.2. Slowly increase the pressure on the downstream/outlet side of the regulator until a repeatable stream of bubbles appears from the vent connection. 4.8.1.3. Note the downstream pressure and this will be the IRVs STD. 4.8.1.4. Slowly reduce the

46、pressure on the outlet side of the regulator until there are no visible bubbles. 4.8.1.5. Note the downstream pressure as this will be the IRVs reseat pressure. 5. ACCEPTANCE STANDARDS 5.1. Manufacturers testing should verify published literature values in order to pass production tests. Any deviati

47、on from what is tested and what is advertised is grounds for rejection. 5.2. Regulator stability should be maintained throughout entire test process without pulsation, hunting, or chattering. Any observed instability would be cause for rejection. ADDITIONAL STANDARDS FROM FCI REGULATOR & CONTROL VAL

48、VE SECTION ANSI/FCI 70-2, Control Valve Seat Leakage FCI 87-2, Power Signal Standard for Spring Diaphragm Actuated Control Valves FCI 91-1, Standard for Qualifications of Control Valve Stem Seals FCI 84-1, Metric Definition of the Valve Flow Coefficient Cv FCI 70-1, Standard Terminology and Definiti

49、on for Filled Thermal Systems for Remote Sensing Temperature Regulators FCI 70-3, Regulator Seat Leakage FCI 79-1, Standard for Proof of Pressure Ratings for Pressure Regulators and Temperature Regulators FCI 86-2, Regulating Valve Terminology FCI 99-2, Standards for Backpressure Regulator Capacity FCI 99-3, Standards for Backpressure Regulator Capacity FCI 4-1, Pressure Regulator Hydrostatic Shell Test Method 6