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FVP Accessed Jan 11, 2018 03:22:15 EMRSN\Lokeshwaran.
© 2014, 2017 Emerson Process Management Regulator Technologies, Inc.
Regulator General Specification

RGS4L401
Revision AG
Hydrostatic Testing
This Document May be Distributed to Customers
USE OF THIS DOCUMENT

The master copy of this document resides in electronic format. Printed
copies of this document are for convenience only.
Verify that the revision of this printed document matches the current
revision of the electronic master before use.
Printed: 20-Jun-17 Page 1 of 20

FVP Accessed Jan 11, 2018 03:22:15 EMRSN\Lokeshwaran.M
RGS4L401
Revision AG
TABLE OF CONTENTS
1. SCOPE ..................................................................................................................................... 3
2. REFERENCES ......................................................................................................................... 3
3. PERSONNEL............................................................................................................................. 3
4. EQUIPMENT .......................................................................................................................... 3
5. HYDROSTATIC TEST FLUID ........................................................................................... 3
6. PREPARATION OF PARTS FOR TESTING .................................................................. 4
7. PROCEDURE ......................................................................................................................... 4
8. DOCUMENTATION.............................................................................................................. 4
9. TABLES .................................................................................................................................... 5
Table 1: Duration of Hydro Test ............................................................................................... 5
Table 2: Hydro Test Pressures ............................................................................................... 5
Table 3: Hydro Pressures for PED components................................................................. 12
APPENDIX A: HYDRO ADDITIONAL SPECIFICATIONS .............................................. 17
10. RELEASE/REVISION RECORD...................................................................................... 19
Printed 20-Jun-17 Page 2 of 20

RGS4L401
Revision AG
1. SCOPE
1.1 The purpose of this document is to provide procedures for production hydrostatic
testing of pressure regulator components to validate structural integrity and leak
tightness. This standard does not cover proof of design hydro testing.
1.2 Hydrostatic testing pressures are based on 1.5 times the regulator’s Maximum
Operating Pressure rounded up to the next higher 25 psig increment (ANSI/FCI 4-1,
EN334, EN14382).
Unless otherwise specified, if the regulator has different Maximum Operating
Pressures for the inlet and outlet chambers the hydrostatic testing will be 1.5 times the
lesser value.
1.3 The specified hydrostatic test pressure and duration is located in the part number's A/S
(Additional Specification).
Note: Contact Sustaining Engineering in cases of differences between the A/S and the
following tables:
Table 1: Duration of Hydro Test
Table 2: Hydro Test Pressure
Table 3: Hydro Pressures for PED components
1.4 Parts should be received hydro tested from the supplier if they have the A/S:
“RGS4L401.99 Supplier HYDRO testing is required”
2. REFERENCES
(a) ANSI/FCI 4-1 Pressure Regulator Hydrostatic Test Method
(b) EN334 Gas Pressure Regulators For Inlet Pressures Up To 100 Bar
(c) EN14382 Safety Devices for Gas Pressure Regulating Stations & Installations
(d) PED 97/23/EC Pressure Equipment Directive
3. PERSONNEL
Personnel must be trained in the safe and proper use of test equipment and procedures.
4. EQUIPMENT
All equipment and procedures must be in compliance with this standard.
5. HYDROSTATIC TEST FLUID

5.1 The hydrostatic test fluid must be below 50 ppm chloride content. Use a mixture of
30% antifreeze and 70% di-ionized water to meet this requirement.

RGS4L401
Revision AG
6. PREPARATION OF PARTS FOR TESTING

6.1 Test the parts separately.
6.2 The parts shall not be painted or otherwise coated with materials capable of sealing
against leakage. Chemical corrosion protection treatments are permitted.
6.3 Part fixtures and plumbing procedures will be determined by Manufacturing
Engineering.
6.4 Forces from fixtures, plumbing and bolting shall be similar to those experienced under
normal installation conditions. There shall be no additional force placed on the parts
being tested.
7. PROCEDURE
Important: Ensure all of the air has been vented from the part prior to pressurization.
7.1 Completely fill the part with hydrostatic test fluid.
7.2 Vent all air.
7.3 Pressurize the part per its required test pressure.
Note: Some regulator body’s inlet and outlet chambers have different pressure ratings.
When this occurs the part number A/S may include hydro pressure values for each
chamber. Separate the chambers with a threaded plug and test each chamber
independently.
7.4 Wait for the specified duration.
7.5 Inspect the part for leakage.
7.6 Reject parts that leak.
8. DOCUMENTATION
8.1 If the part passes stamp an “H” in an inconspicuous location.
8.2 Complete the hydro test section of the Manufacturing order by initialing and dating.
8.3 Complete the hydro certification by writing in the test specification (RGS4L401), that
the test passed with no leakage, the test pressure, the test duration, and the test date.
8.4 Notify QA if a part fails the test

RGS4L401
Revision AG
9. TABLES
Table 1: Duration of Hydro Test
Size Material Body Ends Duration
All All All 3-minutes
Table 2: Hydro Test Pressures

Test Pressure
Type Size Material Body Ends
psig
Cast Iron NPT 75
MR95L
All
MR95LD WCC, LCC, CF3M, CF8M,
ALL 200
MONEL, HAST C, Al-BR
Cast Iron (MR95H/HD only) NPT 375
Class 150 450

NPT, SWE
WCC, LCC Class 300
900
1/4" - 1" Class 600
PN 16/25/40
MR95H Class 150 425
MR95HD NPT, SWE
MR95HP CF3M, CF8M, MONEL,
HAST C, Al-Br Class 300
MR95HT 825
Class 600
MR95HDP PN 16/25/40
Cast Iron (MR95H/HD only) NPT 375
NPT, SWE
WCC, LCC, CF3M, CF8M, Class 300 Inlet: 1625
1 1/2" - 2" MONEL, HAST C, Al-Br Class 600 Outlet: 975
PN 16/25/40
CF3M, CF8M, MONEL, HAST
Class 150 450
C, Al-Br
WCC, LCC Class 150 525

RGS4L401
Revision AG
Table 2: Hydro Test Pressure (Cont’d)
Test Pressure
psig
Cast Iron(MR98L only) NPT 100

MR98L
All
MR98LD WCC, LCC, CF3M, CF8M,
ALL 225
Monel, Hast C, Al-Br
Cast Iron (MR98H only) NPT 450

NPT, SWE, CL300,
MR98H, CL600, PN 600
WCC, LCC 16/25/40
MR98HD, ¼” CL150 450
MR98HH,
NPT, SWE, CL300,
MR98HHD CF3M, CF8M, Monel, Hast C, CL600, PN 600
Al-Br 16/25/40
CL150 425
NPT, SWE, CL300,
MR98H,
CL600, PN 900
MR98HD, WCC, LCC 16/25/40
MR98HH, ½” – 1” CL150 450
NPT, SWE, CL300,
MR98HDP, CL600, PN 825
MR98HHD CF3M, CF8M, Monel, Hast C,
16/25/40
Al-Br
CL150 425
NPT, SWE, CL300,

CL600, PN 900
WCC, LCC 16/25/40
MR98H,
MR98HD, 1 ½”& 2”
CL150 525
MR98HDP
NPT, SWE, CL300,
CL600, PN 825
CF3M, CF8M, Monel, Hast C, 16/25/40
Al-Br
CL150 425

RGS4L401
Revision AG
Inlet: 9000
NPT, SWE
Outlet: 825
Class 150 450
Inlet: 1125
Class 300
Outlet: 825
1301F/G 1/4" All Inlet: 2250
Class 600
Outlet: 825
Inlet: 3375
Class 900
Outlet: 825
Inlet: 5625
Class 1500
Outlet 825
PN 25 550
Note: * Takes into account the allowable nominal design stress at maximum allowable
temperature, according to Annex I - § 7.4 of PED.

RGS4L401
Revision AG
Test Pressure
psig
NPT 600
67DS ALL SST
Class 150 450
NPT
161EB 1/4" SST Class 300 1088
Class 600
Y690/Y695 ALL ALL ALL 225
Cast Iron 225
T205/T208 ALL ALL
Steel, SST 300
NPT, SWE
Class 150
Y692 1 1/2" – 2" Steel, SST, Hastelloy 225
Class 300
PN 16/25/40
NPT, SWE
Class 150
Y696 1 1/2" - 2" Steel, SST, Hastelloy 25
Class 300
PN 16/25/40
Ductile iron NPT 1500
NPT, SWE
Class 900 3000
Class 1500
ALL Class 150 450

WCC, LCC, CF8M
627
PN 16/25/40 875
Class 300 1125
Class 600 2250
1”, 2” A350 LF2 SWE 2175

RGS4L401
Revision AG
BODY ACTUATOR
Size Test Test
Type Body Ends
mm Material Pressure Material Pressure
bar bar
25
PN16 24
50
S235J2G4/E355K2-
M series 65 ASTM A216 WCB 6
1.0920
80 Class 150 30
100
PN16 24 24
CRONOS 25 Class 150 30 30
and 50 ASTM A352 LCB PN 25/40 37.5 ASTM A350 LF2 CLASS 1 37.5
Cronos-FR 80 Class 300 75 75
Class 600 150 150
25 PN16 24
40
50 Class 150 30
FL 65
and 80 N/A PN25 N/A ASTM A350 LF2 CLASS 1 37.5
FL-FR 100
Class 300 75
150
200 Class 600 150
250
25 PN16 24
40 Class 150
50 30
BM5 65 N/A PN25 N/A ASTM A350 LF2 CLASS 1 37.5
80
100 Class 300 75
150 Class 600 150

RGS4L401
Revision AG

Test
Type Material Body Ends Pressure
psig
PN16 400
Steel, SST
Class 150 450
EZH
( Body and PN25/40 925
Actuators)
Class 300 1125
Class 600 2250
NPT 750
Cast Iron Class 125 300
Class 250 750
PN16 400
EZR
EZL Class 150 450
1098-EGR
1190 Steel, SST PN25/40 925
1290
63EG Class 300 1125
MR105
MR108 Class 600 2250
92S
Class 150 350
Bronze Class 300 900
Class 600 1800
NPT 450
Class 150 450

Steel
Class 300 1125
HLSR PN 16 350
Class
375
125/150
Ductile Iron
PN 16 350
Cast Iron NPT 275

RGS4L401
Revision AG
Test
Pressu
Type Material Body Ends
re
psig
PN16 400
OSE
Class 150 450
OSE-LS
Steel PN25/40 925
BLE
Class 300 1125
BLX
Class 600 2250
NPT 375
Rp 375
Ductile Iron
CL 125FF/150FF 375
CSB600 PN 16 350
CSB700 NPT 450
Rp 450
Steel
CL150 RF 450
PN /16 350
NPT 2250
310A Steel Class 300 1125

Class 600 2250

RGS4L401
Revision AG
Table 3: Hydro Pressures for PED components

The part numbers are included in the “PED Parts List” of applicable work orders.
Test
Test Pressure
Type Description Material Duration
psig
minutes
Steel 600 3
63EG Plug
SST 600 3
Cast Iron 375 3
92B Bottom Flange
Steel or SST 450 3
Cast Iron 375 3
Body Flange Steel 450 3
SST 450 3
92S/W
Cylinder SST 450 3
Cylinder Spacer Steel 450 3
Cylinder Spacer SST 450 3
SST 900 3
Inner Guide
Monel 900 3
95HSeries
CastIron 375 3
Spring Case
Steel 900 3
Spring Case Cast Iron 175 3
Upper Casing Cast Iron 175 3
Lower Casing Cast Iron 175 3
99
Valve Body (99HP) Cast Iron 175 3
Relay Valve Body (99) Cast Iron 175 3
Flange Adaptor (99HP) Cast Iron 175 3
Aluminum 15 3
Lower Case
133Series Steel 100 3
Casing Adaptor Steel 100 3

RGS4L401
Revision AG
Table 3: Hydro Pressures for PED components (cont’d)
Test Test
Type Description Material Pressure Duration
psig minutes
Steel 10 3
Head Flange
Cast Iron 10 3
166-2&166-4 Steel 10 3
Bottom Flange
Cast Iron 10 3
Lower Case Steel 10 3
Bottom Flange Steel 15 3
166-5&166-6 Bottom Flange Cast Iron 15 3
Lower Case Aluminum 15 3
Spring Case Aluminum 25 3
289
Closing Cap Aluminum 25 3
Plate Steel 275 3
Upper Case Aluminum 100 3
299H
Inlet Fitting Aluminum 100 3
Steel 2250 3
Lower Casing Ductile Iron 700 3
SST 2250 3
627
Steel 375 3
Spring Case
Ductile Iron 375 3
Closing Cap SST 375 3

RGS4L401
Revision AG
Test
Test Pressure
Type Description Material Duration
psig
minutes
Indicator Fitting Steel 600 3

Indicator Plug Steel 600 3
Indicator Plug SST 600 3
Size 30 Upper Steel 150 3
Size 30H Upper Steel 600 3
Size 30H Upper SST 600 3
1098-EGR Size 40 Upper SST 125 3
Size 30 Lower Steel 150 3
Size 30H Lower Steel 600 3
Size 30H Lower SST 600 3
Size 40 Lower SST 125 3
Body SST 300 3
ACE 95SR Bonnet SST 300 3
Lower Case SST 30 3
Body SST 300 3
ACE97
Bonnet SST 300 3
Indicator Fitting SST 1575 3
EZR &OSEBODY
Indicator Plug SST 1575 3

RGS4L401
Revision AG
Test Test
psig minutes
Indicator Fitting Steel 600 3
Steel 600 3
Indicator Plug
SST 600 3
Steel 600 3
Adaptor
SST 600 3
Steel 600 3
Body Flange SST 600 3
Cast Iron 600 3
Low Pressure Actuator
Upper Casing Steel or SST 125 3
MR105/MR108
Low Pressure Actuator
Lower Casing Steel or SST 125 3
High Pressure Actuator

Upper Casing Steel or SST 600 3
High Pressure Actuator

Lower Casing Steel or SST 600 3
Spring Case Steel or SST 600 3

Spring Case Spacer Steel or SST 125 3
Bonnet Steel or SST 125 3
Bottom Flange Steel 450 3
Intermediary Flange Steel 450 3
SSD Pad Steel & Rubber 450 3
SSD Plug Aluminum 450 3
SSD Box Steel 450 3
HLSR Φ475 mm Actuator Upper Casing Steel 100 3
Φ475 mm Actuator Lower Casing Steel 100 3
Φ350 mm Actuator Upper Casing Steel 100 3
Φ255 mm Actuator Upper Casing Steel 225 3

RGS4L401
Revision AG
Test Test
psig minutes
N310/N410 Globe & Steel 600 3

Gland/Cover Plate
Angle Valves Ductile Iron 600 3
Flange Ductile Iron 600 3
Emergency Valves
Retainer Steel 600 3
Plug SST 600 3
Test Test
psig minutes
Bonnet Steel 125 3
Φ218mm Actuator Spring Case Aluminum 125 3

CSB600 Φ218mm Actuator Lower Casing Aluminum 125 3
CSB700 Φ280mm Actuator Spring Case Aluminum 100 3
Φ280mm Actuator Lower Casing Aluminum 100 3

RGS4L401
Revision AG
APPENDIX A: HYDRO ADDITIONAL SPECIFICATIONS

A/S Requirement
RGS4L401.99 Supplier hydro testing is required
RGS4L401.20 When required Hydro at 25 psig for 3 minute

RGS4L401.22 When required Hydro at 300 psig for 3minute
RGS4L401.43 When required Hydro inlet at 1625 psig and outlet at 975 psig for 3minute
RGS4L401.44 When required Hydro inlet at 9000 psig and outlet at 825 psig for 3 minute

RGS4L401
Revision AG
RGS4L401.15 When required Hydro at 1800 psig for3 minute


RGS4L401
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10. RELEASE/REVISION RECORD

Release/Revision: AA
Date: 12-Feb-2014
Written by: Justin Hart
Approved: Cesar Yanez
Date Approved: 12-Feb-2014
Department: Engineering, McKinney
ECRN: 20112407
Reason: This standard supercedes FMPT13B01 revision Z
Revision: AE
Date Revised: 19-Apr-2017
Revised by: Fiora Chen
Approved by: Ernesto Vasquez
Date Approved: 19-Apr-2017
ECRN: 002450
Reason: Adding type ACE97 for Table 3.
Revision: AF
Date Revised: 08-Mar-2017
Revised by: Adina Todea
Approved by: Justin Hart
Date Approved: 20-Jun-2017
ECRN: 002379
Reason: 1. Change test pressure values in Table 2 for MR95/98
2. Add option for Bronze material- EZR, EZL, 1098-EGR, 1190,63EG,
MR105/ 108, 92S in Table 2.
3. Add test pressure values for CSB600/700

RGS4L401
Revision AG
Revision: AG
Date Revised: 27-Jun-2017
Revised by: Horatiu Tripon
Approved by: Justin Hart
Date Approved: 30-Jun-2017
ECRN: 002564
Reason: Added Type 627OSX for table 2
Added RGS4L401.49 for Appendix A

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FVP Accessed Jan 11, 2018 03:22:15 EMRSN\Lokeshwaran.

© 2014, 2017 Emerson Process Management Regulator Technologies, Inc.

Regulator General Specification

This Document May be Distributed to Customers

USE OF THIS DOCUMENT

Printed: 20-Jun-17 Page 1 of 20

Printed 20-Jun-17 Page 2 of 20

5. HYDROSTATIC TEST FLUID

Printed 20-Jun-17 Page 3 of 20

6. PREPARATION OF PARTS FOR TESTING

Printed 20-Jun-17 Page 4 of 20

Table 1: Duration of Hydro Test

Size Material Body Ends Duration

All All All 3-minutes

Table 2: Hydro Test Pressures

Cast Iron (MR95H/HD only) NPT 375

Class 150 450

WCC, LCC Class 150 525

Printed 20-Jun-17 Page 5 of 20

Table 2: Hydro Test Pressure (Cont’d)

Cast Iron(MR98L only) NPT 100

Cast Iron (MR98H only) NPT 450

Cast Iron (MR98H only) NPT 450

NPT, SWE, CL300,

Printed 20-Jun-17 Page 6 of 20

Class 150 450

Printed 20-Jun-17 Page 7 of 20

Table 2: Hydro Test Pressure (Cont’d)

ALL Class 150 450

Class 300 1125

Class 600 2250

1”, 2” A350 LF2 SWE 2175

Printed 20-Jun-17 Page 8 of 20

Table 2: Hydro Test Pressure (Cont’d)

Printed 20-Jun-17 Page 9 of 20

Table 2: Hydro Test Pressure (Cont’d)

Cast Iron Class 125 300

Class 250 750

Bronze Class 300 900

Class 600 1800

Class 150 450

Cast Iron NPT 275

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Table 2: Hydro Test Pressure (Cont’d)

310A Steel Class 300 1125

Printed 20-Jun-17 Page 11 of 20

Table 3: Hydro Pressures for PED components

Printed 20-Jun-17 Page 12 of 20

Table 3: Hydro Pressures for PED components (cont’d)

Printed 20-Jun-17 Page 13 of 20

Table 3: Hydro Pressures for PED components (cont’d)

Indicator Fitting Steel 600 3

Printed 20-Jun-17 Page 14 of 20

Table 3: Hydro Pressures for PED components (cont’d)

High Pressure Actuator

High Pressure Actuator

Spring Case Steel or SST 600 3

Printed 20-Jun-17 Page 15 of 20

Table 3: Hydro Pressures for PED components (cont’d)

N310/N410 Globe & Steel 600 3

Bonnet Steel 125 3

Φ218mm Actuator Spring Case Aluminum 125 3

Printed 20-Jun-17 Page 16 of 20