MINISTRY OF PETROLEUM AND PETROCHEMICAL INDUSTRY OF THE USSR AGREED WITH Gosgortechnadzor of USSR (letter # 04-11-15/672 dated 02 December

1977) APPROVED BY L. Bychkov, Deputy Minister of Petroleum and Petrochemical Industry of the USSR December 13, 1977

LEAD DIRECTIONS ON OPERATION, INSPECTION AND REPAIR OF SPRING TYPE PSVs -78

VOLGOGRAD 1978

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1. GENERAL
1.1. These lead instructions identify the order of operation, check, inspection and repair works on spring type safety valves which are installed on vessels, apparatus, pipelines and equipment of Petroleum and Petrochemical Industry Enterprises. 1.2. The above mentioned instructions do not relate to Steam Boilers, Steam Overheaters and Economizers PSVs with operational pressure over then 0,7 bar and Hot Water Boilers with water temperature over 115 C which are covered by Steam and Hot Water Boilers General Arrangement and Safe Operation Regulations

2. SAFETY VALVES OPERATION

2.1 Installation 2.1.1 Safety valves installation on vessels and apparatus working under excessive pressure is being conducted in compliance with existing Normative Technical Instructions and Safety Regulations. Quantity, type, place of installation, necessity of pilot valves installation and direction of product release is to be specified by the design. 2.1.2 Any siting of a PSV should provide a free access to it for maintenance, installation and removal. 2.1.3 In case of replacement the release rate of a new PSV should not be lower then the original one. 2.1.4 Safety valves are to be installed vertically in the highest point of a vessel to provide release of steam and gas first. On horizontal cylinder apparatus a safety valve is to be installed along upper element position; on vertical apparatus - on top covers or in the places of largest gas accumulation. Should this demand due to some structural peculiarities can not be fulfilled a PSV can be installed on a pipeline or a special tap in the direct vicinity of the vessel under the condition that there are no block valves between them. 2.1.5 On a column type apparatus with a big quantity of plates (more then 40) and possibility of sudden increase of their resistance due to the process problems which may lead to a considerable difference between cube and top parts of apparatus it is recommended to install a safety valve on the cube part of apparatus in the area of steam phase of a cube. 2.1.6 Nozzle size for a safety valve should not be smaller then safety valve inlet branch pipe. To properly identify the size of pipe joints longer then 1m take in consideration their total resistance. 2.1.7 SV outlet pipe size should not be less the size of the valve outlet nozzle. In case of uniting several PSVs outlet piping installed on one apparatus in to one header its size should not be less then the sum of outlet pipes sizes.In case of combining several PSVs outlets installed on different vessels in to one header its size should be calculated by maximum possible simultaneous discharge of all valves, specified in the project. 2.1.8 A piece of pipe taking aside gas release to atmosphere must be protected from precipitation and have a draining hole of 20-50 mm in the bottom point for draining liquid. Direction of product release and height of the pipe are to be distinguished by the project and Safety Code. 2.1.9 Safety valves release header should be erected with a slope and have a drain line of 50-80 mm in the bottom point with an outlet to drainage sump. Sacks are not permissible on such pipes. 2.1.10. Taking an operational media from branch pipes and connection pipes from a vessel to a PSV on which it is installed is not permissible. 2.1.11. Installation of block valves as well as fire protectors between a vessel and its
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safety valve is not permitted. 2.1.12. After a PSV there can be installed heating, cooling, separation and other treatment devices. Total release resistance should not be higher then specified in 2.1.13. 2.1.13. Release resistance in a release line must not exceed 0,5 kgf/cm2 with consideration for separator, heating-cooling and treatment devices installation. Should operational pressure be less then 1 kgf/cm2 release system resistance must not be higher then 0,2 kgf/cm2 2.1.14.On continuously working apparatus with PSVs on duration of interinspection period of which is less then interinspection period of the unit can be extra PSVs installed with switching over devices. 2.1.15 In case of removing a PSV for inspection from pressurized LPG or HFF storage tanks with boil temperature up to 45 C another PSV prepared in advance is to be installed on this position. Replace it with a block valve or a blind is prohibited. 2.2. Adjustment 2.2.1 PSVs adjustment for the pressure of lift - pressure setting (pop) is conducted on a special rig. Set pressure is to be determined from a vessel or pipeline operational pressure. Operational pressure is maximum excessive pressure permissible for normal operation of a vessel, apparatus or pipeline. With operational pressure in line a PSV holds and provides a tightness rate specified in the related documentation (GOST, TS). 2.2.2 PSVs set pressure is specified in a chart 2.1. 2.2.3 Set pressure of a PSV with the release into a enclosed system with a back pressure should be estimated with taking into consideration this back pressure and PSV type. 2.2.4 Set pressure, regularity of inspection and checks, its actual position on a vessel or pipeline, direction of product release is to be identified in a Set Pressure Register. The Register should be composed for each specific unit by the Head of the Unit or Unit Mechanic and agreed with Technical Inspection Department and approved by Company Chief Engineer. Chart 2.1. Valve t Main Pilot Main Pilot Main Pilot Set pressure Pset, kgf/cm2 Systems of two valves System of one valve (main & pilot) (main only) Pp + 0,5 Pp + 0,3 Pp + 0,3 --1,15 Pp 1,10 Pp 1,08 Pp 1,10 Pp 1,05 Pp 1,05 Pp

Operational pressure Pp, kgf/cm2 Up to 3 including Higher than 3 up to 60 including Higher than 60

2.2.5 A Stainless Steel or Aluminum tag should be firmly attached to each PSV body with the following information stamped on it: a) actual position of the valve - installation area, unit number and vessel designation as specified on P&I Drawing
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b) Set pressure - Pset c) Vessel operational pressure - Pp 2.3. Regularity of inspection and checks. 2.3.1 At the Petroleum and Petrochemical Plants all vessels, apparatus and pipeline PSVs the inspection and check of them should be conducted on a special test rig with their removal from line. Regularity of inspection is identified by operational conditions, corrosion rate of a product and work experience but not less seldom then: a) for the Plants with around the clock operation: - 24 month - on vessels and apparatus of demineralization system and vessels and apparatus working with products which do not cause gate corrosion with absence of possibilities of freezing up, fusing and polymerization (clogging) of valves in operational state; - 12 month - on vessels and apparatus working with products which cause gate parts material corrosion rate up to 0,2 mm/year with absence of possibilities of freezing up, fusing and polymerization (clogging) of valves in operation; - 6 month - on vessels and apparatus working with products which cause gate parts material corrosion rate more then 0,2 mm/year. - 4 month - on vessels and apparatus working in the condition of possible product cocking and formation of solid sediment inside the valve, freezing up or fusing the gate. b) - 4 month - for LPG intermediate and storage tanks as well as tanks for Highly Flammable Liquids with boiling temperature up to 45C c) for the Plants with intermittent operation: - 6 month - under the condition of excluding the possibility of freezing up, fusing and clogging of valves in operational state; - 4 month - on vessels and apparatus working in the condition of possible product cocking and formation of solid sediment inside the valve, freezing up or fusing the gate. 2.3.2 Necessity and regularity of PSVs inspection is identified by the Chief Engineer of the Plant. 2.3.3 Gate parts material corrosion rate is identified through valves operation experience, survey results of their condition during inspection or performance test of sample valves, made of the same steel grade. 2.3.4 PSVs checks and inspection should be conducted as per the schedule compiled in compliance with item 2.3.1 annually for each unit separately, agreed with Technical Inspection Body and company Chief Mechanic and approved by company Chief Engineer. 2.3.5 Chief Engineer is granted the right under his own responsibility to increase in separate justified cases the duration between PSVs inspection but not more then by 30% of specified in schedule. Any case of deviation should be registered officially by Act, approved by Chief Engineer. 2.3.6 PSVs which were received from the factory or from the warehouse should be adjusted and tested just before installation on a pressure testing rig for a set pressure. If preservation period specified in PSVs passport has expired the valve should be stripped down completely and inspected 2.4. Transporting & storage. 2.4.1 PSVs are to be transported to the place of installation or repair in vertical position on wooden supports.
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During transportation it is strictly prohibited to dump them off any platform or place of installation, tumble them carelessly or put down on the ground without pads underneath. 2.4.2. PSVs received from the factory as well as used safety valves should be stored in vertical position completely packed sitting on pads in a dry enclosed premises. Spring is to be released, suction and discharge nozzles are to be covered with wooden caps 2.5. Responsibility for operation, storing and repair. 2.5.1. Head of the Unit is considered to be a responsible person for PSVs installation on the related vessel after inspection, their seals safe keeping, on time inspection, paperwork handling and documentation safe keeping as well as proper storing of PSVs under existing conditions of the unit. 2.5.2. A person responsible for proper storing of PSV received for inspection, for quality of inspection and repair and also for usage of proper materials in repairs is a Foreman (Supervisor) of the valve workshop. 2.5.3. A person responsible for proper acceptance of PSVs from repair is a Unit Mechanic or Engineer Mechanic from Technical Inspection Department. 2.5.4. Unit Mechanic is also responsible for PSVs transporting to its place of installation. Installation team Forman is responsible for proper installation of a PSV. 3. INSPECTION AND REPAIR OF PSVs 3.1. Inspection. 3.1.1. PSVs inspection entails disassembling, cleaning out, checking the parts for defects, body test, body leak test, seat leak test, spring test, lifting pressure set point adjustment. 3.1.2. PSVs inspection is to be conducted in a specialty type of a workshop on a special type of test rigs. 3.1.3. PSVs removed from line for inspection should be steamed and washed out. 3.1.4. Every PSV which passed the inspection and repair should be followed up with an Act which is signed by the repair workshop foreman, an executor of the repair works, Unit Mechanic to which this PSV belong to, or Engineer-Mechanic of Technical Inspection Department. 3.2. Disassembling. 3.2.1. Disassembling of a PSV is to be carried out in the following consequence (fig 5.1 in the attachment #1): - remove the cap installed on studs over the adjustment screw; - release the spring tension by making loose a lock nut of the adjustment screw 2 and screw it out into its top position; - get loosened evenly and than remove the nuts from the studs 4 holding the cover 3. Remove the cover. Before removing the cover put marks on cover flange and body or if the valve has a splitter put the marks on the cover, splitter and the body; - remove the spring with washers 6 and put it in a safe place. Its strictly prohibited to hit or throw the spring etc; - remove from the valve body plugging element together with stem and partition and put them carefully in a safe place in order to avoid any damage of plugging element sealing surface and bending the stem; If there is a splitter in the valve remove it first releasing it from fasteners on the body; - screw out set screws 8 of the adjustment sleeves 9 and 10; - release a guide bushing 11 and remove it from the body together with adjustment sleeve 9. If its tight in its place hit gently the body with a hammer close to the guide bushing to make it easier to get it out;
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- release the spacer bushing 10 and the valve nozzle 12. If the sealing surface of the nozzle has a minor damage it is recommended to rebuild it without screwing out from the seat in the body; 3.3. Checking the condition of parts. 3.3.1. All valve parts should be cleaned out from mud by washing them in kerosene. After that all parts are to be checked for defects. Special attention should be given to seal surfaces of the nozzle and plugging element as well as the spring to identify the degree of their damage. Should any additional parts cleaning be needed use thin glass paper. 3.3.2. All valve parts should not have scorings, dents or bending. In case of damage (scorings, marks, corrosion etc.) the part should be rebuild by machining followed up with lapping. 3.3.3. Adjustment screw thread should be clean and not crushed. All fasteners with bad threads are to be replaced. 3.3.4. PSVs springs are checked visually for cracks and corrosion sores. Springs are considered to be no good if they have dents, cracks and cross marks. Nonparallelism of spring edges should be within the tolerance (Chart 5.4, attachment 1). 3.3.5. At least once a year as per the schedule set up by Technical Inspection Department judging from work experience with PSVs springs should be subject to additional check. Springs of PSVs with regularity of inspection more then a year should be subject to additional check during every inspection. The additional check contains the following points: being triple squeezed under a dead load with maximum deflection, the spring should not have a residual deformation (shrinkage). A maximum deflection is considered to be a spring squeeze with the gap between central coils not more than 0,1 of a spring bars diameter; maximum dead load squeeze, given in the passport or spring specifications. Spring axial shift while doing that should be in the limits specified in the chart 5.4. Check for surface cracks with magnetic or die penetration test. If a non-destructive magnetic inspection instrument is available conduct the spring cracks test with this device. Die penetration test should be used in compliance with The instruction on die penetration testing in petrochemical industry enterprises. 18-03--74. You can check the springs on surface cracks using one of the following methods: well washed spring is immersed in Kerosene and wiped thoroughly after 30 minutes of soaking and then is dusted with a chalk powder. Appearance of a dark lines on a chalk surface indicates the presence of surface cracks and this particular spring is rejected. as per an other method surface cracks are identified by immersing the spring into the heated up to 60-80C mixture of industrial or spindle oil (50%) and Kerosene (50%) soaking the spring in this mixture not less than 30 minutes. Then the spring is dry wiped and is exposed to grid blast cleaning till receiving of even dull surface. After this treatment the spring is thoroughly examined and if any traces of oil found on the surface as dark thin lines of stretches it indicates on presence of cracks and the spring is rejected. 3.3.6. If any traces of corrosion or wear found the valve body thickness is to be checked with a thickness gauge. The body reject due to the wall thickness as well as flanges sealing surfaces is conducted in compliance with items 13.51 and 13.52 of Lead Instructions on Operation, Inspection, Repair and Reject of Process Pipes under pressure up to 100 kgf/cm2 -75 3.4. Assembling 3.4.1. Valve assembling work can be started only after cleaning, inspection and rebuilding of all the parts. Consequence of assembling is as follows (fig.5, attachment 1): set up a nozzle 12 in the valve body 5, check with Kerosene its tightness in the body; put back
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nozzle spacer bushing 10; install a guide bushing 11 with a gasket and upper spacer sleeve into the valve body. A hole for draining the product should face valve discharge nozzle; install the slide 7 connected to the stem in to the guide busing; install the bulkhead 13 and the splitter; install the spring together with end washers 6 on to the stem; put a gasket on to the body split surface and put back the bonnet watching closely not to damage the stem. Then align the bonnet against the projection of guide bushing and secure it evenly on the studs. Proper bonnet installation is identified by equal circumferencial clearance

Fig. 3.1. Adjustment bushings installation scheme. 1. Guide bushing; 2. Slide; 3 Nozzle; 4. Lower adjustment bushing; 5. Upper adjustment bushing;

between the bonnet flange and the body. Before adjusting the spring make sure the stem doesnt seize in guides. When the spring is set up free in the bonnet the stem should rotate free by hand. If the spring is longer then the bonnet height and is compressed a little bit after installation conduct additional check by turning the stem around its axis. If while doing that you apply equal force that will show you that the valve is assembled in a proper way; apply pretension to the spring with an adjustment screw 2 and test it finally on the testing rig; install the cap 1 and tighten the valve nuts. 3.4.2. In case of gas application spacer bushings are installed the following way (fig. 3.1): lower spacer bushing is installed in the top upper position with the clearance between the edge of the bushing and valve slide in the limits of 0,2-0,3 mm. upper spacer busing is preset preliminary face with outer edge of a slide 2; final installation is conducted in top upper position when the valve pops up during the adjustment on the testing rig.

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3.4.3. In case of fluid application the lower spacer is installed in the end bottom position and the upper spacer is installed the same way as described above. 3.4.4. As a testing media for the valves working with steam-gas products can be used air, nitrogen; for the valves working with fluids - water, air and nitrogen. Test media should be clean, free from mechanical impurities. Presence of hard particles in test media can result in seal surfaces failure. 3.4.5. Valve adjustment to the set pressure is executed by tightening or loosening of the adjustment screw. After each adjustment the adjustment screw should be secured with a lock nut. Pressure check during such a test is controlled with 1st accuracy class pressure gauge (GOST 8625-69) 3.4.6. A valve is considered to be properly adjusted when it being air testet on the set pressure opens up and closes down with a clear and distinctive pop. If it's tested with water it lifts up without a pop. 3.5. Testing. 3.5.1. Tightness of a valve flap is tested at the operational pressure. Tightness of the flap and as well as the seat fit in the body after the calibration is checked the following way: some water is poured in to the valve from discharge flange side with its level covering flap sealing surfaces. Under the flap there should be created a desired air pressure. Absence of bubbles within 2 minutes witnesses complete tightness of the flap. If bubbles appear a tightness of the seat and the body is to be checked. To check the tightness of the seat and the body water level should be decreased in such a way for it to be lower than the flap. Absence of bubbles within 2 minutes witnesses complete tightness of the connection. If a valve is not tight in the flap or in the seat it is to be rejected and passed over for additional inspection and repair. 3.5.2. Check of the valve split surfaces for tightness is conducted every inspection by means of applying air to the discharge nozzle. and types of PSVs are tested with the pressure 1,5 Py of discharge flange nozzle rating with 5 minutes hold followed up with decreasing pressure to Py and applying leak detecting liquid to the body split area. PSVs with a diaphragm - with a pressure of 2 kgf/cm2, bellows type PSVs - with the pressure 4 kgf/cm2. 3.5.3. Hydrotest of the intake part of the valve (intake nozzle and seat) is conducted with the pressure of 1,5 Py of intake flange rating with 5 minutes hold followed up with decreasing pressure to Py and visual inspection. Frequency of hydrotests is set up by Technical Inspection Bodies of the enterprise depending on PSVs operation mode and inspection results but it shouldn't be rare than once every 8 years. 3.5.4. Test results are to be recorded in The Valve Inspection and Repair History Register and in the Valve Passport. 3.5.5. All the valves that passed the inspection and repair should be sealed with a special sealing device that is being kept and stored by a repair shop Supervisor. Adjustment bushings set screws and split connections such as "body-bonnet" and "bonnet-cap" are amendatory for sealing. 3.5.6. Approximate list of equipment and testing devices for the specialty type of valve repair and testing shop is represented in the chart 3.1. 3.6. Troubleshooting. 3.6.1. Product leak - media leak through the valve flap at the pressure lower than the set pressure. The causes resulting in leaks may be:

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entrapment of foreign components (scale, process products etc.) on sealing surfaces - is eliminated by blowing down the valve.; damage of the sealing surfaces is restored by lapping or machining followed up with lapping and checking for tightness. Minor damage of sealing surfaces and slide is eliminated by lapping; Rebuilding of sealing surfaces with the depth of damage or corrosion 0,1 mm or more is to be done by machining with restoring the concentricity and removing defective spots followed up with lapping. Repair sizing of slides and seats sealing surfaces are specified in the chart 3.2. The leader denotes a sealing surface configuration after rebuilding, figures denote acceptable amount for machining during rebuilding;

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hart 3.1.
Approximate list of equipment and machines to set up a PSVs inspection and repair workshop.
Equipment Pressure testing / calibration rig for PSV size 50-150 mm and P up to 64 kgf/cm 2 Pressure testing rig for other types of valves with size 50-250 mm and P up to 64 kgf/cm2 Valves disassembling and assembling rig for valves 50-250 mm and P up to 64 kgf/cm2 Spring testing rig Lapping Machine for lapping flat surfaces Washing machine (for valve bodies) Washing machine (for valve parts) Pneumatic grinding machine 9 10 11 Vertical drilling machine 12 13 14 15 16 17 Metal spraying machine 18 19 20 21 22 A workbench A rack for springs and parts Overhead beam crane Electric hoist Abrasive machine Air compressor with a receiver of 150 kgf/cm2 capacity Air compressor with a receiver of 25 kgf/cm2 capacity Dozing pump Hand operated pump 3A64M 202-4/150 BK-25 Power nut drivers on the support balancer Screw-cutting lathe Type, model. CO.2M.00.00 Developer GrozNII, NizhneVolzhsky branch Same Maker Neftekhimzapchast Plant, Volgograd Same Quantity 2 2 Notes For inspection and repair of 1000 PSVs a year (approximately) A part of Valve shop equipment

1 2

1.00.00.
C04.00.00

4 5 6 7 8

C03.00.00 C1.00.00.A T1.00.00. 96

GrozNII, NizhneVolzhsky branch

Neftekhimzapchast Plant, Volgograd Same Same Red Star Cherepovezk Plant Pnevmostroimashina Moscow Plant Pnevmostroimashina Sverdlovsk Plant Krasny proletarii Moscow Plant -/-/-/Melitopol Compressor Plant Chimmash Riga Plant Neftekhimzapchast Plant, Volgograd Neftekhimzapchast Plant, Volgograd -/-/-/-/-

1 1 1 1 2 3 1 1 1 1 1 1 2 1 1 1 1

For 1000 PSV a year Same Same A part of Valve shop equipment Same A part of Valve shop equipment A part of Valve shop equipment -/-/-/-/-/-/-/A part of Valve shop -/-/-/-/-/-

-2001 -3106 -3205

T63 2118A

-/-/-/-/-/-/-/-/-/-/-/GrozNII, NizhneVolzhsky branch GrozNII, NizhneVolzhsky branch -/-/-/-/-/-

-63/160
C08.00.00 CH1.00.00 1983800 SWL 2 t SWL 2 t -103

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Electric fork lift

-/-

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Fig.3.2. Repair dimensions of the slide (a) and the nozzle surfaces.

misalignment of PSV elements due to excessive load - check the intake and outlet lines, eliminate pipe stress. Retighten the studs; spring distortion - replace the spring; conservative lifting value - recalibrate the valve; poor assembling after repair - eliminate assembling drawbacks. 3.6.2. Pulsation - quick and frequent opening and closing of a PSV. It can happen due to the following reasons: excessively large flow capacity of the valve - needs to be replaced with the smaller size PSV or restrict the slide lift. restricted bore of the incoming pipe or apparatus nozzle that makes PSV "starving" thus generating flap chattering - repipe the valve with the pipe size not less than the valve inlet square cross section. 3.6.3 Vibration. Reduced bore and with small radius discharge pipes create high backpressure in the discharge line and may easily be the source of valve vibration. Elimination of this drawback can be achieved by installation of discharge pipe with flow capacity not less than valve discharge nozzle port area with minimum of pipe bending and turns 3.6.4. Scratching of valve moving parts may occur due to unproper assembling or installation of the valve as a result of skewing and occurrence of side forces on moving elements of a valve (slide, stem). All scratching and burrs should be removed by machining or grinding and courses they were the results of are to be eliminated by a qualified assembling. 3.6.5. The valve doesn't lift up at the predetermined set pressure: wrong adjustment of the spring - spring adjustment to the set pressure is needed; spring rate is too high - install a lower rate spring; excessive friction in slide guides - eliminate skewing, check the clearance between the slide and the guide. 4. TECHNICAL DOCUMENTATION.

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4.1.The following technical documentation should be available while dealing with inspection, repair or calibration of a PSV: 1. Operational Passport. 2. Manufacture Passport for PSV and spring. Is kept together with Operational Passport. 3. PSVs set pressure Register with frequencies of inspection and recalibration. 4. PSVs Repair and Inspection Schedule. 5. Act on PSV Nonremoval (elongation of use). 6. Act on PCV inspection, Repair and Calibration. 4.2. In case of absence of the manufacture's passport for the PSV or the spring it is acceptable to compose new passports approved by the Plant Chief Mechanic, Senior Mechanic of the workshop, Foreman who conducted the hydrotest and Representative of Technical inspection Bodies who are authorized by the Plant Chief Engineer. While doing that the hydrotest of the valve and spring test are not required. Technical specs for a PSV and its spring are compiled on the basis of their tags, physical dimensions and testing results. 4.3. All the above mentioned items of documentation are only recommended. Each enterprise is allowed some changes in forms under the condition of remaining of main content.

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SERVICE PASSPORT No Of a pressure safety valve, installed on _______________________________________________________ (vessel, apparatus, unit, KTL) P r e ss u r e sa fe t y va lve c ha r a c t e r ist ic d) Product aggressiveness _______________________ 1. Manufacture _______________________________ 2. Date of installation ____________________________ 3. Valve type __________________________________ 4. Serial number ________________________________ 5. Engineering pressure, kgf/cm2_____________________ 6. Valve port area, mm ____________________________ 7. Service conditions : a) Max. operational pressure, kgf/cm2 ______________ b) Set pressure, kgf/cm2 ________________________ Head of the Unit _____________________________________ c) Product temperature _________________________ W/Shop Senior Mechanic ______________________________ 8. Spring data: a) spring number _______________________________ b) Pressure range, kgf/cm2 _______________________ c) Protection coating ____________________________ 9. Direction of the valve discharge _________________________________________________ ( in atmosphere, to the flare, back pressure, kgf/cm2)

Signatures:

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PSV Inspection and Repair History Record VALVE S. No

Description of inspection and repair. Reason for parts replacement Inspection or repair date Test type Load

SPRING Test
Residual distortion Reusability

Signature of a person responsible for operation

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AGREED Plant Chief Mechanic ----------------------------------------------------------------- ________ ______________________________2001

APPROVED Plant Chief Engineer --------------------------------------------------------------------__________ ________________________________2001

REGISTER of pressure set points and regularity of calibration and inspection of Pressure Safety Valves Unit _________________ KTL ________ Valve discharge direction and back pressure, kgf/cm2

No

Valve Type and designation

Valve Serial No

Apparatus designatio n

Product, valve parts corrosion rate

Product temperatur e, C

Apparatus operationa l pressure, kgf/cm2

Valve set pressure , kgf/cm2

Regularity Spring No of calibration /inspectio n

Head of the Unit: Unit Senior Mechanic: Technical Inspector: AGREED Plant Chief Mechanic
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------------------------------------------------------------------

-------------------------------------------------------------------- ________ ______________________________2001 APPROVED Plant Chief Engineer __________ ________________________________2001

SCHEDULE of Pressure Safety Valves inspection of the Unit ____________________________ KTL ______________________ for 20
Operational conditions No Valve location Valve type Valve serial No Spring No Pressure, kgf/cm2 Temperature C Product Valve discharge I II III IV Scheduled and actual valves inspection V VI VII VIII IX X XI XII

Head of the Unit: Unit Senior Mechanic: Technical Inspector:

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ACT NO Of inspection and repair of Pressure Safety Valves from the Unit ______________________ This Act is composed to confirm that bellow enumerated Pressure Safety Valves from the Unit _________, KTL _________ were repaired, adjusted to the set pressure, pressure tested and secured with a seal of the Valve Repair Workshop. Valve type (size, pressure rating) Repair details, reason for parts replacement, spring test

No

Valve location (apparatus designation)

Valve serial number

Spring No

Set pressure

Valve disc leak test

Valve split surfaces leak test

Notes

Valves issued from repair shop:

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Valves received from repair:

Valve shop Supervisor: _____________________________ ________________________________ Valve shop Foreman: _______________________________ ___________________________

Unit Mechanic Technical Inspector:

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AGREED Plant Chief Mechanic _________________________ 20 . .

APPROVED Plant Chief Engineer _________________________ 20

Dated: ________

ACT No On Pressure Safety Valves On-Stream Time Prolongation 2001.

A Committee, including Section Supervisor ________________________________, Unit Senior Mechanic _________________________, Unit Mechanic __________________________, Head of the Unit _________________________, Technical Inspection Dpt. Supervisor _________________________ has conducted an inspection of the Unit ___________, KTL ________, Pressure Safety Valves condition. Inspected were the valves installed on the apparatus: ______________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ Examination was made by means of visual inspection taking into consideration all parts condition during the last repair. Last inspection and repair date:_____________________________________________ Scheduled date of the next inspection: ________________________________________ Valves regulatory operation period: __________________________________________ Inspection results (technical condition) _________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ ______________________________________________________________________________________ Committee solution: 1. Prolong On-Stream Time of the Pressure Safety Valves __________________________ ______________________________________________________________________________________ (date, month, year) 2. Inform operating personnel about prolongation of On-Stream Time of the PSVs as per the Head of the Unit order recorded in the Shift Register.
Note: The current Act is composed in 2 copies. One copy to be kept at the Unit, another copy in Technical Inspection Department.

Signatures: 1. KTL Supervisor___________________ 2. Head of the Unit___________________ 3. Unit Senior Mechanic _______________
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4. Unit Mechanic ______________________ 5. Technical Inspector: __________________ 6. Deputy of Chief Engineer

on Safety: __________________________ Attachment 1 5. APPLICATION AND TYPES OF A SPRING TYPE SAFETY VALVES. In petrochemical and oil processing industries as main safety devices they use spring type safety valves produced by Blagoveschensk Valve Plant. 5.1. 4 type valves. 5.1.1. 4 spring type safety valve (fig. 5.1 and 5.2) are used for installation on vessels, apparatus and pipe lines with different product and temperature up to 450 - 600C. A spring type safety valve is an automatic action device. A spring forcing the slide down to the seat through the stem counteracts the product pressure applied the valve slide. With operational pressure ina vessel or apparatus the product force counterbalances the spring force. Pressure increase in lines or a vessel higher than permissible breaks this balance, lifting force overcomes the force of a spring, a slide lifts up and a product discharge occurs. It is a full lift valve as the slide lifts up to the height equal or more than 1/4 seat size. High lift of a slide is achieved by using flow energy coming out of the nozzle at high velocity. To achieve this a PSV is equipped with upper and lower adjustment bushings which providing the slide lift and thus performance of the valve, control the pressure of full opening and back fit of the slide on to the seat, i.e. provide the proper valve operation. Adjustment bushings are secured in a definite position by set screws.
Note: In 150 mm and 200 mm size valves an upper adjustment bushing is missing and the slide lift in these valves is provided by a special shape of an oversized bottom part of the slide. (fig.5.3). There are 100 mm size valve in use which have either upper adjustment bushing or special shape of a slide. (fig. 5.3)

For forced opening and test discharge in operation a valve is equipped with a lever. While turning the lever a force is transferred through a bowl, cam and nut to the stem lifting the latter together with the slide thus opening the valve. Spring adjustment to the required pressure is executed with a help of a adjustment screw. A set of changeable springs provides a stepless valve adjustment for any required pressure range. 5.1.2. 4 type valves are currently made in two versions: a) version 1 (fig.5.1) - with a carbon steel body for operational temperature range up to 450C; b) version 2 (fig. 5.2) - with a corrosion-resistant steel body for operational temperature range up to 600C; The design differences between version 1 and version 2 are elongated bonnet and a bulkhead with two guide bushings, protecting the spring from high temperatures during discharge, bigger weight and size. 5.1.3. Till 1955 our industry was making 1 type of valves which were further on replaced with 2 and 3 with the same parameters. Since 1960 they started to make 4 valve type which were much smaller in weight and size comparing with 1 and replaced them completely. Since 1977 4 type of valves were replaced by 4 with the same size and pressure rating. 5.1.4. One of the main characteristics of a PSV is its discharge capacity. Discharge capacity of a PSV is determined in conformity with item 5.4.5. of " General Arrangement and Safe Operation of the Vessels, Working Under Pressure Regulations." 5.1.5. To have the ability to increase the flow ratio in 4type of valve, made before 1976 and installed at the operational facilities the customer if need be is recommended to do the following:
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a) upgrade the guide bushing as per the sketch 5.4. to the dimensions specified in the chart 5.1.; b) install the guide bushing with the holes d and d1 facing discharge nozzle; c) in order to prevent blocking the holes in the guide bushing decrease the width of a gasket between the bulkhead and the guide bushing enlarging its ID. d) proper position of upper and lower bushings is to be identified while adjusting the valve to operational parameters.

Fig.5.1. Spring type Safety valve 4, t up to 450 C. 1 cap; 2 adjustment screw; 3 bonnet; 4 stud; 5 body; 6 thrust washers; 7 slide; 8 set screws; 9 adjustment bushing, upper; 10 - adjustment bushing, lower; 11 guide bushing; 12 nozzle; 13 bulkhead

5.2 4 types of valves. 5.2.1. 4 types of safety valves (fig. 5.5 and 5.6) are made basically on the basis of 4 design, but they don't have a lever device for forced opening and test purge of the valve. They are designed to work on the same units, products and parameters as 4 valves.

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Fig.5.2. Spring type Safety valve 4; t up to 600 C

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Fig.5.3. Variant of the valve 150, 200

Fig. 5.4. A sketch of the guide bushing after modification

5.2.2. 4 type valves are currently made in two versions: a) version 3 (fig.5.5) - with a carbon steel body for operational temperature range up to 450C; b) version 4 (fig. 5.6) - with a corrosion-resistant steel body for operational temperature range up to 600C;

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Same as with 4 valves the design differences between version 4 and version 3 are elongated bonnet and a bulkhead with two guide bushings, protecting the spring from high temperatures during discharge, bigger weight and size. 5.2.3. Till 1955 our industry was making C 1 type of valves which were further on replaced with C 2 and C3 with the same parameters. Since 1960 they started to make C4 valve type which were much smaller in weight and size comparing with C 1 and replaced them completely. Since 1977 C 4 type of valves were replaced by 4 with the increased flow rating "a". 5.2.4.To have the ability to increase the flow ratio in C 4 type of valve, installed at the operational facilities the customer is recommended to do the same upgrade as mentioned in item 5.1.5. 5.3. type of valves. 5.3.1. type of spring type safety valves (fig. 5.7) are used on the vessels, apparatus and pipelines working with liquid and gas chemical and oil products with the temperatures 450 - 600C. type PSVs are designed analogue to 4 and differ from the latter by welded body with coupling joints. To the pipe line it is attached by means of a nipple prefabricated for welding which is screwed in into the coupling. The valve has a lever device for forced opening and test purge. type of valves are currently made with a port area of 25 mm out of carbon steel for temperature rating up to 450C and out of corrosion-resistant steel for temperature rating up to 600C. 5.4. type of valves. 5.4.1. type of spring loaded coupling type valves (fig.5.8.) are designed basically as valves but they era not provided with lever device for forced opening and test purge. 5.4.2. type of spring loaded coupling type valves are used on the same units, products and parameters as type of valves. At the moment type of valves are made out of carbon steel to work in the temperature range up to 450C. 5.5. 2-200-16 type of valves. 5.5.1 In conjunction with an excessive enlargement of the units and increase in apparatus performance there appeared the necessity to increase PSVs performance, which are installed on such apparatus. Spring loaded 2-200-16 type of valve (fig. 5.9) which was manufactured till 1972, has the maximum flow capacity in the whole row of series valves. There are two seats in 2 valve mounted in one body what makes it possible to increase tremendously its performance. They are designed to be operated on the same conditions as type of valves.

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5.5.2 Due to the fact that valve had a lower flow ratio (a=0,4) Blagoveschensk valve Plant developed and designed and since 1972 started to make 4 type of a PSV (fig.5.10) with the port area of 200 mm and 142 mm ID of the seat with engineering pressure 16 kgf/cm2. Flow ratio of this type of a valve is 0,7.

Fig.5.5. Spring type Safety valve 4 up to 450 C

5.6. type of valves.

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Fig. 5.6. Spring type Safety valve 4 up to 600C

5.6.1. When the valves are installed on the tanks with LPG, in flare release lines or in the change over lines of the pumps for astable gasoline the valve spring due to the back pressure presence is all the time in contact with an aggressive media which is deteriorating the spring. Besides, even minor leaks lead to an excessive erosive wear of sealing surfaces thus leading to the valve malfunctioning. With media temperatures

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Fig. 5.7. Spring type Safety valve

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Fig.5.8. Spring type Safety valve

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Fig. 5.9. Spring type Safety valve with a double seat 2 200 - 16

below 0 C it leads to freezing up of the slide to the seat and thus to increase of lifting pressure . In order to eliminate the above drawbacks on the basis of 4 valve was developed and fabricated type of valve (fig. 5.11) in which the spring was isolated from the product with a diaphragm and reliable tightness of the flap was supported by a soft seal on the slide. 5.6.2. type of valves are used for media temperatures from -30 to + 100C and product pressure rating up to 40 kgf/cm2. Other modifications of valve are a valve which doesn't have a diaphragm and valve which doesn't have a soft seal on the slide.
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Fig. 5.10. Spring type Safety valve

200 - 16

At the moment neither of , or valves are manufactured 5.7. Selection and application. 5.7.1. For all PSVs engineering pressure, test pressure and operational pressure are specified by GOST 356-68 (chart 5.2).
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Fig.5.11. Spring type Safety valve

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5.7.2. PSVs application limits depending on product parameters are given in the chart 5.3. 5.7.3. Spring selection for all types of PSVs is conducted in conformity with the chart 5.4. 5.7.4. Specs on PSVs inlet and outlet flange connections is shown in the chart 5.5.

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Chart 5.2. Pressure Safety Valves Test and Operational Pressures.

Engineering Pressure, Pe kgf/cm2 Test pressure, Pt kgf/cm2 Body material Up to 200 250 Maximum operational pressure in kgf/cm2 at the product temperature in C 300 350 400 425 450 475 500 525 560 590 600 16 7,5 19 30 47 75

1 16

2 24

3 20.25 10189 20.25 10189 20.25 10189 20.25 10189 20.25 10189

4 16 16 40 40 64 64 100 100 160 160

5 14 15 36 38 56 60 90 95 140 150

6 12,5 14 32 36 50 56 80 90 125 140

7 11 13 28 34 45 53 71 85 112 133

8 10 12,5 25 32 40 50 64 80 100 123

9 9 12 22 31 36 48 56 77 90 121

10 6,7 11,5 17 30 26 47 42 74 67 117

11 11 28 45 71 113

12 10,5 26 42 67 106

13 10 25 40 63 99

14 9 22 36 56 90

15 8 20 32 50 80

40

60

64

96

100

150

160

240

Extraction from GOST 356 - 08

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Chart 5.3. Pressure Safety Valves Application

No Valve type Brief description Product Corrosio Temperature n rate, ,C mm/year Up to 0,5 -40 +450 Body Seat Material of main parts Slide Stem Guide bushing 3013 12189 Bonnet, cap

4 Version 1 4
Version 2

Flanged with a lever for purging Flanged with a lever for purging and elongated bonnet Flanged

20, 25 10189

2013, 3013 12189 with Stellite weld pad B2K 20X13, 30X13 12189 with Stellite weld pad B2K 30X13

2013, 3013 12189 with Stellite weld pad B2K 20X13, 30X13 12189 with Stellite weld pad B2K 30X13

3013 4514142 or 12189 30X13 4514142 or 12189 30X13

Carbon Steel

More than 0,5

-40 +600

Carbon Steel

4 Version 3 4
Version 4

Up to 0,5

-40 +450

20, 25 10189

30X13 12189 Carbon Steel

Flanged with elongated bonnet

More than 0,5

-40 +600

Coupling type with carbon steel lever for purging Coupling type with corrosion-resistant lever for purging Coupling type

Up to 0,5

-40 +450

Steel 20

Carbon Steel 30X13 Carbon Steel

More than 0,5

-40 +600

10189

12189 with Stellite weld pad B2K 30X13

Up to 0,5

-40 +450

Steel 20

12189 with Stellite weld pad B2K 30X13

4514142 or 12189 30X13

12189

Carbon Steel 30X13

Carbon Steel

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Chart 5.4. Springs for Pressure Safety Valves

Max. pressure load, kg Squareness of edges Released spring height, mm Spring operational coils Full spring coils Port area, mm Engineering pressure, kgf/cm2 Pressure limits kgf/cm2 Spring bar OD, mm Spring bar length, m L 1.4 1.45 2.75 1.6 3.0 1,8 1,45 1,4 1,45 2,76 1,6 1,8 2,0 2,0 2,0 2,0 2,0 4,0 2,0 4,0 2,6 2,6 2,7 2,75 2,6 2,65 2,7 2,7 2,7 2,5 2,5 Compressed spring height, mm Hc 45 57 65 83 78 41 39 45 57 65 83 39 46 50 58 66 74 77 85 93 59 68 78 87 92 101 110 110 120 122 131 Axial displacement with max. load F1 29-34 27-31 31-35 21-25 14-17 57-66 50-58 29-34 27-31 31-35 21-25 28-34 29-36 35-43 32-39 32-39 29-36 33-40 28-35 25-31 36-41 42-51 46-56 46-57 40-49 39-47 39-48 39-48 43-52 34-42 32-40 Spring OD, mm Spring pitch, mm

Valve type

# 1 2 3 4 5 6 7 1 2 3 4 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119
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M
25

100

8-16 16-30 30-64 64-85 85-108 0,5-2 2-4,5 4,5-12 12-19 19-23 23-40 0,5-1,2 1,2-1,9 1,9-3,5 3,5-6 6-10 10-16 16-25 25-35 35-44 0,5-1,3 1,3-2,5 2,5-4,5 4,5-7 7-9,5 9,5-13 13-16 16-18 18-28 28-35 35-44

d 5,5 6.5 7.5 8.5 9 4 4 5,5 6,5 7,5 8,5 4 5 6 7 8 9 10 11 12 6 7 8 9 10 11 12 12 13 14 15

53.5 52.5 52.5 53.5 50 54 44 53,5 52,5 52,5 53,5 54 65 76 77 78 77 82 81 82 81 85 87 89 91 93 95 95 95 94 95

Ho 117-128 114-125 118-129 115-125 103-112 118-126 113-124 117-128 114-125 118-129 115-125 132-145 134-147 141-154 137-150 137-150 134-147 138-151 133-146 136-150 176-194 183-202 188-207 189-209 181-200 179-197 180-200 180-200 186-205 178-196 195-209

t 19 17 17 16 14 14,5 15,3 19 17 17 16 18 20 24 23 23 22 24 23 24 24 25 26 26 26 25 26 26 26 27 28

n 8.5 9.0 9.0 10.0 9.0 10,5 10,0 8,5 9,0 9,0 10,0 10,0 9,5 8,5 8,5 8,5 8,5 8,0 8,0 8,0 10,0 10,0 10,0 10,0 9,5 9,5 9,5 9,5 9,5 9,0 9,0

n 6.0 6.5 6.5 7.5 6.5 8,0 7,5 6,0 6,5 6,5 7,5 7,5 7,0 6,0 6,0 6,0 6,0 5,5 5,5 5,5 7,5 7,5 7,5 7,5 7,0 7,0 7,0 7,0 7,0 6,5 6,5

l 2.46 2.42 2.48 2.52 2.2 2,42 2,42 2,46 2,42 2,48 2,52 2,76 2,82 2,98 2,88 2,88 2,84 2,90 2,84 2,86 3,70 3,92 3,86 3,96 3,8 3,76 3,84 3,84 3,94 3,8 4,04

P1 39 75 161 171 217 16 28 39 75 161 171 8,5 13,4 24,7 42,4 70,7 113 177 247 310 16,3 31,4 56,5 88 119 163 226 226 352 440 552

4 4

16 25 16-40

40

4 4

50

16

40 40-61

16 80

40-64

Spring weight, kg Q 0.22 0.32 0.41 0.59 0.55 0,16 0,12 0,22 0,32 0,41 0,59 0,14 0,26 0,39 0,53 0,69 0,86 1,05 1,22 1,46 0,49 0,69 0,92 1,17 1,39 1,7 2,05 2,05 2,38 2,55 2,93

Spring No

120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 304 305 301 302 303

4 4

16 100

0,5-1 1-1,5 1,5-3,5 3,5-9,5 9,5-20 20-30 30-40 0,5-1 1-1,5 1,5-2 2-3 3-6,5 6,5-11 11-15 15-22 22-28 28-35 35-44 44-50 50-64 64-100 44-50 50-64 64-100 40-48 48-64 100-140 140-160 100-135 135-160 0,5-8 8-16 22-28 28-35 35-40

7 8 9 12 11 16 18 9 10 11 12 14 16 18 20 22 24 26 13 14 16 16 17 19 19 21 18 19 20 22 20 26 22 24 26

2,95 3,35 3,5 3,5 3,55 3,5 3,4 3,7 4,0 3,85 4,0 4,0 4,0 3,9 4,0 4,0 4,2 4,0 4,2 4,0 4,0 2,6 2,3 2,1 3,1 2,8 3,9 1,8 4,6 4,0 3,6 3,4 4,0 3,9 3,7

94 108 114 114 114 116 116 121 135 141 142 134 138 138 148 150 156 156 82 82 82 96 95 95 116 116 92 94 96 96 134 144 148 148 148

210-231 225-248 246-272 251-271 256-281 259-285 251-276 273-300 290-320 288-316 292-320 298-326 302-332 288-316 306-336 309-334 328-358 312-342 160-177 155-172 158-175 205-226 190-211 192-212 248-274 230-254 155-172 160-177 210-225 205-220 299-326 288-323 309-337 319-348 305-333

29 31 35 31 32 32 33 37 43 45 45 39 40 37 42 41 44 44 24 25 27 28 32 33 35 37 32 33 32 34 36 42 40 41 41

10,0 10,0 10,0 10,5 10,5 10,5 10,0 10,0 9,5 9,0 9,0 10,0 10,0 10,0 9,5 9,5 9,5 9,5 9,0 8,5 8,0 9,5 8,5 8,0 9,5 8,5 7,0 7,0 8,5 8,0 9,5 8,5 9,5 9,5 9,0

7,5 7,5 7,5 8,0 8,0 8,0 7,5 7,5 7,0 6,5 6,5 7,5 7,5 7,5 7,0 7,0 7,0 6,5 6,5 6,0 5,5 7,0 6,0 5,5 7,0 6,0 4,5 4,5 6,5 5,5 7,0 6,0 7,0 7,0 6,5

4,42 4,76 4,12 4,0 4,0 4,04 4,0 4,6 4,84 4,8 4,84 4,94 5,02 4,70 4,82 4,78 5,02 4,76 3,38 3,28 3,36 4,32 4,04 4,06 3,92 4,84 3,28 3,38 4,36 4,26 6,0 7,0 2,45 2,5 2,4

19,6 29,5 69 186 393 590 785 41 61 81 122 264 445 610 900 1140 1425 1630 354 452 707 628 800 1257 940 1260 1000 1150 1700 2000 1250 2890 1140 1425 1730

36-44 49-59 80-96 69-85 74-90 65-79 49-60 60-73 75-92 72-88 76-92 80-98 84-102 68-63 74-91 64-78 62-76 46-56 28-34 21-26 17-21 33-41 26-35 24-30 43-54 30-39 17-21 16-20 27-32 18-22 75-92 66-75 64-78 54-68 42-50

0,77 1,15 1,33 2,78 3,72 4,85 5,73 1,64 2,16 2,57 3,06 4,25 5,64 7,02 8,8 10,65 13,15 14,35 1,9 2,04 2,44 3,52 3,51 4,0 6,11 6,75 3,06 3,5 4,75 5,33 7,95 12,6 10,8 12,5 13,8

68 78 88 123 143 164 175 88 92 96 105 136 155 175 185 203 222 225 113 115 124 148 140 147 175 172 120 127 165 170 230 260 200 218 224

16-40 40-64

150

16 16

16-40 150 40

50

64

160 64 80 160 100 64

50 160 80 160

200

16

150

40

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Continuation of chart 5.4.

1. Spring MATERIAL grade 50 as per GOST 14959 69 2. All the springs shown in the chart are made at Blagoveshchensk Valve Plant. 3. Springs that are used in earlier models of valves and so not enrolled in the chart are tested as per analogue to the directions of the current instruction.

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Chart 5.5.

Port area and engineering pressure of spring Pressure Safety Valves flanged connections. Port area of a valve and inlet nozzle, mm 50 80 100 150 Seat size 17 30 40 50 72 142

Valve type

Pe of a valve body and inlet nozzle

25

200

4 4

16 40 64 160

6-40 16-40 -/-/-

Inlet nozzle pressure size rating 6-200 6-125 6-100 6-80 16-200 16-125 16-100 16-80 40-80 40-80 40-100 40-100 40-125 -/-/-/-

6-300 -/-/-/-

Note: PSVs flanges sealing surfaces are made of the following shape: 1. Inlet flange: for 16 kgf/cm2 raised face as per GOST 12821-67 for 40 kgf/cm2 female as per GOST 12822-67 for 64 kgf/cm2 RTJ ring as per GOST 12825-67 for 160 kgf/cm2 RTJ ring as per GOST 12825-67 2. Outlet flange: for 6 kgf/cm2 raised face as per GOST 1235-67 for 16 kgf/cm2 raised face as per GOST 12821-67 for 40 kgf/cm2 male as per GOST 12822-67

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