Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures

PROCEDURES FOR PRESSURE SAFETY VALVES

INSPECTION, TESTING, OVERHAULING, RE-CALIBRATION AND CERTIFICATION

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 Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
CONTENTS Page

1.0 Introduction 3
1.1 Scope 3
1.2 Definitions of Terms 3
1.3 Inspection And Recalibration Plan 5
2.0 Pressure Testing Requirements 5
2.1 Repair/Overhaul Requirements 6
2.2 Safety Requirements 6
2.3 Cleanliness 6
2.4 Personnel Qualification 7
3.0 PSV Testing and Recalibration Procedures 7
3.1 Introduction 7
3.2 As-Received, “Pre-pop” Test 7
3.3 Dismantling, Inspection and Overhauling of PSVs 8
3.4 Conventional (Spring Loaded) Safety Relief Valves 8
3.4.1 Cold Set Pressure Test 8
3.4.2 Seat Tightness Test 9
3.4.3 Body Leak Test 9
4.0 Pilot Operated Valves 10
4.1 Inspection Testing Repair and Setting of Pilot – Operated Valves 10
4.2 Types of Pilot Operated Valves 10
4.3 Definition of Terms for Pilot Operated Valves 10
4.4 Test Procedures 11
4.4.1 Introduction 11
4.4.2 Test Procedure Set Up 11
4.4.3 Set Pressure Adjustment 11
4.4.4 Reseat Adjustment 11
4.4.5 Performance Check – Relieving Pressure 11
4.4.6 Performance Check – Dome Pressure 11
4.5 Leakage Test 12
4.5.1 Leak Test Procedure – Complete Valve Assembly 12
4.5.2 Low Pressure Leakage Check 12
4.5.3 Pressure Leakage Check 12
4.5.4 Main Valve Function Check 13
5.0 Inspection and Replacement of Rupture Disks 13
6.0 Inspection and Testing of Pressure and/or Vacuum Vent Valves 14
7.0 Location Security 15
8.0 Reporting and Certification 15
8.1 Reporting 15
8.2 Certification 15
Appendix A: Annotated Schematic Drawing of Pressure Safety Devices
Appendix B: API 527 Maximum Seat Leakage Rates for Metal – Seated PSVs
Appendix C: Example of Pilot Valve Performance Requirements (Gas or Liquid Service)
Appendix D: Example of Pilot Valve Performance Requirements (Snap Action)
Appendix E: Example of Pilot Valve Performance Requirements (Modulating Action)
Appendix F: Pressure Safety Valve Overhaul Report Format
Appendix G: Pressure Safety Valves Test Certificate and Calibration Report Format
Appendix H: Movements Report for Pressure Safety Valves

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 Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
1.0 Introduction

Pressure Safety Valves are safety critical components and are covered by national legislation
(MOSR, 1997) and company general specification GS EXP 211- Plant Integrity Minimum
Inspection Requirements (Section 3.8) for periodic in - service inspection and calibration.

The service conditions of pressure safety valves vary widely and so exist in different areas of
the process criticality matrix. However, unless a formal Risked Based Inspection approach is
adopted, (which decision may be taken in the future by Head of Asset Integrity), all pressure
safety valves are inspected and recalibrated after not more than 30months in service ( per
MOSR, 1997) or after any lifting and /or passing during normal service conditions.

1.1 Scope
This procedure specifies EPNL’s general requirements for inspection, testing, overhauling,
repairs and recalibration of PSVs at Test Room/Workshops. However, it shall be
supplemented by a number of work instructions (WIs).
Coverage is limited to conventional spring loaded; balanced bellows; pilot operated devices;
rupture or busting disk; thermal expansion relief valves and vacuum breakers which forms
majority of protective devices used in EPNL.
(Hydraulic spill valves, integral to pumps, are not considered to be PSV’s. These shall be
maintained along with their associated equipment)

1.2 Definitions of Terms

Relief Valve:
A relief valve is a spring-loaded pressure relief valve actuated by the static pressure upstream
of the valve. The valve opens normally in proportion to the pressure increase over the
opening pressure. A relief valve is primarily used for liquid service.

Safety Valve:
A safety valve is a spring-loaded pressure relief valve actuated by the static pressure
upstream of the valve and characterized by rapid opening or pop action. A safety valve is
normally used for gas or vapour service.

Safety Relief Valve:

A safety relief valve is a spring-loaded pressure relief valve that may be used as either a
safety or relief valve depending on the application.

Pressure Relief Device:

A pressure relief device is actuated by inlet static pressure and designed to open during an
emergency or abnormal conditions to prevent a rise of internal fluid pressure in excess of a
specified value.

Conventional Pressure Relief Valve:

A conventional pressure relief valve is a spring- loaded pressure relief valve whose
performance characteristics are directly affected by changes in the back pressure on the
valve.

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 Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
Balanced Pressure Relief Valve:
A balanced pressure relief valve is a spring loaded pressure relief valve that incorporates a
means for minimizing the effect of back pressure on the performance characteristics.
Pilot Operated Pressure Relief Valves:
A pilot operated pressure relief valve is a pressure relief valve in which the main valve is
combined with and controlled by an auxiliary pressure relief valve.

Cold Differential Test Pressure:

Cold differential test pressure is the inlet static pressure at which a pressure relief valve is
adjusted to open on the test stand. This test pressure includes corrections for service
conditions of back pressure and/or temperature.

Popping Pressure:
Popping pressure is the value of increasing inlet static pressure at which the disc moves in
the opening direction at a faster rate as compared with corresponding movement at higher or
lower pressures. It applies only to safety or safety relief valves on gas or vapour service.

Overpressure:
Overpressure is a pressure increase over the set pressure of a pressure relief valve, usually
expressed as a percentage of set pressure.

Set Pressure:
Set pressure is the value of increasing inlet static pressure at which a pressure relief valve
displays one of the operational characteristics as defined under "opening pressure”, “popping
pressure”, or “start-to-discharge pressure” depending on service or as designated by the
applicable code or regulation. It is one value of pressure stamped on the pressure relief valve.

Reseating Pressure:
Reseating pressure is the value of decreasing inlet static pressure at which the valve disc re-
establishes contact with the seat or at which lift becomes zero.

Lift:
Lift is the actual travel of the disc away from closed position when a valve is relieving.

Blow-down:
Blow-down is the difference between the set pressure of a pressure relief valve and actual
reseating pressure expressed as a percentage of the set pressure.

Back Pressure:
Back pressure is the static pressure existing at the outlet of a pressure relief device due to
pressure in the discharge system.

Thermal Expansion Relief Valve:

A Thermal expansion relief valve is a device releasing hydrocarbon trapped inside a capacity
(usually a pipeline section) submitted to heat input in order to maintain pressure below design
pressure. The acronym TSV is used.

Bursting or Rupture Disk:

Rupture disk or bursting disk it is a type of sacrificial blind spade designed to burst at a certain
level of pressure contained in the sensitive element to protect.

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Vacuum Relief Valve:
A Vacuum Relief Valve is a Pressure Relief Device designed to admit fluid to prevent an
excessive internal vacuum; it is designed to re-close and prevent further flow of fluid after normal
conditions have been restored.

EPNL Serialisation Numbers:

This is a six digit number generated by UNISUP (SAP) to track PSV’s movement since they
are not treated as a functional location, but as equipment. For PSVs not bearing this number,
it has to be requested for the Asset Integrity Section’s Technical Clerk and hard stamped on
the flange of the PSV before overhaul or recalibration.

1.3 Inspection And Re-calibration Plan

A “general” Inspection and recalibration programme of all PSVs due for inspection and
recertification shall be issued by the Asset Integrity Section from SAP to the General
Maintenance Contractors (GMC). This shall be defined for a rolling twelve months on a
monthly basis.

A “detailed” rolling twelve months’ Inspection and recalibration programme of all PSVs must
be provided by the relevant GMC monthly for EPNL approvals by Maintenance and Asset
Integrity.

The plan shall be sent to:

 DGM’s JV Onshore/Offshore
 Field Operation Managers, Onshore/Offshore
 Methods Managers, Onshore /Offshore
 Respective Site Managers (RSES)
 Head of Process / Treatment Onshore/Offshore
 Head of Maintenance Onshore/Offshore
 Head of Asset Integrity
 Senior Integrity Methods Engineer

2.0 Inspection and Testing Requirements

2.1 Selection of Sub-Contractors and Personnel

Testing, calibration, and certification of EPNL’s PSVs shall only be carried out (in shop or on
site) by a Contractor who has the “Special Category” Permit to operate as an Oil Industry
Service Company, awarded by the Department of Petroleum Resources (DPR) and who has
been approved by EPNL after an audit visit (by Total HSE and Integrity Sections) to check for
compliance of facilities and Procedures to TOTAL’s Standards.

The respective site GMCs shall make available to EPNL a list of proposed Valve Technicians
from each Contractor for approval.
In addition to excellent safety orientation, personnel shall have acquired adequate technical
knowledge and practical experience in the related duties. He/she should be able to carry out
calibration, overhauls and testing of valves according to approved procedures and
manufacturer’s recommendations.

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2.2 Safety Requirements

Adequate measures shall be taken to protect personnel against possible hazards.

These must include, but not be limited to:

 Barriers/shielding must be considered, particularly for high pressure gas tests

 Using properly inspected, calibrated and certified testing components, e.g. pumps,
compressors, pressure control devices, piping system, pressure hoses, and pressure
gauges etc.
 Positioning the valve discharge nozzle to prevent exposure of personnel to a sudden
blast of air, water, or other projectiles from the valve.
 Utilisation of personal protective equipment e.g. ear defenders, eye goggles, safety
boots, etc.
 Not attempting to test valves at pressures above that for which the test bench is
designed.

2.2 Testing, Overhaul and Re-certification Equipment

The following minimum provisions shall be mandatory for carrying out pressure test on valves:
 The test room shall be equipped with pneumatic facilities capable of providing a supply
of air or nitrogen at a pressure above the pressure required for the range of valves to
be tested at the valve test bench.
 There shall be hydraulic facilities for the hydraulic testing of valves.
 Quick change adaptors for different sizes of valves.
 All necessary fixtures, fittings and tools required for the test set up.
 Calibrated and fully certified pressure gauges adequate for the working range pressure
(Gauge range should be maximum of three times the test pressure).
The frequency of calibration shall not exceed one year and the calibration certificates
shall be available at all times for sighting.

In addition, the testing facility shall be equipped with the equipment and tools listed below as
a minimum for overhaul and repairs of metal seated and soft-seated valves.
 A Standard test bench fitted with all necessary accessories
 Lapping machine and accessories.
 Lapping stones.
 Surface plates.
 Grinding kit.
 General hand tools.
 An optimum stock of repair kits for replacement of spare / soft goods i.e. soft seats,
seals, gaskets, etc which should be available before removal of the valve from situ
 Test fluid to be employed should be filtered.

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3.0 PSV Testing and Recalibration Procedures

3.1 Introduction
It is mandatory that an EPNL representative and DPR personnel must be afforded the
opportunity to witness the dirty inspection / pre-pop and overhaul of PSVs.

For a valve in Gas service, the test medium must be Nitrogen or dive-quality air (or other gas
as specified). A valve in liquid service can be tested by liquid or gas.
Prior to testing, the test equipment should be blown out with dry, high pressure air to remove
any dust or particles which may have accumulated. The final testing shall be witnessed by
personnel from EPNL’s Integrity Section and DPR

Note: Currently, DPR require 14 days’ notice, in writing, for planned PSV re-certification.

3.2 As-Received, “Pre-pop” Test

The valve shall be “pre-popped” to determine how it would have performed in service.
If heavy fouling of the valve is observed, it should be considered whether a pre-pop would
damage the valve, in which case the pre-pop can be waived, but such a decision must not be
taken lightly as it is very important to know how the valve would have performed in service.
The nature of the fouling must be investigated (initiated by the Site Integrity Engineer) and
measures taken to prevent future re-occurrences

The inlet side of the valve to be tested should be carefully cleaned to ensure that there is no
dirt, dust or loose particles adhering to the inside of the nozzle or the underside of the disc.

A satisfactory test is one were the valve lifts within -10% and +5% of the CDTP. This test is
done by mounting the PSV on the bench test block and slowly increasing the pressure on the
valve. The relieving pressure is determined by watching a pressure gauge and noting the
point at which the valve pops or relieves.

However, if the valve does not pop before reaching an inlet pressure of 120% of the CDTP,
the test shall be aborted and the valve considered as stuck shut (failed to lift).
This failure to lift shall be directed to the Head of Asset Integrity for further
investigation on a case-by-case basis.

Notes:
 1) Valve Previously in Service: - If, initially, the valve opens at between 105% and 120%
of the CDTP, it shall be popped for a second time to assess how it could have performed
in service. If the second test falls between 90% and 105% of the CDTP, then both
readings are recorded and the test is deemed to be acceptable

 2) New Valve: - To be pre-popped 3 times.

1st Test; - For alignment (can rectify any out-of-alignment from transporting)
2nd and 3RD Tests:- to prove repeatability. The 3rd value is recorded as the value set for
service

The “As-received” tests results shall be recorded on testing report form, Appendices F and G.
An acceptable pre-pop is one where the final lift falls within the limits set pressure tolerances
specified in 3.4.1 below.

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3.3 Dismantling, Inspection, and Overhauling of PSVs

The valve shall be carefully dismantled in accordance with manufacturer’s manuals and
recommendations. At each stage in the dismantling process, the various parts of the valve shall
be visually inspected for evidence of wear, deformation and corrosion.

After dismantling, each part shall be cleaned and examined for wear, corrosion or damage.
Seating surfaces on the disk and nozzle shall be inspected for roughness or damage which
might result in valve leakage. The spring should be checked for evidence of cracking or
deformation. The fit between the guide and the disk or disk holder should be checked for proper
clearance and visually inspected for evidence of scoring. The bellows in balanced-type valves
should be checked for cracks or other failures that may affect performance. The details of this
inspection, including general internal and external condition, shall be recorded in the PSVs
Overhaul Report Sheet and the test certificate and report. See Appendices F and G.

Parts that are worn or damaged must be replaced or reconditioned. Damaged springs or
damaged bellows must be replaced. Replacement parts shall be obtained from the original
manufacturer of the Pressure Relief Valve. The seating surface of the disc and nozzles may be
machined or lapped if evidence of wear or damage is found. Seats lapping shall be carried out
according to the manufacturer’s recommendations and procedures by using proper lapping
blocks and correct lapping compound grades.

After the valve has been inspected and re-conditioned, it must be re-assembled in accordance
with the manufacturer’s instructions. Once the re-assembly is completed, the Pressure Relief
Valve is ready to be tested according to the procedures described hereafter.

Note for Valves Which Have Been Passing in Service: Where possible a repair kit should be
used for a valve which has been passing in service. If a new kit is used the next recertification
date is from the date of fitting; if a new kit is not used and / or the passing valve has not been
overhauled, the next date of inspection runs from the previous full recertification

3.4 Conventional (Spring Loaded) Safety Relief Valves

3.4.1 Cold Set Pressure Test

The valve shall be mounted on the test bench in the vertical position and air pressure slowly
applied to the valve inlet for cold set pressure taking into consideration correction factors for
temperature and back pressure based on the manufacturer recommendations. Valve upper
and lower blow-down rings, where fitted, shall be adjusted as recommended by the valve
manufacturer. This procedure shall be repeated until the required cold set pressure is
obtained.

When the correct cold set pressure is obtained, the valve pops (lifts) and this should be within
the set pressure tolerances specified by below. It is mandatory to verify that the obtained cold
set pressure has remained unchanged by repeating the test – first for alignment, second and
third for repeatability. The value of the third lift shall be recorded in the test report.

 ±2 Psi (±0.13 Bars) for pressure up to and including 70Psi (4.8 Bars)
 ±3% of set pressure for pressure above 70Psi (4.8 Bars)

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The cold set pressure and spring adjustment shall be recorded and entered on the Test
Certificate (See Appendix G). It is recommended that spring adjustment is measured with
reference to the top face of the bonnet and not the top surface of the lock nut.

3.4.2 Seat Tightness Test

Following a successful cold set pressure test, the valve shall be fitted with a suitable flange at
its outlet orifice to test for tightness. This flange has a hole in the centre to take a “bubble test
pot” built to API Standard 527 (see figure 6).

With the valve on the test bench in the vertical position, test pressure is adjusted to 95percent
of the cold set pressure for valves whose cold set pressure is greater than 1015 Psi (70 Bars)
and the leakage rate in bubbles per minute (BPM) determined.

For valve set between 1015 Psi (70 Bars) and 50 Psi (3.45 Bars), the test pressure shall be
adjusted to 90percent of the cold set pressure and the leakage rate in bubbles per minute
(BPM) determined.

For valves set at 50psi or less, the test pressure shall be held at 5psi below the cold set
pressure immediately after popping and leakage rates in bubbles per minute determined.

Seat tightness test for Metal Seated valves are considered acceptable if leakage rates fall
within limits specified by API Standard 527. See Appendix B.
Notes:
1. The valve Technician must be able to determine the orifice size to apply the relevant
acceptable BPM
2. It is permissible to release the pressure and then increase to 90% cold differential set
pressure (CDSP)

3.4.3 Body Leak Test

With the valve remaining on the test bench an appropriate flange is fitted to its outlet and
static test pressure is applied through the outlet flange. This pressure is equal to the valve
outlet flange rating or allowable back pressure whichever, is less.
With pressure being maintained a soapy solution is applied to all the body and bonnet joints
to check for leaks. Test duration between 2-3 minutes.

For bellows fitted valves, the bellows tightness is tested by applying a low pressure (1 bar)
through the valve outlet flange. A check for leaks using a soapy solution is then carried out to
the bonnet vent hole, the blow-down ring adjustment screw connections and the bonnet
flange joint. On satisfactory completion of the above tests the valve upper and lower blow
down rings, where fitted, are to be checked with reference to their initial setting. If any
difference is observed readjustment is to be made as advised by the manufacturer.

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4.0 Pilot Operated Valves

This section establishes the general procedure for assembly, functional testing and normal
performance requirements of pilot operated safety-relief valves. However, because of the
many types of pilot operated valves available, the valve manufacturer’s recommendations for
inspection, repair and testing for the specific valve should be consulted and followed.
(Refer Appendices C, D & E for examples illustrating some of the numerous differences
between pilot operated valves).

4.1 Inspection, Testing, Repair and Setting of Pilot – Operated Valves

Inspection, testing, maintenance, and setting of the pilot mechanism may be handled
separately from the main valve.
The pilot gets tested and re-certified. As a minimum the pilot valve shall be pre-popped,
stripped, examined, cleaned, re-built, calibrated and recertified following valve manufacturer’s
recommendations for inspection, repair, and testing.
The main valve gets inspected:- As a minimum, the integrity engineer carries out a visual
inspection of the main valve inlet and outlet (bearing in mind the specific service) and a visual
of the tie-in piping for cleanliness, fouling, corrosion, etc.
If no problems are observed, the valve can be re-installed, using new gaskets.

Many of the considerations that apply to other pressure relief valves also apply to pilot
operated valves. The following is a list of additional considerations that apply:
 Inspect soft goods (O – rings, diaphragms, gaskets)
 Check for plugging in pilot assembly and external tubing
 Check for material trapped in valve dome area
 Check all tubing fittings for leakage
 Inspect the pressure pick-up device and its orientation

4.2 Types of Pilot Operated Valves

There are two different types of pilot operated valves

• Snap Action (Rapid full Opening and Closing)
• Modulating Action ( Opens proportionally to the over pressure)

4.3 Definition of Terms for Pilot Operated Valves

Set pressure is that pressure at which the pilot valve relieves on increasing inlet pressure to
reduce the dome pressure to 70% or less of supply. On snap action pilots the dome pressure
will decrease very rapidly. For modulating action pilots, the dome pressure will decrease in
proportion to the rate of increase in supply pressure.

Cracking pressure is that inlet pressure at which first leak occurs at the pilot exhaust port on
increasing pressure.

Reseat pressure is that pressure where the dome pressure increases to 75% or more of
supply. For "pop" action pilots this pressure is usually 90% to 92% of set pressure. On
modulating action pilots, it will be 96% to 100% of set pressure.

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Reseat leakage is the leakage across the pilot valve seat at reseat pressure. For snap action
pilots this leakage should be zero at reseat. On modulating action pilots, leakage will occur
until the supply pressure has decreased to the amount specified in the performance
requirements, usually 90% to 95% of set pressure.

Dome pressure is the pressure at the dome connection of the pilot valve.

4.4 Pilot Operated Valves: Test Procedures

4.4.1 Introduction
The test medium shall be shop air or nitrogen at ambient conditions for all main valves and all
gas service pilots, unless otherwise specified. Pilots for liquid service may be set on water.
Full scale of the gauge used shall not be greater than three times set pressure.

All pilot valve assemblies shall be tested to make sure the correct dome pressure is obtained
to operate the main valve. The pilot supply pressure and dome pressure shall be recorded on
the test certificate and report (See Appendix G).

4.4.2 Test Procedure Set Up - Pilot

The following procedures shall be used to test the pilot valve, using air or nitrogen at ambient
temperature as the pressure medium for gas service pilots and water for liquid service pilots,
unless otherwise specified.

Install the pilot valve on a test drum per Figure 4 and 5. The "dome" connection is a blind
connection with a pressure gauge to indicate dome pressure reduction at set pressure.

4.4.3 Set Pressure Adjustment

Adjust the spring adjusting screw to obtain the correct set pressure. Clockwise rotation
increases the set pressure. Tighten the locknut after adjustment is completed.

4.4.4 Reseat Adjustment

On all pilots except modulating pilots, adjust the blow down adjustment screw to obtain the
desired reseat pressure. Tighten the locknut after adjustment is completed.
Note: The reseat value of the main valve with internal pressure pickup for the pilot will be
approximately 3% to 4% less than the reseat value of the pilot only on snap action pilots due
to the pressure loss in the dipper tube.

4.4.5 Performance Check - Relieving Pressure

Cycle the pilot a minimum of three times to make sure it is relieving and reseating at
consistent pressures. Increase the pressure very slowly in order to obtain an accurate
reading of the relieving pressure and to detect any erratic performance.
Note: Each step shall be completed before proceeding to the next step.

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4.4.6 Performance Check - Dome Pressure

Flow the pilot valve except at the set pressure to obtain the dome pressure reading. If
sufficient gas capacity is not available to flow the pilot at the set pressure, read the lowest
dome pressure at the time of reseat. This method is not applicable for modulating pilots. For
the no-flow modulating pilot, increase the supply pressure to 110% of nameplate set. The
dome pressure must decrease to less than 40% of the supply.

4.5 Leakage Test

For gas service pilots, leakage shall be detected using a bubble tube tester of the type shown
in Figure 6. For liquid service pilots, leakage shall be detected visually.

Slowly increase the pressure at the inlet port until leakage is detected at the pilot exhaust
port. This pressure shall be recorded as the cracking pressure.

Further increase the pressure at the inlet port until the pilot actuates or "pops". This pressure
shall be recorded as the set pressure. For the no-flow modulating pilot, no leakage at the
pilot exhaust should occur with inlet supply pressure held constant and the dome pressure
has stabilized.

Shut off the inlet pressure to the test accumulator and allow the pilot to reseat. This pressure
shall be recorded as the reseat pressure. For modulating pilots, reduce the inlet pressure of
the test accumulator in accordance with the specified reseat pressure. Check the valve for
leakage at the exhaust port.

Repeat the steps above a minimum of three times. The cracking pressure, set pressure and
reseat pressure shall be within the limits for three consecutive cycles. The valve action shall
be consistent.

Slowly increase the inlet pressure until the leakage test pressure is reached. Maintain this
pressure for one minute and check for leakage at the exhaust port and at the blow down
adjustment. No leakage shall occur.

4.5.1 Leak Test Procedure - Complete Valve Assembly

Completely assemble the pilot on the main valve. Connect the main valve inlet to a pressure
source as shown in Figure 3. Shop air at ambient temperature shall be used as the test
medium unless otherwise specified. For liquid service valves, a leakage at the pilot exhaust
not to exceed 60 bubbles/minute is acceptable if no leakage occurred when tested on water.

4.4.2 Low Pressure Leakage Check

Slowly increase the inlet pressure to 30% of the set pressure. Check for main valve nozzle,
seat, and piston seal leakage at the main valve outlet. No visible leakage shall occur in 15
seconds. To help in seating the valve seat and piston seal, the valve may be actuated
several times.

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4.4.3 Pressure Leakage Check

Apply pressure to the inlet equal to 90% of the set pressure. Check for leakage at the main
valve outlet. Using a suitable gas and air leak detector solution, check for leakage at the cap
seal and other pressure connections. No leakage shall occur at the valve outlet and no
visible leakage shall be detected at the cap seal or other pressure connections in one minute.
Where superimposed back pressure is specified, the downstream or exhaust connections
which are exposed to the back pressure shall be tested at 1.5 times the specified back
pressure and all mechanical connections so pressurized will be checked for leaks. No visible
leakage shall occur in one minute using a suitable gas and air leak detector solution.

4.4.4 Main Valve Function Check

Caution: This test must be performed at a slow rate of pressure increase to insure that the
main valve does not go into full lift. The pressure applied to the inlet is not to exceed 105% of
nameplate set pressure.

After completing the high pressure leakage check, verify main valve opening as follows.
Remove the bubble tube leakage tester from the outlet flange and slowly increase the inlet
pressure above 90% of set pressure. Continue increasing inlet pressure until an audible
discharge at the valve outlet verifies main valve opening.

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5.0 Inspection and Replacement of Rupture Disks

Rupture disks are used in services where a large relieving capacity is required to give a rapid
drop in pressure. The disks are made from a wide variety of metallic and non-metallic
material. Rupture disks may be inspected visually.

Rupture Disks should be thoroughly inspected after removal from their operational location.
Inspection should include a check of flanges for leakage and a check of the disk for fatigue,
corrosion, failure, and build up of coke or other foreign material that could adversely affect the
disk’s performance. They should be renewed as required, based on their reliability and
condition.

Because they cannot be tested, Rupture Disks should be replaced on a regular schedule
based on their application, the manufacturer’s recommendations, and past experience. This
recommendations and schedule must be provided by the Maintenance Department.

If a block valve is located ahead of the disk, the block valve should be locked open during
operation. If replacement of the disk is necessary, the block valve should be locked closed
until disk installation has been accomplished. Normally in this case, a rupture disk cannot be
inspected without being removed. Therefore, inspection of the disk should be part of the
routine developed for inspection of the Pressure Relief Valves.

A rupture disk installed upstream of the relief valve to prevent valve corrosion is normally set
to burst either at the set pressure of the Pressure Relief Valves it is protecting or at a
pressure 3 % – 5 % less than the set pressure.

Caution: The relief valve must be designed so that it will not fail to open at its proper pressure
setting regardless of any backpressure accumulated between the valve disk and the rupture
disk. If backpressure builds up between an ordinary spring-loaded safety relief valve and a
rupture disk, the valve will not open at its set pressure. In this case, the valve should be
replaced by a specially designed valve such as a diaphragm valve equipped with a bellows
above the disk.

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6.0 Inspection and Testing Of Pressure and/or Vacuum Vent Valves

The relieving devices on tanks may be separated into pressure and/or vacuum relief devices
on atmospheric tanks and PSVs on pressure storage vessels. The inspection, testing,
maintenance, and setting of relieving devices on pressure storage tanks are similar to those
of PSVs on process equipment. Pressure and/or vacuum vent valves on atmospheric tanks
are designed to vent air and vapour from the tank during filling operation and to admit air
when the tank is drawn down. Because pressure and/or vacuum vent valves are in
continuous service, they are prone to failure by sticking unless examined periodically.

The inspection of each vent valve in place should include the checking of the discharge
opening for obstructions. The top of the valve should be removed and the pallets checked for
freedom of movement. Seats should be checked to ensure that there is no sticking or
leakage, since the forces actuating the valve are small. If the valve has a flame arrester on
the inlet nozzle, it should be inspected for excessive fouling or plugging. If necessary, it
should be removed for cleaning.

Caution: Inspection of the flame arrester in service is important because any malfunction may
result in the loss of expensive equipment. Inspection, testing, maintenance, and setting of
pressure and/or vacuum vent valves should include the following special steps:

• Sticking should be corrected and prevented. The disks (pallets) of the devices should be
checked for sticking. If the disks are stuck, the product’s effect on the seal material and on the
disk material should be investigated. If necessary the seal material and the disk material
should be changed.
• The disk should be checked and maintained. Once a disk is removed, it should be cleaned,
and its mass should be determined. Check the mass against the mass required for the
correct relieving pressure of the device. [The setting of a pressure-vacuum device depends
on the mass of the disk compared to the area of the opening covered by the disk. Set
pressure is usually a standard ½ ounce per square inch (0.43 kPa), but may go as high as
24 ounce per square inch (10.43 kPa)] If the mass is not correct, mass must be added or
removed until the correct mass has been achieved. Disk condition and serviceability should
be checked, and unusable disks should be replaced.
• The seats and pallets of the disk seating areas must be checked and cleaned.
• The gaskets at the disk seating areas must be checked and, if necessary, replaced.
• The protective screens must be checked for serviceability and, if necessary, renewed.
• Hinges and hinge pins must be checked for operability and, as necessary, serviced,
lubricated, and replaced.
• Any special coating used internally or externally on the body should be checked and, if
unserviceable, replaced.
• The hood should be inspected and, if unserviceable, replaced.
• The bolts should be checked and, as required, replaced.

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 Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
7.0 Location Security

Every adjustable part of the valve shall be double-checked for correct location and positioning
after testing. On completion of all works, on any type of valve, the spring adjustment must be
secured by copper wire and a crimped lead seal

8.0 Reporting and Certification

8.1 Reporting

Reporting is to provide all related information for the tested valve as contained in appendices
B and C i.e. the as-received conditions; details of overhaul work performed, test results, etc.
Minimum information required should include:
 EPNL Number
 The "as-received" condition of the valve, and the pre-pop pressure.
 Details of the inspection and repair/overhaul work performed.
 Condition of the valve following overhaul and/or re-setting.
 Final pressure test results in figures i.e. cold set pressure, bubbles/minute, and spring
adjustment (MM) position of blow down ring(s) etc.
 A statement that the valve has satisfactorily passed the required tests.
 Other related Valve's information e.g. name plate data, trim details, duty etc. shall be
recorded only once, for registration and inspection purposes. Such information should
be amended, whenever necessary, to indicate any related changes, or modifications.

8.2 Certification

Final tests of valves performed by approved contractors shall be signed off by Valve
Technician and personnel from DPR and EPNL’s Asset Integrity Section who witnessed the
test. The signed off Test Certificate and Calibration Reports shall be in quadruple copies.
These copies shall be distributed as follows: Asset Integrity Office Copy, Field Copy,
Contractor’s Copy and DPR’s Copy

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Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
Appendix A
Annotated Schematic of Pressure Safety Devices

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Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
Appendix A (contd)

Figure 4 – Bubble test for Pilot Valves

Figure 5 – Set Up for Testing of Pilot Valves

Figure 6 – Bubble Test Set Requirements

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Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
Appendix B

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 Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
Appendix C
PILOT OPERATED SAFETY RELIEF VALVE
STANDARD PERFORMANCE REQUIREMENTS
(GAS OR LIQUID SERVICE)
SET PRESSURE
The set pressure is where the dome pressure equals 70% + 2% of the supply pressure. The
indicator must operate at nameplate set +3%.
Set Pressure ASME Performance Tolerance
Above 70 psig + 3% of the specified set pressure (1)
[Above 483 KPAG]
70 psig & below + 2 psig [13.8 kPa] (2)
[483 KPAG & below]
CRACKING PRESSURE
Set Pressure Cracking Pressure (Min.)
15 - 3705 psig 94% of the specified set pressure
[103-25545 KPAG]
RESEAT PRESSURE
The reseat pressure is where the dome pressure equals 75% + 2% of the supply pressure.
Set Pressure Reseat Pressure
15 - 70 psig 3 psig [20.7 KPAG] below specified set
[103-276 KPAG] pressure
71 - 3705 psig 96% to 100% of the specified set
[283-25545 KPAG] pressure
LEAKAGE TEST PRESSURE
No leakage shall occur for one minute at pressures between 30% of specified set pressure
and the cracking pressure when checked with the supply pressure held constant. At
pressures below 30% of set, the leakage rate for gas service pilots shall not exceed 20
bubbles/minute. For liquid service pilots there shall be no leakage. Pilots shall seal bubble
tight at 5.0 psig [34.5 KPAG] for gas service pilots. For liquid service pilots there shall be no
visible leakage.
DOME PRESSURE TEST
Set Pressure Dome Pressure
15-3705 psig Less than 40% of Supply at 110% of
[103-25545 KPAG] specified set pressure
NOTES: EPNL Recommended Setting Tolerance
(1) Adjust set pressure 0% to 2% above nameplate.
(2) Adjust set pressure 1/2 psig [3.45 KPAG] to 1 1/2 psig
[10.34 KPAG] above nameplate.
(3) For ISO-DOME pilots, adjust regulator for Dome supply to
92% + 2% of nameplate set.

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 Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
Appendix D

PILOT OPERATED SAFETY RELIEF VALVE

STANDARD PERFORMANCE REQUIREMENTS
(Snap Action)

SET PRESSURE
Set Pressure ASME Performance Tolerance
Above 70 psig + 3% of the specified set pressure (1)
[Above 483 KPAG]
70 psig & below + 2 psig [13.8 kPa] (2)
[483 KPAG & below]

CRACKING PRESSURE
Set Pressure Cracking Pressure (Min.)
15 psig & above 95% of the specified set pressure
[103 KPAG & above]
Below 15 psig 92 1/2 % of the specified set pressure
[Below 103 KPAG]

RESEAT PRESSURE
Set Pressure Reseat Pressure (3)
15 psig & above 92 1/2% + 1% of the specified set pressure
[103 KPAG & above]
Below 15 psig 92 1/2% + 1% of the specified set pressure
[Below 103 KPAG]

LEAKAGE TEST PRESSURE

There shall be no leakage for one minute at pressures below the cracking pressure or at the
reseat pressure.

DOME PRESSURE TEST

The dome pressure shall decrease rapidly, as with a snap and shall not exceed 20% of the
inlet pressure while the pilot valve is venting at the specified set pressure.

NOTES: EPNL Recommended Setting Tolerance

(1) Adjust set pressure 0% to 1% above nameplate.

(2) Adjust set pressure 0 psig to 1 psig [0 to 6.89 KPAG] above nameplate.
(3) To be checked with pilot flowing.

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 Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
Appendix E

PILOT OPERATED SAFETY RELIEF VALVE

STANDARD PERFORMANCE REQUIREMENTS
(Modulating Action)
(Gas or Liquid Service)
Set Pressure
The set pressure is where the dome pressure equals 70% + 2% of the supply pressure. The
indicator must operate at nameplate set +3%.

Set Pressure ASME Performance Tolerance

Above 70 psig + 3% of the specified set pressure (1)
[Above 483 KPAG]
70 psig & below + 2 psig [13.8 KPAG] (2)
[483 KPAG & below]
Cracking Pressure

Set Pressure Cracking Pressure (Min.)

All 95% of the specified set pressure
Reseat Pressure
The reseat pressure is where the dome pressure equals 76% + 2% of the supply pressure

Set Pressure Reseat Pressure

All 99% to 100% of the specified set pressure

Reseat Leakage Pressure (Pilot Seat)

Set Pressure Reseat Pressure (Min.)

All 95% + 1% of the specified set pressure
Leakage Test Pressure
No leakage shall occur for one minute at pressures below the cracking pressure or at the
reseat leakage pressure when checked per 7.2.6.

NOTES: EPNL Recommended Setting Tolerance

(1) Adjust set pressure 0% to 1% above nameplate.
(2) Adjust set pressure 0 psig to 1 psig [0 to 6.89 KPAG] above nameplate.

It is preferable that pilot valves are set separate from the main valve. However, the complete
assembly, main valve and pilot valve, can still be tested on the test bench following the same
procedure.

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 Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
Appendix F

Pressure Safety Valve - Overhaul Report

Note: This is the PSV workbook in Unisup
(Check data, nameplates, tag
NAMES numbers etc)
00ND 0-Inspection Not
Done/Not inspectable
01NF 1-No finding
02ED 2-Erroneous data
02ID 2-Lack of
Identification/marking
03ED 3-Erroneous data
03ID 3-Lack of
Identification/marking
04ED 4-Erroneous data
04ID 4-Lack of
Identification/marking
(Check internals for debris,
DIRTYS scale, clogging etc)
00ND 0-Inspection Not
Done/Not inspectable
Tick Box
Inspection Not Done/Not inspectable
No finding - No action - Any data is correct and up to
date; Name Plate is still in place and data in line with
any documentation
Minor defect - No action - Data discrepancies compared
to equipment drawings, equipment data sheet, PID,
FAME+ or SAP data base
Minor defect - No action - Nameplate is missing; lack of
identification, tag no., PK post, marker, SWL, etc
Defective - Some action required - Data discrepancies
compared to equipment drawings, equipment data
sheet, PID, FAME+ or SAP data base
Defective - Some action required -Nameplate is missing;
lack of identification, tag no., PK post, marker, SWL, etc
Action needed immediately - Data discrepancies
compared to equipment drawings, equipment data
sheet, PID, FAME+ or SAP data base
Action needed immediately - Nameplate is missing; lack
of identification, tag no., PK post, marker, SWL, etc
Inspection Not Done/Not inspectable

01CL 1-Clean Good condition/As new - No action - No significant

Debris/Deposits, Corrosion products.
Minor defect - No action - Clogged/Plugged (Heat
exchanger, Air cooler and Boiler tubes, or PSV nozzle.)
02CT 2-Clogged/Plugged ; not compromising process
02DD 2-Debris/Deposits Minor defect - Minor Debris/Deposits quantity (Any
(sand, sludge, wax...) type/size); not compromising process
Minor defect - No action - Scale; not compromising
02SC 2-Scales process
Defective - Some action required - Clogged/Plugged
(Heat exchanger, Air cooler and Boiler tubes, or PSV
03CT 3-Clogged/Plugged nozzle.); possibly compromising process
Defective - Some action required - Medium
03DD 3-Debris/Deposits Debris/Deposits quantity (Any type/size); possibly
(sand, sludge, wax...) compromising process
Defective - Some action required - Scale; possibly
03SC 3-Scales compromising process
Action needed immediately Clogged/Plugged (Heat
exchanger, Air cooler and Boiler tubes, or PSV nozzle.);
04CT 4-Clogged/Plugged compromising process

04DD 4-Debris/Deposits Action needed immediately - Major Debris/Deposits

(sand, sludge, wax...) quantity (Any type/size); compromising process
Action needed immediately - Scale; compromising
04SC 4-Scales process
(Check the general condition
PSDBS of the valve body)
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 Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
00ND 0-Inspection Not
Done/Not inspectable Inspection Not Done/Not inspectable
01BG 1-Body in good Good condition/As new - No action - Body in good
condition condition
02BE 2-Body externally Minor defect - No action - Body externally
damaged/corroded damaged/corroded
02BI 2-Body internally Minor defect - No action - Body internally
damaged/corroded damaged/corroded
03BE 3-Body externally Defective - Some action required - Body externally
damaged/corroded damaged/corroded
03BI 3-Body internally Defective - Some action required - Body internally
damaged/corroded damaged/corroded
04BE 4-Body externally Action needed immediately - Body externally
damaged/corroded damaged/corroded
04BI 4-Body internally Action needed immediately - Body internally
damaged/corroded damaged/corroded
(Check the condition of the
PSDIS valve components)
00ND 0-Inspection Not
Done/Not inspectable Inspection Not Done/Not inspectable
01IG 1-Internals in good Good condition/As new - No action - All internal parts in
condition good condition
02DS 2-Disc
damaged/corroded Minor defect - No action - Disc damaged/corroded
02MI 2-Miscellaneous parts Minor defect - No action - Miscellaneous internal parts
condition damaged/corroded
02NO 2-Nozzle
damaged/corroded Minor defect - No action - Nozzle damaged/corroded
02SG 2-Spring
damaged/corroded Minor defect - No action - Spring damaged/corroded
03BU 3-Burst disc Defective - Some action required - Burst disc
damaged/corroded damaged/corroded (corrosion, buckling, pinholes.)
03BW 3-Bellow Defective - Some action required - Bellow
damaged/corroded damaged/corroded
03DS 3-Disc Defective - Some action required -Disc
damaged/corroded damaged/corroded
03MI 3-Miscellaneous parts Defective - Some action required -Miscellaneous
condition internal parts damaged/corroded
03NO 3-Nozzle Defective - Some action required - Nozzle
damaged/corroded damaged/corroded
03SG 3-Spring Defective - Some action required - Spring
damaged/corroded damaged/corroded
04BU 4-Burst disc Action needed immediately - Burst disc
damaged/corroded damaged/corroded (corrosion, buckling, pinholes.)
04BW 4-Bellow
damaged/corroded Action needed immediately - Bellow damaged/corroded
04DS 4-Disc
damaged/corroded Action needed immediately - Disc damaged/corroded
04MI 4-Miscellaneous parts Action needed immediately - Miscellaneous internal
condition parts damaged/corroded
04NO 4-Nozzle
damaged/corroded Action needed immediately - Nozzle damaged/corroded
04SG 4-Spring
damaged/corroded Action needed immediately - Spring damaged/corroded
Enter results below
STATUS Blow off pressure first lift Bar

Post Overhaul Results - Blow

STATUS off pressure Bar
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 Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures

Post Overhaul Results -

STATUS Leakage BPM

Enter any comments below

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 Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
Appendix G

Test Certificate and Calibration Report of Pressure Safety Valves

Client: Date:
Work Order/P/Order No: Ref:
Valve Type (Conventional / Pilot / Bellows):
Location/Protecting Equipment:

VALVE DETAILS
Manufacturer: Cold Diff Set Pressure:
Type (Pilot): Inlet Size/Rating:
Type (Main Valve): Outlet Size/ Rating
Tag No: Orifice Size:
Serial No (Pilot) Temperature:
Serial No(Main Valve) Blow down (%Sp)
Set Pressure: EPNL Serial No:

PRE-POP REPORT
Test Medium:
Pre-Pop pres./Blow-off pres. first lift:
Subsequent Lifts Gauge No & Cal. Date:
Not pre-pop, why?
Carried out by: Sign: Date:

GENERAL CONDITION OF THE VALVE BODY

Body Material:
Body General Condition:
State specific defects& if any:

GENERAL CONDITION OF THE VALVE COMPONENTS

Bonnet:
Spring Material; Part number & Condition:
Disc material; Part number & Condition:
Nozzle material: Part number & Condition:
Disc holder:
O-Ring: Guide:
Adjacent screw/nut:
Diaphragm:
Bellows Material:
Burst disc:

GENERAL CONDITION OF THE MATERIAL

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 Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
THICK AS APPLICABLE
Clean

Clogged/plugged
Debris/Deposits (Sand, Sludge, Wax.)
Scales

POST OVERHAUL RESULTS

Set Pressure:
CDSP:
Leakage Test (No. of Bubbles/Min)

CONCLUSION:

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 Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification Procedures
Appendix H

Movements Report for Pressure Safety Valves

Where the original valve is reinstated in its original tag location only Section 1 should be completed.
In all other cases all three sections should be completed.

1. VALVE WAS REINSTATED AFTER RECERTIFICATION

EPNL SERIAL
TAG LOCATION MANUFACTURER'S SERIAL NUMBER NUMBER

2. VALVE WAS NOT REINSTATED AFTER RECERTIFICATION

VALVE WAS MOVED TO: TAG LOCATION - (ENTER TAG NUMBER)

ON-SITE STORE - ( TICK IF TRUE)

EPNL WAREHOUSE - (TICK IF TRUE)

CONTRACTOR'S PREMISES -
(ENTER NAME OF CONTRACTOR)

VALVE WAS SCRAPPED: (TICK IF TRUE)

3. REPLACEMENT VALVE WAS INSTALLED

EPNL SERIAL
MANUFACTURER'S SERIAL NUMBER NUMBER

VALVE ORIGINATED
FROM: TAG LOCATION - (ENTER TAG NUMBER)

ON-SITE STORE - ( TICK IF TRUE)

EPNL WAREHOUSE - (TICK IF TRUE)

CONTRACTOR'S PREMISES -
(ENTER NAME OF CONTRACTOR)

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