Professional Documents
Culture Documents
Procedures
Of 28
Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification
Procedures
CONTENTS
1.0
Page
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
2
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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
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Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification
Procedures
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
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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Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification
Procedures
2.2
Safety Requirements
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
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
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Pressure Safety Valves Inspection, Testing, Re - Calibration, and Certification
Procedures
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
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, 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
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
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
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
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
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
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
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
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
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
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
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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
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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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)
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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
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Appendix C
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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Procedures
Appendix D
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Procedures
Appendix E
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
NAMES
1-No finding
02ED
2-Erroneous data
02ID 2-Lack of
Identification/marking
03ED 3-Erroneous data
03ID 3-Lack of
Identification/marking
DIRTYS
1-Clean
02CT 2-Clogged/Plugged
02DD 2-Debris/Deposits
(sand, sludge, wax...)
02SC
2-Scales
03CT
3-Clogged/Plugged
03DD 3-Debris/Deposits
(sand, sludge, wax...)
03SC
3-Scales
04CT
4-Clogged/Plugged
04DD 4-Debris/Deposits
(sand, sludge, wax...)
PSDBS
04SC 4-Scales
(Check the general condition
of the valve body)
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
PSDIS
STATUS
STATUS
BPM
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Procedures
Appendix G
Date:
Ref:
VALVE DETAILS
Manufacturer:
Type (Pilot):
Type (Main Valve):
Tag No:
Serial No (Pilot)
Serial No(Main Valve)
Set Pressure:
PRE-POP REPORT
Test Medium:
Pre-Pop pres./Blow-off pres. first lift:
Subsequent Lifts
Not pre-pop, why?
Carried out by:
Sign:
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
EPNL SERIAL
NUMBER
(TICK IF TRUE)
VALVE ORIGINATED
FROM:
28 Of 28
EPNL SERIAL
NUMBER