QC-PSM-MNL-00-0003

PROCESS SAFETY MANAGEMENT

PRESSURE RELIEVING DEVICE
MAINTENANCE QC MANUAL

REV. 1
03-APR-2010
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TABLE OF CONTENTS
1.

INTRODUCTION ................................................................................................ 2

2.

SCOPE / PURPOSE ........................................................................................... 2

3.

DEFINITIONS ..................................................................................................... 2

4.

ORGANIZATION CHART................................................................................... 3

5.

SCOPE OF WORK ............................................................................................. 3

6.

DRAWINGS AND SPECIFICATIONS ................................................................ 4

7.

MATERIALS AND SPARE PARTS .................................................................... 4

8.

REPAIR AND INSPECTION PROGRAM ........................................................... 5

9.

WELDING, NON-DESTRUCTIVE TESTING & HEAT TREATMENT ................. 5

10.

VALVE TESTING, SETTING AND LEAK TESTING ...................................... 5

11.

PRESSURE GAUGE CALIBRATION ............................................................. 6

12.

CONTROLLED COPIES OF THIS MANUAL ................................................. 6

13.

REPAIR PERSONNEL TRAINING/QUALIFICATION .................................... 6

14.

REPAIR NAMEPLATE AND SEALING .......................................................... 7

15.

RESPONSIBILITIES ....................................................................................... 8

16.

REFERENCES ................................................................................................ 9

Rev.

Issue Date

0
1

03-Apr-2007
03-Apr-2010

Amendment Description
First Release
Periodic Review

Page 1 of 10

Prepared
By:
JIK
Jay

Chkd
By:
DRA
CU

Apprd
By:
KAJ
ABM

QC-PSM-MNL-00-0003

PROCESS SAFETY MANAGEMENT

PRESSURE RELIEVING DEVICE
MAINTENANCE QC MANUAL

REV. 1
03-APR-2010
Page 2 of 10

1. INTRODUCTION
This manual defines the requirements concerning Qatar Chemicals commitment to
meeting the Occupational Safety and Health Associations, OSHA, Process Safety
Management (PSM), Q-Chem Operational Excellence system Element 3.8 and the
requirements of paragraph 6.6 of API 510 - Pressure Vessel Inspection Code
concerning the quality control system for the repair organization of Pressure
Relieving Devices.

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2.

SCOPE / PURPOSE
The primary intent of this document is to serve as a bridging document to specific
Quality Control/Quality Assurance documents that support the servicing,
maintenance, inspection and testing of Pressure Relieving Devices (PRDs). All
types of PRDs are covered by the requirements defined in this document as well as
those documents referenced within this document, as applicable.

This Pressure Relieving Device Quality Control Manual shall be used by all
personnel engaged in the servicing, setting, testing and record-keeping of all
pressure relieving devices at Q-Chem, to ensure that pressure relief devices
are serviced and set in accordance with the Q-Chem guidelines/
procedures/policies and with the applicable Sections I or VIII of the ASME
Code, API Code recommendations

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3.

DEFINITIONS
DCC
MOC
EDMS
PM
PMI
SMP
QC

RDD
PRD
PRV
PVRV

Document Control Center

Management of Change
Electronic Document Management System
Preventive Maintenance
Positive Material Identification
Standard Maintenance Procedure
Quality Control, Activity governed by a document containing the
minimum specific requirements to insure the level of quality is
attained for specific activities.
Rupture Disc Devices
Pressure Relieving Device
Pressure Relieving Valve
Pressure Vacuum Relief Valve

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QC-PSM-MNL-00-0003

PROCESS SAFETY MANAGEMENT

PRESSURE RELIEVING DEVICE
MAINTENANCE QC MANUAL

4.

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ORGANIZATION CHART
Management of the overall maintenance servicing and testing of Pressure relieving
devices shall be as per the organization chart below. Responsibilities of all involved
including those individuals who are not directly involved are detailed in different work
procedures referred to in this Manual.

SHOP & SUPPORT SERVICES

SUPERINTENDENT

LEAD PLANNER

WORK SHOP SUPERVISOR

SHOP & SUPPORT SERVICES

PLANNER

VALVE TECHNICIAN

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5.

SCOPE OF WORK
Servicing of Pressure Relief Valves will consist of pre-testing, disassembling,
reconditioning, replacement of soft gaskets/soft O-rings, reassembling and leak/
tightness testing of valves. Only manufacturers supplied spare parts will be used.
Valve parts shall be reconditioned only within manufacturers tolerances. Valves shall
be tamper proof sealed and tagged, as per relevant work procedure, before releasing
for reinstallation on site
Servicing of Pressure/Vacuum Relief Valves will consist of pre-testing where
applicable, disassembling, reconditioning, replacement of soft gaskets/soft O-rings,
reassembling. Testing will be done as and when applicable. Although no adjustment
is required for dead weight valves, seat tightness test shall be done.
Servicing of Rupture Disc Devices (RDD) will mainly consist of removing the (RDD)
assembly, cleaning of all parts and re-installing back on site. Inspection and
replacement of the rupture disc element will be done every time when the (RDD) is
due to servicing.
Servicing of Depressurizing system components such as Pressure Vent Stacks and
Flame Arrestors will consist of dismantling, cleaning and inspection. Internals will be
replaced as and when required.
In addition to the above operational testing, all new PRVs will be tested in Q-Chems
shop prior to initial installation to confirm manufacturers set pressures.
Details of the scope of work are given in the relevant work procedures.
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QC-PSM-MNL-00-0003

PROCESS SAFETY MANAGEMENT

PRESSURE RELIEVING DEVICE
MAINTENANCE QC MANUAL

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6.

DRAWINGS AND SPECIFICATIONS

6.1

Reference/technical/support documents/drawings/datasheets related to pressure

relieving devices shall be stored/made available through Electronic Document
Management System (EDMS) in order to ensure that it is current and readily
available and accessible to all affected employees.
Pressure Relieving Devices Datasheets in a controlled hardcopy form shall be
retained in the Document Control Center.
Creation/Revision Management of documents related to pressure relieving devices
shall
be
through
Document
Management
System
and
following
procedures/policies/forms:

6.2
6.3

TE-DCC-PRO-00-0015
TE-DCC-PRO-00-0003
TE-DCC-SFM-00-0004
6.4

6.5

6.6

6.7

Document Update/Modification Request

Document Numbering
Document, Update/Modification Request Form

Frequency of testing of Pressure Relieving system shall be managed through

inspection management system (Meridium) and which should match with SAP PM
plan frequency.
Pressure Relieving Devices records/information related to maintenance, history,
inspection, and testing are stored in the following locations.
SAP
EDMS
Documents related to calibrations of tools, instruments and pressure gauges used for
calibration and testing of pressure relieving devices shall be maintained by Shop
Supervisor.
Records pertaining to Skill Training and Certification of personnel involved in
servicing and testing of pressure relieving devices shall be maintained by Shop
Supervisor.

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7.

MATERIALS AND SPARE PARTS

Only manufacturers supplied spare parts will be used. All incoming materials/spare
parts will be subject to thorough visual inspection by the Materials Department Materials Warehouse. MA-WHS-PRO-00-0001 Goods Receipt Procedure shall be
followed to ensure that received materials/spare parts meet the specifications
outlined in the purchase order. Positive material identification PMI shall be also
carried out following TE-STA-GLN-00-0001 Positive Material Identification Guideline.
Materials/spare parts that are defective and/or not identified shall be stored in
designated non-compliance areas until resolved.
Q-Chem shall not normally manufacture valve parts; if manufactured, an approved
inspection test plan shall be followed. The Maintenance Shop shall recondition parts
only within manufacturers tolerances.
Materials/spare parts shall be adequately stored so as not to deteriorate or

become damaged.
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QC-PSM-MNL-00-0003

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PRESSURE RELIEVING DEVICE
MAINTENANCE QC MANUAL

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REPAIR AND INSPECTION PROGRAM

All Pressure Relieving Devices and depressurizing system components shall be
inspected/tested at intervals that are frequent enough to verify that the valves
perform reliably. All Pressure Relieving Devices shall be tested prior to installation
and after overhauls/ repair and as per established maintenance/testing frequency or
any valid reason that make the Pressure Relieving Device suspect.
Maintenance/testing frequency of Safety Relief Valves and Pressure/Vacuum Relief
Valves shall be defined as per API 576 and based on actual service conditions,
availability, operating experience etc, and shall be controlled as outlined in TE-STAGLN-00-0035 Guideline for the Maintenance, Inspection, and Testing of Pressure
Relieving Devices. However, other Pressure Relieving Devices, such as rupture
disks, Pressure Vent Stacks and Flame Arrestors shall be thoroughly examined at
intervals determined on the basis of service conditions.
The intervals between pressure relieving device testing and inspection may be also
decided per a Risk Based Inspection analysis as defined in API.
The inspection and testing frequency shall be regularly reviewed and adjusted as
and when necessary, based on the performance of the PRD. All frequency changes
shall be documented using TE-STA-SFM-00-0047 PRD PM Frequency Review
Form.
Maintenance and repair works should be carried out following the best industry
practices and as per TE-STA-GLN-00-0035 Guideline for the Maintenance,
Inspection, and Testing of Pressure Relieving Devices. Details of maintenance,
repair and testing shall be as per the Q-Chems work procedures relevant to each
type of pressure relieving devices as referenced to in this Manual.

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9.

WELDING, NON-DESTRUCTIVE TESTING & HEAT TREATMENT

No welding or heating shall normally be used during servicing or repairing of
Pressure Relief Devices. However, in case it is absolutely required; then welding,
preheating, non-destructive testing and heat treatment will be in strict accordance
with TE-STA-MNL-00-0001 Welding Manual and TE-STA-GLN-00-0044 Stationary
Equipment Repair/Alteration Guideline.
Q-Chem shall not normally manufacture PRD parts; if manufactured, an approved
inspection test plan, with necessary NDTs included, shall be followed. The Work
Shop shall recondition parts only within manufacturers tolerances.

10.

VALVE TESTING, SETTING AND LEAK TESTING

Valve testing, setting, leak testing and sealing shall be in line with the applicable
requirement of the following documents, depending on the type of the valve:

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QC-PSM-MNL-00-0003

PROCESS SAFETY MANAGEMENT

PRESSURE RELIEVING DEVICE
MAINTENANCE QC MANUAL
TE-STA-GLN-00-0035
TE-STA-PRO-00-0029
TE-STA-PRO-00-0030
TE-STA-PRO-00-0031
TE-STA-PRO-00-0032
TE-STA-PRO-00-0034
TE-STA-PRO-00-0035
TE-STA-PRO-00-0036
TE-STA-PRO-00-0037
TE-STA-PRO-00-0039
TE-STA-PRO-00-0040

11.

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Guideline for the Maintenance, Inspection, and Testing

of Pressure Relieving Devices
Vendor Doc 05.9040.270, AGW-Pilot Operated Safety
Valve Maintenance Instructions, Type 443/453/463
Vendor Doc 05.9040.233, AGW-Pilot Operated Safety
Valve Maintenance Instructions, Type 9390
Vendor Doc 05.2252.000, AGW-Piston Lift Stop
Adjustment, Pilot Operated PRV'S
Vendor Doc Fig 121, AG Marvac Installation and
Instruction for PVRV
Vendor Doc, Breetec Installation and Maintenance
Instruction for PVRV
Vendor Doc, IMI Marston Maintenance Instruction for
Rupture Disc Assemblies
Hot Setting of Safety Valves Procedure
Spring Loaded Safety Relief Valves Test Procedure
Pilot Operated Safety Relief Valves Test Procedure
Pressure/Vacuum Relief Valve Test Procedure

PRESSURE GAUGE CALIBRATION

All pressure gauges used for Pressure Relief Valve testing shall be recalibrated as
per Standard Maintenance Procedure MC-INS-SMP-00-0006 (Pressure Gauge) and shall
be properly stored. The Shop Supervisor will ensure the following:

12.

All Test Gauges will be recalibrated by the Valve Shops or approved off-site
facilities.

The maximum interval between recalibration will be six month or whenever

error is suspected.

All test gauges will be identified by serial number and date of last calibration
and a record maintained in a logbook for this purpose. Logbook and
calibration documents shall be duly maintained by the Shop Supervisor.

CONTROLLED COPIES OF THIS MANUAL

Electronic copy of this manual is available at EDMS and accessible to all personnel.
Original paper copy as well as electronic copy is controlled by DCC as per Records
and Document Management Policy QC-IMT-PCY-00-0002 and Key Document Types
and Signing Authority QC-IMT-PCY-00-0003.
No other controlled copies are intended to be maintained.

13.

REPAIR PERSONNEL TRAINING/QUALIFICATION

The valve repair personnel engaged on Pressure Relief Devices servicing and
testing shall meet the requirements detailed in TE-STA-GLN-00-0035 Guideline for
the Maintenance, Inspection, and Testing of Pressure Relieving Devices. Records of
qualifications and experience are kept in the Valve Shop office. It is the Valve Shop
Supervisors responsibility to ensure these qualifications are maintained and
updated.

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PRESSURE RELIEVING DEVICE

MAINTENANCE QC MANUAL

14.

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REPAIR NAMEPLATE AND SEALING

Sealing the serviced/tested Pressure Relieving Device shall be carried out in order to
protect the spring setting from changes/adjustments by unauthorized persons. A
tamper proof seal shall be installed such that the cap cannot be opened without
breaking the seal and to eliminate possible tampering and/or changes to the valve
set pressure or blow-down due to vibration, rough handling or unauthorized
adjustments.
A stainless steel repair nameplate of 25mmX100mmX0.8mm thick shall be attached
to the valve through the stainless steel wire of tamper proof seal and shall be listing
the following fields (see figure-1):

Servicing Party (i.e. Contractors Name, Q-Chem Valve Repair Shop etc.
as applicable)

Equipment Tag Number

Date of Inspection

Set Pressure

Cold Differential Set Pressure (if applicable)

All information shall be stamped into repair nameplate or mechanically scribed only.
Name of Servicing Party
Equipment Tag Number

Date of Inspection

Set Pressure

Cold Differential Set Pressure

Figure 1 - Valve Repair Nameplate

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QC-PSM-MNL-00-0003

PROCESS SAFETY MANAGEMENT

PRESSURE RELIEVING DEVICE
MAINTENANCE QC MANUAL

15.

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RESPONSIBILITIES
MAINTENANCE:
Implement of this manual and any future amendments.
Identify, initiate and provide solutions to any problem related to servicing and setting
safety relief devices. Involve Technical ERG as and when necessary.
Notify Technical ERG of any valve failing pre-test.
Schedule/coordinate release of Pressure Relieving Devices/Flame Arrestors/
Pressure Vents from Production for subsequent inspection.
Overhaul and/or arrange with the Contractors to overhaul and test Pressure
Relieving Devices/Flame Arrestor/Pressure Vent as per the relevant procedure as
and when they are due/available.
Witness and certify final set pressure and leakage tests.
Seal and tag all Pressure Relieving Devices after testing is completed.
Transport and reinstall the PRD in the correct location.
Fill relevant checklist and file completed checklist in EDMS.
Load completed Checklist in EDMS and forward hard copy to Stationary Equipment
Inspector / Engineer.

TECHNICAL/ERG:
Provide technical support, and assistance with any quality control problem which
cannot be resolved by Maintenance/Materials.
Identify/review the inspection/test frequency of Pressure Relief Devices/Flame
Arrestor/Pressure Vent.
Randomly audit maintenance/inspection/testing activities of PRDs.
Update inspection records and test data in inspection management system
(Meridium)..
Conduct quality assurance audit for Pressure Relieving Devices PM completion
verification.

PRODUCTION:
Release all Pressure Relieving Devices at the scheduled date.
Verify/ensure the installation of all Pressure Relieving Devices in correct location.
Ensure that all isolating valves to Pressure Relieving Devices are car sealed at
Open position during normal operation.

MATERIALS:
Materials Warehouse will ensure that all incoming spare parts/materials related to
Pressure Relieving Devices meet the specifications outlined in the purchase order
and entering the materials into the computerized inventory control system.
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PRESSURE RELIEVING DEVICE
MAINTENANCE QC MANUAL

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Received parts shall have a thorough visual inspection and positive materials
identification. Parts that are defective and/or not identified/meeting the specs shall
be stored in designated non-compliance areas until resolved.
Maintaining inventory levels as specified by Maintenance Department.
Ensuring spare parts are stored so as not to deteriorate or become damaged.

16.

REFERENCES

Policy
HSE-HGN-PCY-00-0001
QC-PSM-PCY-00-0008
QC-PSM-PCY-00-0010
QC-IMT-PCY-00-0002
QC-IMT-PCY-00-0003
Guidelines
TE-STA-GLN-00-0035
TE-ERG-GLN-00-0010
TE-STA-GLN-00-0001
TE-STA-GLN-00-0044
Procedures
TE-STA-PRO-00-0029
TE-STA-PRO-00-0030
TE-STA-PRO-00-0031
TE-STA-PRO-00-0032
TE-STA-PRO-00-0033
TE-STA-PRO-00-0034
TE-STA-PRO-00-0035
TE-STA-PRO-00-0036
TE-STA-PRO-00-0037
TE-STA-PRO-00-0039
TE-STA-PRO-00-0040
TE-STA-PRO-00-0041
TE-ERG-PRO-00-0006
TE-DCC-PRO-00-0015
TE-DCC-PRO-00-0003
PD-PGN-PRO-00-0001
MA-WHS-PRO-00-0001
MC-INS-SMP-00-0006

Operational Excellence Policy

Equipment Integrity Policy
Management of Change Policy
Document Management Policy (under approval)
Key Document Types and Signing Authority.

Guideline for the Maintenance/Inspection of Pressure

Relieving Devices
Material Purchase, Verification, Storage, and Handling
Guideline
Positive Material Identification Guideline
Stationary Equipment Repair/Alteration Guideline

Vendor Doc 05.9040.270, AGW-Pilot Operated Safety

Valve Maintenance Instructions, Type 443/453/463
Vendor Doc 05.9040.233, AGW-Pilot Operated Safety
Valve Maintenance Instructions, Type 9390
Vendor Doc 05.2252.000, AGW-Piston Lift Stop
Adjustment, Pilot Operated PRV'S
Vendor Doc Fig 121, AG MARVAC Installation and
Instruction for PVRV
Vendor Doc, GLENFIELD Install, Operation, and
Maintenance Instructions for APEX Air Release Valve
Vendor Doc, BREETEC Installation and Maintenance
Instruction for PVRV
Vendor Doc, IMI MARTSON Maintenance Instruction
for Rupture Disc Assemblies
Hot Setting of Safety Valves Procedure
Spring Loaded Safety Relief Valves Test Procedure
Pilot Operated Safety Relief Valves Test Procedure
Pressure/Vacuum Relief Valve Test Procedure
Rupture Disc Inspection Procedure
Non-Conformance Reporting Procedure
Document Update/Modification Request
Document Numbering
Relief Device Removal, Tracking, and Reinstatement
Procedure
Goods Receipt Procedure
Pressure Gauge

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QC-PSM-MNL-00-0003

PROCESS SAFETY MANAGEMENT

PRESSURE RELIEVING DEVICE
MAINTENANCE QC MANUAL
Manuals
TE-STA-MNL-00-0001
Standard Forms
TE-STA-SFM-00-0003
TE-STA-SFM-00-0004
TE-STA-SFM-00-0005
TE-STA-SFM-00-0006
TE-STA-SFM-00-0007
TE-ERG-SFM-00-0008
TE-STA-SFM-00-0023
TE-STA-SFM-00-0024
TE-STA-SFM-00-0032
TE-DCC-SFM-00-0009
QC-PSM-SFM-00-0010
TE-DCC-SFM-00-0004
TE-STA-SFM-00-0047
Plans
QC-PSM-PLN-00-0003

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Welding Manual

Spring Loaded Safety Relief Valve Inspection Checklist

400 Series Pilot Operated Safety Relief Valve
Inspection Checklist
Pressure/Vacuum Relief Valve Inspection Checklist
Rupture Disc Inspection Checklist
Safety Valve Hot Setting Checklist
Non-Conformance Report Form
Positive Material Identification Technician Training
Checklist
Positive Material Identification Report Form
Flame Arrestor and Pressure Vent Inspection Checklist
Document Creation/Revision Form
Equipment Integrity, Deviation From
Document, Update/Modification Request Form
PRD PM Frequency Review Form

Quality Assurance Audit Plan for Relief Device PM

Completion Verification

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