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OISD STANDARD - 132

First Edition, August 1990
Reaffirmed, August, 1999

FOR RESTRICTED
CIRCULATION

INSPECTION
OF
PRESSURE RELIEVING DEVICES

Prepared by

COMMITTEE ON
INSPECTION OF STATIC EQUIPMENT

OIL INDUSTRY SAFETY DIRECTORATE

7TH FLOOR, NEW DELHI HOUSE
27, BARAKHAMBA ROAD
NEW DELHI – 110 001
 NOTES
OISD publications are prepared for use in the Oil and
gas industry under Ministry of Petroleum and Natural Gas.
These are the property of Ministry of Petroleum and Natural
Gas and shall not be reproduced or copied and loaned or
exhibited to others without written consent from OISD.

Though every effort has been made to assure the

accuracy and reliability of data contained in these
documents, OISD hereby expressly disclaims any liability or
responsibility for loss or damage resulting from their use.

These documents are intended only to supplement

and not replace the prevailing statutory requirements.
 FOREWORD

The Oil Industry in India is 100 years old. Because

of various collaboration agreements a variety of international
codes, standards and practices have been in vogue.
Standardisation in design philosophies and operating and
maintenance practices at a national level was hardly in
existence. This, coupled with feed back from some serious
accidents that occurred in the recent past in India and
abroad, emphasized the need for the industry to review the
existing state of art in designing, operating and maintaining
oil and gas installations.

With this in view, the then Ministry of Petroleum &

Natural Gas, in 1986, constituted a Safety Council assisted
by Oil Industry Safety Directorate (OISD), staffed from within
the industry, in formulating and implementing a series of self
regulatory measures aimed at removing obsolescence,
standardising and upgrading the existing standards to ensure
safer operations. Accordingly, OISD constituted a number of
Functional Committees comprising of experts nominated
from the industry to draw up standards and guidelines on
various subjects.

The present standard on “Inspection of Pressure

Relieving Devices” has been prepared by the Functional
Committee on “Inspection of Static Equipment”. This
document is based on the accumulated knowledge and
experience of industry members and the various national and
international codes and practices. This document is meant to
be used as a supplement and not as a replacement for
existing codes and practices. It is hoped that the provisions
of this document, when adopted may go a long way to
improve the safety and reduce accidents in the Oil and Gas
Industry. Users are cautioned that no standard can be a
substitute for judgment of a responsible qualified Inspection
Engineer. Suggestions are invited from the users, after it is
put into practice, to improve the document further.
Suggestions for amendments to this document should be
addressed to

The Co-ordinator,
Committee on “Inspection of Static Equipment,
OIL INDUSTRY SAFETY DIRECTORATE
th
7 Floor, ‘New Delhi House’
27, Barakhamba Road
New Delhi – 110 001

This standard in no way supercedes the statutory

regulations of CCE, Factory Inspectorate, IBR or any other
Govt. body which must be followed as applicable.
 FUNCTIONAL COMMITTEE ON
INSPECTION OF STATIC EQUIPMENT
List of Members
---------------------------------------------------------------------------------------------------------------------------
Name Designation & Status
Organisation
---------------------------------------------------------------------------------------------------------------------------
1. Sh. R.K. Sabharwal CMNM-IOC (R & P) Leader
2. Sh.D.P. Dhall CH INSP & AE MGR-BPC (REF) Member
3 Sh.R.H. Vohra DGM-IOC (Mkt.) Member
4. Sh.V.K. Moorthy DY.SUPTD. ENGINEER-ONGC. Member
5. Sh.I.M. Advani MGR - (PROJ) HPC (REF) Member
6. Sh.P. Dasgupta SR. MANAGER - INSPECTION IOC (R & P) Member
7. Sh.R.M.N. Marar Jt.Director, OISD Member
Co-ordinator.
---------------------------------------------------------------------------------------------------------------------------
In addition to the above, several other experts from the industry contributed in the preparation,
review and finalisation of this document.
 INSPECTION OF PRESSURE RELIEVING DEVICES
CONTENTS

SECTION PAGE NO.

1.0 Introduction
2.0 Scope
3.0 Definition & Types of Pressure Relieving Devices
3.1 Definitions
3.2 Types of Pressure Relieving Devices
3.2.1 Types of Pressure Relieving Devices
3.2.2 Rupture Disc
3.2.3 Pressure Vacuum Relief Devices
4.0 Role of Inspection
5.0 Inspection of New Pressure Relieving Devices
5.1 Inspection at Manufacturer’s Shop
5.2 Inspection on receipt at site
5.2.1 General Information
5.2.2 Checklist for Pressure Relief Valve
5.2.3 Checklist for inspection of rupture disc
5.2.4 Checklist for inspection of PV Vent Valve
5.3 Inspection prior to Installation
6.0 Pre-Commission checklist for inspection of
Pressure Relieving Devices
6.1 Safety Relief Valve
6.2 Rupture Disc
6.3 Pressure Vacuum Relief Valve/Devices
7.0 Likely Location of Deterioration of
Pressure Relieving Devices
7.1 Relief Valves/Safety Relief Valve
7.2 Rupture Disc
7.3 Breather valve
7.4 Vents
8.0 Frequency of Inspection
8.1 General
8.2 Inspection Frequency
8.2.1 Safety Relief Valve
8.2.2 Breather Valve
8.2.3 Rupture Disc
8.2.4 Vents
9.0 Inspection of On-line Pressure Relieving Devices
9.1 On stream Inspection
9.1.1 Safety Relief Valve
9.1.2 Pressure and Vacuum Relief Valves on Storage Tanks
9.1.3 Rupture Disc
9.2 Shut Down Inspection
9.2.1 Safety Relief Valves
9.2.2 Rupture Disc
9.2.3 Pressure Vacuum Relief Devices
10.0 Testing of Pressure Relieving Devices
10.1 Safety Relief Valve
10.1.1 Set Pressure Test
10.1.2 Leak Test
10.1.3 Locking
10.2 Safety Valves on Boilers
10.3 Inspection & Testing of Pilot Operated
Safety Relief Valve
10.4 Inspection & Testing of PV Vent Valves
11.0 Documentation
12.0 References

ANNEXURES

I Definition of Related Terms

II & III Graphical Illustration of Relationship

of various terms
IV Leak Test for Seat Tightness
of Safety Relief Valve
V Technical Data, Test and History Card of
Rupture Disc

VI Technical Data, Test and History Card of

Rupture Disc

VII Technical Data, Test & History Card of

PV Vent Valves
 INSPECTION OF PRESSURE RELIEVING DEVICES

1.0 INTRODUCTION pressure upstream of the valve. The valve

opens in proportion to the increase over
the opening pressure. Thermal Safety
Pressure Relieving Devices are
Valves are meant to take care of pressure
installed on Process Equipment, tankages
increase resulting from thermal expansion
and piping to release excess pressure
of fluid.
resulting from operational upsets and other
causes like fire etc. Malfunctioning of
these devices could result in process c) Safety Valve
upsets and/or failure of equipment and
hence the necessity for proper inspection A Safety valve is an automatic
and maintenance of these devices. pressure-relieving device actuated by the
static pressure upstream of the valve and
characterised by rapid full opening of pop
2.0 SCOPE action. It is normally used for
steam/gas/vapour service.
This inspection standard outlines
the minimum inspection and testing 3.2.1 Types of Safety Relief Valves
requirements applicable for all pressure
relieving devices including those for
Types of Safety Relief Valves in use are:
vacuum service used in the petroleum
industry. Control valves as means of
i) Conventional
relieving pressure into flare system
ii) Balanced and
however are covered in this standard.
iii) Pilot operated Valves
3.0 DEFINITION AND TYPES i) Conventional Safety Relief Valve:
OF PRESSURE
RELIEVING DEVICES Conventional safety relief valves are
susceptible to both superimposed and
3.1 DEFINITIONS built up back pressure and are not
recommended when the total back
Definitions of terms related to pressure exceeds 10% of the set
pressure relieving devices are given in pressure.
Annexure-I. Graphic relationship between
these terms are illustrated in Annexure-II & These type of valves are shown in
III. figure 1 and 3. In figure 3a, the bonnet
is open vented to atmosphere and the
3.2 TYPES OF PRESSURE effect of back pressure is to reduce the
RELIEVING DEVICES set pressure. In figure 3b, the bonnet is
vented to valve outlet and the effect of
back pressure is to increase the set
a) Safety Relief Valve
pressure.
A safety relief valve is an ii) Balanced Safety Relief Valve:
automatic pressure-relieving device
suitable for use either as a Safety or Relief The balanced safety relief valve
Valve depending on application. incorporates means of minimising the
effects of back pressure on the
Pressure Relief Valve is a generic performance characteristics, set
term used to denote Relief/Safety/Safety pressure, reseat pressure, lift and
Relief Valve. relieving capacity. These valves are of
two types:
b) Relief Valve/Thermal Safety Valve
(TSV) a) Piston type
b) Bellows type
Primarily used for liquid service, a
Relief Valve is an automatic pressure- a) Piston Type
relieving device actuated by the static
 pressure and vacuum side, the
A typical piston type balanced valve is pallets being calibrated to open at
shown in figure 4a. In this valve, the very low pressures. Although
guide is vented so that the back pressure and vacuum valves are
pressure on opposing faces of the available as separate units, they
discs cancels itself. The top face of are usually built as combination
the piston which has the same area units as an integral body and
as the nozzle seat area is subjected frequently referred to as breather
to atmospheric pressure by venting valves.
the bonnet. The bonnet vented gases
from balanced piston type valve b) Hydraulic Safety Valve/Liquid
should be disposed of safely. Seal Valves

b) Bellows type In liquid seal valve, a liquid

provides the closure against flow
Typical bellows type valves are through the vent until over
shown in figure 2 and 4b. In the pressure or over vacuum occurs.
bellows type of balanced valve, the
effective bellows area is the same as c) Vents
the nozzle seat area and by
attachment to the valve body, Vents are open pipes of suitable
excludes the back pressure from capacity fitted on tanks and are
acting on the top side of the area of meant to function as breather
the disc to provide for a possible valves.
bellows failure or leak. The bonnet
must be vented separately from the
4.0 ROLE OF INSPECTION
discharge to a safe location.
The following are the
iii) Pilot Operated Safety Valves
responsibilities of the Inspection division:
In pilot operated safety valves (Figure i) To prepare inspection schedule
5), the main Safety Valve opens guided by experience and
through a pilot valve. Both the pilot requirements of statutes and assure
and the main valve contain flexible their implementation.
membranes which can withstand only
ordinary service temperatures. ii) To inspect and determine the
Because of this and the risk of physical condition of the different
fouling, their use is limited to very parts (sub assemblies) of the device,
clean services. record abnormalities and suggest
repairs wherever necessary.
3.2.2 Rupture Disc
iii) To study the abnormalities
A rupture disc is a thin metal /deterioration with a view to:
diaphragm held between ranges. It
is actuated by inlet static pressure a) Prevent the damage by suitable
and designed to function by the remedial measures or reduce the
bursting of the disc. Once burst, it is extent of deterioration.
not reusable and has to be replaced.
b) Plan procurement of spare device/
3.2.3 Pressure & Vacuum Relief spare parts, well in time.
Devices

a) Breather Valve iv) To inspect quality of maintenance.

Pressure and Vacuum Relief v) To witness and certify “after-

Valves are automatic pressure or maintenance testing “ of the device
vacuum relieving devices actuated and ensure that the device is fitted
by the pressure or vacuum in the back at its own place.
storage tank. These valves are
usually weight loaded on both the
vi) To provide feed back to the operations
department as to the condition of the x) Stamping of device after inspection.
devices.
5.2 INSPECTION ON RECEIPT AT SITE
vii) To maintain Data Sheets and History
Sheets of all Pressure Relieving On receipt at site, the new Pressure
Devices, and keep them updated. relieving Devices shall be checked as per
the following check list:
viii) To assure the quality of new devices
and spares. 5.2.1 General Information

The following general information

5.0 INSPECTION OF NEW shall form part of the check list:
PRESSURE RELIEVING Plant :
DEVICES Purchase Order No. :
Duty :
Flange Sizes :
New Pressure Relieving Devices
Nozzle Sizes :
shall be inspected in three phases:
Manufacturer’s Serial
Number and Type
i) At the manufacturers shop,
Date of Inspection
ii) On receipt at the users work site and
Inspector
iii) Prior to installation.
5.2.2 Check List for Pressure Relief
5.1 INSPECTION AT MANUFACTURER’S
Valve
SHOP

The Pressure Relieving Device Action Remark

shall be inspected at the manufacturer’s
shop during various stages of fabrication 1) Check physical Condition
and assembly. The inspection shall 2) Check Name Plate
include following aspects as applicable. 3) Verify Capacity & Set Pressure.

i) A check for compliance with the 5.2.3 Check List for Inspection of
specifications and codes-as Rupture Disc
enumerated in the purchase order.
i) Check Physical Condition
ii) Identification of materials. ii) Check Name Plate for
a) Manufacturer’s identification/
iii) Physical inspections of the device and Marks
its sub-assemblies. b) Material of Construction
c) Lot Number
iv) Inspection of Castings/weld joints, if d) Size
any. e) Bursting Pressure
f) Design Temperature
v) Hydraulic testing of the parts /sub- g) Capacity
assemblies.

vi) Bench test for Set Pressure, blowdown 5.2.4 Check List for Inspection of PV
and Leak Test. Vent Valves

vii) Material quality and thickness The following checks shall be

performance test in the case of rupture carried out on PV - Vents:
disc.
a) Check Physical Condition
viii) Weight of the pallets and performance b) Check the Name Plate
test in case of PV valves. c) Verify Set Pressure & Capacity
d) Check proper weights of pallets
ix) Quality of sealing liquid and e) Check type and level of oil/sealing
performance test in the case of liquid liquid.
seal type PV valves.
5.3 Inspection prior to installation ii) The name plate for capacity, pressure
& temperature.
All Pressure Relieving Devices
shall be bench tested for Set Pressure, iii) Isolation valve, is in line and locked
Blowdown & leakage as applicable prior to open.
installation.
iv) Use of proper gasket, nuts & bolts.
6.0 PRE-COMMISSIONING
v) Outlet piping is connected to a safe
CHECK LIST FOR location.
INSPECTION OF
PRESSURE RELIEVING vi) When used in combination with
DEVICES pressure relief valve, vent for the
intervening space, if specified, is
Before installation and provided.
commissioning the following shall be
assured: 6.3 PRESSURE VACUUM RELIEF
VALVES/DEVICES
i) All new devices have been inspected
and tested as detailed in Section-5.0 The following shall be inspected:

ii) That the upstream system has been i) The tag number for proper location
flushed thoroughly. and service.

iii) Before start-up of the installation the ii) The Name Plate for
test gag, if any, shall be replaced by a Pressure/temperature & capacity.
test plug.
iii) Use of specified gasket, nuts and
6.1 SAFETY RELIEF VALVE bolts.

The following shall be checked: iv) In the case of breather valves, the
checks shall be for:
i) Tag number for proper location and
service. a) Correct weight & free movement of
pallets.
ii) Name Plate for capacity & set
pressure. v) In the case of hydraulic Safety Valves,
check shall be for:
iii) Gaskets, nuts & bolts for correct
specifications. a) Right type of sealing liquid.
b) Proper level of the sealing liquid,
iv) Installation of valve.
vi) In case of vents, check shall be for:
v) Relief valve isolation valves are in line
and in locked open position. a) Proper size of vent.
b) Proper size of mesh of flame
vi) Connecting pipelines do not strain the arrestor, if provided.
valve.
7.0 LIKELY LOCATION OF
vii) Outlet piping is connected to a safe DETERIORATION
location away from all likely sources of
ignition.
Different parts of the various
pressure relieving devices are likely to
6.2 RUPTURE DISC deteriorate due to any one or more of the
following reasons.
The following shall be checked:
7.1 Relief Valves /Safety Relief
i) Disc tag Number for proper location &
Valves
service.
LOCATION LIKELY NATURE OF inlet and
DETERIORATION discharge
a) Inlet and outlet Fouling/plugging due opening
nozzles to deposits, foreign g) Flame deposit/fouling/blockage,
material and arrestor corrosion and erosion.
corrosion products Internal
b) Flanges of inlet Pitting and corrugated
and outlet nozzles roughening due to sheets/me
corrosion, mechanical sh
damage.
c) Disc and nozzle Roughness, uneven
surface fouling and 7.4 VENTS
corrosion, chattering
mark. Location Likely nature of deterioration
d) Stem Roughening, wear, a) Body Blockage, internal and
corrosion. external corrosion.
e) Guide Roughening, wear,
corrosion. b) Flame Mechanical damage, external
f) Spring Bending, corrosion, Arrestor corrosion.
cracking, loss of Body
stiffness. c) Flame Fouling, obstruction in the
g) Bellows Corrosion and Outlet openings.
cracking
h) Body and Bonnet Metal loss, corrosion d) Flame Deposits/fouling, blockage,
and mechanical arrestor corrosion and erosion.
damage Internal
mesh
7.2 RUPTURE DISC
8.0 FREQUENCY OF INSPECTION AND
LOCATION Likely nature of TESTING
a) Disc Cracks, Fatigue
b) Disc holding flanges Mechanical distortion, 8.1 GENERAL
wire drawing, damage
in gasket seating face. The frequency of inspection depends
upon:

7.3 BREATHER VALVES i) Statutory requirements

ii) Service
LOCATION LIKELY NATURE OF iii) Vibration and pulsating loads
DETERIORATION iv) Difference between set and operating
pressures.
a) Body Mechanical damage, external v) History
corrosion
8.2 INSPECTION FREQUENCY
b) Inlet and Fouling, obstruction in the
discharge opening. Following inspection frequency shall
opening. be observed:

c) Oil Contamination of Oil or fall in 8.2.1 Safety Relief Valve

level.
LOCATION FREQUENCY
d) Pallets Fouling, obstruction to
movement, loss in weight, i) Battery area
corrosion/surface roughening.
a) New Unit
e) Flame Mechanical damage, external
arrestor corrosion. i) Corrosive & Within a year of
Body High commissioning.
f) Flame Fouling, obstruction in the temperature within two years of
arrestor openings. areas commissioning.
 or by hand touch at outlet nozzle
ii) Non critical Every turnaround but not wherever practicable.
areas later than 4 years. e) The continuous operation of heat
tracing provision, if any, provided for
b) Existing Unit low temperature application on valve
and discharge piping.
ii) LPG Bullet/ f) Condition of insulation and cladding on
Sphere the heat traced piping and valves.
chemical
storage & Once in a year 9.1.2 Pressure and Vacuum Relief
Pressure Valve on Storage Tanks
storage tanks
(API 620) i) The following inspection checks shall
be carried out once in every six
iii) Steam Each statutory turn months for breather valves on Storage
around. Tanks.

iv) Offsite piping once in 5 years a) Discharge opening should be

checked for obstruction.
8.2.2 Breather Valve b) Flame arrestor wherever provided
shall be inspected, for fouling, bird
i) Insitu Inspection Once in 6 months nests or clogging. Element shall
be inspected for mechanical
ii) Shop Inspection damage, deposits, scaling etc. and
& Testing cleaned before onset of monsoon.
a) Corrosive Once in two years. c) Oil filled type liquid seal valve shall
Service be inspected for oil level, fouling,
b) Non Corrosive Once in four years. bird nests, foreign material etc.
Services d) Free movement of pallet shall be
checked.
8.2.3 Rupture Disc
9.1.3 Rupture Disc
Inspection and Every turn around
Cleaning The integrity of the rupture disc shall
be verified with the help of thermography,
8.2.4 Vents temperature indicating crayons contact
Inspection and once in a year. thermometers or by hand touch.
cleaning
9.2 SHUTDOWN INSPECTION
9.0 INSPECTION OF ONLINE
PRESSURE RELIEVING 9.2.1 Safety Valves/Relief Valves
DEVICES
Following inspection and tests
9.1 ONSTREAM INSPECTION shall be carried out:

9.1.1 Safety Valves/Relief Valves a) Inspection and test of the valve in as

received condition. This is important
An on stream visual inspection should be and helps in establishing the frequency
carried out at least once in every 6 months of inspection.
to check the following:
b) Visual inspection of different parts of
a) Gags, blinds do not exist. safety valve shall be done after
b) Upstream and down stream isolation dismantling to check the following:
valves, if any, are opened and sealed.
c) Seals protecting the spring setting i) Condition of flanges for pitting,
have not been broken. roughening, decrease in width of
d) Relief device is not leaking. This may seating surface etc.
be checked visually and by
thermography, contact thermometers
 ii) Spring, for evidence of bending,
corrosion or cracking, free length These devices shall be checked
of spring. for the following damage, depending on
the type of the device.
iii) Bellows (if applicable) for damage.
i) Loss in weight/fouling of pallets
iv) Position of set screws and opening ii) Corrosion and surface roughening of
in bonnet. pallets.
iii) Quality of sealing liquid.
v) Inlet/outlet nozzles for evidence of iv) Internal corrosion of vents & flame
deposits foreign material and arrestor bodies.
corrosion.
10.0 TESTING PROCEDURE
vi) Condition of external surface and
FOR PRESSURE
evidence of mechanical damage.
RELIEVING DEVICES
vii) Body wall thickness.
Testing of all Pressure Relieving
viii) Conditions of steam, guide disc, Devices shall be carried out at frequencies
nozzles etc. for evidence of wear indicated in Chapter 8.0
and corrosion.
10.1 SAFETY RELIEF VALVE
ix) Seating surface of disc and nozzle
shall be critically examined for 10.1.1 Set Pressure Test
roughness or damage which could
result in valve leakage and may It shall be ensured that correct
need correction. Care must be calibrated test gauge is used. All safety
taken to ensure flatness of seats. relief valves shall be tested in accordance
with the relevant code to which the
x) It is recommended that springs be protected equipment is designed. After
tested for stiffness. final adjustment the valve shall be popped
at set pressure at least once to prove the
a) 10th year after installation and accuracy of setting. PSV test pressure
subsequently every 5 years. tolerance shall be 0.5% of the set
pressure. Allowance for hot setting shall
b) Immediately where be made as per manufacturers
malfunctioning is suspected. recommendations. The set pressure
If load and compression adjustment shall be sealed.
valves do not match with
original valves, the spring Reseat pressure shall be checked
should be replaced. during testing of safety valve. The spring
in a pressure relief valve in service for
9.2.2 Rupture Disc pressures up to and including 250 psi shall
not be reset for any pressure more than
During shutdown inspection, the 10% above or 10% below that for which
rupture disc shall be examined for: the valve is marked. For higher pressures,
the spring shall not be reset for any
i) Cracks and fatigue of the disc. pressure more than 5% above or 5%
below that for which the safety or relief
ii) Mechanical distortion, wire drawing valve is marked. Working of hand popping
and damage in gasket seating face of device shall be checked during testing.
the disc holding flanges.
10.1.2 LEAK TEST
It is however recommended that
rupture disc should be replaced on a Leak test shall be performed in
schedule guided by manufacturer’s accordance with the relevant code.
recommendations & past experience.
10.1.3 LOCKING
9.2.3 Pressure Vacuum Relief
Devices After set pressure test and leak test,
the valve shall be sealed after tightening
the lock nut of gas, as well as hand
popping (if provided). 11.0 DOCUMENTATION
The documents to be maintained
10.2 SAFETY VALVES ON BOILERS shall include:

Safety Valves shall be tested as (i) Data sheets covering the type, make,
per IBR at the time of the statutory design, and constructional aspects of
inspection. Initial setting of the safety shall the device.
be checked in workshop. (ii) History card depicting the number and
frequency of failures/repairs with
Reseating Pressure and blowdown probable causes type of failure/repair.
shall also be checked as per IBR, by (iii) Test/inspection report revealing the
adjusting blowdown rings. The blowdown status of the device and its parts, its
shall be kept within 3-5% of set pressure. suitability for continued use and
suggestions for present/future repair
When a safety valve fails to and maintenance.
operate at the set popping pressure,
attempt should not be made to free it by Typical Formats of combinations
striking the body or other parts of the of above three documents are given in
valve. The valve shall be popped by Annexure-5,6 & 7.
means of the lifting lever and allowed to
reseat, after which the pressure of the 12.0 REFERENCE
boiler should be raised to the set pressure.
If the valve does not still pop, the boiler
shall be taken out of operation and safety (i) API RP 520 Part I & II Design and
valve attended. installation of pressure relieving
system in Refineries.
It is advisable to check lifting lever (ii) API RP 521 Guide for pressure and
for free operation when there is at least 75 depressuring system.
% of full working pressure on boiler. This (iii) API 526 Flanged Steel Safety Relief
ensures that moving parts are free to Valves.
operate. (iv) API 527 Seat tightness of Safety Relief
Valves.
(v) API 2000 Venting atmospheric and low
10.3 INSPECTION AND TESTING OF pressure storage tanks.
PILOT OPERATED SAFETY (vi) API 2521 Use of PV Vent Valves for
RELIEF VALVE Atmospheric Pressure Tanks to
reduce Evaporation Loss.
Inspection of pilot operated valves (vii) API Guide Chapter XVI Pressure
is divided into two separate phases, the Relieving Devices.
pilot mechanism & the main valve. In (viii)Guide for Inspection of Refinery
some types of valves, the pilot can be Equipment Chapter XIII Atmospheric &
blocked off from the vessel for inspection Low Pressure storage Tanks.
and testing while the spring loaded main (ix) ASME Boiler and Pressure Vessel
valve continues to protect the vessel. The Code Sec. VIII Div. 1 and Div. 2.
diaphragms in both the pilot and the main (x) The Static and Mobile Pressure
valve of certain designs shall be inspected Vessels (unfired) Rules 1981.
and replaced, if necessary with the main (xi) Indian Boiler Regulation(IBR).
valve in service. Manufacturers (xii)Fire Protection Manual by Charles
recommendation for inspection, testing Verravlin Volume-I.
and repairs shall be followed.

10.4 INSPECTION & TESTING OF PV

VALVES

PV Valves shall be inspected and

tested as per relevant code for tightness &
positive operation at set pressure. Testing
shall be done as outlined in API 2521.
 ANNEXURE-1

DEFINITIONS OF RELATED TERMS

expressed as percentage of the maximum

1. Maximum Allowable Working allowable working pressure.
Pressure(MAWP)
5. Over Pressure
Maximum Allowable Working
Pressure is the maximum pressure at Over Pressure is the pressure
designated temperature or its equivalent at increase over the set pressure of the
any metal temperature other than design relieving device. It is the same as the
temperature at which a vessel may be accumulation if the device is set at
operated consequently for that metal maximum allowable working pressure. It
temperature, it is the highest pressure at may be greater than the accumulation if
which the primary pressure relieving the valve is set at a lower pressure than
device is set to open. MAWP or vice versa.

2. Set Pressure 6. Blow Down

In a relief or safety relief valve on Blow Down is the difference

liquid service, set pressure is the inlet between the set pressure and reseating
pressure at which the valve starts to pressure and normally expressed as
discharge under service conditions. In a percentage of the set pressure.
safety or safety relief valve on gas
services, the set pressure is the inlet 7. Back Pressure
pressure at which the valve pops under
service conditions. Back pressure is the pressure
existing at the outlet of the pressure relief
Set pressure should not exceed device due to pressure in the discharge
the maximum allowable working pressure. system.
However, where more than one safety
valve is installed, any one valve need to be 8. Superimposed Back Pressure
set to open at or below maximum
allowable working pressure. The Superimposed back pressure is
additional valve may be set at maximum the pressure in discharge header before
105% of MAWP. the safety relief valve opens (where more
than one device discharges into a common
If the pressure relieving devices header).
are used for protection against fire or any
other external heat, the additional devices 9. Built up Back Pressure
can be set at a pressure not exceeding
110% of MAWP. Built up Back Pressure is the
pressure in the discharge header, which
3. Relieving Pressure develops as a result of flow after the safety
valve opens.
Relieving Pressure is the operating
pressure increased by the amount of over 10 . Lift
pressure at full lift of relief valve.
The rise of the disc in a pressure
4. Accumulation relief valve is called lift.

Accumulation is the pressure increase

over the maximum allowable working
pressure of the vessel during discharge 11. Chatter
through the pressure relief valve and is
 Chatter is an abnormal Crack Pressure is a supply
reciprocating motion of the movable parts pressure at which gas flow begins at the
of a pressure relief valve in which the disc pilot exhaust. This term is frequently used
contacts the seat, producing sound. in connection with pilot operated safety
relief valves.
12. Simmer
14. Cold differential test Pressure
Simmer is the audible escape of
fluid between the seat and disc at end inlet Cold differential test Pressure is
pressure below the popping pressure. In the inlet pressure at which a pressure relief
this, valve is only slightly open and valve is adjusted to open on the test
therefore discharging a small percentage bench. This test pressure includes
of its rated capacity. correction for service conditions of back
pressure and/or temperature.

13. Crack Pressure

 ANNEXURE IV

Leak Test for Seat tightness of Safety Relief Valves

A. Test Apparatus immediately after popping. The test

pressure shall be applied for a minimum of
A typical test arrangement for 1 minute for valves of inlet sizes through
determining seat tightness for safety relief 50 mm, 2 mins, for sizes 63 mm, 75 mm
valves is shown in figure (6) leakage and 100mm, 5mins for 150mm and
measurement shall be made with the use 200mm. Air at approximate ambient
of 0.8 mm OD tubing. The tube end shall temperature shall be used as the pressure
be cut square and smooth. It shall be medium.
parallel to end 13 mm below the surface of
water. C. Tightness Standard

B. Procedure The leakage rate in bubbles per

minute shall not exceed the value
With the valve mounted vertically the indicated in figure in the graphs (figure 7).
leakage rate in bubbles/mnt shall be
determined with pressure at the pressure,
 ANNEXURE-V

Card No._________

TECHNICAL DATA, TEST & HISTORY CARD OF SAFETY RELIEF VALVES.

A. Technical Data:

Information Conditions Dimensions

Location: __________ Service: __________ Inlet: __________

Tag No. __________ Relief __________ Outlet: __________

Pressure:
Make: __________ Cold set __________ Orifice: __________
Pressure:

Model/Type: __________ Back __________ Spring __________

Pressure: Number &
Length:
Catalogue __________ Operating __________ Materials:
Ref. Pressure: Body: __________

Drawing No. __________ Operating __________ Bonnet: __________

Temp.

Order No. __________ Changes in Disc: __________

operating:

Relief __________ Conditions: Nozzle: __________

Capacity: (if any, with Spring: __________
date)

B. Test Report & History:-

R S
Sl. Date Reason Set Date Cold E Leakag Details Recom Date of I
no of of pressure of Set Pr. S e rate of mendati installat G
. removal before test After E Repair ons/Re ion N
R dismantli Repair T & marks A
E ng Replac- T
M P ement U
O R R
V . E
A
L
 ANNEXURE-VI
Card No.______________

TECHNICAL DATA, TEST & HISTORY CARD OF RUPTURE DISC

A. Technical Data:-

Information: Conditions Dimensions

Location: __________ Service: __________ Size: ___________

Tag. No. ___________ Bursting

Pressure: ___________

Make ___________ Design Temp. ___________ Materials:

Lot No. ___________ Operating Disc: ___________

Pressure ___________

Catalogue ___________ Operating

Ref. Temp. ___________
___________
Drawing No.
___________
Order No.

Relief
Capacity ___________

B. Test Report & History:-

Sl. No. Date of Reason for Inspection Recommen Date of Signature

Removal Removal Observations dations for installation
Reuse/Repl
acement
 ANNEXURE-VII

Card No. ______________

TECHNICAL DATA, TEST & HISTORY OF PV VENT VALVE

A. Technical Data:-

Information Conditions Dimensions

Locations: __________ Service: __________ Inlet

Tag. No. __________ Set Working Outlet __________

range over
Pressure
Vaccum
Make: __________ Pallets __________
weight

Model/Type:

Catalogue
Ref: __________ Materials :

System
Drawing No. Operating Body: __________
Pressure: __________ Seat: __________
Pallets __________

Order No. __________ Sealing

Liquid __________

Relief Operating
capacity: _________ Temp: __________

B. Test Report and History:-

Sl. Date of Reason Leakage Date Leakage Details of Recomm Date of Signature
No removal for rate before of rate after Repair & endation installation
. removal dismantling Test Testing Replacem s/
______ ______ ent Remarks
Pressure Pressure
Vacuum Vacuum
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