SAFETY VALVES

SL CONTENTS

1.0 Purpose

2.0 Scope

3.0 Definitions

4.0 References & Standards

5.0 Types of safety valves installed in Gujarat Refinery

6.0 Need for Inspection

7.0 Frequency of Inspection

8.0 Safety Aspects

9.0 Inspection Procedure

10.0 Tools Required for inspection

11.0 Inspection of New safety valves

12.0 Inspection during repairs

15.0 Testing

16.0 Corrosion Control Measures

17.0 Inspection report

18.0 Documentation

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 SAFETY VALVES

1.0 PURPOSE

This manual specifies the requirement of;

1.1 Inspection and testing of safety valves

1.2 Inspection of safety valves under statutory rules
1.3 Repair/replacement of worn out/ damaged spares for safety valves

2.0 SCOPE

The manual shall include inspection method for on-stream and shop
inspection of various types of safety valves.

3.0 DEFINITIONS

3.1 SAFETY VALVE

Safety valve is a pressure relief valve actuated by inlet static pressure and
characterized by rapid opening or pop action. It is normally used for steam or
air service.

3.2 RELIEF VALVE

It is a pressure-relieving device actuated by inlet static pressure, which opens

in proportion to the increase in pressure over opening pressure.

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3.3 SAFETY RELIEF VALVE

A safety relief valve is a pressure relief valve actuated by inlet static pressure
and characterized by rapid opening or pop action or by opening in proportion
to the increase in pressure over opening pressure depending on application. It
can be used either as a safety valve or relief valve.

3.4 RUPTURE DISC

A rupture disc is a thin metal diaphragm held between flanges and designed to
rupture automatically at a pre-determined pressure.

3.5 SET PRESSURE

It is the pressure at the inlet at which the safety relief valve is adjusted to open
and there is a measurable lift. This pressure should not exceed the maximum
allowable working pressure.

3.6 COLD SET PRESSURE

It is the inlet pressure at which the pressure relief valve is adjusted to open on
the test bench. This test pressure includes correction for service conditions of
back pressure and / or temperature.

Cold Set Pressure = Set pressure – Back Pressure + Temp correction as per
manufacturers’ instructions.

3.7 BACK PRESSURE

It is the pressure at the outlet of the safety valve.

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3.8 RESEAT PRESSURE

It is the pressure at which valve closes after discharging. Reseat pressure

should always be above the operating pressure.

3.9 BLOW DOWN

It is the difference between set pressure and reseating pressure normally

expressed as percentage of set pressure.

4.0 REFERENCES AND STANDARDS

4.1 API RP 520 Part 1 & 2 : Design and installation of Pressure relieving systems
in refineries.
4.2 API RP 521 : Guide for pressure relief and depressurizing systems
4.3 API Guide Chapter-16 : Pressure relieving devices
4.4 API 526 : Flanged Steel safety relief valves
4.5 API 527 : Seat tightness of safety relief valves
4.6 IBR rules for safety valves on Steam Generators
4.7 SMPV rules – 1981
4.8 ASME BPV code section VIII Div.1

5.0 TYPES OF SAFETY VALVES INSTALLED IN GUJARAT

REFINERY

In Gujarat Refinery all types of relief valves and pressure relieving devices are
used. New types of safety valves i.e. Pilot Operated Valves and Rupture Disc
have been installed in FCCU, DHDS, Nitrogen and New Hydrogen unit.

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 Various types of safety valves are listed below;

5.1 Conventional spring type safety valves.

5.2 Safety valves for steam service with open spring.
5.3 Safety valves with bellow for variable back pressure.
5.4 Pilot operated safety valves

6.0 NEED FOR INSPECTION

Safety valves are the primary devices for protection of equipment from
overpressure situations. The proper working of a safety valve is very essential
for ensuring that the equipment on which it is mounted is adequately
protected. To maintain the safety of the equipment, the safety valve shall be
inspected at defined intervals.

7.0 FREQUENCY OF INSPECTION

The following service conditions are taken into consideration to determine the
frequency of inspection:

7.1 Fouling and corrosive service

7.2 Non-fouling and clean service
7.3 Vibration and pulsating loads
7.4 Low differential between set and operating pressures
7.5 Operational experiences.

The following inspection frequency is recommended which can however be

modified depending upon the history of the valve and any change in service
conditions;

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 Nature of service Inspection/testing frequency

1) Clean / Non fouling service During planned turnaround or outage of

equipment but not more than 3 years.
2) Corrosion / Fouling/ As per experience but not more than
Pulsating two years
3) New process conditions As soon as possible after commissioning of
the unit but not later than a year.
4) Safety valves for steam As per IBR requirements.
service Unfired Boilers – Every two years
Fired Boilers -- Every year
5) LPG bullet/ Horton sphere At least once a year as per SMPV rules
and equipment In (1981)
SO2,ammonia, Nitrogen and
Hydrogen Service
6) New safety valves All new safety valves to be Tested before
commissioning
Pressure and vacuum vents Inspection and cleaning to be carried out at
Of atmospheric storage tanks least yearly before Monsoon

8.0 SAFETY ASPECTS

The safety valve should be installed as per the installation instructions of

manufacturers and relevant codes and standards. The valve shall be kept in
vertical position after revisioning and testing to avoid mal-operation. After
testing the safety valve shall be sealed from inlet and outlet nozzles till it is
installed on the equipment to avoid from dust and debris which may affect the
operation of safety valve.

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9.0 INSPECTION PROCEDURE

9.1 ON-STREAM INSPECTION

The following shall be ensured;

9.1.1 Correct relief device is installed.

9.1.2 Identification tag shows proper pressure setting.
9.1.3 Gas, blinds, closed valves or piping obstructions do not exist.
9.1.4 Seals protecting the spring setting have not been broken.
9.1.5 Relief device is not leaking – this may be checked visually and by
Petroscanner, contact thermometer or by hand touch at outlet nozzle
wherever practicable.
9.1.6 Ultrasonic leak test using special instrument (Physical Acoustic Leak Detector)
wherever passing of safety valve is reported by Production department.

9.2 SHOP INSPECTION

9.2.1 Inspect and test the relief valve in “as received” condition. This is important
and helps in establishing the frequency of inspection.

9.2.2 General visual inspection of different parts of safety valves shall be done after
dismantling to check the following;

9.2.2.1 Condition of flange for pitting, roughening, decrease in width of seating

surface etc.
9.2.2.2 Spring for evidence of bending, corrosion or cracking. Check the free length
of spring.
9.2.2.3 Bellows (if applicable) for damage/crack.
9.2.2.4 Position of set screw and opening in bonnet.

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9.2.2.5 Inlet / outlet nozzles for evidence of deposits, foreign material and corrosion.
9.2.2.6 Condition of external surface and evidence of mechanical damage.
9.2.2.7 Body wall thickness.
9.2.2.8 Condition of stem, guide, disc and nozzle etc. should be visually inspected for
evidence of wear and corrosion.
9.2.2.9 Seating surface of disc and nozzle should be critically examined for roughness
or damage, which could result in valve leakage and may need correction.
Care must be taken to ensure flatness of seats.
9.2.2.10 Springs should be tested for at least those safety valves, which are already
identified for malfunctioning during operation, or found defective during testing
on test bench. If the load and compression relationship is not matching with
the original values, it may be concluded that the spring is losing stiffness and
needs replacement.

9.3 SPECIAL REQUIREMENTS FOR STATUTORY VALVES

9.3.1 For IBR valves, position of lock nut washer are measured and it is maintained
for future reference. This also prevents in changing/tampering of valve settings
by unauthorized persons.
9.3.2 The flotation test of safety valves for fired boilers is done in position by
adjusting the blow down ring. The blow down for IBR safety valves shall be in
the range of 3%-5%.
9.3.3 For the safety valves covered under SMPV rules immediately after testing a
certificate of compliance is issued in form-19 as per SMPV rule and one copy
sent to CCE Nagpur.

10.0 TOOLS REQUIRED FOR INSPECTION

10.1 Magnifying glass

10.2 Torch

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10.3 Vernier calipers

11.0 INSPECTION OF NEW SAFETY VALVES

Since, the setting of valves may get disturbed due to mis-handling, all the new
safety valves are tested as per manufacturer’s recommendation before
installation to check the performance and ensure trouble free operation.

12.0 INSPECTION DURING REPAIRS

Check all valve parts for wear and corrosion. The valve seats and both
nozzles and disc inserts must be examined to determine if they have been
damaged. Valve springs and bellows should be inspected for evidence of
pitting, cracking and deformation. The bearing surfaces on the guide and disc
holder shall be checked for residual product build up and any evidence of
scouring. Lapping the valve seats is done to restore them to their original
condition. The valve seats are visually inspected with help of magnifying glass
after lapping to check the removal of scouring and scratch marks.

13.0 TESTING

13.1 SET PRESSURE TEST

13.1.1 After final adjustment, the valve should be popped at set pressure at least
once to prove the accuracy of setting. Final pop should be within + 0.5% for
required cold set pressure before valve is approved for service. Allowance for
hot setting is to be made as per manufacturer’s recommendations.

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13.1.2 Reseat pressure should also be checked during testing of safety valve.
Reseat pressure should be more than working pressure. In no case, it should
go below more than 10% of the cold set pressure.
13.1.3 Working of hand popping device should be checked during testing.

13.2 SEAT TIGHTNESS TEST

Valve can be tested for seat tightness after set pressure test on the test bench
by applying pressure on the valve at 90% to 95% of set pressure and
observing the discharge side of valve for evidence of leakage. The leak test
pressure should always be more than working pressure. During testing
preferably no leakage should be permitted to ensure better performance in
operation.

After the test, individual safety valve has to be sealed in presence of

Inspector.

13.3 SPECIAL REQUIREMENTS

The safety valves of pilot type are having different designs. The
manufacturer’s manual for inspection and testing shall be strictly adhered to
for carrying out inspection and revisioning of these valves.

14.0 CORROSION CONTROL MEASURES

Corrosion may result in pitting of valve parts, failures of various valve parts,
build up of corrosive products and general deterioration of valve products.

Corrosive attack is controlled trough following measures;

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14.1.1 Selection of suitable material and painting on springs/other parts
14.1.2 By employing a bellows seal to isolate the valve spring adjusting bolts, spindle
and guiding surfaces from the corrosive attack of the process fluids.
14.1.3 Generally Stainless steel materials with stelliting on the seating surface and
solid stainless steels for the disc inserts and nozzle are used.

15.0 INSPECTION REPORT

Based on the inspection findings, a detailed report is prepared and

recommendations are issued for corrective actions.

16.0 DOCUMENTATION

16.1 A Data / History Card is maintained and updated after every test and
revisioning for the safety valve.
16.2 Certificate for safety valves covered under SMPV rules in form-19.

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