Saep 319

Engineering Procedure
SAEP-319 2 March 2020

Inspection and Testing Requirements for Pressure Relief Devices
Document Responsibility: Inspection Engineering Standards Committee
Contents
1 Scope .......................................................................... 2
2 Conflicts and Deviations .............................................. 3
3 References .................................................................. 3
4 Definitions .................................................................... 4
5 Responsibilities ............................................................ 7
6 Authorization Requirements ...................................... 16
7 Instructions ................................................................ 17
8 Marking and Identifying RVs ...................................... 34
9 Pressure Testing RVs ................................................ 35
10 Relief Valve Test Stand (RVTS) Instructions ............. 36
11 Test Stand Requirements .......................................... 37
12 Relief Valve Technician Certification ......................... 40
Appendix A - Relief Valve Operating System Approval
Workflow Process......................................... 44
Appendix B - Initiation of Workflow for RV Equipment
Master through Operating System
Transaction IE01/IE02 .................................. 45
Appendix C - Sample RV Testing Activities Workflow ....... 50
Appendix D - RV Deviation Approval WF .......................... 51
Appendix E - Operating System Roles
and Responsible Party ................................. 52
Appendix F - Test Interval Exception Services .................. 53
Appendix G - Standard Checklist....................................... 54
Appendix H - Test Conductor Requirements ..................... 58
Appendix I - Spring Loaded RV Testing and Inspection .... 60
Appendix J - Pilot RV Testing and Inspection .................... 61
Appendix K - Tank Breather Valve Testing
and Inspection .............................................. 62
Appendix L - RV Checklist for External Inspection ............ 63
Appendix M - Example of RV In-place Test Report ........... 64
Appendix N - RV Shop Audit Form .................................... 65
Revision History................................................................. 66
Previous Issue: 2 July 2017 Next Revision: 2 July 2022

Revised paragraphs are indicated in the right margin Page 1 of 66
Contact: (lodhizf)
©Saudi Aramco 2020. All rights reserved.
Saudi Aramco: Company General Use

Document Responsibility: Inspection Engineering Standards Committee SAEP-319
Publish Date: 2 March 2020
Next Revision: 3 July 2022 Inspection and Testing Requirements for Pressure Relief Devices
1 Scope
1.1 This engineering procedure covers the identification, installation, approval, authorization,
addition, deletion, replacement, mothballing, inspection, maintenance and testing and
responsibilities for Pressure Relief Devices (PRDs).
1.2 This procedure also contains instructions for Relief Valve Test Stands (RVTS).
1.3 This procedure shall also apply to flow modulating, i.e., Ful-Flo or equivalent, relief
valves, providing:
1.3.1 They are the sole relieving device for the system being protected.
1.3.2 They can be tested in-place when an approved In-place Test Procedure is used.
1.4 PRDs in Saudi Aramco operating facilities which are owned and operated by
Contractors or tested by third party RV Shop shall be tested, inspected and tracked
through Operating System or a PM program in accordance with this procedure.
1.5 It establishes the minimum requirements for PRDs Test Conductors and Technicians
Certifications involved in testing/repair of PRDs at Saudi Aramco facilities.
1.6 Exclusions
1.6.1 The following are excluded from the requirements of this procedure:
a) Residence water heaters PRDs
b) PRDs in water heaters of less than 100 gallon capacity
c) Turbine alarm (sentinel) valves
d) Bottled gas cylinders PRDs
e) Surge suppression valves
f) Pressure reducing and let-down valves
g) Pressure controllers and regulator valves
h) Integral pump and compressor casing PRDs
i) PRDs in air compressors mounted on vehicles (portable)
j) Tank Rim Vent valves
k) ¼-inch NPT Relief Valves in Well Shut Down (WSD) hydraulic cabinets.
l) Non-industrial application chillers including A/C chillers.
m) Industrial Chillers with RV size ½-inch and below.
1.6.2 RVs excluded from the RV Program must be maintained or replaced
periodically, in accordance with a documented maintenance program that can
only be altered with Operating Facility Manager’s approval.
©Saudi Aramco 2020. All rights reserved. Page 2 of 66

2 Conflicts and Deviations
Any conflicts between this document and other applicable Mandatory Saudi Aramco
Engineering Requirements (MSAERs) shall be addressed in writing to the EK&RD
Coordinator.
Any deviation from the requirements herein shall follow internal company procedure
SAEP-302, Waiver of a Mandatory Saudi Aramco Engineering Requirement.
3 References
The following references or associated documents are required by this SAEP.
3.1 Saudi Aramco Documents
Saudi Aramco Engineering Procedures

SAEP-20 Equipment Inspection Schedule
SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering Requirement
SAEP-309 Inspection of Community and Operations Support Facilities
SAEP-1027 Pressure Relief Valve Conventional and Balanced Types
Saudi Aramco Engineering Standards

SAES-A-004 Pressure Testing
SAES-A-206 Positive Material Identification
SAES-B-067 Safety Identification and Safety Colors
SAES-H-001 Coating Selection and Application Requirements for Industrial Plants
and Equipment
SAES-J-600 Pressure Relief Devices
SAES-J-605 Surge Relief Protection Systems
Saudi Aramco Best Practice

SABP-J-600 In-place Testing of Safety Valves
Saudi Aramco Forms and Data Sheets

PM02 Maintenance Work Order
SA-3750 Relief Valve Maintenance Report
SA-8020-605 Instrumentation Specification Sheet - Surge Relief Valves
SA-8020-611 Instrument Specification Sheet - Conventional and Balanced Relief
Valves

SA-8020-612 Instrument Specification Sheet - Pilot Operated Safety Relief Valves

SA-8020-613 Instrument Specification Sheet - Pressure-Vacuum Relief Valves
SA-8020-614 Instrument Specification Sheet - Rupture Disks
Saudi Aramco Technical Alert

ALERT-94-016 Body Pressure Relief Valve (PRV) Leakage - GROVE Ball Valves,
Model B-5
3.2 Industry Codes and Standards
American Petroleum Institute

API STD 527 Commercial Seat Tightness of Safety Relief Valves with Metal-to-
Metal Seats
American Society of Mechanical Engineers/Boiler and Pressure Vessel Code

ASME SEC I Rules for Construction of Power Boilers
ASME SEC VIII D1 Rules for Construction of Pressure Vessels
4 Definitions
Base Test Interval: The interval assigned to a new valve that is derived from past
experience with similar service and RV design.
Backpressure: The pressure that exists at the outlet of a pressure-relief device as a
result of the pressure in the discharge system. It is the sum of the superimposed and
built-up backpressures.
Blowdown: The difference between the set pressure and the closing pressure of a
pressure-relief valve, expressed as a percentage of the set pressure or in pressure units.
Built-up Backpressure: The increase in pressure at the outlet of a pressure-relief
device that develops as a result of flow after the pressure relief device opens.
Burst Pressure: The burst pressure of a rupture disk at the specified temperature is the
value of the upstream static pressure minus the value of the downstream static pressure
just prior to when the disk bursts. When the downstream pressure is atmospheric, the
burst pressure is the upstream static gauge pressure.
Burst-Pressure Tolerance: The variation around the marked burst pressure at the
specified disk temperature in which a rupture disk will burst.
Closing Pressure: The value of decreasing inlet static pressure at which the valve disc
reestablishes contact with the seat or at which lift becomes zero, as determined by
seeing, feeling, or hearing.

Cold Differential Test Pressure (CDTP): The pressure at which a pressure-relief

valve is adjusted to open on the test stand. The CDTP includes corrections for the
service conditions of backpressure or temperatures or both.
Car seal: A locking seal that when placed in position and closed, locks and must be cut
or physically broken to be removed.
Changes that affect RV Operation: Mechanical and operational changes that affect
RV reliability and operation, such as: set pressure, back pressure, spring range, spring
number, nozzle orifice size, service, operating temperature, disassembly indicator,
mothballing/demothballing, design code, material, not identical location inlet and outlet
pipe sizes, and test intervals.
Changes that do not affect RV Operation: Changes that do not directly affect valve
reliability and operation, such as: RV identical location, installation code, RV type
indicators, ISS drawing number, PZV tag number, and other non-mechanical changes.
Instrument Specification Sheet (ISS): Data sheet, for verification of RV design for
installation into any Saudi Aramco facility, which is the permanent record of initial
design.
Leak-Test Pressure: The specified inlet static pressure at which a seat leak test is
performed.
Lift: The actual travel of the disk away from the closed position when a pressure-relief
valve is relieving.
Maintenance Plan Processor: An authorized person from Maintenance organization
having Role ID number 32 in Plant Maintenance module of Operating System.
Maximum Allowable Working Pressure (MAWP): The maximum gauge pressure
permissible at the top of a completed vessel in its normal operating position at the
designated coincident temperature specified for that pressure.
Non-reclosing Pressure-relief Device: A pressure-relief device, which remains open
after operation. A manual resetting means may be provided.
Orinator Engineer: Operation/Plant Engineer or Project Engineer who intiates/change
the RV installtion according to the requirments of this procedure, that requires
authorization approvals by providing the design and specification information.
Opening Pressure: The value of increasing inlet static pressure whereby there is a
measurable lift of the disk or at which discharge of the fluid becomes continuous, as
determined by seeing, feeling or hearing.
Overpressure: The pressure increase over the set pressure of a pressure relief of a
relieving device allowed achieving rated flow. Overpressure is expressed in pressure

units or as a percentage of set pressure. It is the same as accumulation only when the
relieving device is set to open at the MAWP of the vessel.
Pin-actuated Device: A non-reclosing pressure-relief device actuated by static pressure
and designed to function by buckling or breaking a pin which holds a piston or a plug in
place. Upon buckling or breaking of the pin, the piston or plug instantly moves to the
full open position.
Pressure Relief Device (PRD): All PRDs including Safety valves, relief valves,
pressure relief valves, surge relief valves, vacuum breakers, buckling pin valves and
Rupture Disks (RD) are referred to as RVs in this SAEP.
PRDs Used in Low Capacity: These include individual residence hot water heaters of
less than 100 gallon capacity, Turbine alarm (sentinel) valves, Bottled gas cylinders,
Surge suppression valves, Pressure reducing and let-down valves, Pressure controllers
and regulator valves, Integral pump and compressor casing PRDs, PRDs in air
compressors mounted on vehicles (portable), Tank Rim Vent valves.
Rated Relieving Capacity: The relieving capacity used as the basis for the application
of a pressure-relief device. This capacity is determined in accordance with the
applicable code or regulation and is provided by the manufacturer.
Replacement “IN-KIND”: Replacement of a RV with an identical RV from the same
manufacturer,i.e., same application and design code.
Operating System R/3: Operating System in data processing. “R” means 'real-time
processing.
Set Pressure: The inlet gauge pressure at which a pressure-relief valve is set to open
under service conditions.
Simmer: The audible or visible escape of compressible fluid between the seat and disc,
which may occur at an inlet static pressure below the set pressure prior to opening.
Specified Burst Pressure: The specified burst pressure of a rupture disk is the burst
pressure specified by the user. The marked burst pressure may be greater than or less
than the specified burst pressure but shall be within the manufacturing design range.
The user is cautioned to consider manufacturing range, superimposed backpressure and
specified temperature when determining a specified burst pressure.
Superimposed Backpressure: The static pressure that exists at the outlet of a
pressure-relief device at the time the device is required to operate. It is the result of
pressure in the discharge system coming from other sources and may be constant or
variable.
Safety Valve: A safety valve is a direct spring-loaded pressure-relief valve that is
actuated by the static pressure upstream of the valve and characterized by rapid opening
or pop action.

Stamped Relieving Capacity: The rated relieving capacity that appears on the device
nameplate and based on the rated relieving capacity determined at the specified set
pressure or burst pressure plus the allowable overpressure.
5 Responsibilities
5.1 Inspection Technical Support Division (ITSD), Inspection Department

5.1.1 Responsible for overall administration of the RV Program company-wide.
5.1.2 Reviews and concurs Relief Valve external deviation requests WFs
(i.e., > 3 months) to deviate from Equipment Inspection Schedule.
5.2 RV Administrator
5.2.1 Evaluates the designated Maintenance Relief Valve Test conductors.
5.2.2 Conducts final evaluation of RVTS used in Saudi Aramco facilities upon
request.
5.2.3 Performs periodical assessment on RV program.
5.2.4 Administrates the Pressure Relief Devices programs.
5.2.5 Reviews and concurs RV external deviation requests.
5.2.6 Provides guidance and consultation to RV Coordinators and RV technicians.
5.2.7 Verifies and Approves the RV Work Flow (WF) data in Operating System.
5.2.8 Administers the authorization of RV Tracking Program in Operating System.
5.2.9 Authorize transfer of the custody of any RV in Operating System.
5.3 Process & Control Systems Department (P&CSD)

5.3.1 Provide consultations to Plant Engineering on RV upon request.
5.3.2 Provide consultations, to Engineering for new RV manufacturer, material, and
testing technology.
5.4 Area Loss Prevention Representative
Reviews and concurs RV in-place testing procedures and external deviation requests as
required by this procedure.
5.5 Corporate Business Application Department (CBAD)
5.5.1 Troubleshoots the RV Operating System related issues and maintains RV database.

5.5.2 Provides Operating System technical support to all Saudi Aramco facilities.
5.5.3 Provides Operating System transaction codes that are used for RV tracking
system.
5.6 Mechanical Services Shops Department (MSSD)
5.6.1 Manages and approves Contractor RV repair shops based on Contractor's

approved capabilities.
5.6.2 Audits Contractor facilities annually.
5.6.3 Performs RV T&Is in Mechanical Services Shop for Saudi Aramco facilities.
5.6.4 Notifies the RV proponent when problems are identified, such as stuck, dirty,
corroded, etc., so that an Engineering decision can be made prior to
release/testing of the RV.
5.7 Manager, Operating Facility
5.7.1 Approves RV In-place Testing procedure.
5.7.2 Approves Relief Valve external deviation requests WFs (i.e., > 3 months) to
deviate from Equipment Inspection Schedule.
5.8 Originating Engineer
5.8.1 Verifies that the RV conforms to Saudi Aramco Specifications.
5.8.2 Prepares and attaches the scanned copy of ISS (SA-8020-6XX) for each RV
type. Refer to SAEP-1027 for conventional and bellows RV types.
5.8.3 Initiates the RV Authorization WF in Operating System (see Appendices A and B)

and attaches current P&IDs, approved MOC and associated SIS (if applicable).
5.8.4 Enters the RV data into the Operating System using Transaction Code IE01
with Equipment Category “R” for new RVs or IE02 for any updates.
5.8.5 Tracks the Approval of Operating System Authorization WF till completion

through Transaction Code ZI0071.
5.8.6 Assures that no unauthorized RVs are installed in-site.
5.8.7 Verifies that the PM02 Work Order is created by Operating System R/3
through Transaction Code ZI0014 and Code IW39 for Displaying Service and
Maintenance Orders.

5.8.8 Requests support such as corrosion engineer, CSD/P&CSD/ID/ Manufacturer,

etc., for any required technical evaluation or failure analysis.
5.8.9 Submits deviation requests through Operating System transaction ZIF0015.

The P&ID, last 2 T&I reports, RV Check list, approval letter, and Root Cause
Analysis (RCA) report (if required) shall be attached in Operating System.
5.8.10 Provides feedback within 90 days to the initiator of RV Interval Change

Recommendation letter based on Operating System Transaction ZI0112.
5.8.11 Proposes RV Test Interval optimization through OME and initiate Operating
System Workflow through transaction IE02.
5.9 Senior Project Engineer
5.9.1 Approves RV Operating System Authorization WF after ensuring that all

required documentation is attached under the RV record in Operating System.
5.9.2 Maintains a current technical library that includes applicable relief valve
documentation for the RVs used in the Facility under Construction.
5.9.3 Provides a review of damaged, corroded, stuck or malfunctioning RVs in

cooperation with Project Inspection Division.
5.9.4 Verifies that all RVs installed in the newly constructed facility are approved in
the RV Operating System tracking system, tested and properly tagged prior to
final MCC and PMT turnover of the facility to Saudi Aramco operations.
5.9.5 Provides all required RV documentation to initiate the approval WF in

Operating System such as ISS, SIS, and P&ID are made available prior to
signing MCC. This documentation should be obtained and uploaded into
Operating System.
5.9.6 Verifies that RVTS used for testing PRD in projects meets the requirements of
this procedure.
5.10 Operations Engineering Supervisor
5.10.1 Approves RV design and specification.
5.10.2 Concurs RV Operating System Deviation WF and ensure all required

documents are attached.
5.10.3 Verifies applicable documentation for the RVs are properly maintained.
5.10.4 Obtains required approval stated in this procedure for In-place Test.

5.10.5 Reviews corroded, stuck or malfunctioning RVs in cooperation with Operations

Inspection Unit.
5.10.6 Assign an engineer to participate in the two years comprehensive physical

review mentioned in this procedure.
5.10.7 Verifies that all RVs installed in the newly constructed facility are entered and
approved in RV Operating System prior to Saudi Aramco operations accepting
facility from PMT.
5.11 RV Coordinator
5.11.1 Administers the RV tracking program for all facilities under his area of
responsibility.
5.11.2 Verifies and approves the Relief Valve Operating System Authorization WF
data against the Form SA-8020.
5.11.3 Reviews RV deviation and ensures required documents are attached.
5.11.4 Investigates why RV is not tested if period following Operating System

approval exceeds 3 months.
5.11.5 Verifies that copies of all RV data are scanned and attached to the WF such as
latest P&ID drawing, SIS, and MOC, if applicable.
5.11.6 Verifies that all technical reports, Form SA-3750, annual external inspection,
P&ID, SIS / ISS, Defect Notification, and other correspondence related to the
RV are attached in the Operating System RV records.
5.11.7 Reviews all information in Operating System prior to approving maintenance

report on Form SA-3750 through Operating System Transaction QA11.
Rejects the test results in case of any discrepancy in testing.
5.11.8 Conducts an annual internal RV Tracking Program audits including RV T&I

Shop. Sample RV shop Audit is provided in Appendix N.
5.11.9 Assists Originating Engineer if requested, with the Relief Valve Operating
System Authorization and deviation WF, to ensure conformance with the
requirements of this procedure.
5.11.10 Maintains or has access to current RV reference material, e.g., manufacturer's

manuals and copy of local RV Shop QA Manual.
5.11.11 Assists local Inspectors and maintenance to resolve questions concerning test
interval revisions, deletions, additions, change requests, test shop activity and
troubleshooting RV problems.

5.11.12 Update the approval responsibility through Operating System Transaction

Code ZI0127.
5.11.13 Check that Operating System authorization and deviation WF is initiated by

the originator engineer and each approval position has a backup.
5.11.14 Confirms that the maintenance plan status is set to deleted/inactive prior to
deleting/mothballing RV.
5.11.15 Verifies that the PRD approved interval in Operating System is reflected in the
maintenance plan task list by displaying Operating System Transaction ZI0094.
5.12 Project Inspection Supervisor or His Delegate
5.12.1 Verifies the Relief Valve Operating System Authorization WF data against
approved Form SA-8020-6XX, and approves RV for newly constructed
facilities.
5.12.2 Verifies that PRD pressure testing matches design specification provided by
PMT.
5.12.3 Verifies third party RV Shop is approved by Saudi Aramco if the RV testing
in a third party non Saudi Aramco facility.
5.12.4 Verifies correct installation and identification marking of RVs is in accordance

with this SAEP.
5.12.5 Verifies that installed RVs are sealed, in the correct location as per current
verified P&ID, correctly painted and properly piped to a safe location per
SAES-J-600.
5.12.6 Verifies that block valves are properly installed and painted, as per SAES-J-600
and SAES-B-067.
5.12.7 Verifies that the isolation valve installed between the remote pressure gauge
and the area being monitored (the area between the rupture disk or rupture pin
and the relief valve) is locked open.
5.12.8 Verifies that RV bonnets are vented to a safe location, per SAES-J-600, and
painted green for bellows type RVs, per SAES-B-067.
5.12.9 Verifies that installation, deletion or a change has taken place through visual
inspection.
5.13 Supervisor/Field Supervisor of the Operations Inspection Unit
For remote areas, the Inspection Field Supervisor has the authority to act on behalf of

the Inspection Supervisor for the following items:
5.13.1 Provides an audit of the RV T&I Program once a year as required by this
procedure and generates audit report within 14 days.
5.13.2 Assigns/ train a member of Inspection Unit as 'RV Coordinator'.
5.13.3 Verifies that area inspectors complete the due RV external checklist.
5.13.4 Provides inspection to witness In-place RV testing and engineering reviews of

corroded, dirty, stuck, and malfunctioning RVs.
5.13.5 Verifies that installed RVs are approved in Operating System, tagged, sealed, in
the correct location, and piped to a safe location, as required by SAES-J-600,
during annual external inspections by designated OIU staff.
5.13.6 Verifies that block valves are properly installed and painted, as per SAES-J-600
and SAES-B-067, during annual external inspections by designated OIU staff.
5.13.7 Verifies the Relief Valve Operating System Authorization WF data against
approved Form SA-8020-6XX, and approves the RV in the Operating System
system.
5.13.8 Investigates RVs that have been commissioned without a Relief Valve
Authorization in Operating System and reports findings to Engineering for
initiation of the Operating System Authorization WF.
5.13.9 Confirms the availability of written procedures for RV Tracking Program

auditing for areas under his responsibilities.
5.13.10 Recommends interval updates annually to Plant/Operations engineer.
5.13.11 Verifies that the two-year periodic, comprehensive physical review mentioned
in this procedure is completed including:
a. assigning a member of the Inspection Unit as team member
b. timely completion
c. documenting the result of the physical review and follow up on corrective
actions.
5.14 Operations Superintendent
5.14.1 Approves new RV installations, changes which affect RV operation

replacements, retirements, or removals in Operating System WF.
5.14.2 Concurs/Approves RV deviation requests in Operating System Work Flow.

5.14.3 Approves RV in-place testing, and assures that the correct equipment pressure
is strictly maintained during the test.
5.14.4 Assures that RV Work Orders are distributed for timely RV T&Is.
5.14.5 Verifies that a comprehensive physical review is conducted every two years.
The two years’ periodic comprehensive physical review involves:
a. Punchlisting of deficiencies by a team with representatives from
Inspection Unit, Operations/Plant Engineering and Operations.
b. Scheduling by the Area Operations Foreman.
c. Verifying all RVs are installed at locations specified in Operating System
and in good condition (i.e., no leaks, cracks, corrosion, etc.).
5.14.6 Verifies and assures that a monthly RV checklist is used by the responsible
Operations personnel.
5.14.7 Verifies the monthly RV checklist should be created to include data for all
fields in Appendix L signed by Area Operator and approved by Supervising
Operator (SO) and Area Foreman.
5.14.8 Verifies that any RV found not to be entered in the RV Operating Tracking
System prior to turnover of newly constructed facility to Saudi Aramco
operations is entered in the Operating Tracking System by Engineering within
thirty (30) days from date of discovery of the RV.
5.15 Operations Foreman / Commissioning Supervisor
5.15.1 Verifies and concur with the RV approval and deviation WF in Operating System.
5.15.2 Verifies that the RV location and marking are correct as per the current
verified P&ID.
5.15.3 Verifies that inlet and outlet block valves, for active RVs, are open completely
and properly sealed.
5.15.4 Verifies that the block valves are painted orange, as required by SAES-J-600
and SAES-B-067.
5.15.5 Verifies that the block valve stems are oriented horizontally or sloping away
down maximum 45 degree from the valve as per SAES-J-600.
5.15.6 Verifies that all RVs are in Operations RV Checklist whenever RV is installed
on site after being tested and inspected.
5.15.7 Concurs with approval to conduct In-place RV testing.

5.15.8 Initiates Maintenance Orders for the repairs of RVs not due for T&I under the
Preventive Maintenance system in Operating System and attach the Operating
System notification with the SA-3750 maintenance report.
5.15.9 Verifies that a pressure gauge is present between a reclosing RV and an in-
series rupture disk.
5.15.10 Prepare and approves field generated RV T&I Work Order PM07, as required.
5.15.11 Verifies every installed RV is tagged, sealed properly and transportation gauge
is removed.
5.15.12 Verifies the vents on bellows RV's are opened or piped to a safe location.
5.16 Foreman/Supervisor RV Maintenance Shop
5.16.1 Verifies the performance of physical inspection, testing, and repair of RVs in
accordance with the RV Tracking Program and SAEPs.
5.16.2 Verifies that the RV technician entering the test Data is trained to use the
Operating System System and familiar with the terminology for RV repair to
recognize data entry messages and errors.
5.16.3 Approves Relief Valve Maintenance Report, Form SA-3750, for each RV
repair activity entered in the Operating System.
5.16.4 Verifies the integrity of the data prior to requesting approval by the RV
Coordinator.
5.16.5 Sends the original Form SA-3750 to the local Inspection Unit/RV Coordinator
for test results approval.
5.16.6 Verifies that the manufacturer's nameplate is attached, in good condition,

readable and the RV has an ASME stamp, where required.
5.16.7 Verifies that each RV conforms to its design description in Operating System
Data.
5.16.8 Verifies or applies RV ID tags, stamps, required paints, and adjustment of

seals, as required by this procedure.
5.16.9 Maintains “TEST” RVs for pressure testing purposes, with associated service
and design records.
5.16.10 Verifies availability of calibrated RV test stand.
5.16.11 Verifies that the RV Technicians are certified and tracks training schedule.

5.16.12 Verifies up to date QA Manual is approved by maintenance manager / facility

manager and available in the RV Shop.
5.16.13 Maintains access to Operating System Database and Transactions. The database
should consists of all RV data including ISS, P&ID, SA-3750 communication
letters, memos, and any other related information pertaining to RVs.
5.16.14 Maintains and update the RV Test Shop Annual Audit items. A quarterly
report on the status of agreed corrective actions and ETC shall be sent to plant
Inspection Unit.
5.16.15 Verifies the re-installation of RVs that have been tested within 14 days after
the completion date in Operating System.
5.17 RV Maintenance Technician
5.17.1 Tests and inspects RVs according to manufacturer's requirements, per this
procedure, QA Manual.
5.17.2 Follow an approved In-place Testing procedure during RV in place test.
5.17.3 Perform RV pop and leak tests using an approved test stand per this procedure.
5.17.4 Records the test results and the condition of the RV on Maintenance Report
(Form SA-3750) and any additional format needed to provide a meaningful
historical record of RV condition and performance through Operating System
Transaction QE17.
5.17.5 Communicates RV condition to RV Shop Supervisor when an engineering

review, evaluation or further inspection is required.
5.17.6 Replaces the tag after calibration, interval change, or when tag has faded or lost.
5.17.7 Handles and transport RV's carefully and maintain RV at vertical position at
all times.
5.17.8 Overhauls RV when disassemble indicator is due per RV Operating System

record, or when it fails initial testing, or when requested by Inspection,
Operations, or Engineering.
5.17.9 Leak tests RV bellows and closed bonnet, where applicable, using minimum
acceptance criteria per this procedure.
5.17.10 Apply the adjustment seals upon completion of the T&I (overhaul).
5.17.11 Affix metal tag and seal properly.

5.18 Maintenance Planner
5.18.1 Provides RV Maintenance data to the originator upon request. The originator
must verify the integrity of the data prior to requesting an RV number.
5.18.2 Creates maintenance package, plan, and develops task list and other items
related to the PM program for all approved RVs.
5.18.3 Ensures the availability of critical material spare parts list for PRDs in
Operating System which are used in proponent facilities.
6 Authorization Requirements
6.1 To authorize a new RV installation, the Originating Engineer completes, attaches the
ISS Form SA-8020-6XX and other relevant documents, then starts the Relief Valve
Operating System Workflow.
6.1.1 The Originating Engineer should coordinate with the Maintenance Division
and the local RV Coordinator in order to fill in the Maintenance Plant,
Functional Location, and Plant Number in Operating System. If the Plant
Number does not exist in the Operating System, the Originating Engineer or
his assignee shall make a request to the Hydrocarbon Applications Department
(HAD)/Plant Maintenance & Industrial Services Applications Group to add
the new Saudi Aramco Engineering Plant Number (EPN) to the Operating
System Location Table.
6.1.2 The Originating Engineer enters the data into the corporate Operating System
using the Transaction Code IE01 (Create Equipment). At this stage of the
process, the RV is assigned a permanent number which should be kept in a
permanent RV data records having “CRTD” Created mode in User Status.
Once all required RV data records are entered, then the Originator should select
“Awaiting Approval” mode in User Status field of the Operating System.
6.1.3 The Originating Engineer shall notify the Operations Foreman or Project
Supervisor to execute the RV Maintenance Order for testing and field installation.
6.1.4 After RV physical installation, RV's shall be verified and documented in the
RV Monthly Operation Checklist.
6.1.5 New RV Installation and change Authorization Procedures are described in

Appendix B.
6.1.6 Authorization IS REQUIRED for new RV installations on site, changes,

replacement, mothball, and deletion.
6.1.7 Changes that AFFECT RV operations require the Operating System

Authorization WF approval of the Supervisor of Operations Engineering, and

should be reviewed by the local RV Coordinator, Supervisor of the Operations
Inspection Unit prior to approval by Operations Superintendent.
6.1.8 Changes that DO NOT AFFECT RV operations require the Operating System
Authorization WF approval of the Supervisor of Operations Engineering, and
should be reviewed by the local RV Coordinator and Supervisor of the
Operations Inspection Unit.
6.1.9 Deletion of an existing Relief Valve number can only be authorized through
Operating System Authorization WF and only when the equipment being
protected has been permanently dismantled, when the existing RV is to be
replaced or if the RV is lost.
6.1.10 When a deleted RV is to be replaced with another RV, authorization for the
new RV should be completed through Operating System Authorization WF
and a new RV number assigned, prior to deleting the old RV.
6.2 Verification Requirements
6.2.1 Verification responsibility is given to the Operations Foreman for operating

facilities, and to the Supervisor of Projects Inspection and the Commissioning
Supervisor for new projects.
6.2.2 Verification is required to assure that RV addition, deletion or change has

actually taken place in the field through Operations Checklist and OME
Meeting documentation
6.2.3 Verification is required within three months of RV authorized activity after the
Operating System workflow approval.
6.3 Replacement Procedure
Replacement is requested through Operations Engineering by the RV Shop. The RV

Shop shall verify with Operations Engineering that the replacement is identical. A new
Operating System Authorization WF through Transaction Code IE01 shall be initiated
according to this procedure. For additional information about the authorization process
local RV Coordinator or ID RV Administrator should be consulted.
7 Instructions
7.1 Test Interval
7.1.1 RV Base Test Interval

7.1.1.1 All new RVs entered in the Operating System must have base or
initial test intervals set by Originator Engineer.

7.1.1.2 The Plant Inspection Unit and Maintenance RV Shop shall be

consulted to review historical data for the service intended prior to
setting the base test interval. The base test interval shall not exceed
36 months for any RV.
7.1.1.3 The following factors should be considered when determining the base
test interval, and subsequent intervals such as service conditions, RV
types, similar service experience, manufacturer's recommendations,
industry experience and recommendations of RBI or SAEP-20.
7.1.2 Disassembly Interval
7.1.2.1 Base Dis-assembly Interval Indicator:

 The originator engineer shall assign the base dis-assembly
interval indicator.
 The maximum base dis-assembly indicator in corrosive service shall
be 2, except when RVor internal parts was replaced due to failure in
service or malfunctioning. The new indicator setting shall be
reduced by one (1) except where the previous setting was 1.
7.1.2.2 All RVs shall, as a minimum, be shop disassembled at every third
test interval for an internal inspection.
7.1.2.3 The maximum test interval for RVs with operating history equal to or
higher than one full cycle of the base test interval shall be 60 months
except for:
 Steam Boilers which have a maximum of 24 months.
 Services listed in “Appendix F” which have a maximum of
36 months.
 Integral RVs with Grove Ball, Model B-5 Valves shall be
replaced at mandated intervals as per Technical Alert
ALERT-94-016. When mandated intervals are reached, the
Operating System-generated Maintenance Report will state that
the valves must be replaced.
7.1.3 Other Considerations for Test Interval Setting
7.1.3.1 Rupture Disk (RD) shall be replaced at every test interval and update
the system with the new Operating System number. The disassemble
indicator for the RD shall be set to zero.
7.1.3.2 Rupture Pin (Buckling Pin) shall be tested in place according to an

approved procedure.

7.1.3.3 Obtain MOC approval for “not in kind” RV replacement.
7.1.3.4 The RV Maintenance Report (SA-3750) and the approved MOC

copy is entered into the Operating System showing a test date which
reflects the actual installation date of the ball valves or RV.
7.1.3.5 Once the integral RVs with Grove Model B-5 ball valves is due for
replacement then delete the existing RV from the Operating System
using transaction IE02, then create a new Operating System number
through transaction IE01as required by this procedure.
7.2 Test and Inspection Scheduling
7.2.1 T&I (Testing & Inspection) schedules for RV's are defined by the Operating
System Maintenance Plans which are scheduled based on predetermined
inspection intervals assigned to each RV through allocated Maintenance
Packages.
7.2.2 Test and Inspection Maintenance Planned date is controlled from within the
Operating System by use of the Maintenance Plan.
7.2.3 The Operating System RV Maintenance Plan, generates and releases the Work
Order (PM02) sixty (60) days prior to the planned T&I date which marks the
start of testing activity.
7.2.4 Maintenance Planner will download a list of outstanding Work Orders using
Operating System Transaction Code IW39 (Work Order List Editing), and
coordinate execution of the RV T&I with the proponent organization.
7.2.5 After completion of the RV T&I the RV test results are entered into Operating
System by the maintenance technician using Operating System Transaction
QE17 or as required by this procedure under Responsibilities section.
7.2.6 The Usage Decision (UD) is completed by RV Coordinator, Inspection Unit

through QA11, at which point the Maintenance Plan automatically indicates
the test completion and update the next planned date.
7.2.7 Transaction ZI0069 is used to display and print the RV Due and Overdue list
for a facility. The Operating System will generate due/overdue notifcation to
upper management.
7.3 Early or Delayed ONE TIME RV Test Schedule Change
7.3.1 For maximum maintenance efficiency RV test schedule may be performend

earlier without changing the test Interval.

7.3.2 Scheduling early T&I can be approved by the local Operations Foreman by
starting the Work Order (PM02) to initiate the work. The next planned due
date is automatically adjusted when the Maintenance Report, Operating
System-generated Form SA-3750, is entered into Operating System and after
Usage Decision is made based on the entered test result date.
7.3.3 Delayed T&I (local deviation) schedule shall be approved by the local
Operations Superintendent providing the delay does not exceed 3 months
through Operating System WF. The WF shall be initiated by the Operation
Forman or Plant Engineer and reviewed by OIU Supervisor prior to
Operations Superintendent approval. This action will still show RV in
Operating System as overdue.
7.4 T&I Schedule Delay Exceeding 3 Months
7.4.1 To deviate the T&I schdule for RVs, Operation Foreman or Plant Engineer
shall intiate RV Deviation Request through Operating System tansaction
ZIF0015 prior to the planned date. After the WF approval, the system will
reflect the proposed T&I date in Operating System under the column
“Deviation Approved Till Date”.
7.4.2 Area Loss Prevention Representative cuncurance is required for RV deviation

except for the following:
I. When the overdue RV is only waiting for spare parts in the shop and the
equipment with the overdue RV is protected by another RV.
II. When the protected equipment is out of service and not pressurized.
7.4.3 Only T&I extensions approved by ID Manager or his delegate shall be
considered as Approved Overdue with a “deviation till date” shown in
Operating System; otherwise, it will be shown as overdue.
7.5 RV Testing and Inspection Practices
7.5.1 RV Testing and inspection shall be in compliance with this procedure.

a) An approved Work Order, Form PM02, must be issued and presented
before the RV T&I is conducted.
b) T&I disassembly and testing shall be performed by or under the
supervision of a Qualified and Certified RV Technician using written
Shop Procedures that details the steps involved for each type of RV
serviced.
c) Each RV T&I shall be completely documented and reported by means of
the Operating System-generated RV Maintenance Report, Form SA-3750.
Only one Maintenance Report entry shall be completed for each RV T&I.

d) The defects and comments section of RV Maintenance Report shall be

used to record detailed history of repairs.
e) When an in-place test is conducted, the technician conducting the test
shall complete and send the maintenance report to responsible person
within his Maintenance Organization for data entry.
f) If the RV was repaired in the Shop prior to the In-place Test; then, the
Shop Technician completes the initial sections of the form and leaves the
final set pressure section blank.
g) Testing Surge Relief (SR) valves differs from other RV testing as follows:
 When SR valve Test Operation is due, the valve is to be tested
‘In-Place’ (initial set pressure test, visual inspection and final set
pressure test).
 When SR Valve Disassembly and Test Operation is due, the valve is
tested In-place for the initial test results (initial set pressure test and
visual inspection) and then tested In-shop (initial valve shell test, initial
seat leak test, document reason for disassembly, visual inspection
results, final valve shell test and final seat leak test). Finally, the SR
valve is tested In-place for the final test results (final set pressure test).
For data entry and processing, this procedure shall apply.
h) The set pressure test for Surge Relief (SR) valve shall be performed
‘In-place' and not in 'shop'. Manufacturer's recommendations and the
approved test procedure (which must be part of the Plant Maintenance
QA Manual) shall be followed for the maintenance and testing.
i) QA Manual shall be followed for the maintenance and testing.
j) RV Manufacturer's nameplate shall not be damaged or painted during
T&I and nameplate data shall be documented in the RV Shop file records.
k) RV tag/equipment number shall be verified with the Test Shop files and
the body identification stamp before starting any testing or repairing
activity. If the RV tag is missing or the RV identification cannot be verified;
then, contact local engineering for verification or replacement of the RV.
l) On T&I completion, tag and seal the RV immediately upon final setting.
The seal shall be a wire lock that must be broken before the pressure
setting can be altered.
7.5.2 Initial Visual Inspection
a) Initial visual inspection shall be conducted prior to testing and/or
disassembly to evaluate the overall condition of the RV. The technician
should look for corrosion, scale, obstruction, and obvious damage before
attempting the “as received” POP test.
b) Engineering and Inspection shall be contacted immediately if problems
defined in this procedure are found.

7.5.3 As Received POP Test
Conduct the “As Received” POP test on an adequately sized Test Stand that
causes a “sharp pop” when testing a gas service RV. A simmer RV action
shall not be a valid test for gas service.
7.5.4 As Received Leak Test
“As Received” Leak Test shall be conducted immediately after the

“As Received” POP test to evaluate the RV seating surface. A leak test
procedure, part of the QA Manual, shall be used as required by this procedure.
7.5.5 RV Bellows Test
Leak test bellows to verify that the bellows sealing joint is 100% effective and the
bellows is not leaking. An approved bellows test procedure shall be included
in the QA Manual. The procedure shall minimally cover the following:
a) A test shall be conducted by pressurizing the external side of the bellows
to 30 psig or 25% of CDTP, whichever is smaller. Over pressure can
damage the bellows.
b) Check the non-pressurized side of the bellows using a method that is
sensitive to low volume flow, e.g., an apparatus similar to the seat leak
test is recommended.
7.5.6 RV Sealed Bonnet Leak Test
a) RVs that are intended to have sealed bonnets and body joints and
connected to closed discharge systems shall be tested for tightness of the
bonnet and body joints to assure that NO discharge gases or liquids
escape to atmosphere.
b) Test shall be conducted by applying a 30 psig regulated air pressure to the
RV body and bonnet cavity. There should be no evidence of leakage at
anybody joint. A soap test should be conducted to ensure the integrity of
the body joints.
7.5.7 Final Cold Differential Test Pressure, CDTP
a) Final CDTP shall be conducted on an approved test stand from an
approved source by Saudi Aramco. This shall meet the requirements of this
procedure and shall be included in the QA Manual.
b) CDTP tolerance shall conform to ASME Table XI requirements for spring
and pilot operated RVs. Tank breather and pressure / vacuum relief valve
tolerances shall conform to manufacturers' guidelines.
c) CDTP shall be within the spring range except for temperature
compensated settings, as required by the manufacturer.

d) CDTP shall be adjusted only for conventional type RV to compensate for

any superimposed constant backpressure when a valve is installed in a
closed relief system. The superimposed backpressure shall not exceed
limits set in SAES-J-600.
e) Pilot operated valves may be adjusted separately; however, the final test
shall be with the pilot and the main valves connected and tested together.
7.5.8 Final Seat Leak Test
The final seat leak test shall be conducted immediately after the final pressure
setting is achieved per this prpocedure and API STD 527.
7.5.9 Testing and Inspection of Tank Breather RVs

a) Tank breather RVs shall be included in the RV Program, and they shall be
serviced at specified intervals to assure reliable performance.
b) Tank breather valves may be tested in place using an approved procedure
as required by this procedure. In addition to the pressure test, the
procedure should include cleaning requirements, pallet weight inspection
and measuring requirements, soft goods inspection, and parts replacement
criteria.
7.5.10 Pilot Operated RV Testing
a) The T&I requirements are the same as spring actuated RVs.
b) While the pilot and main body may be tested separately, the final pressure
test shall be as a complete assembly.
c) Blowdown is independently adjusted in the pilot valve, and the setting
procedure shall be done as recommended in the manufacturer's
maintenance manual. Refer to manufacturer maintenance manuals when
disassembling and assembling pilot relief valves.
d) Soft parts should be changed during T&I as a preventive maintenance
measure.
e) Pilot control parts have very critical dimensions and surface finishes;
replacement is recommended rather than reconditioning, when they are
found damaged.
7.5.11 RV External Inspection
a) After each successful T&I, an external inspection of the RV shall be
conducted by Inspection Unit to ensure proper installation and
identification.
b) The required RV checklist in Appendix L of this procedure shall be used
whenever RV is tested and reinstalled.
c) Completed RV checklist shall be kept in each RV Operating System record

as required by this procedure.

7.6 Additional Requirements
7.6.1 In-place Testing and Inspection

a) All In-place Testing procedure shall be prepared by the Department’s
Operations Engineering Unit.
b) The procedure activities shall require field witnessing by the Plant
Inspection Unit.
c) An In-place RV T&I shall be approved when it is feasible and safe to
adjust the RV on line, and the RV has satisfied the disassembly
requirements, as required in this procedure.
d) An In-place Test shall be limited to service conditions that are clean,
sweet, and non-corrosive, such as: LPG, Lube oil, steam. In-place
Testing shall only be permitted when a test procedure, approved per this
SAEP, is available.
e) All steam safety valves, under the jurisdiction of ASME SEC I, shall be
tested In-place per SABP-J-600.
f) All In-place Testing including RP and SR valves shall be tested in place
by step-by-step written procedure approved by Area Loss Prevention and
Facility Manager.
7.6.2 Maintenance
RV shop disassembly shall be required for the following conditions:

a) Minimum at the third consecutive RV operating interval.
b) When a boiler RV fails the shop test, the In-place Test or after two
operating intervals.
c) When disassembly is requested by Operations, Engineering, or Plant
Inspection.
d) After every T&I, if the RV is in severe service having a history of
corrosion, fouling, plugging, sticking or failures that are continuous or
frequent.
e) When RV fails the “As Received” leak or pop test.
f) When worn parts, corrosion or damage are observed.
g) When disassembly is scheduled by Operating System, as indicated on the
“Other” tab Disassembly Indicator field. This indicator automatically
requests a disassembly on the RV Maintenance Report Form SA-3750.
h) New valves which are not compliant with SAES-A-206 internal
inspection requirements expected of the manufacturer. Shall be
completed prior to initial installation, to verify that internal parts meet
specifications and to positively identify materials.

7.6.3 RV disassembly shall include the following:

a) Correct tools, QA Manual with step by step instructions, manufacturer
instructions and tolerances shall be present before work begins.
b) Record Critical Dimensions, details of repair, and actual steam valve ring
and collar adjustments into RV Shop files.
c) Replace all soft goods, such as: Gaskets, O-rings, etc.
d) Clean all parts to remove all scale and expose bare metal for inspection.
e) Evaluate parts with critical dimensions and critical surfaces per the RV
manufacturer's specifications. Restore critical dimensions within
manufacturer tolerances, and restore critical surfaces so that they are free
of mechanical and corrosion damage and meet surface finishes as required
by the manufacturer.
f) Replacement parts shall meet manufacturer's specification. Parts shall not
be fabricated by Saudi Aramco unless certified and complete
manufacturer shop drawings, fabrication instructions, and material
specifications are reviewed and approved by the local Engineering Unit.
g) Seats and disks shall be restored using a written lapping procedure that
describes lapping compounds, lap rings and lapping machine use and
calibration. As recommended by most manufacturers, surface finish
evaluation techniques that include visual or monochromatic light with
optical flats, should be utilized.
h) Verify the correct spring is installed as specified in Operating System.
Paint the bonnet “green” on all bellow RVs as required by SAES-B-067.
Paint all other external surfaces and exposed springs with a coating system
similar to SAES-H-001, APCS-4, which specifies aluminum color alkyd
coating with primer. Painting is done either in the shop or in the field, as
determined by Operation procedures. In either case, instruct the painters
not to paint or damage the nameplate or foul external or internal moving
parts.
i) Test according to ASME SEC VIII D1 and ensure that the mating spring
washers are not separated from the spring. Replace the spring if the set
pressure cannot be adjusted, the spring coating is deteriorated, or cracks
and/or severe corrosion are visible.
j) Internals are not normally coated. However, a rust inhibitor may be
applied to internal parts and should only be used where free movement of
the relief valve internals is not impeded.
7.6.4 Re-assembling the RV after T&I shall include:
a) Verification that the reconditioned or new parts are correct and that all
parts are included per manufacturer's assembly sketches.
b) Bolt assemblies together using torque loads, as required by the manufacturer.

c) Initial position of adjustable parts are set according to manufacturer's

recommendations.
7.7 Revision of Test Interval
7.7.1 Revising T&I Intervals
7.7.1.1 Testing and inspection results shall be used to determine whether

T&I intervals need to be adjusted.
7.7.1.2 Factors that may initiate revisions:

a) RV condition reported during shop inspection
b) Recurring conditions
c) Unexpected conditions
d) Leaking while in service
e) Will not open at set pressure
f) Engineering evaluation corrosion problems - anticipated or
experienced
g) Deposit build-up
h) Material limitations
i) Conformance to Plant T&I schedules; or access to RV
j) RV Program Computer generated recommendations
7.7.2 Annual Test Interval Revisions
7.7.2.1 RV Coordinator, using Operating System Transaction ZI0112, shall

annually generate a list of RVs (if any) and propose interval changes
as part of the RV Regulating System of this procedure.
7.7.2.2 Originator Engineer shall annually review the generated list of RVs
and recommend interval changes as part of the RV Regulating
System of this procedure.
7.7.2.3 Test Interval Revisions can be made for RVs which have been in
service based on key data in the Relief Valve Maintenance Report.
7.7.2.4 Approved Interval Revisions shall be reviewed annually by

Operations Engineering, Maintenance, and Inspection Unit to ensure
all RVs are being tested on a safe interval or on a cost effective basis.
7.7.3 Conditions for Test Interval Revisions

a) RV Maintenance Reports show that a relief valve has been disassembled
at least once.

b) RV has passed the visual inspection, pop, and reset tests.

c) RV has no part replacement for the past three (3) successive test
occasions.
d) Test interval increase shall be gradual.
e) Increase in test interval period shall not exceed 12 months.
f) Approved MOC is obtained.
g) Maximum test intervals increases shall not exceed the maximum intervals
specified in this SAEP.
7.7.3.1 Maintenance Report Form SA-3750, indicate the disassembled codes
“P001,” “P002,” popped outside tolerance or Major Repair Work will
require a review by Operations Engineering and Inspection Unit to
reduce the interval.
7.7.3.2 Frequent poor inspection ratings shall initiate the T&I regulating
system according to this procedure.
7.7.3.3 An interval change shall be initiated by the Originator Engineer

through Operating System Workflow using Transaction IE02
according to this procedure.
7.8 RV Removal, Handling, and re-Installation Practices
7.8.1 Care must be exercised to avoid mishandling or improper transportation of RVs.

If RV's are subject to mishandling during removal and/or transportation it affects
their ability to lift-off at the specified set pressure and their blowdown limits.
7.8.2 Maintenance shall exercise care in handling RV's at all times that is
appropriate for a delicate mechanism. Do not drop or jar, avoid stressing the
RV body and parts, protect flanges and nozzles.
7.8.3 Store, transport and install RVs in the vertical position, and thoroughly secure
during transport. Cover flanges, threads and nozzles with tape or special
plastic plugs (available from storehouse stock) to protect the RV from dirt and
mechanical damage during storage and transport.
7.8.4 A gag may be applied to a weighted flapper type breather valve during rough
transportation to avoid damage. Retest the RV when an unusual rough
transport or handling occurs. Be sure that the gag is designed so that the RV
cannot be installed until the gag is removed.
7.8.5 Operations shall verify that the RV is isolated from the process when
removing a RV from in-service active equipment by checking the following:
7.8.5.1 Verify block valves are closed and car-sealed (both inlet and outlet

lines/connections).
7.8.5.2 Verify that the block valves are not passing by unscrewing the vent
plug and slowly crack open the vent block valve. Vent any trapped
fluid to a safe area. A blind flange is required to be installed on all
flanged connections immediately after removing the RV for testing.
(Refer to SAES-J-600 for safe venting locations).
7.8.5.3 Verify bonnet vent lines are bled and isolated.
7.8.5.4 Verify all pressure has been removed from the points of isolation at
inlets and outlets of RVs. Verify contained liquids have been
removed and drained to a safe location such as oily water sewers.
7.8.5.5 Verify the equipment is protected by an alternate RV of adequate

capacity on the equipment or connecting equipment, and any
intervening block valves are locked or car sealed open.
7.8.5.6 Identify the type of work permit that should be used for the job.
Control or specify associated hazards and required protection on the
work permit, such as high pressure, H2S hazard, gas release, and
nearby sources of ignition.
7.9 Special Considerations Intervals
7.9.1 Intervals for RVs in Mothballed Facilities
7.9.1.1 When a RV is mothballed, the RV database in Operating System

record is to be put on an inactive status. Testing is postponed until
the RV and the protected equipment is demothballed. The RV
database record in Operating System is to be activated as part of the
commissioning activities. The RV shall be retested during the
demothballing operation and before start-up of the facility.
7.9.1.2 If the external inspection per SAEP-20 of the mothballed facility finds
a problem with the RV protection measures; then, the RV Regulating
Program, as defined in this SAEP, shall be initiated to evaluate RV
condition and T&I needs.
7.9.2 Intervals for RVs “Pressure Test”
7.9.2.1 The test interval shall be within the following periods prior to its
intended use in a pressure test, per SAES-A-004.
7.9.2.2 In addition, pressure test RVs shall have a T&I if it functions

improperly. As a minimum, pressure test RVs shall be disassembled

annually. A repair record shall be locally maintained by the RV shop

for each pressure test RV.
7.9.3 Intervals for Rupture Disks and Rupture Pins
7.9.3.1 Factors used to evaluate a Rupture Disk interval.

a) Mechanical damage; flexing, or installation damage.
b) Leakage; occurring during operation.
c) Corrosion; pitting.
d) Creep (physical distortion of the disk or pin); replace when any
distortion has occurred.
e) Access; coincide schedule with in-series reclosing RV.
f) Fatigue; Fine and intergranular cracks.
g) Severe Pulsating or cyclic service.
h) RD or RP manufacturers’ recommendations.
7.9.3.2 The Interval of a Rupture Disk and a Rupture Pin in-series or parallel
service shall not exceed the interval of the associated reclosing RV.
7.9.3.3 The Interval of a Rupture Disk or Rupture Pin in independent service

shall be determined by its life expectancy, but shall not exceed the
maximum RV interval limits set in this SAEP.
7.9.3.4 The Interval of a Rupture Disk in pulsating or cyclic service, and

with an operating pressure that is more than 70% of the burst
pressure shall not exceed one year.
7.9.4 Intervals for RVs in Multiple or Dual Installations
Intervals for RVs in multiple (or dual) installations and the spare RV in a
multiple installation shall be the same when performing the steps outlined in
Appendices B, C, and D of this procedure.
7.10 Interval of Surge Relief (SR) Valves
7.10.1 The Interval of a Surge Relief (SR) valve shall be determined by its life
expectancy but shall not exceed the maximum interval limit set in SAES-J-605.
Change or update of SR valve interval shall follow the provision stated in this
procedure.
7.10.2 Intervals and Maintenance of RVs Used for Pressure Testing
7.10.2.1 Complete records shall be maintained by the RV Shop, and the

Pressure Test RVs shall only be released to the field for pressure

testing if it has been set and tested within the time frame limits set
in SAES-A-004 for the intended use:
a) New construction projects
b) Maintenance operations.
7.10.2.2 The user is responsible for returning the “Pressure Test” RV to the
shop.
7.10.3 Intervals and Maintenance of Rupture Discs and Buckling Pins
7.10.3.1 T&I interval changes shall be determined by Rupture Disc and

Buckling Pin service conditions. Replacement is required when
any of the RV conditions specified in this procedure are found
unacceptable. Reconditioning is not permitted for rupture discs
assembly and the pin in buckling pin assembly.
7.10.3.2 Rupture Discs valves shall be replaced at every T&I interval.

The Disassemble indicator for any Rupture Disc shall be set at “0”
on the equipment “Other” tab in Operating System.
7.10.3.3 Buckling pin valves shall be tested in place as mandated by this

procedure.
7.10.3.4 An approved procedure, which is part of the QA Manual, shall be

used to inspect rupture disks and buckling pins, and shall
minimally include:
a) Evaluation criteria for both the rupture disk holder assembly
and buckling pin mechanism.
b) Requirements for careful and controlled handling of the
disk/pin.
c) Installation requirements for bolt torque.
7.10.3.5 A maintenance RV technician shall remove or supervise the
removal of a disk/pin and disk/pin holder assembly to ensure no
damage occurs prior to disk/pin replacement.
7.10.3.6 The Local Inspection Unit shall evaluate disk/pin condition, complete
the Pressure Relieving Device Maintenance Report, Operating
System-generated Form SA-3750 and approve installation.
7.10.3.7 Operations shall approve removal and installation.
7.10.3.8 Local Inspection shall verify that the inlet and discharge piping is
clean.

7.10.3.9 Local Inspection shall verify that the RV number is stamped on the
holder.
7.10.3.10 Local Inspection shall verify that a pressure gauge is installed

between an in-line RV and rupture disk installation.
7.11 Quality Assurance
7.11.1 Quality Assurance Manual
7.11.1.1 All Saudi Aramco RV Maintenance Test Facilities shall have a

Quality Assurance Manual prepared by the Shop, and approved by
the Maintenance Manager and the local Inspection Unit Supervisor.
This manual shall contain procedures that address and provide for
control of all activities and requirements relating to inspection and
testing of RVs. The QA Manual shall be reviewed and revised,
every three years.
7.11.1.2 The QA Manual is a written record of the detailed work procedures

used to repair and test RVs. The purpose of the Manual is to have
a central reference source that describes or references the shop
work methods, repair procedures, testing procedures,
responsibilities, procedure revision, and personnel qualifications.
7.11.2 RV Test & Inspection (T&I) Regulating System
7.11.2.1 The T&I Regulating System is a mandatory method of generating

recommendations through consultation and analysis between
Engineering, Inspection Unit and Maintenance. The purpose is to
improve the reliability of the relief valve program in Saudi
Aramco. The Regulating System may be initiated as a result of:
a) Pressure setting changes while operating.
b) RV may not be opening completely.
c) Design is incorrect for service conditions,
i.e., metallurgy, sizing, inlet/outlet piping, etc.
d) Excessive corrosion is causing performance failure.
e) RV inlet or outlet is damaged.
f) More than two Relief Valve Maintenance Reports, Form
SA-3750, that indicate major repair, stuck, severe corrosion
attack, or severe plugging conditions.
g) Parts are abnormally worn.
h) Abnormal damage to bellows or other parts.
i) The interval continually remains less than one year.

j) Frequent recurring problem(s).

k) Stuck (Valve does not open at a pressure greater than 10% of
the set pressure).
l) Replacement parts are not available.
m) Critical dimensions are unknown, and unavailable.
n) Fouling.
o) Does not close while in operation.
p) Mothballed plant audit indicates failed protection.
q) General Alert Report initiated from another source.
r) Inspection or Engineering observations.
7.11.2.2 One of the above conditions shall cause the RV Technician to
contact the RV Shop Foreman, or equivalent position, who will
report the problem to the Operations Engineering Supervisor.
7.11.2.3 The Engineer assigned to the investigation consults with Inspection

Unit, Maintenance staff, and Operators.
7.11.2.4 The Engineer shall generate a final report that defines the RV
condition, the cause of the condition, and the corrective action
recommended. The report is to be submitted to the Operations
Foreman for approval. The Engineer shall update the Test Interval,
if required. Maintenance shall make the recommended repairs upon
approval by the Operations Foreman. Recommendations shall
include measures that will prevent any similar future problems.
7.11.2.5 Required work to correct the condition shall be initiated on a

Maintenance Work Order approved by the Operations
Superintendent. Engineering and Inspection shall verify the work
is completed and documented in the RV Coordinator's files.
7.11.2.6 A copy of the report shall be sent to the RV Administrator who will
distribute it to other Saudi Aramco Operating Units with similar
RV applications.
7.11.3 RV T&I Audit Program
7.11.3.1 An audit of every RV T&I Program shall be conducted a minimum

of once every year by the associated local Inspection Unit.
This includes RV facilities within the local Operation's support
facilities, per SAEP-309. The Inspection Technical Support
Division (ITSD), Dhahran, will assist Inspection Units in
conducting a RV T&I Program audit, upon request.

7.11.3.2 The audit shall determine if the RV T&I Program conforms to the
requirements of the RV SAEPs, has adequate information and
equipment to perform the work, implements the Quality Assurance
Manual procedures, maintains adequate records and parts
inventory, participates in the Regulating System, and provides
active training for the RV technicians.
7.11.3.3 The local Inspection Unit shall publish the audit findings and
recommendations and track them quarterly to completion.
7.11.4 QA Outline - Maintenance Quality Assurance Document
Each Maintenance RV Shop shall prepare a Quality Assurance Manual.

The contents of the manual shall at least include:
a) Purpose Statement: Describe the quality assurance system and purpose of
the manual
b) Revision log: Issuing Date and authorization
c) Log of changes in this section
d) Roles and Responsibility
7.11.5 RV Testing and Setting
a) Ensure that every valve is tested, set and sealed.
b) Write a detailed RV bellow, bonnet and seat leak test procedure.
The procedure should explain how each type of leak test is performed for
each type of RV used within the operating area.
c) Add any further provisions you consider necessary.
7.11.6 Tagging
a) Describe tagging requirements.
b) Refer to Appendices B, C, and D
7.11.7 Calibration of Measurements and Test Gauges

a) Write a calibration procedure for the test pressure gauges. Describe how
you schedule gauges and digital instruments for calibration, what the time
periods between calibrations are, and how you verify that no measuring
equipment is used unless it is calibrated.
b) Include a history log of calibration where all gauges are numbered and
tagged which will make it easy to trace any gauge.
c) The title of the authorized person carrying out the calibrations.
d) Describe calibration stickers/seals that are attached to gauges.

7.11.8 Lapping
a) Recognize that lapping is a specialized function, and provide the necessary
special tools and describe their functions (example: Optical comparators
for checking seat flatness, Measuring Magnifier, Straight Edge).
b) Prepare a more detailed lapping procedure than those shown in the
manufacturer's services manuals, if possible. Describe which type of
lapping compounds and blocks are used when lapping a disk and seat
(with or without an angle). Note any special lapping problems that the
Machinist should expect to run into and how to resolve them.
c) Describe how to make sure that all lapping equipment is inventoried,
functional, clean, and complete. (This may be best achieved by assigning
this responsibility to a RV technician).
7.11.9 Records
Describe records system, i.e., initiation, identification, filing, maintenance, and

retention of all RV records.
7.11.10 Recruitment and Training

a) Outline the job entry qualifications in terms of the academic and
industrial background of the technicians and machinists.
b) Indicate the training program for the staff involved in assuring the quality
of testing and repair of RVs.
c) Indicate the type and frequency of the training.
d) Outline the job entry qualifications in terms of the academic and industrial
background of the test conductor per the requirements of this procedure.
8 Marking and Identifying RVs
8.1 Each RV shall be identified by attaching a corrosion resistant metal tag FIRMLY
secured by a 16 gage stainless steel wire. Tags are available from storehouse stock
(SCM Operating System Stock # 1000168143). For rupture disks and rupture pins,
attach the tag to the holder. (Galvanized metal tags should not be used).
8.2 The tag shall be die stamped in the same units specifying at least RV number, Set Pressure,
CDTP, Test Date, and Due Date.
8.3 The Due Date on the RV tag equals to the Planned Date which is designated
automatically by Operating System based on the last test date. This represents the date
at which the next T&I is due for a RV based on the specified interval.
8.4 The RV number, as described in tag requirements, shall be die stamped on the body of
screw type valves. The RV number shall be stamped on the outlet flange of flanged

RVs. Stamping the mating pipe flange or installing a field RV number tag is
recommended to avoid installation errors.
8.5 The mounting flange of a rupture disk or a rupture pin holder shall be die stamped with
the disk/pin RV number.
8.6 The bonnets of all bellows type RVs shall be painted GREEN, per SAES-B-067.
This is to indicate that the bonnet must be vented and the vent piping is to be directed
away from other equipment or walkways.
8.7 All other RVs shall be painted with the mandatory aluminum color, as per SAES-B-067.
9 Pressure Testing RVs
9.1 Pressure Testing RVs shall be administered as follows:
9.1.1 Each RV shall be assigned with a serial number for tracking and record
purposes.
9.1.2 Each RV shall have a history log file in Operating System. This file should
include the RV Engineering data, and components (i.e.; spring), changes, and
updates.
9.1.3 TEST RVs used for PRESSURE TESTING shall be identified with a
corrosion resistant metal tag specifying at least TEST RV number, Spring
Number, Set Pressure and Test Date.
9.1.4 TEST RV must not be stamped.
9.1.5 TEST RV shall not have a data base RV number assigned to it.
9.2 Mothballed RVs
9.2.1 RVs in mothballed facility shall remain in Operating System under Relief
Valve equipment category.
9.2.2 To deactivate mothballed RVs, use Operating System WF through Transaction

IE02 by selecting “SDEC” – Awaiting Deactivate to put the Operating System
Tracking for RVs on “MOTH” - mothballed status. Test and inspection are
not required provided the facility is properly mothballed. The condition of the
mothballed facility shall be periodically reviewed in order to determine if RV
inspection and preventive maintenance is needed.
9.2.3 The Maintenance Plan (Maintenance Order) shall be put on “INAK” status,
i.e., Inactive, by the responsible Plant Maintenance Plan Processor.
9.2.4 The maintenance data records cannot be updated if the RV is mothballed.

9.2.5 To re-activate mothballed RVs, use Operating System WF through

Transaction IE02 by selecting “RDEC” - Awaiting Activate to put the
Operating System for RVs on “Active” status.
9.2.6 When a MOTHBALLED RV is to be reactivated, it shall be inspected, tested,

and the Maintenance Plan in the Operating System status “activated” and the
RV master record shall be approved through Operating System WF prior to
the RV use.
10 Relief Valve Test Stand (RVTS) Instructions
10.1 The test stand shall have a volume large enough to provide reliable RV adjustment and
pressure testing at the specified, Cold Differential Test Pressure (CDTP) within the
tolerances set by the applicable Code.
10.2 For gas service, a test stand must be able to cause a sharp pop of the RV for the test to
be valid. Simple opening and passing of air or nitrogen is not acceptable. The gas
service test stand design described in this procedure is intended to provide a sharp pop
action with minimum altering of the blowdown ring adjustment. However, the
blowdown ring may be adjusted to assist in achieving a valid pop action for the test.
Upon these occasions it is essential that the blowdown ring be returned to its original
operating position upon completion of the test.
10.3 The RV test stand shall provide sufficient capacity to adequately verify the pressure at
which the RV pops without damaging the valve trim. Insufficient volume, poor
pressure control, inaccurate gauges or contaminated test media may cause unreliable
testing and/or additional maintenance. Test stand design is intended to produce a pop
action, because a pre-simmer action is not the true opening pressure of a gas service
RV, by manufacturer's definition. This pre-simmer test method can result in a 10-15%
difference in the actual popping pressure. RV manufacturers have recommended that
“lift restrictors” be used for testing even with the Saudi Aramco test stand.
10.4 Blowdown adjustments shall be made in place with an approved RV In-place Test
Procedure.
10.5 Pre-Test Requirements
10.5.1 Relief Valve Test Stand (RVTS) General Requirements:-

a) The RVTS must be adequately sized to ensure RV action is consistent
with the set pressure and tolerances required for reliable RV performance.
b) The RVTS used in Saudi Aramco Facilities shall be approved by
Inspection/ITSD/IEU.
c) The RVTS shall have an assigned Saudi Aramco equipment number.
d) As built drawings, Safety Instruction Sheet, and Design Data Form shall

be available and entered into the SAO Drawing System by the User.
e) If a test drum is included in the RVTS design, the test drum shall have an
approved Equipment Inspection Schedules (EIS) per SAEP-20 with a
maximum of 60 months interval.
10.5.2 Relief Valve Test Stand (RVTS) Pressure Gauges
a) The test gauges shall have a range of 1.25 to 2.0 times the RV CDTP set
pressure.
b) Gauges shall have scale markings in the same measurement units as those
of the RV set pressure shown on the. Conversions between units shall not
be made. The gauge scale definition shall be adequate to determine the
pressure tolerances.
c) All gauges must have evidence of calibration within three months.
d) Re-calibrate gauge if it appears to be functioning improperly.
e) New gauges shall be calibrated before use.
f) Gauge calibration procedures shall be included or referenced in the QA
document. The procedure shall include calibration stickers and a
calibration log for scheduling to assure the task is performed and the
responsibility is defined.
g) Units for installed gauges shall be standard units.
11 Test Stand Requirements
11.1 Test stand control valve configuration and/or regulators shall be designed for the
necessary control needed for leak testing and low set pressures.
11.2 A vacuum pump shall be included in the Test Facility where vacuum type breather
valves are maintained.
11.3 All fabricated flange adapters shall be approved by RVTS manufacturer prior to use.
11.4 Adapter plates and special fixtures shall be readily available for mounting and testing
the various types of RVs being maintained.
11.5 The pilot of Pilot RVs may be adjusted using the gas test stand or a specialized pilot test
stand.
11.6 A single unit with capacity to test multiple services (gas and liquid) is acceptable
provided purging capacity is built in.
11.7 Accumulator tank size specification and other design specification shall be adequate to
prevent RV seat hammering.
11.8 Computerized test bench is an optional requirement.

11.9 Any modification to the original design of the RVTS shall include proponent approved
engineering package, MOC document, and ITSD re-validation, if modification exceeds
the maximum design pressure limit.
11.10 Safety Requirements
11.10.1 RVTS shall be installed in safe location away from shop traffic with adequate
barrier to protect personnel not involved with the RV testing.
11.10.2 The Test Stand shall be rigid/safe on the appropriate holders.
11.10.3 A safety RV to protect the piping from overpressure.
11.10.4 T-claws and hydraulic clamping mechanism are installed.
11.10.5 Interlock device is installed to prevent release of the clamping pressure unless
test pressure is first released.
11.10.6 Safe venting and pressure release system installed.
11.10.7 Safety shatter resistant screen between the RV Test Technician and the clamp
bench installed.
11.10.8 An approved Equipment Inspection Schedule (EIS) exist for the RV Test Stand.
11.10.9 Noise suppression shall be used when necessary to maintain safe working
conditions, as required by Industrial Hygiene measurement of sound levels.
Exhaust piping, mufflers or hose shall be large enough to prevent back
pressure rise, and shall be vented to a safe location. Noise suppression may be
by vertical upward venting, venting to a large insulated baffle chamber, or any
other method acceptable to local Loss Prevention.
11.10.10 Ensure visual and audible safety alarms in the RVTS are available.
11.11 Preventive Maintenance
11.11.1 Annual external inspection checklist shall be developed by the proponent in

accordance with RVTS manufacturer recommendation.
11.11.2 Preventive maintenance plan shall meet the RVTS manufacturer recommendation
and this procedure.
11.11.3 Minimum Spare parts for the test stand shall be maintained.
11.12 Test Stand Operation

a) A test stand operating procedure shall be prepared and included in the RV Shop
QA Manual. The procedure shall be based on the RVTS manufacturer

recommended operating procedure and shall be approved by the facility manager.

The procedure shall include safety requirements such as eye and ear protection,
safe tool operation, and installation of air compressor filters.
b) A Certified RV Technician, shall operate the Test Stand.
c) RVs in liquid service can be tested with gas or liquid.
d) RV's in vapor, air, gas, or a combination of liquid and gas service shall only be
tested with gases (air or nitrogen).
e) RVs in boiler steam service may have the initial pop pressure set in the Test Shop
using air, but the final pressure and blow-down setting shall be made with steam,
on the boiler using an approved In-place Procedure.
11.12.1 Attach the special flange and water bubbler (it shall be designed with a rupture
seal that will vent full flow in the event the RV should open) and seal all other
RV body outlets or vents.
11.12.2 Hold 90% of CDTP for the required test period as follows:
 One minute for 0.5” to 2” RV inlet size
 Two minutes for 2.5” to 4” RV inlet size
 Five minutes for all other larger inlets sizes
11.12.3 Compare BUBBLES PER MINUTE leakage rate to the acceptance criteria, as
follows:
 Table XII for RV's with CDTP up to 1,000 psig.
 Table XIII for RV's with CDTP over 1,000 psig.
11.12.4 When the RV body can not be sealed for the API STD 527 test method (such as
an open bonnet RV design) then use the Half Gasket Dam Leak Test Method.
a) Cover the lower half of the outlet flange with a half gasket or a fabricated
device that allows the body cavity to be partially filled with water.
b) Fill the body cavity with water to cover the seating joint.
c) Raise the test bench pressure to 90% of the CDTP set pressure and look
for evidence of bubbling from the seating joint. Use a mirror to observe
the activity; never look directly into a RV outlet while it is under pressure.
No bubbles are acceptable with this method.
11.12.5 For small screwed RVs, attach an elbow on the outlet, and fill the body cavity
and the elbow with water. Raise the test bench pressure to 90% of the CDTP
set pressure and look for evidence of bubbling at the open elbow. Never look
directly into the elbow while it is under pressure. No bubbles are acceptable
with this method.
11.12.6 The maximum test pressure for RVs tested in the RVTS shall be specified and

included in the Quality Assurance (QA).
11.12.7 Dryness procedure for RVs tested in liquid shall be available and included in
the Quality Assurance (QA).
11.12.8 Post-test Requirements: All post tests shall comply with this procedure
requirements.
11.12.9 Use a lift restrictor to limit the disk travel when momentum forces cause
hammering damage to the disk. Dresser Consolidated recommends 1900
Series valves with orifice sizes D and greater be tested with lift restrictors.
Crosby also state that their valves should be tested with lift restrictors.
Contact ID/ITSD for fabrication and adjustment details.
11.12.10 Avoid testing with incorrect test equipment. Contact ITSD or Dhahran Shops,
Planning and Coordinating Unit, Dhahran, if assistance is needed in locating a
RV Shop with a larger capacity or specialized test equipment.
11.12.11 Steam boiler safety valves shall not have the blow down adjusted on a test
bench.
11.13 Specialty RV Testing Devices
11.13.1 Specialized RV testing Devices, such as direct spring assist units, shall be
ASME stamped. Inspection Department and P&CSD approval is required and
concurrence by Loss Prevention prior to using the equipment.
11.13.2 A direct spring assist device should incorporate precise, accurate, and
repeatable pressure recording, as a minimum.
11.13.3 An approved written Operating Procedure shall be developed by the User's

Engineering Unit that includes calibration details, limitations, Operator
training, and tolerance requirements.
12 Relief Valve Technician Certification
RVs shall be repaired by certified technicians only. Corporate Job Task Standard (JTS)
shall be completed for each Standardized RV Technician Certification categories listed
below prior to certifying by a Certified Test Conductor. The prerequisites, types and
duration of trainings for each category are listed in the table below.

Hands-On
Training
Category Description Prerequisites Class Room Training
Duration,
months
Completes Safety Relief
Inspection, repair and testing of
Valves Training
1- Liquid liquid service spring actuated N/A 6
Operating System
(conventional / Bellows) RVs.
# 40008311
Valves Training
2- Gas gas service spring actuated N/A 12
Operating System
(conventional/Bellows) RVs
# 40008311
Completes Pilot valve
3- Pilot N/A Training Operating 12
pilot operated RVs.
System # 40009969
Completes Steam Valve
4- Steam Inspection, repair and testing of
Valid Category #2 (Gas) Certificate Training Operating 18
Boiler steam boiler safety RVs.
System # 40009871
Completes TK training
5- TK N/A Operating System 18
breather/vacuum breaker RVs.
# 40076450
6- Inspection, repair and testing of Valves Training
N/A 24
Spheroid spheroid RVs. Operating System
# 40008311
- Valid Certification for
- Complete Category #2
Category #2 and 4.
and 4. Training.
- On-job training for assisting
- Completion of a
7- In-place in testing of a minimum of 5
In-place testing of RVs. manufacturer's 24
Test In- Place tests followed by
maintenance course
performing a min of 5 tests
for Steam Safety
with assistance & monitoring
Valves
by Certified Technician.
Other RVs inspection, repair and Completion of the
8- SR &
testing,Surge Relief Valves, N/A required training of the
RD
Rupture Disc, Buckling Pin specific RV type
12.1 Each category shall be individually evaluated and certified by the Certified Test
Conductor designated by the ITSD, Dhahran and Maintenance Superintendent except
for Category # 8. Test conductor shall meet the requirements listed in Appendix H.
12.2 Technician Certification shall be valid for all Saudi Aramco facilities. All certifications
shall be valid for three (3) years except Category # 8 that must be trained by the
manufacturer of the specific RV type.
12.3 Certification Renewal
12.3.1 Certification can be renewed without re-evaluation if the RV Technician has

continued to practice his craft full time. A renewal shall be granted by written
notification to the RV Technician from the RV Shop Foreman, and concurred
by the Maintenance Superintendent. The notification shall be kept in the RV
Technician file, and a copy shall be held by the RV Shop Foreman.

12.3.2 For recertification for a RV Technician who does not practice RV repairs full
time will not be granted until the technician has completed the recommended
formal instruction, and a minimum of a 6 months on-job training. On-job
Training (OJT) shall be carried out full time in the RV Test Shop according to
manufacturer and company repair procedures. The trainee shall be assigned a
Certified RV Technician to mentor in the JTS Tasks in test and repair of all
the RV types for which the Shop is responsible.
12.4 Work Experience Waiver
Experienced expatriate technicians in the RV Test Shop or possessing RV work

background may have the training waived upon successfully passing the Certification
Test (written and hands-on). If the technician fails in the test, the technician shall attend
formal training.
The Maintenance Superintendent shall decide if a Waiver is to be granted after the

Technician is observed at least 90 days, and the Technician has met the objectives of
both classroom and on-job training requirements.
12.5 Arranging a Certification Test

a) The Maintenance Superintendent shall initiate a certification test upon
recommendation from the RV Test Shop Supervisor. The test date shall be
concurred with by all participants, local inspection, test conductor, and provide ten
days advanced notification.
b) The RV Shop Foreman/Supervisor of the local maintenance department, shall
nominate a test conductor based on availability, test location, and impartiality. The test
conductor's Supervisor shall be contacted, and the test date shall be accepted.
12.6 Testing
a) The test conductor shall use the standard checklist listed in Appendix G as a guide
for the practical test, and a written test may be conducted for all categories except
In-place if the test conductor feels it is needed to support the test assessment.
b) All tests shall be conducted in the RV facility where the RV technician works.
This allows the test conductor to review and comment on facilities, files, records,
etc.
c) Shop tests shall be under the direction of the test conductor only and local
Inspection attendance during the entire test is optional, but recommended.
d) Test Results, there are three results:
 Acceptable skills for Certification
 Unacceptable; re-examination in one month
 Unacceptable performance; requires retraining
e) The Maintenance Superintendent shall authorize certification of the technician

based on the recommendations of the test conductor and the Shop Supervisor.
f) When an examination is rated “unacceptable performance” the maintenance unit
shall assign additional training based on the results of the test as interpreted by the
test conductor and the Shop Supervisor.
12.7 Validity of Certification
 Technician certification shall be valid at all times. The certification shall be from an
international RV Technician Certification Agency.
 Periodic Verification of Qualifications
 Contractor technician shall have a valid certification for the category of RVs they
are repairing.
 To maintain validity of RV Repair Shop Certification, Contractor shall invite MSSD
and ID/ITSD for periodic assessment every 3 years or earlier if required.

Appendix A - Relief Valve Operating System Approval Workflow Process

ORIGINATOR
Engineer
IE02
Project
PROJECT / NON-PROJECT
Non -Project
Senior Supervisor
Project Reject Reject Operation
Engineer Engineering
Accept Accept
End of Process
Terminate Workflow
RV RV
Reject Reject
Coordinator Coordinator
Reject
Accept Accept
Send Mail to
Supervisor Originator Supervisor
Project Reject Engineer Reject Operation
Inspection And Inspection
RV Coordinator
Accept Accept
Superintendent Superintendent
Reject Reject
Operation Operation
Reject
RV
Accept Accept
Administrator
APPROVED

Appendix B - Initiation of Workflow for RV Equipment Master through Operating

System Transaction IE01/IE02
B-A. Workflow for approval of specification of Project RV equipment master.
Initiation of Workflow
II - Initiation for RV Equipment
of Workflow Master through
for RV Equipment MasterTransaction IE01/IE02. IE01/IE02
through Transaction
START
IE 02
IE 01
Change RV equipment
Create RV equipment master
master in SAP
status= “created”
status= “change”
Set RV equipment
status “AWAP”
(awaiting approval)
POP-UP
Screen
NON
PROJECT
PROJECT
Project with Project with Non -Project with Non-Project with

Specification Function Specification Function
Display Display Display Display

Approval Approval Approval Approval
List List List List
Continue Continue Continue Continue
A B C D

B-B. Workflow for approval of specification of Non-project RV equipment master
A
Workflow Get Batch E-mail to RV
No
Started User ID Coord. And Originator
Notify in SAP inbox to

Yes
Next Approver
Enter Batch E-mail to RV Set RV Status Terminate

Comments Coord. And Originator = “Rejected” Workflow
Reject
Get Batch E-mail to RV

Sr. Project Engineer Decision Approve No
User ID Coord. And Originator

Yes
Next Approver

Reject

RV Coordinator Decision Approve No

Yes
Next Approver

Reject
Project Inspection Get Batch E-mail to RV

Decision Approve No
Supervisor User ID Coord. And Originator
Yes
Check Notify in SAP inbox to

Not Affecting
operation Next Approver

Affecting
Reject
Superintendent Get Batch E-mail to RV

Decision Approve No
Operation User ID Coord. And Originator
Yes
Next Approver

Reject
Batch E-mail to RV Set RV Status Workflow

RV Administrator Decision Approve
Coord. And Originator = “Approval” Approved

B-C. Workflow for approval of Functions of Project RV equipment master

No

Yes
Next Approver
Remove The
Enter Batch E-mail to RV Terminate
RV Equipment Functions
Comments Coord. And Originator Workflow
System Status
Reject

Sr. Project Engineer Decision Approve No

Yes
Next Approver
Remove The
Reject System Status


Yes
Next Approver
Remove The
Reject System Status
Project Inspection Get Batch E-mail to RV

Decision Approve No
Supervisor User ID Coord. And Originator
Yes
Next Approver
Remove The
System Status
Reject

Decision Approve No
Yes

Next Approver
Remove The
System Status
Reject
Change RV system as
Batch E-mail to RV Workflow
RV Administrator Decision Approve per WF and reflect
Coord. And Originator Approved
equipment status in SAP

B-D. Workflow for approval of Functions of Non-project RV equipment master.

No

Yes
Next Approver

Reject
Operation
Engineering Decision Approve No
Supervisor

Yes
Next Approver

Reject


Yes
Next Approver

Reject
Operation
Inspection Decision Approve No
Supervisor
Yes
Not Affecting Check Notify in SAP inbox to

The operation operation Next Approver

Affecting the operation
Reject

Decision Approve No
Yes
Next Approver

Reject


B-E. Effect of change in user status of RV equipment master during active workflow.
D
No

Yes
Next Approver
Remove The
Enter Batch E-mail to RV RV Equipment Terminate
Comments Coord. And Originator Functions System Workflow
Reject Status
Operation
Engineering Decision Approve No
Supervisor

Yes
Next Approver
Remove The
Reject Status


Yes
Next Approver
Remove The
Reject Status
Operation
Inspection Decision Approve No
Supervisor
Yes

Next Approver
Remove The
Status
Reject

Decision Approve No
Yes
Next Approver
Remove The
Reject Status


Appendix C - Sample RV Testing Activities Workflow
Generate Work Order in SAP

60 Days Prior to Due Date
Maintenance Planner Notify

Maintenance RV Shop
Maintenance Remove RV to
RV shop
Certified
Pass Maintenance Technician Fail
Test RV
Maintenance Fill Form 3750 Certified Maintenance

and Technician Notify the
Enter Result in SAP Responsible Engineer
and RV Coordinator
Maintenance Return RV to Responsible Engineer

the Field Investigate Failure and
Recommend Solution
Operations Foreman Verify Certified Maintenance

RV Installation Technician Implement
Solution
RV Coordinator use SAP

Transaction QA11 to verify RV Coordinator Verify
Test Results in SAP and sign Implemented Solution
form 3750
Maintenance Planner Close

Work Order

Appendix D - RV Deviation Approval WF
RV
RV Deviation
Deviation WF
WF Approval
Approval Charts
Charts
Local Deviation Deviation Extension
Approval WF Approval WF
Start Start
Operation Foreman/ Operation Foreman/

Reject Reject
Plant Engineer Plant Engineer
Accepted Accepted
Supervisor Supervisor
Operation Reject Reject Operation
Engineering Engineering
Accepted Accepted
WF
REJECTED
RV Reject System release RV
Reject
Coordinator notification to Coordinator
originator and
RV Coordinator
Accepted Accepted
Inspection Unit Inspection Unit

Reject Reject
Supervisor Supervisor
Accepted Accepted
Operation Reject RV Administrators

Reject
Superintendent
Accepted
WF Closed Reject IEU Supervisor
Accepted
Reject OID Superintendent
Accepted
*LP AREA
Superintendent
Reject
(under the procedure
condition)
Accepted
Reject Plant Manager
*LP
WF Closed
*LPArea
AreaSuperintendent
Superintendent––--The
Thecoucur
coucurof
ofLP
LPisisin
inaccordance
accordancewith
withthe
theconditions
conditionsof
ofthis
thisprocedure.
procedure.

Appendix E - Operating System Roles and Responsible Party

e-Learning Prerequisite Course #40037089 is required prior requesting below Operating System roles:
Role : 04 Engineer
TRANSACTION TASK
IE01 Create equipment
IE02 Change equipment
Role : 35 RV Coordinator
TRANSACTION TASK
IE03 Display equipment
IH08 Display equipment list
QE17 Record test results and defects
ZI0069 Overdue RV report
QA11 Make Usage Decision
QA12 Reset (re-opens) Usage Decision
QE03 Display Results by Inspection Lot
QE53 List all open Inspection Lots
ZI0035 Equipment Listing Report
ZI0087 Scheduling overview list form
ZI0127 Maintain RV Workflow Approvers by Cost Center, Plant for a Project or Non-Project
ZI0112 RV interval change recommendation
ZIF0015 Creation of Relief Valve Deviation
ZIF0016 List of RV Deiation Requests
Role : 19 Maintenance
Transaction Description
IW22 Change PM Notification
IW3D Print Order
QE17 Record results for equipment
QE18 Change results for equipment
QE53 Worklist: Record results for equip.
QF03 Display defect data
ZI0084 Inspection Result Printout
IP24 Scheduling overview list form

Appendix F - Test Interval Exception Services
Service Service Definition

ALKALINE ALKALINE
AMINE AMINE
AMMONIA AMMONIA
ASPHALT ASPHALT
BRINE WATER BRINE WATER
CAUSTIC CAUSTIC
CHLORINE CHLORINE
CO CARBON MONOXIDE
CO2 CARBON DIOXIDE
CONDENSATE SO SOUR CONDENSATE
FLUORIDE SOL. FLUORIDE SOLUTION
FUEL GAS FUEL GAS
H2 HYDROGEN
HEAVY SLOP HEAVY SLOP
HEXANE+ HEXANE PLUS
HYPOCLORITE HYPOCLORITE
JAUF GAS JAUF GAS
MERCAPTANT MERCAPTANT
MOLTEN SULFUR MOLTEN SULFUR (S2)
MORPHOLINE MORPHOLINE
OILY WATER OILY WATER
OVERHEADS OVERHEADS
RECYCLE GAS RECYCLE GAS
SALT WATER SALT WATER
SEA WATER SEA WATER
SOUR ADIP SOUR ADIP
SOUR AMINE SOUR AMINE
SOUR CRUDE OI SOUR CRUDE OIL
SOUR DGA SOUR DGA
SOUR GAS SOUR GAS
SOUR WATER SOUR WATER
SPENT CAUSTIC SPENT CAUSTIC
SULFUR DIOXID SULFUR DIOXIDE
SULFUR VAPOR SULFUR VAPOR
VAC BTMS VACUUM TOWER BOTTOMS
WET CRUDE WET CRUDE
WET GAS WET GAS

Appendix G - Standard Checklist
1. RV Qualification Test Checklist
This checklist shall be the standard practice used by the test conductor to test and
evaluate the performance of the RV technician.
2. Initial Contact
2.1 Prior to scheduling a RV technician candidate test, an initial contact should be
made with the RV test shop Supervisor that includes the following questions:
2.2 Confirm that the technician has successfully completed the required classroom
training.
2.3 Confirm that the technician has taken the vendor course for the RV being
worked on, if the test conductor deems the course to be necessary.
2.4 Confirm that the RV shop QC manual, is complete and in use.
2.5 Confirm that RV manufacturer and SAEP reference data is available.
2.6 Confirm that the parts inventory is available to repair the RV.
2.7 Confirm that proper tools and shop facilities are available.
3. Test Checklist of RV Technician Skills

3.1 Technician works safely, and is familiar with this procedure and shop safety
procedures, and the RV shop QA manual safety requirements.
3.2 Technician is aware of and can use available repair reference material.
3.3 Understands and follows the practices outlined in the SAEPs.
3.4 Uses vendor manuals, as needed, for machining tolerances and recommended
inspection or repair steps.
3.5 Can locate ASME, NBIC, and SAEP tolerances.
3.6 Can describe basic RV functions and parts.
3.7 Can describe specific repair requirements for the RVs used in his facility.
3.8 Understands the importance of careful handling. Demonstrates this while
lifting, storing, using crane rigging, and general handling of parts.
4. Initial Diagnosis of Pop Test

4.1 Performs a visual inspection before pressuring.
4.2 Starts comprehensive report data gathering by filling in the Saudi Aramco Form
SA-3750, reviews past records, and service.

4.3 Records nameplate data that is missing from the RV file, such as orifice size,
serial no., material, rating, size, model/type, manufacturer.
4.4 Performs the pop test using the basic steps in this procedure connects the valve
to bench with the right tools and bolts, makes provisions for discharge, records
pop pressure.
4.5 Followed safe practices for a dirty RV by using face shield; recognizes the need
for minor cleaning which does not affect the test, or stopped the test if not safe.
4.6 Aware of correct calibration. Uses correct gauge, and does not test beyond
110% of CDTP, Cold Differential Test Pressure (i.e., the pressure at which the
RV is adjusted to open on the test stand after temperature and backpressure
corrections).
5. Disassembly of the RV
5.1 Avoids loss or mixing of parts.
5.2 Sequence of parts removal is in accordance with the appropriate RV procedure's
manual.
5.3 All parts are visually inspected.
5.4 Part identification is verified when stamped.
5.5 Spring correctness is verified, and spring and washers are carefully inspected for
damage. The spring is measured to verify that it meets the manufacturer's
requirements.
5.6 Critical dimensions are measured and recorded as per shop procedure and
manufacturer manuals. Should include, but not be limited to: seat to body
dimension, upper and lower ring positions, spring set nut position, overlap collar
position, spring washer positions (factory matched with spring), steam service
blowdown vent orifice size.
5.7 Uses measuring tools per procedures.
5.8 Knows where to obtain tolerance data.
6. Technician Can Identify Causes of Improper RV Performance

6.1 Corrosion
6.2 Damage from handling
6.3 Broken springs
6.4 Hang-ups, plugging, sticking
6.5 Pipe strain
6.6 Disk/seat cut damage

6.7 Chattering
6.8 Simmering
6.9 Spindle runout
6.10 Body corrosion/damage
6.11 General wear
6.12 Cracks in any part
6.13 Burrs, nicks, scratches, scoring.
7. Technician can list the steps or methods that are available to help determine the cause or
extent of a problem, and that the local Inspection unit and Engineering Unit are
available through his Supervisor.
8. Technician can evaluate: when a seat and disk need lapping, critical dimensions of seat
and disk, lapping compounds to use, lapping ring sizes and conditions, final surface
acceptance using optical and visual evaluation.
9. Technician can evaluate RV part condition to determine whether it should be repaired

or replaced if tolerance is exceeded, if a repair will restore to original condition.
Reports unresolved conditions to Supervisor.
10. Technician can Perform Final Adjustment and Pressure Testing

10.1 Knows which pressure testing is applicable: bonnet leak test, body leak test,
bellows leak test, initial pressure test, final pop set and pressure test, and CDTP
requirements.
10.2 The Technician obtains a sharp pop test, recognizes the limits of the test bench,
and knows how to compensate by adjusting rings and using a lift restrictor. He
will abort a test if the results are not satisfactory, and report it to his Supervisor.
10.3 Technician can evaluate the test without full lift, can recognize and correct
simmer or chattering through ring adjustment.
10.4 Technician can identify the proper bench settings for blowdown using
manufacturer's specs, and performs the adjustments.
10.5 Technician can install and use spindle travel limiter (lift restrictor).
Can measure spindle travel when required.
11. Technician can conduct leak tests using this procedure, API STD 527, and
manufacturer's manual instructions. Knows where to find tolerance information, and
can evaluate the test results.

12. Technician Can Conduct an In-place Blowdown Adjustment

12.1 Can obtain the necessary Work Permits, can verify safe conditions, works
closely with operator.
12.2 Has taken vendor courses.
12.3 Familiar with the In-place test procedure, familiar with the manufacturer's
adjustment requirements or has them available, knows the tolerances and
settings that must be achieved.
12.4 Demonstrates good judgment and skill when choosing how many notches to
turn, and which ring or adjustment to turn.
12.5 Records the test results on Form SA-3750, as required by this procedure.

Appendix H - Test Conductor Requirements
1. Job Requirements
1.1 In general, the test conductor should be an individual who is a good communicator,
has a positive work attitude, is committed to improving Saudi Aramco, and has
extensive knowledge and skill in maintaining safety relief valves.
1.2 Can commit the time for testing.
1.3 Can work independently.
1.4 Must be organizationally separate from the technician being tested to avoid
biased judgment.
1.5 Must be designated by Operations Inspection Division, Dhahran.
2. Background and Training Requirements
2.1 Has achieved at least 7B English Level.
2.2 Attended available vendor RV courses.
2.3 Completed Saudi Aramco Phase 2 Machinist Training Program, or equivalent.
2.4 Capable RV trainer candidate. Has or will attend Trainer Courses.
2.5 Knowledgeable on Saudi Aramco RV specs, SAEPs, and SAES-J-600.
2.6 Working knowledge of the RV computer management system. He should be

able to retrieve data for repair or design, retrieve information from Operating
System, and enter data into the relief valve program.
2.7 The test conductor should have access to a current library of RV shop manuals
and Vendor catalogs, and applicable code data.
2.8 RV shop repair experience should be a minimum of 5 years which has resulted
in a good practical working knowledge of repairing all RV styles, as defined in
SAES-J-600.
2.9 Has valid certificates for all RV categories except Category 8.
2.10 Completed PEDD RV course PCI 210 (Relief Valve Sizing and System
Analysis) or equivalent vendor course.

2.11 Has through knowledge of this procedure and SAES-J-600.
3. The test conductor must be able to evaluate the following categories based on his
knowledge and the guidelines set forth in the related Saudi Aramco Engineering
Procedures, Specifications, and Industry Standards.
3.1 Evaluate safe work procedures, RV Shop QA Manual, and In-place testing.
3.2 Evaluate technician's knowledge of available repair reference material

(QA Manual, SAESs, SAEPs, Manufacturer's manuals, Codes).
3.3 Evaluate technician's ability to identify causes of improper RV performance.
3.4 Evaluate technician's understanding of methods available to assist in defining

suspected problems, and knows how to initiate NDE, and get results of testing.
3.5 Evaluate technician's ability to obtain a sharp pop test.
3.6 Evaluate technician's ability to identify critical measurements and surfaces, measure
them accurately, and determine if they are within tolerance.
4. A test conductor should be able to evaluate a written In-place test procedure, and
determine if a technician is capable of performing the test. He shall have adjusted
boiler RV blowdown In-place, and attended a vendor course on blowdown adjustment.

Appendix I - Spring Loaded RV Testing and Inspection
VISUAL INSPECTION
1.Verify the RV Identification by comparing the tag and nameplate against the database description.
2.Begin recording T&I data on SA-3750-ENG form.
3.Examine RV visually per manufacture's manual and shop QA manual, looking for corrosion, scale, debris, clogging
and mechanical damage.
4.Conduct initial "As Received" pop and leak tests to determine if RV is operational.
5.Disassembly is required if either tests fails, if it is third interval or as defined in QA manual.
6.If RV is not to be disassembled, and it passes all tests, go to TEST TAG SEAL.
Disassembly
1.Disassemble RV per manufacturer’s instructions or QA manual's procedures.
2.Control all parts to ensure they are not mixed or lost.
3.Record obvious corrosion or damage on SA-3750-ENG form as the RV is disassembled.
4.Immediately contact Engineering and Inspection for further evaluation before cleaning, if unexpected damage or
corrosion is found.
Cleaning
1.Clean all parts to bare metal for further detailed inspection.
2.Body and other "rough surface" parts can be abrasively cleaned, as limited by manufactures’ instructions.
3.Protect the nameplate from damage.
4.Critical dimension parts and surfaces shall be cleaned with methods that do not cause damage to the surface
finishes and contours.
Inspection
1.Inspect all parts per manufacturer's manual and QA manual procedures.
2.Request NDE examination by Inspection where required for crack detection or wall thickness measurements.
3.Check critical surfaces and dimensions.
4.Check for wear, corrosion, free movement, mechanical damage and bent or cracked parts.
5.Check spindle and spring for straightness.
6.Evaluate the capability of parts to be reconditioned.
7.Record finding on SA-3750-ENG report form.
Repairs
1.Restore parts within manufacturer's tolerances.
2.Lap metal seating surface and replace soft seats as defined in manufacturer's manual.
3.Use tools adequate for the work intended.
4.Evaluate parts with suitable measurement instruments.
5.Replace parts that do not meet manufacturers’ requirements and all soft goods.
6.Replacement shall be manufacturer supplied or made from approved material per manufacturer's drawings.
7.All external surfaces shall be cleaned to bare metal and coated.
8.Paint bonnets or bellows RVs green.
Test Tag Seal

1.Adjust to obtain the correct opening pressure (pop).
2.The RV repair is accepted or rejected by the valve function within the pressure test tolerances.
3.Apply the wire seal to the RV adjustment screws so that the seal must be broken to change the adjustments.
4.Attach the identification tag with the RV number, T&I date, next T&I date and test pressure to the RV.

Appendix J - Pilot RV Testing and Inspection
VISUAL INSPECTION
Disassembly
corrosion is found.
5.Check pilot tube for plugging, the pilot pistons for sticking and main valve piston for sticking.
Cleaning
5.Verify that all pilot control cavities and orifice surfaces are clean.
Inspection
3.Check critical surfaces and dimensions.
4.Check for wear, corrosion, free movement, mechanical damage and bent or cracked parts.
5.Check spindle and spring for straightness.
6.Evaluate the capability of parts to be reconditioned.
7.Record finding on SA-3750-ENG report form.
Repairs
2.Lap metal seating surface and replace soft seats as defined in manufacturer's manual.
5.Replace all soft goods and pilot control parts that are worn, corroded and do not meet manufacturer's
requirements.
6.Replace pilot tubing if damaged.
Test Tag Seal

4.Attach the identification tag with the RV number, T&I date, next T&I date and test pressure to the RV.
5.Both the pilot and main valves shall be tagged if they are mounted separately.

Appendix K - Tank Breather Valve Testing and Inspection
VISUAL INSPECTION
Disassembly
corrosion is found.
5.Check pilot tube for plugging, the pilot pistons for sticking and main valve piston for sticking.
Cleaning
5.Remove all Soft goods and clean for inspection.
Inspection
3.Check condition of all soft goods.
4.Evaluate seating and moving part surface to determine if repair or replacement is required.
5.Record findings on SA-3750-ENG report form.
Repairs
2.Lap metal seating surface in their assembled position using a reconditioned in manufacturer's repair manual and
assure that the soft goods are lying smoothly.
5.Replace parts that do not meet manufacturer's requirements.
Test Tag Seal

4.Attach the identification tag with the RV number, T&I date, next T&I date and test pressure to the RV

Appendix L - RV Checklist for External Inspection

Attachment A to SAEP-319 Date: ___________________ Page__ of __
RV Checklist for External Inspection
Department Name: ________________________________ SAP Plant No.: ___________________ Plant/Unit No.:______________
RV No. Old RV RV Set Test Due Bellow RV Upstream Downstream Remarks

(from SAP) No. Location Pres. CDTP Date Date Type Block Valve Block Valve
PZV tag (Equipment No.) Painted Safe Position Car Stem Painted Position Car Stem Painted
No. Green Vent O/C Sealed Position Orange O/C/A Sealed Position Orange
10
11
12
Block Valve Legend: Stem Position Legend:

O = Open, C = Close, A = Atmosphere V = Vertical, H = Horizontal, SA = Sloping Away from valve
(Vertical stem is not to be allowed per SAES-J-600)
Checked By (Area Inspector): _______________________________ Inspection Field Supervisor: __________________________________
Verified by (RV Coordinator): _______________________________ Corrective Action made by: _______________________Date: _____________

Appendix M - Example of RV In-place Test Report
SAFETY VALVE “IN-PLACE TEST” RECORD
Safety Valve No: _______ Set Pressure: ___________ Location: ______________

Boiler/STM. Drum No.: _____________…Test Date:____________…Inlet Size:___________
Valve Adjustment
Valve Action
Test
Commission Screw
No. Anti-
Simmer Chatter Reseat Blow Clockwise Lower Upper Overlap
Time Clockwise
PSIG PSIG At Down Turns Ring Ring Collar
Turns
R L R L R L
Remarks:
Certified RV Tech. Name: Inspector Name: Supv. OPS. Name:
Badge No.: Badge No.: Badge No.:

Asst. Badge No.: Asst. Badge No.

Appendix N - RV Shop Audit Form

Revision History
2 March 2020 Editorial revision primarily to change the Next Revision date, removed Figure II in 11.12.1,
and changed SAP to Operating System.
2 July 2017 Major revision. The document is revised to:
1. Merge all 6 SAEPs into one comprehensive document on Pressure Relief Devices
covering all Inspection, testing, and training requirements
2. Align the RV inspection and testing requirements with other MSAERs and international
standards
3. Address the automation of RV authorization through Operating System
4. Address the escalation process of overdue RV
3 July 2012 Major revision.

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Engineering Procedure

SAEP-319 2 March 2020

Previous Issue: 2 July 2017 Next Revision: 2 July 2022

Saudi Aramco: Company General Use

©Saudi Aramco 2020. All rights reserved. Page 2 of 66

Saudi Aramco: Company General Use

2 Conflicts and Deviations

The following references or associated documents are required by this SAEP.

3.1 Saudi Aramco Documents

Saudi Aramco Engineering Procedures

Saudi Aramco Engineering Standards

Saudi Aramco Best Practice

Saudi Aramco Forms and Data Sheets

©Saudi Aramco 2020. All rights reserved. Page 3 of 66

Saudi Aramco: Company General Use

SA-8020-612 Instrument Specification Sheet - Pilot Operated Safety Relief Valves

Saudi Aramco Technical Alert

3.2 Industry Codes and Standards

American Petroleum Institute

American Society of Mechanical Engineers/Boiler and Pressure Vessel Code

©Saudi Aramco 2020. All rights reserved. Page 4 of 66

Saudi Aramco: Company General Use

Cold Differential Test Pressure (CDTP): The pressure at which a pressure-relief

©Saudi Aramco 2020. All rights reserved. Page 5 of 66

Saudi Aramco: Company General Use

©Saudi Aramco 2020. All rights reserved. Page 6 of 66

Saudi Aramco: Company General Use

5.1 Inspection Technical Support Division (ITSD), Inspection Department

5.3 Process & Control Systems Department (P&CSD)

5.4 Area Loss Prevention Representative

5.5 Corporate Business Application Department (CBAD)

©Saudi Aramco 2020. All rights reserved. Page 7 of 66

Saudi Aramco: Company General Use

5.6 Mechanical Services Shops Department (MSSD)

5.6.1 Manages and approves Contractor RV repair shops based on Contractor's

5.6.2 Audits Contractor facilities annually.

5.7 Manager, Operating Facility

5.7.1 Approves RV In-place Testing procedure.

5.8 Originating Engineer

5.8.1 Verifies that the RV conforms to Saudi Aramco Specifications.

5.8.3 Initiates the RV Authorization WF in Operating System (see Appendices A and B)

5.8.5 Tracks the Approval of Operating System Authorization WF till completion

5.8.6 Assures that no unauthorized RVs are installed in-site.

©Saudi Aramco 2020. All rights reserved. Page 8 of 66

Saudi Aramco: Company General Use

5.8.8 Requests support such as corrosion engineer, CSD/P&CSD/ID/ Manufacturer,

5.8.9 Submits deviation requests through Operating System transaction ZIF0015.

5.8.10 Provides feedback within 90 days to the initiator of RV Interval Change

5.9 Senior Project Engineer

5.9.1 Approves RV Operating System Authorization WF after ensuring that all

5.9.3 Provides a review of damaged, corroded, stuck or malfunctioning RVs in

5.9.5 Provides all required RV documentation to initiate the approval WF in

5.10 Operations Engineering Supervisor

5.10.1 Approves RV design and specification.

5.10.2 Concurs RV Operating System Deviation WF and ensure all required

©Saudi Aramco 2020. All rights reserved. Page 9 of 66

Saudi Aramco: Company General Use

5.10.5 Reviews corroded, stuck or malfunctioning RVs in cooperation with Operations

5.10.6 Assign an engineer to participate in the two years comprehensive physical