Testing of Safety Valves


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Testing Safety valves

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  • Pressure at outlet while the PRV is closed. Can be constant or variable. Due to pressure in discharge system, Because of a constant purge pressure, and/or discharge of other devices into A closed header system ,particularly P r v ’s Constant superimposed (present all the time) deduct from set to give cold set. Variable superimposed bellows required.
  • 1)Usually Foreign Material in Process. 2)10% Below set recommended for tight seat never less than 5%. 3)Distorts body misalignment of internals = leak. 4)API 520 Part II for piping-reactive force-handling and dirt. 5)Re-assembly testing manuf.inst.not followed. 6)Technician/site incorrect calibration or gauge? 7)Only genuine original manuf.parts to be used. 8)Causes disc to rub on seat – leakage. 9)Bad or improper action / bad alignment. 10)Sensitive instrument, handle store and protect. Never- carry By lift lever / Drag/ transport on side. NOTES
  • Testing of Safety Valves

    1. 1. Workshop Delta ProcessAcademyTesting of Safety Valves
    2. 2. Pressure ReliefDevicesProtect Personnel and Property.Last Line of Defence. *
    3. 3. Usages Petrochemical Nuclear Pulp & Paper Aerospace Refining Fossil Power Oil & Gas Production ChemicalSubmarine Service Pharmaceutical Tank Cars Food & Beverage *
    4. 4. What Is A Pressure ReliefDevice ?A device that opens in a state of emergency or when in abnormal conditions.Prevents a rise in pressure in excess of a specified value: Blocked Discharge Thermal Expansion Exposure to External Fire Failure of other Equipment such as a Control ValveCan be either a safety valve. a non reclosing pressure relief device. or a vacuum relief valve. *
    5. 5. Pressure ReliefValvesMust open at a predetermined pressure. (Set Pressure)Achieve a rated relieving capacity at a specified pressure above the opening point. (Overpressure)After a given drop in inlet pressure below the opening point, it should close and reseat tightly. (Blow down) *
    6. 6. Balance BeamStyleJean Disaquliers 1718 DEAD-WEIGHT SAFETY VALVE Open Discharge Pattern FORCE Weight *
    7. 7. Pressure / Vacuum Vent (Breather Valve) Inlet Air Outlet Change Over Valve, Rupture Disc and Purge7 *
    8. 8. Pilot OperatedSafety ? ?? ?
    9. 9. Pilot Op. Vs Spring Loaded ? 6R8 Valve Direct Spring 150# Inlet Set 5 barg Pilot Operated 116 cm Set 20 barg w/out Lever 227 kg 64 cm 111 kg
    10. 10. The Control Ring: Huddlingchamber up :  Blowdown Ring  Small chamber  Sharp opening  Long blowdown Fd Different disk designs Blowdown Ring down :  Large Huddling Chamber A’  Sluggish Opening (Simmer)  Short Blowdown Huddling A Chamber Can be DANGEROUS  The valve may never reach its full A = Orifice flow before 10% over-pressure P Control (Blowdown) Ring Nozzle *
    11. 11. A New Factor: Back Pressure Spring Bonnet P2 Back Pressure Body P1 *
    12. 12. Superimposed Back Pressure To Flare, Recovery System, or Atmosphere Possible Pressure Source Discharge Header System Possible Pressure Source BPS PRV (Closed)Possible Pressure Source Protected System Constant Purge? *
    13. 13. Most Important Characteristics Needed for Overhaul and Testing:  Inlet Size  Outlet Size  MSDS + cleaning declaration  Bellow Present (vent always open)  Back Pressure On Site  Required Back Test Pressure  Max. Set Pressure (Cold Set)  NB Witness / Lloyds  O2 – FDA Service  Type of Soft Good Materials  Test pressures in writing
    14. 14. Transport
    15. 15. Overhaul & testing
    16. 16. Valve testing Procedures Conventional Spring Valve:  Adjusted & Verify Set Pressure  Repeatability Test  Seat Tightness Test According API 527  Shell Test / Body Test  Bellow Integrity *
    17. 17. Pressure % Where PRDs Normally Sized (Except Fire Case) 110 Set Pressure Tolerance Allowable Overpressure 100 MAWP Blowdown % of Set Typical Set Pressure 95Reseat Pressure of PRV Typical Operating Pressure 90 (“the money maker”) *
    18. 18. Valve testing Procedures •SHELL TEST External pressure source 100 PSIG (7 BAR/G ) *
    19. 19. Valve testing Procedures •BELLOWS INTEGRITY Vent has to be always open! External pressure source 14.5 PSIG (1 BAR/G ) *
    20. 20. Testing Specs Tolerance On Set Pressure CDTP(PSIG) TOLERANCE 5 TO 70 +/- 2 PSIG +70 TO 300 +/- 3% +300 TO 500 +/- 2% +500 TO 6000 +/- 1% Temperature adjustment %TEMPERATURE OPERATING TEMPERATURE COMPENSATION 0 TO 150ºF -18 TO 65ºC NONE 151 TO 600ºF 66 TO 315ºC 1% 601 TO 800ºF 316 TO 426ºC 2% 801 TO 1000ºF 427 TO 537ºC 3%
    21. 21. Causes of SeatLeakage  Damaged valve seating surfaces.  Operating pressure to close to set pressure.  Pipe strains  Incorrect installation  Incorrect maintenance  Incorrect calibration  Misapplication of materials  Vibration  Damaged springs  Rough handling / transport / montage  Manipulation of lift handle  Yousing lift handle as means of transportation *
    22. 22. In line testing  Requires accurate knowledge of  system pressure  nozzle area  Valve always opens  Time consuming Hydraulic Unit Recorder Force / Lift *
    23. 23. Safety Valve NomenclatureMAWP Maximum Allowable Working Pressure. The specified maximum safe “design pressure” of a vessel or system. It is often the “Set Pressure” of the safety valve.Operating Pressure The normal working pressure in a pipe or vessel.Set Pressure The pre determined pressure at which a safety valve starts to open and relieve.
    24. 24. Safety Valve NomenclatureOverpressure The pressure over and above the set pressure required for the safety valve to fully open – expressed as a percentage.Accumulation The pressure rise above the MAWP (term often confused with overpressure which can be different).Blowdown Difference between set and reseating pressure of a safety valve expressed as a percentage.
    25. 25. Safety Valve NomenclatureOperating Gap (or difference) Difference between the working (normal operating) pressure of the vessel or system and the set pressure of the safety valve.Back Pressure A pressure opposing the set pressure that is present in the outlet side of the safety valve. Influences valve size, style and selection.Inlet Temperature The fluid temperature at the moment of relief.
    26. 26. Other Important Safety Valve TermsOrifice Area The minimum cross sectional area of the inlet flow path (nozzle) of a safety valve. This is what is “sized”.Lift Actual travel of the disc away from the closed position when a safety valve is relieving.Seat The area formed between the contact of non moveable and moveable components that maintain safety valve tightness.
    27. 27. Guided Tour or Documentation Questions ? Carl.stevens@cofelyfabricom-gdfsuez.com Wim.morel@cofelyfabricom-gdfsuez.com
    28. 28. Sources Tyco Formation  Main Valve Maintenance  Model Numbering  Pilot Valves  Spring Valves Operations  Poor Performance  Safety Valve Terminologie  Test Procedures  Valve Types Sarasin Manuel Sapag Manuel Crosby Manual Belangrijkste normeringen USA ASME I Boiler applications ASME III Nuclear applications ASME VIII Unfired Pressure Vessel Applications ANSI/ASME PTC 25.3 Safety and Relief Valves - performance test codes API RP 520 Sizing selection and installation of pressure relieving devices in refineries, Part 1 Design, Part 2 Installation API RP 521 Guide for pressure relieving and depressurizing systems API STD 526 Flanged steel pressure relief valves API STD 527 Seat tightness of pressure relief valves Europe EN ISO 4126 Safety devices for protection against excessive pressure International ISO 4126 Safety valves - general requirements