For any facility that uses a pressure system or boiler, pressure relief valve testing is a must. While every facility has different testing requirements depending on industry and local code, the way you test pressure relief valves is much the same, regardless of how often you&#;re required to do it. If you&#;re gearing up for regular pressure relief valve testing, here are a few best practices to keep in mind as your testing schedule begins:
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Pressure relief valve testing and inspection can include high noise levels and the discharge of high velocity and high-temperature fluids. Technicians should always take care to wear appropriate personal protective equipment, like eye and ear protection. When entering client facilities, it&#;s important that valve technicians also ask about and follow the facility&#;s unique PPE guidelines as well.
Pressure relief valve testing is most effective when completed on a regular schedule. Though every industry has a unique set of pressure relief valve testing requirements and guidelines, all facilities are best served with regular, comprehensive testing that includes both an operational test, and the verification of the valve&#;s nameplate set pressure.
Operate-in-Place Test
If a pressure relief valve has never been tested before or has no record of prior testing, the National Board states that it must first be tested by lifting the test lever. If the valve doesn&#;t open and is stuck, it&#;s important that the equipment be immediately removed from service, until the valve can be replaced or repaired.
Pressure relief valves are necessary for the safe operation of any facility. If a valve is stuck, the equipment is considered hazardous, and testing must be completed under controlled conditions.
Verify Nameplate Set Pressure
If the valve has been previously tested and has passed the operate-in-place test, it&#;s important to complete a test to verify nameplate set pressure. Every industry varies on the mandated frequency of these tests, but it is important to complete this type of pressure relief valve testing at least as regularly as your industry mandates, as it is the only way to verify that pressure relief valves are actuating at the appropriate setpoint.
Again, inline testing is a convenient and exceptionally accurate testing method here, as you do not have to halt operations to test valves inline. Bench testing is occasionally mandated, but because it requires full-facility downtime, it&#;s often best to opt for inline testing whenever possible.
An important best practice when testing pressure relief valves is to be aware of a valve&#;s pop-off pressure point. Pressure relief valve testing does work to verify the valve&#;s set point, but you never want to force the valve to pop open.
Instead, proper testing pushes the valve just to its simmer point, where the valve begins to lift, both so your technician gets an accurate read on the valve&#;s set point, and so no damage is done to the valve. Forcing the valve to pop-off with too much pressure can cause damage to the valve, and doesn&#;t always return an accurate setpoint, as the valve is overpressurized, rather than just tested to its specific simmer and setpoint.
Best practices for pressure relief valve testing indicate that technicians should test valves carefully, with a constant awareness of the valve&#;s pop-off pressure point, in order to avoid damage and to more accurately test the valve.
A key component of pressure relief valve testing is understanding when the valve needs maintenance. This is part of the reason we always recommend inline testing, where technicians are required to complete the testing. A valve technician understands the key signs of pressure relief valve failure and can replace or repair faulty valves onsite when testing valve inline.
Not every valve will pass pressure relief valve testing. It&#;s important that you understand when the replacement or repair of pressure relief valves is necessary, so you can keep your facility running safely and efficiently.
Does your company follow these best practices for pressure relief valve testing? Make the process easier and more efficient with AccuTEST&#;s advanced inline pressure relief valve testing system. See our system in action with a live webinar demo, or learn more about how inline pressure relief valve testing can increase your profitability.
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Relief Valve testing requirements
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If you are looking for more details, kindly visit Sealing Test Bench.
(Mechanical)
(OP)
13 Apr 11 16:51Our company is located in Louisiana. We are an LNG facility with approximately 140 relief valves. My past experience is to always use a third party inspection company to do our annual relief valve testing (annual because one of the LNG codes requires it).
Our company is going to have our mechanics test the relief valves this year in order to save money. My question is...are we allowed to test our own relief valves? We have no certifications.
All of our relief valves have inlet and outlet blocks and bleeds and the systems are such that we can easily prepare the valves to be safely tested in line using nitrogen as the test media.
My "gut" tells me we should stick with the NBIC approved third party but I cannot back this up.
Any thoughts?
David Wene, P.E.
(Industrial)
13 Apr 11 17:28Your company can do the work internally
If They hold a 'VR' ASME code-stamp
as an Owner-User.last device between the system and catastrophic release and/or fire, with resultant damage in the $$ millions, and probable maiming and/or death.
The risk is immense, the cost savings is puny compaired to the new, added risk exposure. Refer your in-house 'genius' to any good AI or Insurance underwriter.(Mechanical)
(OP)
13 Apr 11 17:32Excellent response. Any other have input? FYI - we would send any that fail our internal test to the VR shop down the road.
I would appreciate as many responses as possible. I've lost the first round of debate and would like to be better armed with for my next argument.
(Chemical)
14 Apr 11 15:42Qualified and trained personnel are a definate requirement, but I'm not sure that means the repair facility must have a VR stamp. I know of some global operating companies that have internal valve shops (non-VR rated) that repair safety valves. These are skilled valve specialists, but they just don't have VR certification from the National Board.
Refer to API 510. That explains the qualification requirements. Possibly it would be Ok for your internal folks to do the pop test and visual inspections, but I'd leave all repair tasks to a qualified valve technician.
BTW.... Duwe6, some of us married folks might not answer that break repairman question the same way as you would :)
(Industrial)
17 Apr 11 21:14To meet ASME Code, any and all valve repairs are to be done under a VR codestamp.
You can 'pop-test'and reset your own valves w/o a VR stamp, but everything else requires the Stamp. Fully trained and qualified people, but lacking certification; or a fully equipped, properly calibrated valve test bench without a VR stamp are not allowed to work on Code valves. This is a legal requirement. Thus my firm suggestion that
dwene
refer his boss to an AI or Insurance underwriter. Wouldn't hurt to have the corporate legal advisor to look at this too. Might want to have a de-fibrillator standing by -- this proposal may give Legal a heart attack.(Mechanical)
(OP)
17 Apr 11 22:07Quick update...I made my recommendations and the bosses disagree with me. They said we don't need to check with insurance or legal and have canceled the PO that we gave to the RV shop I've used for years.
What do I know...I just the only PE at our site.
(Industrial)
18 Apr 11 12:07Try copying off all of this discussion and submitting it to your CEO [your boss's boss, or higher]. Maybe he/she will have enough sense to see that this is NOT a place to try to same money.
Alternatively,QUIT. IMMEDIATLY.
Nobody will hire anyone from the [] MI dept of BP after the debacle in Houston that killed 15 & injured 108 in . Don't let this be you.
(Chemical)
18 Apr 11 13:02Duwe6...please cite your source for saying this is a legal requirement. I'm not saying you're wrong, but I haven't seen this in my review of ASME & API documents.
In God we trust.....everyone else ought to cite references.
(Industrial)
19 Apr 11 10:50NBIC - "National Board" requires that all repairs to Code pressure relief devices be made by a Code-Certified shop possessing a "VR" stamp. ASME and NBIC have been incorporated into USA and Canadian law.
In USA, the only non-Code states are Idaho and Wyoming [all Canadian provences mandate Code]. In the rest, ASME & NBIC have force-of-law. Thus, using 'Joes Valve and Fender shop' to repair your Code PRV's is a legal violation, [assuming Joe doesn't hold a VR stamp].
(Chemical)
21 Apr 11 19:20Duwe6... are you're comments based on ASME Sec I and Sec VIII or just for Sec I?
For Sec VIII there are states other than those you mentioned which are not code states. For example, the OP is in a state (Louisiana) which isn't a code state.
(Chemical)
27 Apr 11 16:12i think the "not a code state" argument is a red herring. OSHA's general purpose clause basically says you need to follow good engineerig practices or GEP.as far as i am concerned, GEP is defined by the codes. not sure i would quit over it but i would have it fully documented via e-mails, etc.the problem i have when good people quit is that those that remain are even less likely to do anything right. this can be the beginning of a "death spiral"on the other hand, if you are of retirement age anyways, you might consider the whistleblower card if you can snag a % of the fines. i think this has a better likelihood of a pay-out than most lotteries.
(Chemical)
27 Apr 11 16:14fyi, a pfizer whistleblower hit the jackpot for over $50 million:
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