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OISD STANDARD - 132

First Edition, August 1990
Reaffirmed, August, 1999

FOR RESTRICTED
CIRCULATION

INSPECTION
OF
PRESSURE RELIEVING DEVICES

Prepared by

COMMITTEE ON
INSPECTION OF STATIC EQUIPMENT

OIL INDUSTRY SAFETY DIRECTORATE

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

Though every effort has been made to assure the

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

These documents are intended only to supplement

and not replace the prevailing statutory requirements.
 FOREWORD

The Oil Industry in India is 100 years old. Because

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

With this in view, the then Ministry of Petroleum &

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

The present standard on “Inspection of Pressure

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

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

This standard in no way supercedes the statutory

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

SECTION PAGE NO.

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

ANNEXURES

I Definition of Related Terms

II & III Graphical Illustration of Relationship

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

VI Technical Data, Test and History Card of

Rupture Disc

VII Technical Data, Test & History Card of

PV Vent Valves
 INSPECTION OF PRESSURE RELIEVING DEVICES
1.0 INTRODUCTION
Pressure Relieving Devices are
installed on Process Equipment, tankages
and piping to release excess pressure
resulting from operational upsets and other
causes like fire etc. Malfunctioning of
these devices could result in process
upsets and/or failure of equipment and
hence the necessity for proper inspection
and maintenance of these devices.
2.0 SCOPE
This inspection standard outlines
the minimum inspection and testing
requirements applicable for all pressure
relieving devices including those for
vacuum service used in the petroleum
industry. Control valves as means of
relieving pressure into flare system
however are covered in this standard.
3.0 DEFINITION AND TYPES
OF PRESSURE
RELIEVING DEVICES
3.1 DEFINITIONS
Definitions of terms related to
pressure relieving devices are given in
Annexure-I. Graphic relationship between
these terms are illustrated in Annexure-II &
III.
3.2 TYPES OF PRESSURE
RELIEVING DEVICES
a) Safety Relief Valve
A safety relief valve is an
automatic pressure-relieving device
suitable for use either as a Safety or Relief
Valve depending on application.
Pressure Relief Valve is a generic
term used to denote Relief/Safety/Safety
Relief Valve.
b) Relief Valve/Thermal Safety Valve
(TSV)
Primarily used for liquid service, a
Relief Valve is an automatic pressure-
relieving device actuated by the static
pressure upstream of the valve. The valve
opens in proportion to the increase over
the opening pressure. Thermal Safety
Valves are meant to take care of pressure
increase resulting from thermal expansion
of fluid.
c) Safety Valve
A Safety valve is an automatic
pressure-relieving device actuated by the
static pressure upstream of the valve and
characterised by rapid full opening of pop
action. It is normally used for
steam/gas/vapour service.
3.2.1 Types of Safety Relief Valves
Types of Safety Relief Valves in use are:
i) Conventional
ii) Balanced and
iii) Pilot operated Valves
i) Conventional Safety Relief Valve:
Conventional safety relief valves are
susceptible to both superimposed and
built up back pressure and are not
recommended when the total back
pressure exceeds 10% of the set
pressure.
These type of valves are shown in
figure 1 and 3. In figure 3a, the bonnet
is open vented to atmosphere and the
effect of back pressure is to reduce the
set pressure. In figure 3b, the bonnet is
vented to valve outlet and the effect of
back pressure is to increase the set
pressure.
ii) Balanced Safety Relief Valve:
The balanced safety relief valve
incorporates means of minimising the
effects of back pressure on the
performance characteristics, set
pressure, reseat pressure, lift and
relieving capacity. These valves are of
two types:
a) Piston type
b) Bellows type
a) Piston Type

A typical piston type balanced valve is
shown in figure 4a. In this valve, the
guide is vented so that the back
pressure on opposing faces of the
discs cancels itself. The top face of
the piston which has the same area
as the nozzle seat area is subjected
to atmospheric pressure by venting
the bonnet. The bonnet vented gases
from balanced piston type valve
should be disposed of safely.
b) Bellows type
Typical bellows type valves are
shown in figure 2 and 4b. In the
bellows type of balanced valve, the
effective bellows area is the same as
the nozzle seat area and by
attachment to the valve body,
excludes the back pressure from
acting on the top side of the area of
the disc to provide for a possible
bellows failure or leak. The bonnet
must be vented separately from the
discharge to a safe location.
iii) Pilot Operated Safety Valves
In pilot operated safety valves (Figure
5), the main Safety Valve opens
through a pilot valve. Both the pilot
and the main valve contain flexible
membranes which can withstand only
ordinary service temperatures.
Because of this and the risk of
fouling, their use is limited to very
clean services.
3.2.2 Rupture Disc
A rupture disc is a thin metal
diaphragm held between ranges. It
is actuated by inlet static pressure
and designed to function by the
bursting of the disc. Once burst, it is
not reusable and has to be replaced.
3.2.3 Pressure & Vacuum Relief
Devices
a) Breather Valve
Pressure and Vacuum Relief
Valves are automatic pressure or
vacuum relieving devices actuated
by the pressure or vacuum in the
storage tank. These valves are
usually weight loaded on both the
pressure and vacuum side, the
pallets being calibrated to open at
very low pressures. Although
pressure and vacuum valves are
available as separate units, they
are usually built as combination
units as an integral body and
frequently referred to as breather
valves.
b) Hydraulic Safety Valve/Liquid
Seal Valves
In liquid seal valve, a liquid
provides the closure against flow
through the vent until over
pressure or over vacuum occurs.
c) Vents
Vents are open pipes of suitable
capacity fitted on tanks and are
meant to function as breather
valves.
4.0 ROLE OF INSPECTION
The following are the
responsibilities of the Inspection division:
i) To prepare inspection schedule
guided by experience and
requirements of statutes and assure
their implementation.
ii) To inspect and determine the
physical condition of the different
parts (sub assemblies) of the device,
record abnormalities and suggest
repairs wherever necessary.
iii) To study the abnormalities
/deterioration with a view to:
a) Prevent the damage by suitable
remedial measures or reduce the
extent of deterioration.
b) Plan procurement of spare device/
spare parts, well in time.
iv) To inspect quality of maintenance.
v) To witness and certify “after-
maintenance testing “ of the device
and ensure that the device is fitted
back at its own place.
vi) To provide feed back to the operations
department as to the condition of the
devices.
vii) To maintain Data Sheets and History
Sheets of all Pressure Relieving
Devices, and keep them updated.
viii) To assure the quality of new devices
and spares.
x) Stamping of device after inspection.
5.2 INSPECTION ON RECEIPT AT SITE
On receipt at site, the new Pressure
relieving Devices shall be checked as per
the following check list:
5.2.1 General Information

The following general information

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

The Pressure Relieving Device Action Remark

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

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

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

vii) Material quality and thickness The following checks shall be

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

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

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

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

7.3 BREATHER VALVES i) Statutory requirements

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

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

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

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

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

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

An on stream visual inspection should be
carried out at least once in every 6 months
to check the following:
b) Visual inspection of different parts of
a) Gags, blinds do not exist.
b) Upstream and down stream isolation
valves, if any, are opened and sealed.
c) Seals protecting the spring setting
have not been broken.
d) Relief device is not leaking. This may
be checked visually and by
thermography, contact thermometers
received condition. This is important
and helps in establishing the frequency
of inspection.
safety valve shall be done after
dismantling to check the following:
i) Condition of flanges for pitting,
roughening, decrease in width of
seating surface etc.
 ii) Spring, for evidence of bending,
corrosion or cracking, free length
of spring.
iii) Bellows (if applicable) for damage.
iv) Position of set screws and opening
in bonnet.
v) Inlet/outlet nozzles for evidence of
deposits foreign material and
corrosion.
vi) Condition of external surface and
evidence of mechanical damage.
vii) Body wall thickness.
viii) Conditions of steam, guide disc,
nozzles etc. for evidence of wear
and corrosion.
ix) Seating surface of disc and nozzle
shall be critically examined for
roughness or damage which could
result in valve leakage and may
need correction. Care must be
taken to ensure flatness of seats.
x) It is recommended that springs be
tested for stiffness.
a) 10th year after installation and
subsequently every 5 years.
b) Immediately where
malfunctioning is suspected.
If load and compression
valves do not match with
original valves, the spring
should be replaced.
9.2.2 Rupture Disc
During shutdown inspection, the
rupture disc shall be examined for:
i) Cracks and fatigue of the disc.
ii) Mechanical distortion, wire drawing
and damage in gasket seating face of
the disc holding flanges.
It is however recommended that
rupture disc should be replaced on a
schedule guided by manufacturer’s
recommendations & past experience.
9.2.3 Pressure Vacuum Relief
Devices
These devices shall be checked
for the following damage, depending on
the type of the device.
i) Loss in weight/fouling of pallets
ii) Corrosion and surface roughening of
pallets.
iii) Quality of sealing liquid.
iv) Internal corrosion of vents & flame
arrestor bodies.
10.0 TESTING PROCEDURE
FOR PRESSURE
RELIEVING DEVICES
Testing of all Pressure Relieving
Devices shall be carried out at frequencies
indicated in Chapter 8.0
10.1 SAFETY RELIEF VALVE
10.1.1 Set Pressure Test
It shall be ensured that correct
calibrated test gauge is used. All safety
relief valves shall be tested in accordance
with the relevant code to which the
protected equipment is designed. After
final adjustment the valve shall be popped
at set pressure at least once to prove the
accuracy of setting. PSV test pressure
tolerance shall be 0.5% of the set
pressure. Allowance for hot setting shall
be made as per manufacturers
recommendations. The set pressure
adjustment shall be sealed.
Reseat pressure shall be checked
during testing of safety valve. The spring
in a pressure relief valve in service for
pressures up to and including 250 psi shall
not be reset for any pressure more than
10% above or 10% below that for which
the valve is marked. For higher pressures,
the spring shall not be reset for any
pressure more than 5% above or 5%
below that for which the safety or relief
valve is marked. Working of hand popping
device shall be checked during testing.
10.1.2 LEAK TEST
Leak test shall be performed in
accordance with the relevant code.
10.1.3 LOCKING
After set pressure test and leak test,
the valve shall be sealed after tightening
the lock nut of gas, as well as hand
popping (if provided).
10.2 SAFETY VALVES ON BOILERS
Safety Valves shall be tested as
per IBR at the time of the statutory
inspection. Initial setting of the safety shall
be checked in workshop.
Reseating Pressure and blowdown
shall also be checked as per IBR, by
adjusting blowdown rings. The blowdown
shall be kept within 3-5% of set pressure.
When a safety valve fails to
operate at the set popping pressure,
attempt should not be made to free it by
striking the body or other parts of the
valve. The valve shall be popped by
means of the lifting lever and allowed to
reseat, after which the pressure of the
boiler should be raised to the set pressure.
If the valve does not still pop, the boiler
shall be taken out of operation and safety
valve attended.
It is advisable to check lifting lever
for free operation when there is at least 75
% of full working pressure on boiler. This
ensures that moving parts are free to
operate.
10.3 INSPECTION AND TESTING OF
PILOT OPERATED SAFETY
RELIEF VALVE
Inspection of pilot operated valves
is divided into two separate phases, the
pilot mechanism & the main valve. In
some types of valves, the pilot can be
blocked off from the vessel for inspection
and testing while the spring loaded main
valve continues to protect the vessel. The
diaphragms in both the pilot and the main
valve of certain designs shall be inspected
and replaced, if necessary with the main
valve in service. Manufacturers
recommendation for inspection, testing
and repairs shall be followed.
10.4 INSPECTION & TESTING OF PV
VALVES
PV Valves shall be inspected and
tested as per relevant code for tightness &
positive operation at set pressure. Testing
shall be done as outlined in API 2521.
11.0 DOCUMENTATION
The documents to be maintained
shall include:
(i) Data sheets covering the type, make,
design, and constructional aspects of
the device.
(ii) History card depicting the number and
frequency of failures/repairs with
probable causes type of failure/repair.
(iii) Test/inspection report revealing the
status of the device and its parts, its
suitability for continued use and
suggestions for present/future repair
and maintenance.
Typical Formats of combinations
of above three documents are given in
Annexure-5,6 & 7.
12.0 REFERENCE
(i) API RP 520 Part I & II Design and
installation of pressure relieving
system in Refineries.
(ii) API RP 521 Guide for pressure and
depressuring system.
(iii) API 526 Flanged Steel Safety Relief
Valves.
(iv) API 527 Seat tightness of Safety Relief
Valves.
(v) API 2000 Venting atmospheric and low
pressure storage tanks.
(vi) API 2521 Use of PV Vent Valves for
Atmospheric Pressure Tanks to
reduce Evaporation Loss.
(vii) API Guide Chapter XVI Pressure
Relieving Devices.
(viii)Guide for Inspection of Refinery
Equipment Chapter XIII Atmospheric &
Low Pressure storage Tanks.
(ix) ASME Boiler and Pressure Vessel
Code Sec. VIII Div. 1 and Div. 2.
(x) The Static and Mobile Pressure
Vessels (unfired) Rules 1981.
(xi) Indian Boiler Regulation(IBR).
(xii)Fire Protection Manual by Charles
Verravlin Volume-I.

DEFINITIONS OF RELATED TERMS
1. Maximum Allowable Working
Pressure(MAWP)
Maximum Allowable Working
Pressure is the maximum pressure at
designated temperature or its equivalent at
any metal temperature other than design
temperature at which a vessel may be
operated consequently for that metal
temperature, it is the highest pressure at
which the primary pressure relieving
device is set to open.
2. Set Pressure
In a relief or safety relief valve on
liquid service, set pressure is the inlet
pressure at which the valve starts to
discharge under service conditions. In a
safety or safety relief valve on gas
services, the set pressure is the inlet
pressure at which the valve pops under
service conditions.
Set pressure should not exceed
the maximum allowable working pressure.
However, where more than one safety
valve is installed, any one valve need to be
set to open at or below maximum
allowable working pressure. The
additional valve may be set at maximum
105% of MAWP.
If the pressure relieving devices
are used for protection against fire or any
other external heat, the additional devices
can be set at a pressure not exceeding
110% of MAWP.
3. Relieving Pressure
Relieving Pressure is the operating
pressure increased by the amount of over
pressure at full lift of relief valve.
4. Accumulation
Accumulation is the pressure increase
over the maximum allowable working
pressure of the vessel during discharge
through the pressure relief valve and is
ANNEXURE-1
expressed as percentage of the maximum
allowable working pressure.
5. Over Pressure
Over Pressure is the pressure
increase over the set pressure of the
relieving device. It is the same as the
accumulation if the device is set at
maximum allowable working pressure. It
may be greater than the accumulation if
the valve is set at a lower pressure than
MAWP or vice versa.
6. Blow Down
Blow Down is the difference
between the set pressure and reseating
pressure and normally expressed as
percentage of the set pressure.
7. Back Pressure
Back pressure is the pressure
existing at the outlet of the pressure relief
device due to pressure in the discharge
system.
8. Superimposed Back Pressure
Superimposed back pressure is
the pressure in discharge header before
the safety relief valve opens (where more
than one device discharges into a common
header).
9. Built up Back Pressure
Built up Back Pressure is the
pressure in the discharge header, which
develops as a result of flow after the safety
valve opens.
10 . Lift
The rise of the disc in a pressure
relief valve is called lift.
11. Chatter
 Chatter is an abnormal
reciprocating motion of the movable parts
of a pressure relief valve in which the disc
contacts the seat, producing sound.
12. Simmer
Simmer is the audible escape of
fluid between the seat and disc at end inlet
pressure below the popping pressure. In
this, valve is only slightly open and
therefore discharging a small percentage
of its rated capacity.
Crack Pressure is a supply
pressure at which gas flow begins at the
pilot exhaust. This term is frequently used
in connection with pilot operated safety
relief valves.
14. Cold differential test Pressure
Cold differential test Pressure is
the inlet pressure at which a pressure relief
valve is adjusted to open on the test
bench. This test pressure includes
correction for service conditions of back
pressure and/or temperature.

13. Crack Pressure


Leak Test for Seat tightness of Safety Relief Valves
A. Test Apparatus
A typical test arrangement for
determining seat tightness for safety relief
valves is shown in figure (6) leakage
measurement shall be made with the use
of 0.8 mm OD tubing. The tube end shall
be cut square and smooth. It shall be
parallel to end 13 mm below the surface of
water.
B. Procedure
With the valve mounted vertically the
leakage rate in bubbles/mnt shall be
determined with pressure at the pressure,
ANNEXURE IV
immediately after popping. The test
pressure shall be applied for a minimum of
1 minute for valves of inlet sizes through
50 mm, 2 mins, for sizes 63 mm, 75 mm
and 100mm, 5mins for 150mm and
200mm. Air at approximate ambient
temperature shall be used as the pressure
medium.
C. Tightness Standard
The leakage rate in bubbles per
minute shall not exceed the value
indicated in figure in the graphs (figure 7).
 ANNEXURE-V

Card No._________

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

A. Technical Data:

Information Conditions Dimensions

Location: __________ Service: __________ Inlet: __________

Tag No. __________ Relief __________ Outlet: __________

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

Model/Type: __________ Back __________ Spring __________

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

Drawing No. __________ Operating __________ Bonnet: __________

Temp.

Order No. __________ Changes in Disc: __________

operating:

Relief __________ Conditions: Nozzle: __________

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

B. Test Report & History:-

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

TECHNICAL DATA, TEST & HISTORY CARD OF RUPTURE DISC

A. Technical Data:-

Information: Conditions Dimensions

Location: __________ Service: __________ Size: ___________

Tag. No. ___________ Bursting

Pressure: ___________

Make ___________ Design Temp. ___________ Materials:

Lot No. ___________ Operating Disc: ___________

Pressure ___________

Catalogue ___________ Operating

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

Relief
Capacity ___________

B. Test Report & History:-

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

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

Card No. ______________

TECHNICAL DATA, TEST & HISTORY OF PV VENT VALVE

A. Technical Data:-

Information Conditions Dimensions

Locations: __________ Service: __________ Inlet

Tag. No. __________ Set Working Outlet __________

range over
Pressure
Vaccum
Make: __________ Pallets __________
weight

Model/Type:

Catalogue
Ref: __________ Materials :

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

Order No. __________ Sealing

Liquid __________

Relief Operating
capacity: _________ Temp: __________

B. Test Report and History:-

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