Standard Specification for

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Safety Relief Valves

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Table of Content

1.0 SCOPE ........................................................................................................................... 4

1.1 Purpose ............................................................................................................... 4
1.2 Definitions of Terms ............................................................................................. 4

2.0 ENVIRONMENTAL DESIGN CRITERIA ......................................................................... 4

2.1 Climatic Conditions .............................................................................................. 4
2.2 Design Life .......................................................................................................... 4
2.3 Area Classification ............................................................................................... 4

3.0 CODES, STANDARDS AND REFERENCE DOCUMENTS ............................................ 5

3.1 Reference Project Document ............................................................................... 5
3.2 International Codes and Standards...................................................................... 5

4.0 DESIGN REQUIREMENTS ............................................................................................. 5

4.1 General................................................................................................................ 6
4.2 Bonnet ................................................................................................................. 7
4.3 Body .................................................................................................................... 7
4.4 Nozzle ................................................................................................................. 7
4.5 Spring .................................................................................................................. 7
4.6 Instrument tagging / Identification ........................................................................ 7

5.0 MATERIALS AND FABRICATION ................................................................................. 8

5.1 Materials .............................................................................................................. 8
5.2 Material Identification and Certification ................................................................ 8
5.3 Welding ............................................................................................................... 8

6.0 INSPECTION AND TESTING ......................................................................................... 9

6.1 General................................................................................................................ 9
6.2 Factory Acceptance Test (FAT) ........................................................................... 9
6.3 Non-Destructive Testing .................................................................................... 10
6.4 Hydrostatic Tests ............................................................................................... 10

7.0 PROTECTIVE COATING AND PAINTING ................................................................... 10

8.0 QUALITY ASSURANCE AND QUALITY CONTROL ................................................... 10

9.0 GUARANTEES AND WARRANTIES ........................................................................... 11

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10.0 SPARES AND SPECIAL TOOLS ................................................................................. 11

10.1 Spares ............................................................................................................... 11
10.2 Special Tools ..................................................................................................... 12

11.0 PACKING, SHIPMENT AND PRESERVATION ............................................................ 12

11.1 Packing and Shipment ....................................................................................... 12
11.2 Preservation ...................................................................................................... 12

12.0 VENDOR DATA REQUIREMENT ................................................................................. 13

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1.0 SCOPE

1.1 Purpose
This specification defines the minimum requirements for the design, material procurement,
fabrication, inspection, testing and shipment of Safety Relief Valves.
The requirements of this specification are to be considered as minimum requirements and
VENDOR may submit to the PURCHASER, for agreement, any possible solutions, with
supporting calculation notes that could give technical and / or economic improvement
Any omission in this requirement shall not relieve the VENDOR of his responsibility to
deliver the equipment along with other associated items, which are complete, of proven
design, and conforms to the Performance Requirements.
1.2 Definitions of Terms
The CLIENT / COMPANY / OWNER where used in this specification shall mean the
ultimate user / owner of the plant and facilities.
The CONTRACTOR / PURCHASER where used in this specification shall mean the party,
who undertake LSTK / EPC contract for the above project.
The VENDOR / SUPPLIER where used in this specification shall mean the party, who
manufactures or supplies the equipment and services specified.
The INSPECTOR / TPA where used in this specification shall mean the PURCHASER /
COMPANY or their authorized agency for carrying out the inspection.
The ENGINEER / DEC where used in this specification shall mean the party, who perform
Design Engineering Consultancy and Project Management for Company.

2.0 ENVIRONMENTAL DESIGN CRITERIA

2.1 Climatic Conditions

The equipment shall be designed for out-door location, suited to corrosive, desert / salt
laden and marine environment. Climatic conditions under which equipment designed /
operated shall be as per Project Design Basis and Equipment Datasheet.

2.2 Design Life

Equipment shall be designed and constructed for continuous operation, outdoor and for a
minimum service life of 25 years or as per Project Design Basis and Equipment Datasheet
whichever is more.

2.3 Area Classification

All Electrical and Instrumentation equipment supplied including equipment supplied as part
of mechanical equipment and packages shall be suitable for the applicable Hazardous

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Area Classification as specified in equipment datasheet.

3.0 CODES, STANDARDS AND REFERENCE DOCUMENTS

3.1 Reference Project Document

The latest revision of following project specification / documents shall form integral part of
this specification.
P6EC-STD-PP-S-1001 : Piping Material Specification

3.2 International Codes and Standards

The design, materials, fabrication, inspection, testing, and preparation for equipment and
packages shall be in accordance with this specification and the latest edition (including
addenda/errata) of applicable codes and standards as listed below.
API RP-520 : Sizing, Selection and Installation of Pressure Relieving
Devices in Refineries, Part I – Sizing & Selection.

API RP 521 : Guide for Pressure relieving and de-pressurizing system

API RP-526 : Flanged Steel Pressure Safety Valves.

API RP 527 : Seat Tightness of Pressure Relief Valves.

API 1973 : Guidelines on noise. Medical Research report EA 7301

ASME B16.5 : Pipe Flanges and Flanged Fittings

ASME SECVIII : Boiler and Pressure Vessel Code Rules for construction
of Pressure Vessels

ANSI B 1.20 : Pipe threads

IS - 875 : Codes of practice for design loads (other than

earthquake) for buildings and structures.
IS - 1893 : Codes of practice for Earthquake Design
OMR : Oil Mines Regulations
OISD : Oil Industry Safety Directorate regulations
DGMS : Directorate General of Mines Safety
IER : Indian Electricity Rules
CPCB : Central Pollution Control Board of India

4.0 DESIGN REQUIREMENTS

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4.1 General
The Safety relief valves shall be direct spring loaded closed bonnet type unless or
otherwise the operating conditions demand a pilot operated valve.
The design sizing and selection of the Safety relief valves shall conform to API RP-520
and API RP 526.
The actual ASME certified Coefficient of discharge shall be used for sizing of the valve.
The valves shall be provided with low friction guide, self-aligning spring assembly, and
normally be of full nozzle type.
Spring setting range shall be minimum + 5%.
The allowable tolerance in set pressures is as below:
a) ±0.14 kg/cm2 g for set pressure up to and including 5kg/cm2 g.
b) ±3% for set pressure above 5kg/cm2 g.
Safety relief valves shall be fitted with manual seat lifting devices and or with test gags
when specified in the data sheets.
Plain lifting lever in general shall be provided for the relief valves used for hot water, air
and steam service application.
Conventional PSV's may be used for application with constant back-pressure, as long as
the back pressure is within 10% of the set pressure.
In case of variable back pressure up to 50% of the set pressure balanced bellows type
shall be selected and in case the back pressure exceeds 50% of the set pressure pilot
operated valves shall be selected
Pilot operated valves may be used in service where the valve is not subject to freezing,
hydrate formation etc. If the operating pressure is within 5 % of the set pressure for gas
and 10 % of set pressure for liquid, a pilot operated safety relief valve shall be used.
Pilot valves shall be supplied with suitable filters in the pilot sensing line in case of dirty
service and particles are expected
Pilot valves when selected shall be with Non- flowing pilot and shall be supplied with
suitable back flow preventer
All relief valves with 1” and larger size shall have flanged inlet-outlet process connection as
per ASME B16.5 and thermal relief valves shall have ¾” NPT process connection.
Unless otherwise specified, the following shall govern:

• Threaded end connections shall be to NPT as per ASME B1.20.1.

• Flanged end connections shall be as per ASME B 16.5.

• Grooves of ring type joint flanges shall be octagonal as per ASME B 16.20.

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For very low capacity if API orifice is offered, VENDOR shall provide mechanical stop to
prevent lifting. Vendor shall demonstrate the capacity test of such valves during inspection.
For special corrosion and toxic application bellows shall be installed in top guided valves,
when specified, to prevent all parts of body except body, disc, blowdown, and pin (which
are in contact with process fluid).
4.2 Bonnet
Bonnets shall be bolted to the valve bodies. The bonnet and body material shall be
identical. Open bonnet shall be used for steam or air discharging to atmosphere. Closed
bonnet shall be used for other services.
4.3 Body
The body material shall be in accordance with the piping class specification. Cast iron
body is forbidden.
4.4 Nozzle
A full nozzle shall be used for conventional PSV. Semi-nozzle is acceptable for pilot
operated PSV. Nozzles shall not be welded to the body. Nozzle material shall be
compatible with the process fluid and, as a minimum, shall be 316 SS.
Nozzles shall be designed to prevent other parts, with the exception of the disc, from being
in contact with the process when the safety relief valve is closed.
4.5 Spring
Spring material shall be suitable for relieving temperature, specified in the datasheet. Caps
shall be provided over the spring adjusting screw for all valves except as required by code.
The cap and bonnet shall be provided with wire seal unless otherwise specified, to prevent
unauthorised adjustment.
4.6 Instrument tagging / Identification
VENDOR shall furnish tagging as per the datasheets. Tagging shall be via nameplates that
are mounted on the unit with 316 SS hardware. If the item is such that screws or rivets are
not acceptable, or if a supplemental tag is required, a 316 SS tag may be wired to the item
using a minimum of 18 AWG 316 SS wire. Adhesives alone shall not be used. The above
information is in addition to manufacturer's standard tagging information, such as model
number and serial number.
The data plate shall contain VENDOR required information and as a minimum, the
following:

• Manufacturer

• Valve body model number

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• Body material

• Body/ flange rating

5.0 MATERIALS AND FABRICATION

5.1 Materials
Material of construction shall be as per datasheet. Materials procured and used for
fabrication shall be new and of first quality and shall meet the requirements of relevant
specification.
The VENDOR must submit all proposed substitute materials for the PURCHASER’s
approval at enquiry stage. All material substitutes must be equal to or better than the
material specified. This applies to both pressure and non-pressure parts. No material
substitution to be made without written approval from PURCHASER.
The impact test temperature shall be minimum design metal temperature or test
temperature as per applicable material specification, or as specified in datasheet,
whichever is lower. Impact testing requirement shall be established as per code, and when
required as per code all materials used for low temperature shall be impact tested to meet
the code requirement.
5.2 Material Identification and Certification
The VENDOR shall submit to the INSPECTOR / PURCHASER certification of material
compliance for all materials used in pressure parts and process stream. The material
certificate for pressure parts and process stream shall be minimum BS EN 10204, type 3.2
and non-pressure parts attached to pressure parts shall be type 2.2.
The VENDOR shall provide records for Positive Identification of materials at all stages,
whereby any part of the equipment can be identified with the material from which it was
cut.
5.3 Welding
All the welding shall be carried out as per ASME Sec IX / applicable specifications and
approved quality assurance plan. Structural welding shall be as per AWS D.1.1
Welder qualifications, welding procedure specifications (WPS’s) together with the
supporting procedure qualification records (PQR’s) shall be submitted to INSPECTOR for
review and acceptability before commencement of fabrication.
Each WPS submitted should closely relate to the production weld it represents. For
example the actual joint preparation, fit up and weld consumables to be used shall be
described.
Previously qualified procedures (less than 2 years) and previously qualified welders (less
than 6 months) may be acceptable subject to PURCHASER approval. All welding shall be

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performed in accordance with an approved procedure using consumables as described in

the procedure.
All welding including tack welding and non-pressure parts welding shall be performed by a
welder who qualified as per code.
The PURCHASER reserves the right to request the withdrawal from the work any welder
whose performance in the opinion of the PURCHASER’s Inspector is unsatisfactory
All butt weld joints shall be welded with full penetration, full fusion and double sided.
No welding or weld repair is permitted on pressure parts after Post Weld Heat Treatment
(PWHT), unless specifically approved.

6.0 INSPECTION AND TESTING

6.1 General
Unless specified otherwise, all inspection and testing shall be carried out as per
requirement of this specification, datasheet, codes and standard.
Inspection shall be carried out for materials, during fabrication and before delivery of
equipment. In addition to final inspection and certification by INSPECTOR. VENDOR shall
obtain INSPECTOR’s written approval/acceptance at all stages of fabrication, inspection
and testing.
The VENDOR shall supply, at his own expense, all appropriate equipment and facilities to
perform the required inspection and testing.
The acceptance of any piece of equipment or component by an INSPECTOR /
PURCHASER shall not diminish or any way affect the VENDOR’ s sole of responsibility for
the freedom of the equipment from defects and for the observance of all the terms and
conditions of the order.
Final acceptance of the equipment shall be after commissioning of the equipment.
6.2 Factory Acceptance Test (FAT)
Instruments shall be subjected to a complete Factory Acceptance Test (FAT) prior to
shipment at the supplier works. VENDOR shall submit proposed FAT procedures for
COMPANY review. As a minimum the VENOR shall perform the following tests as part of
FAT
All materials and fabrication shall be thoroughly inspected before, during and after
assembly to assure correctness of design and workmanship, and the COMPANY may
inspect at any stage prior to shipping.
The performance test including visual check shall be applied for instruments using
VENDOR’s facilities in VENDOR’s factory before shipped and installed at site.
The following inspection and testing shall be performed as a minimum

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• Valve Dimensional and visual check

• Review/Verify Mill certificates for traceability

• Valve function check / Pop Test at CDTP

• Hydrostatic test

• NDT as per ITP.

6.3 Non-Destructive Testing
VENDOR shall employ Non-destructive test operators, qualified as required by code.
VENDOR shall also certify that each operator, engaged in NDT, is qualified to meet the
code requirement.
As a minimum the following NDT shall be done for all the valves

• 100 % DPT for all welding joints

• 100% Magnetic particle examination for

• 100% Radiography for valve flange rating more than or equal to 600#

• 10% radiography for valve flanges rating less than 600#

• Ultrasonic test as applicable

6.4 Hydrostatic Tests
The valves complete with all pressure retaining parts shall be hydrostatically tested on
completion of all other tests and PWHT.
The minimum hydrostatic test pressure and the time of testing shall be as per the relevant
code.
Potable water with additives shall be used for hydrostatic test. For austenitic stainless steel
Valves the hydrostatic test water shall not contain more than 25 ppm chlorides.

7.0 PROTECTIVE COATING AND PAINTING

The equipment, piping, valves, skids and all other items shall be painted as per project
painting specification.

8.0 QUALITY ASSURANCE AND QUALITY CONTROL

1) VENDOR shall be fully responsible for their Quality Assurance and associated Quality
Control process.
2) Unless otherwise agreed by the PURCHASER, the VENDOR’s Quality System shall
meet the requirements of ISO 9001:2015 Quality System and shall be accredited by a
recognized authority.
3) VENDOR is required to establish an acceptable Quality Plan, inclusive of quality

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manual and procedures that cover all activities of the order, in order to comply with the
Quality System requirements.
4) VENDOR shall be responsible for arranging / liaising with the Third Party Inspection
Agency and other agencies for design appraisal, inspection, survey and certification
requirements as required by the specification / requisition.
5) When required, waiver and acceptance of non-conformances shall be subjected to
Third Party Inspection Agency approval before PURCHASER endorsement. These
concession records shall be included in the Manufacturer’s Final Documentation.

9.0 GUARANTEES AND WARRANTIES

1) The VENDOR shall guarantee the equipment and their selection, design, material,
workmanship and the process performance requirements as stated in this specification
and / or particular equipment datasheet, to achieve continuously for all the conditions
stated, for the period as specified in the Requisition / Purchase Order.
2) The VENDOR shall guarantee that all work will be performed in accordance with good
and sound engineering and construction practices and within the requirements of this
specification. The equipment, accessories and all materials supplied by the VENDOR
shall be free from defects, shall be suitable for the use for which they are intended and
shall perform in accordance with the requirements of this specification.
3) The VENDOR shall agree to promptly correct, at his own cost at site, all the defects
and mal-performance of the equipment and / or the accessories supplied by VENDOR
or failure by VENDOR to comply with the obligation expressed or implied under the
Purchase Order and to extend the warranty period for the duration required to remedy
such defects.
4) The VENDOR shall assume full responsibility for the proprietary equipment and
components supplied by him, and his sub-vendors, incorporated in the package are
accordance with this specification.
5) The VENDOR shall guarantee the suitability of the material of construction for the
duties required, even if the PURCHASER has specified the type and grade of material
to be used. In such case VENDOR shall notify the PURCHASER the unsuitability of the
material for the specified service. However, if the PURCHASER has so defined the
material, the VENDOR shall not be responsible for the corrosion characteristics of the
material with regard to the process liquid.

10.0 SPARES AND SPECIAL TOOLS

10.1 Spares
Installation, Pre- Commissioning, Commissioning and Start-up Spares.
VENDOR shall include the spares required for the Installation, pre-commissioning,

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commissioning and start-up along with the firm scope of supply.

2-Years Operating Spares
VENDOR shall furnish the separate priced list for 2-years operating spares recommended
for the package.
10.2 Special Tools
VENDOR shall include the special tools, if any, required for installation, commissioning,
operation and maintenance along with the firm scope of supply.

11.0 PACKING, SHIPMENT AND PRESERVATION

11.1 Packing and Shipment

The valves shall be prepared for shipment by VENDOR after all testing and inspections
have been completed, and the equipment has been painted.
The valves shall be prepared for the type of shipment specified, in the requisition.
The VENDOR shall be responsible for loading, anchoring and protecting the equipment
during transportation. Care should be taken when loading and unloading to ensure that
lifting hawsers, ropes, chains, etc. do not damage any finish coated surface.
VENDOR shall supply a delivery dossier to be sent along with the equipment on delivery.
The dossier shall include, but not limiting to the following:
(i) General Arrangement Drawing
(ii) Weight Certificate
(iii) Hazardous Substance Certificate / Data Sheet
(iv) A copy of any punch list and packing list
Materials shipped separately shall be identified by securely attached corrosion-resistant
metal tags indicating the item and serial number of the equipment for which it is intended.
Crated equipment shall be shipped with duplicate packing lists, one inside and one on the
outside of the crate. The data to be recorded on each packing list shall contain following:
(i) Name and address of VENDOR
(ii) Purchase order number
(iii) Case identification number
(iv) Overall dimensions in meter
(v) Gross weight of the case
(vi) Itemized list of the contents
11.2 Preservation
The interior of all valves shall be clean, free from scale, welding spatter, and foreign

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objects. Mechanical equipment shall be sprayed or flushed with a rust prevention agents
that can be removed with solvent.

12.0 VENDOR DATA REQUIREMENT

1) All documents and drawings shall be identified using a format acceptable to the
PURCHASER.
2) All documents, drawings, certificate, manuals shall be submitted in English language.
3) The units of measurement to be used on the project are generally to be in accordance
with the International System of Units (SI). Where appropriate however, standard
oilfield units will be used.
4) All documents shall be clearly identifiable on each page with project title and number,
document number, revision number, equipment title and item number, as a minimum.
5) Unless specifically excluded otherwise, VENDOR shall provide following documents
Final Documents, as a minimum.
(i) Manufacturer’s Data Report(MDR)
6) Manufacturer Data Report (MDR) shall include the following documents, as a
minimum. All the documents attached with MDR should be duly reviewed / verified and
certified / approved by VENDOR’s QC and INSPECTOR.
(i) Complete set of “AS-BUILT” drawings.
(ii) Design calculations.
(iii) Certificate of compliance of manufacturer and / or material manufacturer’s mill
certificates with supporting test reports for all materials.
(iv) Quality plan / ITP containing all inspection stages and test plan duly signed by
VENDOR’s QC and INSPECTOR in all stages.
(v) Approved Welding procedure and qualification test reports ( WPS & PQR)
(vi) Destructive and Non-destructive procedures, test reports
(vii) Radiographic examination procedure, reports and films
(viii) Painting / coating procedure and reports
(ix) Final dimensional check records
(x) Final inspection certificate, hydrostatic test witness certificate and release note
from INSPECTOR.
(xi) Name plate rubbing or photograph duly witnessed by INSPECTOR
(xii) Packager’s (VENDOR’s) certificate of compliance and performance guarantee /
warranty certificates
7) VENDOR shall prepare and submit the required number of Final Documentation /

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Completion Files as per Purchase Order.

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