PRESSURE SAFETY VALVES

Supporting Codes

1.
2.
3.
4.
5.
6.
7.

Applicable codes and standards

API576 (Inspection of Pressure Relieving Devices)
API527 (Seat Tightness of Pressure Relief Valves)
ASME SEC-I (Power Boilers Code)
ASME SEC-III (Nuclear Systems)
ASME SEC-VIII (Construction of Pressure Vessels)
API526 (Flanged Steel Safety Relieve Valves)
ASMEB31.3 (Process Piping Construction Code)

Content

Basic types of reliving devices

Terminology of PSV
Construction & Types of PSVs
Maintenance Activities
Pressure and leak Testing

Basic Types of Reliving Devices

Basic types
BASIC TERMINOLOGY

BASIC TERMINOLOGY

BASIC TERMINOLOGY

BASIC TERMINOLOGY

Set Pressure

The value of increasing inlet static pressure at which a PRV displays

one of the operational characteristics as define under opening
pressure, popping pressure or start to leak pressure.

Popping pressure

The value of increasing inlet static pressure at which the disc moves in
the opening direction at a faster rate as compared with
corresponding movement at higher or lower pressure.

Opening Pressure

The value of increasing inlet static pressure at which there is a

measurable lift or at which the discharge becomes continuous as
determined seeing, feeling or hearing.
8

BASIC TERMINOLOGY

Construction & Types of safety valve

Conventional

type

Bellow

type
Pilot operated

10

Conventional safety valves

Operational characteristics are affected by any backpressure in

the discharge system.

Back Pressure = Superimposed back pressure + Built-up back

pressure

Superimposed backpressure - The static pressure that exists on

the outlet side of a closed valve

Built-up backpressure - The additional pressure generated on

the outlet side when the valve is discharging

11

Construction

12

Advantages / Disadvantages
Conventional Valve

Advantages
+ Most reliable type if properly sized and operated
+ Versatile -- can be used in many services
Disadvantages
Relieving pressure affected by back pressure
Susceptible to chatter if built-up back pressure is
too high

13

Bellow type
Parts
Application

Corrosive services
Back pressure accommodations

14

15

Advantages / Disadvantages
Balanced Bellows Valve

Advantages
+ Relieving pressure not affected by back pressure
+ Can handle higher built-up back pressure
+ Protects spring from corrosion
Disadvantages
Bellows susceptible to fatigue/rupture
May release flammables/toxics to atmosphere
Requires separate venting system
16

Piston type Pilot Operated PSV

17

Advantages / Disadvantages
Pilot Operated Valve

Advantages
+ Relieving pressure not affected by backpressure
+ Can operate at up to 98% of set pressure
+ Less susceptible to chatter (some models)
Disadvantages
Pilot is susceptible to plugging
Limited chemical and high temperature use by Oring seals
Vapor condensation and liquid accumulation above
the piston may cause problems
Potential for back flow
18

Maintenance Activities

Disassembly from equipment

Inspection in as received condition
Measure distance or count thread (Adjusting nut)
Dismantle PSV
Cleaning

19

Inspection Activities

Inspection Check points

Stem or spindle concentricity

Seating surface condition (nozzle and disc)
Guide and holder clearance (Min & Max)
The spring (heart of psv)
(spring range,pitting,unven coil space,squareness)

20

Inspection Activities

Stem or spindle concentricity

21

Inspection Activities

Seating surface condition (nozzle and disc)

22

Inspection Activities

Guide and holder clearance (Min & Max)

23

Inspection Activities

The spring (heart of psv)

(spring range,pitting,unven coil space,squareness)

24

Inspection
Vital inspection points
Threads and landings

Flanges
Gasket surface
Assemble the psv after lapping stage

25

Pressure and leakage test

Clamp psv at test stand

Set at its set pressure
Psv testing tolerances permissible
ASME SEC-I Criteria

Popping tolerance in accordance with the code requirement shall be

plus or minus +/- 2%. Up to 70 PSI, +/-3% for pressures of 71- 300
PSIG, +/- 10 PSI for 301 -1000 PSI and + /- 1 % for pressures above
1000 PSI.
ASME SEC-VIII Criteria
Popping tolerance in accordance with the code requirement shall be plus
or minus 2 Ibs. Up to 70 PSI, +/- 3 % for pressures >70 PSI.

26

Pressure and leakage test

Back pressure compensation: Set Pressure Back Pressure

Back Pressure PSV: PSV shall be checked at 1.5 times the

Back pressure from the outlet flange for any possible leakage
from bonnet, Cap, and Blow Down ring lock nut.

If PSV is found leaking from the Bonnet after tightening the

Bonnet, then PSV shall be re-calibrated.

Balance Seal PSV: PSV shall be checked from the outlet flange
with air to ensure the integrity of the Bellow. Leaking Bellows
shall be replaced.

27

Leak test

Will be conducted at 90% of set pressure and 95% for boiler psvs
Acceptance criteria

28

Blow down adjustment

Why do we need blow down ring adjustment?
To control the
area of the
huddling
chamber and
therefore the
reseating
of the PSV.
Blow down
adjustment of
Double Blow
down PSV
29

Hot setting of PSV

All boiler PSV need hot setting over and above cold test settings as
covered in the ASME section 1.

On the site PSV are calibrated in the descending order. The PSV
that is to be hot set at the highest pressure is taken up first and the
lower PSVs are gagged with help of clamps.

If the PSV does not pops, 10 to 15psig above the set pressure, the
boiler pressure is reduced to about 70% and PSVs adjusting screw
is loosened.
The boiler pressure is increased again till the PSV is hot set.

30

Best Quality Practices

Checking of PSV on receipt

PSV shop technician checks PSV on receipt for physical attributes

like
condition of flanges, damages etc.
Servicing after dismantling, lapping of seat and disc.
Second party (inspection) witnessing.
Verification and calibration.

31

 Thank

You

32