PRESSURE SAFETY VALVES

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Supporting Codes
 Applicable codes and standards
1. API576 (Inspection of Pressure Relieving Devices)
2. API527 (Seat Tightness of Pressure Relief Valves)
3. ASME SEC-I (Power Boilers Code)
4. ASME SEC-III (Nuclear Systems)
5. ASME SEC-VIII (Construction of Pressure Vessels)
6. API526 (Flanged Steel Safety Relieve Valves)
7. ASMEB31.3 (Process Piping Construction Code)

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Content
 Construction & Types of PSVs
 Maintenance Activities
 Pressure and leak Testing

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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.

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Construction & Types of safety valve

 Conventional type
 Bellow type
 Pilot operated

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 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

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Construction

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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

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Bellow type
 Parts
 Application
 Corrosive services
 Back pressure accommodations

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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

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Piston type Pilot Operated PSV

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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 “O-
ring” seals
 Vapor condensation and liquid accumulation above
the piston may cause problems
 Potential for back flow

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Maintenance Activities
 Disassembly from equipment
 Inspection in as received condition
 Measure distance or count thread (Adjusting nut)
 Dismantle PSV
 Cleaning

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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.

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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.

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Leak test
 Will be conducted at 90% of set pressure and 95% for boiler psv’s
 Acceptance criteria

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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

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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.

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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.

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 Thank You

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