SAUDI ARAMCO LUBRICATING OIL REFINING COMPANY (LUBEREF)

Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

Table of Contents

1 Scope 2
2 Definitions 2
3 References 2
4 Reporting 2
5 Responsibility 2
6 Intervals and test media 4
7 RV Removal and Handling 5
8 RV Testing and Inspection 5
9 Maintenance of RVs Used for Pressure Testing 9
10 Maintenance of Rupture Disks 9
11 In-Place Testing and Inspection 10
12 Quality Assurance Outline 10
13 Records 12
14 Appendix 1(Master RV list
15 Appendix 2 (Test stand Specification)
16 Attachment I (maintenance report form)

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Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

1 Scope

This procedure is controlled by inspection section, which defines the requirements for the
Safety Relief Device routine testing, inspection, maintenance, operations, and repair
program in Saudi Aramco lubricating oil company operating facilities. The Program goal
is to improve relieve valve (RV) performance by assuring that safety relief devices will
open at the specified set pressure within the tolerances set by the ASME Boiler and
Pressure Vessel Code, and remain in good physical condition. This procedure applies to all
safety relief devices (RVs)
2 Definitions
Severe Service: Any service in which corrosion, plugging, sticking or similar problems
are continuous or frequent.
Set Pressure: The inlet gauge pressure at which the pressure relief valve is set to open
under service condition.
Cold Differential Test Pressure (CDTP): The pressure at which a pressure relief valve is
adjusted to open on the test stand. The CDTP includes the corrections for the service
conditions of backpressure or temperatures or both.
Blow down: The difference between the set pressure and the closing pressure of a pressure
relief valve, expressed as a percentage of the set pressure or in pressure unit.
Leak test: increasing the pressure up to 90% of CDTP and observing the discharge side of
the valve for evidence of leakage.
Below test: Pressurizing the external side of the bellows to 26 psig (138 kpa) or 25% of
CDTP whichever is smaller.

3 References

API 576
SAEP-319

4 Reporting

A RV report should be issued quarterly and distributed to maintenance manager, operation

manager, central engineering manager and plant manager.

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Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

5 Responsibility

5.1 Maintenance department:

5.1.1 Perform the testing and inspection for all RV in the set schedule.
5.1.2 Report the condition of the valve and fill the RV maintenance report form #
RV-001 (see Attachment I).
5.1.3 Maintain adequate stock of spare parts for all RV.
5.1.4 Coordinates with operation for RV Removal or in place testing and obtain
the required work permits.
5.1.5 Enter the test data in Maintenance Department Software and maintain an
updated list of RV. The list should include the RV number, set pressure,
location, service, test media, Inspection interval and due date.
5.1.6 Agree with inspection for any delay on scheduled RV testing & inspection.
5.1.7 Maintaining a complete record of the nameplate data, data sheet, originals of
RV Maintenance report and all relevant data and testing records.
5.1.8 Develop RV quality control manual which should include but not limited to
the following: the master list of all PSV, detailed RV bellow, bonnet and
seat leak test procedure, lapping procedure and calibration procedure for the
test pressure gauges.

5.1.9 Keep bench test stands data and drawing.

5.1.10 Inform inspector of any unusual corrosion, deposits, or conditions are noted
in the RV.

5.1.11 Call the inspector to witness RV tests

5.2 Operation Department.

5.2.1 Report any abnormal condition on the RV’s to the inspection section
including any opening of RV during normal operation.
5.2.2 Apply in place testing procedure # LUB-IPT-001 for boilers relief valves.
Moreover, develop and be aware of precaution that must be taken in case
removing the PSV while equipment is in operation.
5.2.3 Keep & Update Operator PSV check list that should include PSV master list,
guidance for visual on stream inspection, availability of block valve, and

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Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

whether the valve can be isolated on stream or not. Moreover, keep and
update if required in place test procedure.
5.2.4 Verify the correct installation of new RV according to approved
modification proposal.
5.2.5 Prepare waiver for overdue PSV's that can not be handed to maintenance for
overhauling.
5.2.6 Conduct a survey in two year basis for all PSV to confirm its existence on
the site as per approved master list.

5.3 Inspection Section

5.3.1 Witness pressure test and highlight any abnormal condition in the RV.
5.3.2 Maintain approved updated copy of RV master list for comparisons and
reporting purpose.
5.3.3 Issue quarterly report showing number of RV tested, overdue and RV due for
upcoming period.
5.3.4 Review RV’s procedure in three years cycle, including the RV’s master list and
update accordingly. Inspection Supt. Shall be notified on review findings report
5.3.5.Review RV inspection history and recommended RV
frequency adjustment

6 Interval
6.1 The Maximum Test Interval Shall Be 36 Months.
Exceptions:

Steam Boilers 12 months

Lube oil 48 months
Instrument Air & Freon 60 months
Integral RVs in Grove Ball Valves, Model B-5
Oil Service 96 months.
LPG/NGL Service 60 months

Any RV’s needed to be tested on shorter intervals, should be listed

and forwarded to inspection for tracking purpose provided that the
required approval is obtained.
Based on RV test results, RV frequency can be increased or reduced
in order to optimize RV overhaul without jeopardizing the safety of
refinery. The review shall consider stable unit operation and
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Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

consistent test results. The recommended RV frequency adjustment

shall be conducted by inspection and communicated to operation,
Safety and process for final approval and master list update.
A RV shall, as a minimum, be shop disassembled at every 2nd test interval for an
internal inspection.
6.2 Early or Delayed On RV Test Schedule.
6.2.1 Scheduling a RV T&I early can be approved by Operations manager. The
next planned due date is automatically adjusted when the Relief Valve
Maintenance Report, entered in Maintenance Software system.
6.2.2 Delayed T&I schedule can be approved by the plant manager provided that
the delay does not exceed 3 months.
6.2.3 T&I schedule delay will exceed the limits set in paragraph 6.2.2, then
Approval Request to Deviate from Inspection Schedule shall be submitted
by the initiator to plant manager and central engineering manager prior to
the delay.
Approval of the deviation request, per paragraph 6.2.3, still results in the RV
being shown as overdue. The approved interval is shown on the quarterly
report.
6.3 Test Media
 RVs in liquid service shall be tested with liquids only, however, they may be
LEAK tested with gases (air or nitrogen).
 RV's in vapor, air, gas, or a combination of liquid and gas service shall only
be tested with air.

RVs in boiler steam service may have the initial pop pressure set in the Test
Shop using air, but the final pressure and blow-down setting shall be made
with steam, on the boiler using an approved In-place Procedure
7 RV Removal and Handling Practices
7.1 Maintenance shall exercise CARE IN HANDLING RV's at all times that is
appropriate for a delicate mechanism. Do not drop or jar, avoid stressing the RV
body and parts, protect flanges and nozzles.
7.2 Store and transport RVs in the vertical position, and thoroughly secure during
transport. Cover flanges, threads and nozzles with tape or special plastic plugs
(available from storehouse stock) to protect the RV from dirt and mechanical
damage during storage and transport.
A gag may be applied to a weighted flapper type breather valve during rough
transportation to avoid damage. Retest the RV when an unusual rough transport or
handling occurs. Be sure that the gag is designed so that the RV can not be installed
until the gag is removed.

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Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

7.3 Operations shall verify that the RV is isolated from the process when removing a
RV from in-service ACTIVE equipment by checking the following:
7.3.1 Verify block valves are closed and car-sealed (both inlet and outlet
lines/connections).
7.3.2 Verify that the block valves are not passing by unscrewing the vent plug and
slowly crack open the vent block valve. Vent any trapped fluid to a safe
area. A blind flange is required to be installed on all flanged connections
immediately after removing the RV for testing.
7.3.3 Verify bonnet vent lines are bled and isolated.
7.3.4 Verify all pressure has been removed from the points of isolation at inlets
and outlets of RVs. Verify contained liquids have been removed and drained
to a safe location such as oily water sewers.
7.3.5 Verify the equipment is protected by an alternate RV of adequate capacity
on the equipment or connecting equipment, and any intervening block
valves are locked or car sealed open.
7.3.6 Identify the type of work permit that should be used for the job. Control or
specify associated hazards and required protection on the work permit, such
as high pressure, H2S hazard, gas release and nearby sources of ignition.
8 RV Testing and Inspection Practices
8.1 T&I disassembly and testing shall be performed by, or under the supervision of, a
Qualified RV Technician using written Shop Procedures that detail the steps
involved for each type of RV serviced.
8.2 Each RV T&I shall be completely documented and reported by means of the Relief
Valve Maintenance Report,
8.3 RV Manufacturer's nameplate data should be documented in the RV Shop file by
maintaining a facsimile or a complete record of the nameplate data. During the
RV T&I verify that the nameplate is secured to the RV and is not damaged or
painted.
Remember nameplates are often rendered illegible after normal field exposure.
Recording this data is essential.
8.4 Verify that the RV tag/equipment number agrees with the Test Shop files and the
body identification stamp before the testing or repairing begins. If the RV tag is
missing or the RV identification can not be verified, then contact local Engineering
for verification or replacement of the RV.
8.5 Tag and seal the RV when the T&I is complete. The seal shall be applied
immediately upon final setting. The seal shall be a wire lock that must be broken to
alter the pressure setting. Tag should contain the following information: valve no.,
set pressure, date of inspection, CDTP and due date.

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Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

8.6 Initial visual inspection shall be conducted prior to testing and/or disassembly to
evaluate the overall condition of the RV. The Technician should look for corrosion,
scale, obstruction, and obvious damage before attempting the "as received" POP
test.
Engineering and Inspection should be contacted immediately if major finding are
found.
8.7 Conduct the "As Received" POP test on an adequately sized Test Stand that causes
a "sharp pop" when testing a gas service RV. A simmer RV action shall not be a
valid test for gas service.
8.8 "As Received" LEAK TEST shall be conducted immediately after the "As
Received" POP test to evaluate the RV seating surface.
8.9 RV shop disassembly shall be required for the following conditions:
8.9.1 Minimally, at the 2nd consecutive RV operating interval.
8.9.2 When a boiler RV fails the shop TEST, the In-place test or after two
operating intervals.
8.9.3 When disassembly is requested by Operations, Engineering or Inspection.
8.9.4 After every T&I if the RV is in severe service having a history of corrosion,
fouling, plugging, sticking or failures that are continuous or frequent.
8.9.5 When a RV fails the "As Received" leak or pop test.
8.9.6 When worn parts, corrosion or damage are observed.
8.9.7 New valves, prior to initial installation, to verify that internal parts meet
specifications and to positively identify materials if not done by the
manufacturer .
8.10 RV disassembly shall include the following:
8.10.1 Correct tools, QA Manual with step by step instructions, manufacturer
instructions and tolerances shall be present before work begins.
8.10.2 Record Critical Dimensions, details of repair, and actual steam valve ring
and collar adjustments into RV Shop files.
8.10.3 Replace all soft goods, such as: Gaskets, O-rings, etc.
8.10.4 Clean all parts to remove all scale and expose bare metal for inspection.
8.10.5 Evaluate parts with critical dimensions and critical surfaces per the RV
manufacturer's specifications. Restore critical dimensions within
manufacturer tolerances, and restore critical surfaces so that they are free
of mechanical and corrosion damage and meet surface finishes as required
by the manufacturer.

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Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

8.10.6 Replacement parts shall meet manufacturer's specification. Parts shall not
be fabricated by Saudi Aramco lubricating company unless certified and
complete manufacturer shop drawings, fabrication instructions, and
material specifications are reviewed and approved by the local
Engineering Unit.
8.10.7 Seats and disks shall be restored using a written lapping procedure that
describes lapping compounds, lap rings and lapping machine use and
calibration. As recommended by most manufacturers, surface finish
evaluation techniques that include visual or monochromatic light with
optical flats, should be utilized.
8.10.8 Verify the correct spring is installed. Paint the bonnet green in all bellow
RVs. Paint all other external surfaces and exposed springs with a coating
system, which specifies aluminum color alkyd coating with primer.
Painting is done either in the shop or in the field,. In either case, instruct the
painters not to paint or damage the nameplate or foul external or internal
moving parts.
Down stream and up stream block valves for all RV should be painted
Orange.
8.10.9 Test according to ASME SEC VIII D1 and ensure that the mating spring
washers are not separated from the spring. Replace the spring if the set
pressure cannot be adjusted, the spring coating is deteriorated, or cracks
and/or severe corrosion are visible.
8.10.10 Internals are NOT normally coated. However, a rust inhibitor ,Rust
Proof Compound L, may be applied to internal parts. Rust inhibitors can
become 'sticky', and should only be used where free movement of the relief
valve internals is not impeded.
8.11 Re-assembling the RV after T&I shall include:
8.11.1 Verify that the reconditioned or new parts are correct and that all parts are
included per manufacturer's assembly sketches.
Bolt assemblies together using torque loads, as required by the
manufacturer.
8.11.2 Set the initial position of adjustable parts according to manufacturer's
recommendations.

8.12 RV Bellows Test

8.12.1 Leak test bellows to verify that the bellows sealing joint is 100% effective
and the bellows is not leaking. An approved bellows test procedure shall
be included in the QA Manual. The procedure shall minimally cover the
following:
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Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

8.12.1.1 A test shall be conducted by pressurizing the external side of

the bellows to 26 psig (138 kPa) or 25% of CDTP, Cold
Differential Test Pressure (i.e., the pressure at which the RV is
adjusted to open on the test stand) whichever is smaller. Over
pressure can damage the bellows.
8.12.1.2 Check the non-pressurized side of the bellows using a method
that is sensitive to low volume flow. An apparatus similar to
the seat leak test is recommended so that all possible escaping
air is directed out through a tube that is submerged in water to
detect bubbles.
8.12.2 An in-place test procedure is acceptable providing it is prepared and
approved as described in Section 10, below.
8.13 RV Sealed Bonnet Leak Test
8.13.1 RVs that are intended to have sealed bonnets and body joints and
connected to closed discharge systems shall be tested for tightness of the
bonnet and body joints to assure that NO discharge gases or liquids escape
to atmosphere.
8.13.2 Per an approved procedure, part of the QA Manual, a test shall be
conducted by applying a 20 to 25 psig regulated air pressure to the RV
body and bonnet cavity. There should be no evidence of leakage at any
body joint. A soap test should be conducted to ensure the integrity of the
body joints.
8.14 Final Set Pressure, CDTP Test
8.14.1 The final CDTP set pressure shall be conducted on an approved test bench
that meets the requirements of SAEP-1132, attached in Appendix 2
8.14.2 The set pressure tolerance shall conform to Table I of SAEP-1132, for
spring and pilot operated RVs. Tank breather and pressure/vacuum relief
valve tolerances shall conform to manufacturers' guidelines.
8.14.3 The cold differential set pressure, CDTP, shall be temperature
compensated as required by the manufacturer temperature charts based on
normal operating temperature. CDTP is not applicable to RV with open
bonnet.
8.14.4 The cold differential pressure shall also be adjusted to compensate for any
backpressure when a valve is installed in a closed relief system.
8.14.5 Pilot operated valves may be adjusted separately, however, the final test
shall be with the pilot and the main valves connected and tested together.

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Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

8.15 Final Seat Leak Test

The final seat leak test shall be conducted immediately after the final pressure
setting is achieved.
8.16 Testing and Inspection of Tank Breather RVs
8.16.1 Tank breather RVs shall be included in the RV Program, and they shall be
serviced at specified intervals to assure reliable performance.
8.16.2 Tank breather valves may be tested in place using an approved procedure.
The procedure should include the pressure test, cleaning requirements,
pallet weight inspection and measuring requirements, soft goods
inspection, and parts replacement criteria.
8.17 Pilot Operated RV Testing
The T&I requirements are the same as spring actuated RVs. While the pilot and
main body may be tested separately, the final pressure test shall be as a complete
assembly. Blow down is independently adjusted in the pilot valve, and the setting
procedure shall be done as recommended in the manufacturer's maintenance
manual. Refer to manufacturer maintenance manuals when disassembling and
assembling pilot relief valves. Soft goods should be changed as a preventive
maintenance measure. Pilot control parts have very critical dimensions and surface
finishes; replacement is recommended rather than reconditioning, when they are
found damaged.
8.18 RV External Inspection
After each successful T&I, an external inspection on a RV shall be conducted by
Inspection Unit to ensure proper installation and identification. The required RV
checklist in Attachment A of this procedure shall be used whenever a RV is tested
and reinstalled. The completed RV checklist shall be kept in the Inspection Unit
equipment file for each relief valve.
9 Maintenance of RVs Used for Pressure Testing
9.1 Set pressure shall be maintained within the spring range, and the RV shall be used
and maintained within the design requirements intended. Complete records shall be
maintained by the RV Shop, and the PRESSURE TEST RVs shall only be released
to the field for pressure testing if it has been set within the following periods of the
intended use:
9.1.1 One week for new construction projects or
9.1.2 One month for maintenance operations.
9.2 The User is responsible for returning the "PRESSURE TEST" RV to the shop.
10 Maintenance of Rupture Disks & Rupture Pins
10.1 A visual inspection is made at every scheduled T&I, as per Section 5 of this SAEP.
T&I interval changes are determined by Disk and Pin condition. Replacement is
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Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

required when any of the conditions of paragraph 5.8.1 are found unacceptable.
Reconditioning is not permitted.
10.2 An approved procedure, part of the QA Manual, shall be used to inspect rupture
disks and rupture pins, and shall minimally include: Evaluation criteria for both the
rupture disk/pin and disk/pin holder assembly. Handling requirements to ensure the
disk/pin remains in the disk/pin holder assembly, and controlled handling of the
disk/pin. Installation requirements for bolt torque.
- A maintenance RV technician should remove or supervise the removal of a
disk/pin and disk/pin holder assembly to ensure no damage occurs prior to
disk/pin evaluation.
- The Inspection Unit shall evaluate disk/pin condition.
- Operations shall approve removal and installation.
- Inspection shall verify that the inlet and discharge piping is clean.
- Inspection shall verify that the RV number is stamped on the holder.
- Inspection shall verify that a pressure gauge is installed between an in-line RV
and rupture disk installation.
11 In-Place Testing and Inspection
11.1 An In-place RV T&I shall be approved when it is feasible and safe to adjust a RV
on line, and the RV has satisfied the disassembly requirements, as required in
paragraph 8.9. An in-place test should be limited to service conditions that are
clean, sweet, and non-corrosive, such as boilers. In-place testing shall only be
permitted when approved test procedure is available.
All steam safety valves, under the jurisdiction of ASME SEC I, shall be tested in-
place for final set pressure and blow down adjustment. Also, all steam safety
valves shall be tested in-place for final set pressure and blow down whenever
removed from their position for any reason.
Commentary Note:
Care must be exercised to avoid mishandling or improper
transportation. RV's are often subject to mishandling during removal
and/or transportation, which affects their ability to lift-off at the
specified set pressure and their blow down limits.

12 QA Outline – Maintenance Quality Assurance Document

1. Maintain updated list of RV. The list should include the RV #, set pressure, location,
services, test media. Inspection interval, due date.

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Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

2. Write a detailed RV bellow, bonnet and seat leak test procedure. The procedure
should explain how each type of leak test is performed for each type of RV used
within the operating area.
3. any further provisions you consider necessary.

4. Tagging:
1. Describe tagging requirements.
5. Calibration of Measurements and Test Gauges:
1. Write a calibration procedure for the test pressure gauges. Describe how you
schedule gauges and digital instruments for calibration, what the time periods
between calibrations are, and how you verify that no measuring equipment is used
unless it is calibrated.
Include a history log of calibration where all gauges are numbered and tagged
which will make it easy to trace any gauge.
2. The title of the authorized person carrying out the calibrations.
3. Describe calibration stickers/seals that are attached to gauges.
6. Lapping:
1. Recognize that lapping is a specialized function, and provide the necessary
special tools and describe their functions (example: Optical comparators for
checking seat flatness, Measuring Magnifier, Straight Edge).

2. Prepare a more detailed lapping procedure than those shown in the manufacturer's
services manuals, if possible. Describe which type of lapping compounds and
blocks are used when lapping a disk and seat (with or without an angle). Note
any special lapping problems that the Machinist should expect to run into and
how to resolve them.
3. Describe how to make sure that all lapping equipment is inventoried, functional,
clean, and complete. (This may be best achieved by assigning this responsibility
to a RV technician).
13 Records:

1. Originals of RV Maintenance report - form # RV-001. In this form the technician

should fill and sign the form. Moreover, the shop supervisor should counter sign
the form and obtain inspection representative signature.

2. Maintain the QC manual at workshop.

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Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

3. Maintain updated list of RV. The list should include the RV #, set pressure,
location, services, test media. Inspection interval, due date.

4. Maintaining a facsimile or a complete record of the nameplate data, bench test

stands data and drawing.

Prepared By:

____________________ ___________________
Abdulrahman Jahlan Abdulhamid Al-Akel
Inspection Supervisor - LRY Inspection Superintendent

concurred by:

_______________________ __________________________
Khalid M. Al-Harbi Shaker Al-Thobaity
Operation Manager - LRJ Operation Manager (A) - LRY

_______________________ __________________________
Ali-Safar Al-Ghamdi Saeed A. Badgaish
Maintenance Manager – LRJ Maintenance Manager - LRY

_______________________ ___________________________
Abdul Rahman Babsail Abdulhamid Al-Akel
Industrial Safety & Security Manager Central Engineering (A)

_________________________ ___________________________
Sameer Khan Jalal Saad
Refinery Manager -LRJ Refinery Manager (A)- LRY

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Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

__________________________
Sulaiman Bilaus
VP - Manufacturing

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Subject : Pressure Relief Valves Procedure Procedure # Lub-RV-001

RV MAINTENANCE REPORT
form # RV -001 Attachment I

PSV #: ____________________ Service: _______________

Location: ____________________ Date: _________________

As received Pop pressure ______bar. Leak Test : Pass Fail

Disassembly Finding

Type of Valve:

Bellows type Conventional type Other _ _ _ _ _

 Corrosion Attack: Severe Minor No Corrosion

 Foreign Material: Partially Plugged Severely Plugged

 Mechanical Damage: Yes No Good Condition: Yes No

 Other Defect: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Replaced Parts:
_ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

Type of work Performed

Overhaul Machined Lapped Cleaned Other

Final Test Results

●Set Pressure _______ bar. Back pressure ___________ bar

●Leak Test Pass Fail

Recommendation:-
________________________________________________

Maintenance Representative: _______________ Inspection Representative_______________

Data entered to Maximo by __________________ Date: ________________

Original to Maintenance , CC: Inspection

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