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DOCUMENT CODE

MWP-WP-IMS-010

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REV. DATE 30-11-2012

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WORK PROCEDURE
MECHANICAL WORKSHOP 1. PURPOSE

MECHANICAL WORKSHOP

1.1 This Standard Procedure provides guidelines to be follo ed for re!oval" overhauling " calibration # testing and installation of $Pressure %elief &evices' herein after called $P%&s' constituting of Safet( %elief )alves *S%)s+ and %upture &iscs in order to, -nsure that the( operate ithin the set li!its for !echanical and environ!ental safet( and integrit(. -nsure that the( protect the e/uip!ent # piping fro! over-pressuring " vacuu!. 2. SCOPE 2.1 This procedure applies to inspection1 repair1 calibration # testing1 replace!ent and docu!entation of all P%&s in Pa2arab 3ertili0ers co!ple4. The ter! P%&s also applies to )acuu! %elief )alves " )acuu! 5rea2ers for the sa2e of this procedure. 3. RESPONSIBILITIES 3.1 General re !"n #$#l#%#e 3.1.1 Inspection 6nit is responsible to follo this procedure during inspections # -nsure that right safet( device is installed at right place. -nsure that an( un-authori0ed in their settings is not !ade. -stablish their inspection " replace!ent interval.

testing. The inspection engineer or his designated inspector is called as the 7uthori0ed Inspector. The 7uthori0ed Inspector shall have ade/uate

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DOCUMENT CODE

MWP-WP-IMS-010

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WORK PROCEDURE
MECHANICAL WORKSHOP inspections.

MECHANICAL WORKSHOP

e4perience and " or certification as per 7PI 910 in perfor!ing P%&s

3.1.2 7uthori0ed Inspector is responsible for docu!enting valve !aintaining histor(" inspection records and schedules. 3.1.3 :peration &epart!ent shall issue notification to Maintenance &epart!ent for re!oval of P%&s as per schedule. 3.1.; :peration &epart!ent shall get the Maintenance &epart!ent. 3.1.9 Maintenance &epart!ent shall plan # re!ove P%&s1 for re/uired inspection # testing and transport # deliver the P%&s to repair or2shop. 3.2 Re !"n #$#l#%, "- (a#n%a#n#n* %.e re/"r0 3.2.1 %elief device design and installation details shall be !aintained as a part of Process Safet( Infor!ation b( the Maintenance 7rea : ner. 3.2.2 <hanges to %elief devices shall be docu!ented and updated in Process Safet( Infor!ation !aintained b( the Maintenance 7rea : ner. 3.2.3 :peration &epart!ent shall 2eep and update record of to Maintenance Planner. 3.2.; Schedule of P%&s updated list of classified P%&s shall be !aintained b( Maintenance Planner. 3.2.9 Inspection and test reports1 copies of defer!ents etc. shall be !aintained b( 7rea : ners. <opies of Inspection and test reports shall be !aintained b( Maintenance and Inspection &epart!ent. 1. SA'ET&
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aiver approved fro! the !anage!ent if aiver shall be sent to

P%& cannot be released as scheduled. <op( of the

aivers

ith a cop(

ith service conditions

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DOCUMENT CODE

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WORK PROCEDURE
MECHANICAL WORKSHOP

MECHANICAL WORKSHOP

1.1 Safet( re/uire!ent including but not li!ited to PTW1 PP-1 scaffolding safet(1 =S71 87>:P etc. as per Pa2arab 3ertili0ers safet( rules # regulations shall be co!plied ith. hile or2ing at heights *e.g. Scaffolding+ shall

1.2 7ll necessar( safet( precautions be ta2en.

1.3 The %elief &evice shall be isolated1 de-pressuri0ed and purged b( :perations &epart!ent before re!oval for overhauling and calibration. 2. DE'INITIONS 2.1 Pre 3re4Rel#e5#n* De5#/e 6 These are used to protect e/uip!ent and

personnel b( auto!aticall( opening at predeter!ined pressures and preventing the destructive conse/uences of e4cessive pressures in process s(ste!s and storage vessels. 7 pressure relief device is actuated b( inlet static pressure and designed to open during e!ergenc( or abnor!al conditions to prevent arise of internal fluid pressure in e4cess of a specified design value. The device also !a( be designed to prevent e4cessive internal vacuu!. The device !a(be a pressure relief valve1 a non-reclosing pressure relief device or a vacuu! relief valve. <o!!on e4a!ples include direct spring loaded pressure relief valves1 pilotoperated pressure relief valves1 rupture dis2s1 pressure and"or vacuu! vent valves 2.2 Pre 3re Rel#e- Val5e6 7 safet( relief valve is an auto!atic pressure relieving hich !a( be used as either a safet( or relief valve1 depending on eight-loaded devices1 and

device

application. 7 safet( valve is used to protect personnel and e/uip!ent b( preventing e4cessive over pressure. 2.3 Sa-e%, Val5e6 7 safet( valve is an auto!atic pressure reliving device actuated b( the static pressure upstrea! of the valve1 and characteri0ed b( rapid opening or pop action.
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MWP-WP-IMS-010

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WORK PROCEDURE
MECHANICAL WORKSHOP the static pressure upstrea! of the valve1 increase in pressure over opening pressure. 2.2 Se% Pre 3re6 Set pressure is the gauge pressure at the inlet1 for

MECHANICAL WORKSHOP

2.1 Rel#e- 5al5e6 7 relief valve is an auto!atic pressure relieving device actuated b( hich opens in proportion to the

hich the relief

valve has been ad?ust to open under service conditions. 2.7 C"l0 D#--eren%#al Se% Pre pressure at 3re 8CDS96 <old differential set pressure is the

hich the valve is ad?usted to open on test stand. This pressure

includes correction for bac2-pressure and"or operating te!perature. 2.: Bl"; 0";n6 it is the difference bet een set pressure and reseating pressure of a pressure relief valve1 e4pressed as a percentage of the set pressure or so!eti!es as actual pressure units. 2.< Ba/= Pre 3re6 It is the pressure that e4ists at the outlet of a pressure relief

device as a result of the pressure in the discharge s(ste!. 2.> R3!%3re D# /6 7 rupture disc is a differential pressure device burst pressure is e/ual *vessel+ to at the the difference ti!e of upstrea! pressure here the specified the desired disc burst and

bet een rupture

do nstrea! pressure *bac2 pressure+. 7. CLASSI'ICATION

%elief devices shall be classified as per follo ing guidelines, 7.1 Cla i. ii. iii. @e I6 %elief devices that are,Installed on e4tre!el( corrosive service. Sub?ect to plugging due to solid particles. installations here there is no previous e4perience or service

conditions that are un2no n.


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WORK PROCEDURE
MECHANICAL WORKSHOP iv. 7.2 Cla Installed on fired pressure vessels.

MECHANICAL WORKSHOP

II6 %elief devices that are installed on process feed and product strea!s in

clean service and non-corrosive strea!s. 7.3 Cla :. III6 %elief devices that are installed in non-process services.

'RE?UENC& :.1 The follo ing intervals shall be follo ed for #n#%#al #n !e/%#"n of the %elief devices, a. $. /. Cla Cla Cla I6 1 (ear or less. II6 less than 3 (ears. III6 5ased on vendorAs reco!!endation1 and e4perience but shall not

e4ceed 9 (ears.
CLASSI'IC ATION Installation

CLASS4I a. b. c. Installed on e4tre!el(

CLASS4II

CLASS4III

corrosive services Sub?ect to plugging due to solids @e installations here there is no previous e4periences or service conditions are un2no n d. Installed on fired Pressure vessels. 3re/uenc( of
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Installed and

on Installed on non-process

process feed services product in nonstrea!s and corrosive Strea!s.

clean service

1 Bear or less
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Cess than 3

5ased

on

vendorAs and

reco!!endation
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DOCUMENT CODE

MWP-WP-IMS-010

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WORK PROCEDURE
MECHANICAL WORKSHOP
Inspection (ears

MECHANICAL WORKSHOP

e4perience but shall not e4ceed 9 (ears.

:.2 The inspection interval of the class I %elief &evices *e4cept for %elief valves installed on fired pressure vessels+ !a( be increased b( a !a4i!u! of 2 ti!es the current interval1 if on t o consecutive interval inspection the device pops at the set pressures and sho s no indication of e4cessive fouling"plugging. 7ccordingl(1 the inspection #n%er5al !a( be increased up to a !a4i!u! of 3 (ears. :.3 The %elief devices on fired pressure vessels shall be tested ever( (ear. 8ot setting of %elief devices on fired pressure vessels shall be carried out the %elief valve is installed after calibration. :.1 The inspection #n%er5al of the class II and class III %elief devices !a( be increased b( a !a4i!u! of t ice the current interval1 if on t o consecutive inspections the devices pops at the set pressures and sho s on indication of e4cessive fouling. 7ccordingl(1 the inspection interval !a( be increased up to a !a4i!u! of 10 (ears. :.2 The inspection -re@3en/, shall be increased in the follo ing case, a. 3or %elief device that has set pressure of !ore than ;19 2Pag1 if it pops at !ore than 9E of the set pressure during pre-test. $. 3or %elief device that has set pressure up to ;19 2Pag1 if it pops at !ore than 20 2Pag of the set pressure during pre-test1 and /. If inspection indicates that the %elief devices is heavil( fouled or tuc2. hen

In such cases the inspection interval shall be reduced bac2 to the previous successful interval or F of the current interval.
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DOCUMENT CODE

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WORK PROCEDURE
MECHANICAL WORKSHOP :.7 %upture disc should be replaced on a regular schedule

MECHANICAL WORKSHOP

ith a t o (ears

!a4i!u! period1 unless e4perience sho s that a longer ti!e period is acceptable. Shorter and"or longer ti!e periods !a( be acceptable based on e4perience and !anufacturer reco!!endations. :.: 7n( device that is !ore than 3 !onths overdue shall receive a revie device that is !ore than 6 !onths overdue shall receive revie and and ritten ritten

authori0ation for continued operation fro! :peration &epart!ent Manager. 7n( authori0ation for continued operation b( the Heneral Manager *:peration+. 7 defer!ents obtained shall be !aintained in the histor( file of the %elief device and its cop( shall be sent to Maintenance Planner. <. PROCEDURE <.1 In#%#a%#"n "- Re@3e % -"r Te %#n* + Re!la/e(en% G.1.1 Maintenance 7rea : ner shall prepare # !aintain updated histor( file of all P%&s at plant pre!ises to include all the relevant data such as set pressure1 calibration # testing date1 result of $7s received' pop test etc. Iuarterl( report listing the S%)s due for testing"calibration and the due date shall be generated b( Maintenance Planner and issued to :peration one !onth in advance. G.1.2 :perations &epart!ent shall refer to the /uarterl( report and offer the P%&s for testing"calibration"replace!ent or ta2e the necessar( device cannot be handed over on the due date. <.2 Re("5al "- PRD -"r Te %#n*+Cal#$ra%#"n+Re!la/e(en% G.2.1 Maintenance &epart!ent shall notif( in advance to I7"I< &epart!ent prior to the re!oval of safet( relief valve so that its Inspector has an opportunit( to inspect the S%) visuall( before re!oval.
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aiver if the relief

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DOCUMENT CODE

MWP-WP-IMS-010

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WORK PROCEDURE
MECHANICAL WORKSHOP to prevent entr( of foreign !atter.

MECHANICAL WORKSHOP

G.2.2 Maintenance &epart!ent shall cover the !ating flanges of e/uip!ent"piping

G.2.3 )alve shall be transported in the upright position to prevent internal co!ponent da!age. 3lange faces and threaded connection should be protected. G.2.; Maintenance &epart!ent shall arrange to transport and deliver safet( relief valve to repair organi0ation *in-house or outside plant pre!ises+. <.3 G3#0el#ne -"r Sa-e%, Rel#e- Val5e In !e/%#"n A Ma#n%enan/e Procedure for overhauling1 repair1 calibration and testing of pressure %elief &evices shall be as follo s, G.3.1 7n $7s %eceived' initial bench test shall be perfor!ed and docu!entation of the initial lifting pressure shall be recorded. G.3.2 3or ever( test1 the class I Safet( %elief valves shall be disasse!bled and inspected to chec2 the condition of the seats1 spring1 degree of corrosion or plug gage and an( unusual proble!s. G.3.3 <lass II and III Safet( relief valves shall be disasse!bled and inspected at least on ever( second test. The condition of the seats1 spring1 degree of corrosion or plug gauge and an( unusual proble!s shall be noted valve is disasse!bled. G.3.; The results of the relief device inspection and test shall be revie ed to decide hether the test fre/uenc( should be increased" decreased or re!ain the sa!e. This reco!!endation " deter!ination shall be done for each test of each relief device. hen the

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WORK PROCEDURE
MECHANICAL WORKSHOP

MECHANICAL WORKSHOP

G.3.9 7s soon as the Safet( %elief valve is re!oved1 its general conditions shall be recorded. Maintenance &epart!ent shall infor! Inspection 6nit before pretesting of the valve for perfor!ing visual inspection before atte!pting the $7s %eceived Pretest' and all the observations such as corrosion1 scaling1 deposit and other obvious da!ages shall be recorded in the 3or! $Pressure %elief )alve <alibration' b( the valve test bench operator before atte!pting the $7s %eceived Pre-test'. G.3.6 The pre-test of Safet( %elief valve in $7s %eceived' condition shall be carried out at the or2 shop on a test stand"bench. The test results shall be docu!ented1 sho ing details of pop pressure1 re-seating pressure and lea2age if an( on 3or! $Pressure %elief )alve <alibration' <.1 D# a e($l, an0 Re/"n0#%#"n#n*

8A9 'OR CONVENTIONAL SPRING LOADED PSV G.;.1 The ad?usting scre spring ad?usting scre G.;.2 The ?a! nut is no loosened. G.;.3 The bonnet studs are re!oved and the bonnet is re!oved fro! the valve bod(. G.;.; The spring and button is re!oved. Si!ilarl( the holder and guide are re!oved. G.;.9 The ste! and disc holder is dis!antled. Si!ilarl( the disc holder is separated fro! its guide. 3inall( the disc is re!oved fro! its disc holder. !easure!ent is recorded b( &ial )ernier along to the ?a! out. loosened and then the spring ad?usting scre is ith the

nu!ber of threads. The nu!ber of threads is counted fro! the flats on the

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DOCUMENT CODE

MWP-WP-IMS-010

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WORK PROCEDURE
MECHANICAL WORKSHOP G.;.6 The blo do n loc2 nut *ring+ is loosened. The blo

MECHANICAL WORKSHOP

do n ring is re!oved.

G.;.D The no00le is re!oved. The disasse!bled parts are inspected and if an( foreign !aterial found accu!ulated is collected and reported to the Wor2shop -ngineer. G.;.G The parts are than cleaned K the disc in inspected and then lapped in round or figure of eight pattern to the sa!e lapped. G.;.J The condition of both the seats is chec2ed through !agnif(ing glass ith a( the fe!ale seat i.e. no00le is also

ade/uate lighting. 7s an added practice the seat # disc are both polished b( using polishing paper *grade 0;+. The polished condition is then again inspected b( !agnif(ing glass. G.;.10 The ste! run out is chec2ed. If the run out is 0.003 to 0.00D in the ste! is considered to be used !aterial. G.;.11 The clearance bet een guide and disc holder is recorded on the chec2 list. The no00le or disc if it is not available in spare is eld built up using satellite. The disc and seat are then !achined and lapped and inspected. G.;.12 The valve is then reasse!bled b( inserting the no00le in the bod( and the no00le threads are tightened. The disc holder is asse!bled in the disc holder. The disc holder is inserted in the guide. The ste! is tightened and the blo do n ring is put in position and the blo do n ring is inserted in the lo est position1 the disc holder and the ste! asse!bl( is placed in the bod(. Has2et is inserted belo placed on the valve bod(.
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ithout straightening. :ther ise a ne

ste! is !ade

as per inspection reco!!endation based on !anufacturing is used a

he guide. It is 2no n as bod( gas2et. The button

and spring is inserted. 5onnet gas2et is inserted and then the bonnet is

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WORK PROCEDURE
MECHANICAL WORKSHOP

MECHANICAL WORKSHOP

G.;.13 The 5onnet bolts are placed in the holes and tightened. 7d?usting scre s are tightened and bought into the sa!e level as per original chec2 list then ?a! out is tightened and the PS) is !ounted on the test bench. G.;.1; The blo do n ring is set as per the set pressure and the PS) is then

popped. The PS) is then lea2 tested. If the nu!bers of bubbles e4ceed the vendor reco!!endation for that particular t(pe1 then the PS) is opened up and the disc and seat are re-lapped. G.;.19 When the PS) !atches the vendor reco!!endation for lea2 test and there is an audible popping sound the PS) technician calls the inspector for itnessing. G.;.16 The pop test and lea2 test are repeated and verified b( inspection. If there is proble! of resetting1 the blo do n ring is read?usted. The loc2 nut is placed. ith the date <ap gas2et is placed and cap is lightened. The PS) is tagged prevent an( foreign !aterial. It is !ounted on a suitable

and set pressure. Its flanges are sealed in the presence of inspector to ooden pallet.

G.;.1D The no00le is casted into the bod( so cannot be re!oved fro! the bod( and is inspected for crac2s etc. all the parts are inspected and cleaned. &isc1 @o00le1 &isc guide1 &isc holder1 ste! run out1 Spring 5utton and 5earing are inspected. Capping of disc and no00le are follo ed 5earing surface are polished using e!er( paste" paper. G.;.1G The @o00les blo do n ring is installedL disc holder guide is installed

follo ed b( inserting of disc in holder. The ste! is inserted in the disc holder. The ste!" disc asse!bl( is slided into the guide. The disc sta(s on the no00le. Co er button1 spring1 6pper button and 5earing are installed. 5onnet is placed on the bod( and the bolts are tightened. 7d?usting scre s are tightened as per original !easure!ent sa!e as before the disasse!bl(. The
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WORK PROCEDURE
MECHANICAL WORKSHOP PS) is installed on the test bench and blo PS) is popped and follo ed b( Cea2 test.

MECHANICAL WORKSHOP

do n ring is ad?usted. Then the

G.;.1J PS) is inspected and if :M the <hec2 nut is installed. Ste! lift and Spacer lifting asse!bl( is installed. The lifter lever and its asse!bl( is re!oved. The ste! lift spacer is chec2ed nut. The lift lever asse!bl( is installed and the scre is tightened. The lift lever is installed ith its pin carr(ing the split pin. ith their The PS) is seated and finall( blo loc2 pins properl( loc2ed. G.;.20 PS) is placed on pallet and bolted and sent to the re/uired area" destination. 8B9 'OR PILOT OPERATED PSV G.;.21 The length bet een the ad?usting nut and the ?a! nut is !easured. The second !easure!ent of rests is !easured bet een the ste! cap and reset self-loc2ing nut. G.;.22 The =a! nut is loosened and the self-loc2ing nut is loosened and the ad?usting nut is loosened. The bonnet is re!oved. The disc is re!oved and the pilot and the spring and button is re!oved. G.;.23 The Ste! is re!oved. The shuttle is re!oved. The shuttle $:-ring' re!oved. Then the seat retainer is re!oved. The disc is re!oved and the blo do n rod is re!oved. The guide is re!oved. The $:-ring' no00le and seat is re!oved. The no00le is re!oved. The shuttle seat is re!oved. The liner $:ring is re!oved and then liner is re!oved. G.;.2; The bod( of the pilot is re!oved. The piston is re!oved. Sleeve is re!oved. Sleeve $:-%ing' is re!oved. These parts are inspected and cleaned. <ritical blo do n rods run out is !easured do n ring are ad?usted and set

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MWP-WP-IMS-010

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WORK PROCEDURE
MECHANICAL WORKSHOP G.;.29 The asse!bl( starts ith the $:-ring' being placed on blo disc is then placed on the blo ith the help of set scre .

MECHANICAL WORKSHOP

do n rod. The do n rod

do n rod and secured on the blo

G.;.26 The liner is inserted in the pilot bod(. The shuttle is then placed in the liner. $:-ring' is placed on the shuttle. The seat retainer is placed on the shuttle. Ciner :-ring is placed on the liner. The shuttle seat is placed on the liner :ring. G.;.2D The no00le is placed on the shuttle seat. $:-ring' is placed on the no00le. &isc seat $:-ring' is placed on no00le. Then the guide is placed on the no00le $:-ring' 3inall( the 5lo do n rod is placed in the asse!bl(. Then the button is placed on the disc. Then the spring is placed on the button. Then the top button is placed on the spring. The bonnet is tightened on the pilot bod(. G.;.2G The ad?usting scre s are tightened. Then a tube is placed on the blo do n rod and then the self-loc2ing out is tightened. G.;.2J The pilot bod( asse!bl( starts ith the Sleeve $:-ring' is placed on the the

sleeve and then the sleeve is inserted in the pilot bod(. The piston is fitted top and botto! and botto! $:-ring'. Then the seat is tightened on to the bod(. G.;.30 This co!pletes the pilot asse!bl(. The pilot is placed on the test bench and then it is popped and then its reseating is chec2ed. If the pilot resets as per set pressure1 the pilot is considered to be :2 other ise the $:-rings' are chec2ed and replaced if found da!aged or scored. <.2 Ta**#n* "- Te %e0 + Cal#$ra%e0 SRV G.9.1 7ll tested"calibrated S%)s shall be properl( tagged and sealed b( the shop. Testing shall be preferabl( be done on a !etallic plate *all
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or2

eather

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WORK PROCEDURE
MECHANICAL WORKSHOP

MECHANICAL WORKSHOP

proof1 either alu!inu! or S.S.+. T(picall( the tag plate should indicate unit designation1 identification nu!ber1 e/uip!ent nu!ber1 set pressure"<&S and testing date. :ld tag shall be re!oved. <.7 Tran !"r%a%#"n "- Sa-e%, Rel#e- Val5e $e%;een W"r= ."! %" Plan% an0 In %alla%#"n G.6.1 Maintenance 7rea Tea! shall ta2e care for transportation of the S%) in vertical1 upright position on ooden pallets as per MWP-WP-IMS-002 *%ev. 00+ *Safe 8andling # Transportation of PS)Ns+ >. RE'ERENCES >.1 API J.1.1 S%an0ar0421B6 Pressure vessel inspection code J.1.2 RP422B6 %eco!!ended practice for design and installation of pressure relieving s(ste!s in refineries. *Part I # II+ J.1.3 RP42216 Huide for pressure relief and de-pressuring s(ste!s J.1.; S%an0ar0 22:6 Sea% T#*.%ne J.1.9 RP42:76 In !e/%#"n "- !re "- Pre 3re Rel#e- Val5e

3re C rel#e5#n* 0e5#/e .

J.1.6 S%an0ar0 2276 'lan*e0 %eel a-e%, rel#e- 5al5e >.2 ASME J.2.1 Se/%#"n I6 Po er boilers J.2.2 Se/%#"n VI6 %eco!!ended rules for care # operations of heating boilers. J.2.3 Se/%#"n VII6 %eco!!ended guidelines for care of po er boilers.
ROUTE Na(e Da%e De #*.+S#*n.
W.Shop -ngr S8 W.Shop

PREPARED B& HAM)A NOUMAN

REVIEWED B& )EESHAN NASIM

APPROVED B& ABDUL NASIR MM

RE'ERENCE

DOCUMENT CODE

MWP-WP-IMS-010

REV. #

00

REV. DATE 30-11-2012

PAGE

16 of 16

WORK PROCEDURE
MECHANICAL WORKSHOP J.2.; Se/%#"n VIII6 %ules for construction of pressure vessels. >.3 NBBPVI J.3.1 @ational 5oard for 5oiler and pressure )essel Inspection. 1B. 'ORMS 1B.1 1B.2 P%-SS6%- %-CI-3 )7C)- <7CI5%7TI:@ 3:%M 8IST:%B %-<:%& 3:% 7 P%-SS6%- %-CI-)I@H &-)I<-

MECHANICAL WORKSHOP

ROUTE Na(e Da%e De #*.+S#*n.

PREPARED B& HAM)A NOUMAN


W.Shop -ngr

REVIEWED B& )EESHAN NASIM


S8 W.Shop

APPROVED B& ABDUL NASIR MM

RE'ERENCE