PROCEDURES MANUAL Ref.

: HPSL/HUB/ENG/M/009 Page 1
VOLUME FOUR Issue: F Level: 3 of 6
Subject: Approved Date
Safety Valve Testing and
Inspection Procedure 25/10/2018
Revalidation:

1.0 PURPOSE

Safety valves are required to prevent a predetermined safe system pressure being exceeded.
Adequate testing, maintenance and record keeping for all safety valve systems is essential for the safe
operation of pressurised plant and to satisfy statutory requirements. This procedure details the
maintenance methods and the procedure for setting the main boiler safety valve lift pressures.

2.0 SCOPE

This procedure applies to all safety valves that protect main boilers pressure system at Hub Power
Station Baluchistan.

3.0 REFERENCE

1) H6.1 Valves Operating & Maintenance Manual

4.0 PROCEDURE

4.1 Responsibilities

1) The Manager Maintenance is responsible to nominate in writing, persons with sufficient

knowledge to avoid danger and set the valves correctly as Designated Engineer (Safety
Valves).

2) The Designated Engineer (Safety valves) is responsible for carrying out the tests and
measurements necessary to secure safe and reliable operation of the safety valves He is also
responsible for recording the results and passing the completed records to the Planning
Manager.

3) The Planning Manager is responsible for retaining the records passed to him from the
Designated Engineer (Safety Valves).

4) The Shift Manager is responsible for liaising with the Designated Engineer (Safety Valves) to
agree a safe method of work and boiler operation during the setting of boiler safety valves.

4.2 Procedure for the management of safety valves

The procedure for the management of safety valves is in 4 parts.

1) Defining the Operational Period.

2) Overhaul and Inspection.
3) Testing and setting.
4) Special Operational Arrangements.

1) Defining the operational period

The Operating Period between successive overhauls of a safety valve shall be defined in the
relative PM of individual valve in CMMS.
Written By: D. Stansfiled Reviewed By: Amir Bashir
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PROCEDURES MANUAL Issue: F Level: 3 of 6

2) Overhaul and inspection

At the end of an Operational Period, valve shall be dismantled and components examined.
Should a significant defect be found in the valve dismantle other similar KKS code valves on
remaining units on the first available opportunity.

The detailed requirements are:

a)
a) The spring shall be checked with visually for apparent defects.
b)
b) The spindle shall be checked with dye penetrant NDT for cracking, particularly at changes
in section. In addition a truth check shall be carried out.
c)
c) The seat and nozzle components shall be checked with dye penetrant NDT for cracking.
d)
d) The valve bowl shall be inspected visually for corrosion and cracking.
e)
e) The drain connections shall be checked for integrity and absence of blockages.
f)
f) The vent pipe shall be inspected for wastage and security to the surrounding supports.
g)
g) The valve seat and nozzle shall be lapped to the satisfaction of the inspecting Engineer or
Supervisor.
h)
h) Any defective components shall only be renewed with full specification spare.
i)
i) During assembly the full lift of the valve shall be measured and recorded.
j)
j) On completion of the repair work the valve body shall be thermally insulated.
k)
3) Testing and Setting

Following unit overhaul and prior to commercial operation the normal requirement shall be to
set the super heater, and drum valves using the assisted lift method. In addition one super heater
(preferable) or one drum valve (# 404) shall be floated to confirm the reliability and accuracy of
the assisted lift method. Power actuated Safety valve setting shall also be tested by actual
pressure raising. As soon as practicable after return to service the cold and hot re heater valves
shall be set using the assisted lift method. In the remote chance that a cold re heater valve sticks
open and cannot be closed by using the hydraulic system, the Unit Operator shall be
immediately informed to reduce Unit load to avoid damage to the re heater due to partial steam
starvation.

The detailed requirements for setting boiler safety valves by unassisted or assisted means are:

a) Arrangements to be made prior to setting safety valves

I) The area at the boiler drum level will be delineated to prevent casual access of
personnel to the test area.

II) The signalling system consisting of a telephone and radio backup shall be confirmed
operational.

III) Calibrated Standard Pressure Gauges for drum, super heater and re heater pressure
measurement as appropriate shall be installed.
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PROCEDURES MANUAL Issue: F Level: 3 of 6

IV) The Operator shall be informed by the designated engineer what base pressure is
required for the testing

b) Responsibilities of the Designated Engineer (Safety Valves)

1)
I) Setting up the signalling system.

II) Having calibrated Standard Pressure gauges fitted at the point of testing.

III) Giving PERSONAL SUPERVISION to the testing.

IV) Ensuring that all adjustments are made at a safe pressure and that safe methods of
work prevail during the tests.

V) Informing the Shift Manager of the testing requirements to allow the necessary
adjustments to be made.

c) General Procedure for testing safety valves by floating (Actual popping)

This is done by raising boiler pressure up to popping pressure of safety valve. Power
actuated Safety valve and Super heater Safety valve shall be tested by this method.

I) Lock movement of spindle by gagging on Drum Safety valves and Super heater
valve. Confirm Power Actuated valve is not isolated from system.

II) Ensure close coordination with operator on radio. It will be preferable that an APO
shall be deputed in testing area/field for better coordination between working party
and control room.

III) Confirm from field instrumentation that Power Actuated valve set pressure is 182
kg/cm2 and reset pressure is 180 kg/cm2. Instruct Operator to switch Power Actuated
valve on auto control mode and raise the pressure. As the valve actuates the set
pressure shall be recorded and as the valve closes the reset pressure shall be
recorded.

IV) Instruct Operator to decrease Boiler pressure up to 175 kg/cm2 and to switch Power
Actuated valve to manual mode.

V) Remove gag from Super heater Safety valve and raise the boiler pressure to its
popping pressure

VI) As the valve lifts the lift pressure raising shall be halted and the pressure shall be
recorded similarly as the valve closes the blowdown pressure shall also be recorded.

VII) At the end of the testing all gags shall be removed and personally accounted for by
the Designated Engineer (Safety Valves).

VIII) Through direct contact with the Shift Manager the boiler can then be returned to
Operation’s control.

d) Procedure for checking and adjusting boiler drum super heater and re-heater safety
valves using assisted lift (Trevi test method)

Trevi testing provides an accredited method of achieving the set pressure of safety valves
without recourse to floating safety valves. The procedure depends upon applying an
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PROCEDURES MANUAL Issue: F Level: 3 of 6

accurately known force to the valve spindle. To achieve the setting the line pressure and
the “effective” seat area need to be known. Valve setting is carried out at about 80% of set
pressure. The equipment that carries out the testing is hydraulically powered, capable of
re-seating the valve and provides a permanent record of the pressure and spindle travel.
Experience with boiler safety valves demonstrates that settings well within 3 bar can be
achieved. Although the trace of spindle travel gives an indication of blowdown pressure
Trevitesting should not be used to adjust blowdown settings.

e) Procedure for setting and adjusting boiler drum and super heater valves

This work shall be carried out under the direct supervision of the Designated Engineer
(Safety Valves)

I) Establish communications and test conditions as in section (b)

II) Raise the boiler pressure to 160kg/cm2

III) Hold the boiler pressure at 160kg/cm2 and carry out the Trevi test twice on each
drum valve to demonstrate consistency.

IV) Raise the boiler pressure to 150kg/cm2 and carry out the Trevitest twice on each
superheater valve to demonstrate consistency.
V) When testing is complete the Designated Engineer (Safety Valves) shall confirm
that no gags remain on the valves.

VI) Through direct contact with the Shift Manager the boiler can then be returned to
Operations control.

f) Procedure for checking and adjusting hot and cold re-heat safety valves

I) Establish communications and test conditions as in section (b)

II) With the boiler on steady load carry out the Trevi test twice on each hot and cold re
heat valve.

III) In the event of a cold reheater valve sticking open and not responding to the close
command, the condition shall be communicated without delay to the Shift Manager
and a request made to reduce Unit load until the valve can be re-seated.

IV) When testing is completed the Designated Engineer (Safety Valves) shall confirm
that no gags remain on the valves.

V) Through direct contact with the Shift Manager the completion of valve testing shall
be communicated.

4) Special operational arrangements (gagging of safety valve during operation)

In the event of drift in a safety valve setting it may be required to gag a valve and continue to
operate the plant. The following safety valve capacity calculation demonstrates that the only
valve, which can be gagged with the plant available for full load, is the power actuated valve.
Should unit operation with other valves out of service be required, the maximum evaporating
rate and hence maximum load must be restricted to less than the remaining safety valve
capacity. SOC (Safe Operation Committee) written approval is mandatory before gagging any
one of Safety valve except Power Actuated valve.
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PROCEDURES MANUAL Issue: F Level: 3 of 6

a) Procedure for the gagging of safety valves

The Designated Engineer (Safety Valves) shall ensure that the following actions are
carried out when gagging safety valves is deemed necessary.

I) Confirm by calculation that adequate relief capacity will still be provided by the
remaining valves.

II) Identify and communicate to the Shift Manager any load or other operational
restrictions which might apply to the unit.
III) Witness the fitting of the gag to ensure it is fitted to the correct valve and
subsequently inform the Shift Manager that a gag has been fitted.

IV) Record the fitting of the gag in the station record system (through the MOC
procedure) and schedule the valve repair.
V) The cause of all passing safety valves shall be thoroughly investigated with a view to
minimising the need for gagging in the future.

b) Safety valve capacity

Evaporation rate of the boiler at is 1,030,100Kg/hr with Super heater outlet steam
conditions of 175Kg/Cm2 and 541C.

The Safety valve discharge capacities at lifting pressure are;

HAD10 HAD10 HAD10 HAD10 LAB10 LAB10

AA401 AA402 AA403 AA404 AA401 AA403
Set press. Kg/cm2 202 202 200 197 185 182
Blowdn Pressure 8 8 8 7.8 7.4 2

Capacity Kg/Hr 216595 216595 213521 208853 174743 104982

Lift mm 12.7 12.7 12.7 12.7 14.2

From the above table total discharge capacity of boiler is 1,135,289 Kg/Hr

Over capacity = (1,135,289/1,030,100) 100 = 110.21%.

Spare capacity =1,135,289 - 1,030,100 = 10, 5189 Kg/Hr

5) Conclusion

Only the power actuated superheat safety valve can be gagged and at the same time maintain
sufficient escape capacity from the remaining safety valves for full unit output.

Any further requirement for gagging would require a reduction in maximum firing rate and
consequential loss of unit load.

4.3 Records

Records shall be maintained of both the fixed data specific to the valves and all maintenance and
testing data.
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PROCEDURES MANUAL Issue: F Level: 3 of 6

1) Fixed data

a) KKS plant identity no.

b) Valve manufacturer
c) Valve serial no.
d) Plant location
e) Plant/system protected
f) Design set pressure
g) Design valve lift (spindle travel)
h) Seat dimensions (needed for assisted lift calculations)
i) Any special features

2) Operation, maintenance and testing data

a) Actual set pressure

b) Actual valve lift (spindle travel)
c) Actual re-seat pressure (blowdown pressure) where appropriate
d) Condition of valve “as found” at overhaul
e) Details of any repairs/reconditioning carried out

5.0 ATTACHMENTS

1) Designated person authorisation sheet

2) Trevi-Test of Boiler Safety Valves
3) Procedure compliance check sheet
4) Safety valve overhauling check sheet
 HUB POWER STATION

Authorisation of Designated Engineers for setting safety valves by floating or assisted lift method.

The Manager Maintenance has authorised you to set boiler safety valves on the Hub Power Site Using either
floating or assisted lift method as appropriate.

Name: …………………………………….

Manager Maintenance

…………………………………………..

Date: …………………………………..

Attachment #1
HPSL/HUB/ENG/M/009
 HUB POWER STATION

TREVI TEST OF BOILER SAFETY VALVES (Boiler 1~4)

Trevi Test
Plant KKS
S.No Plant Description Design Set Pressure Tolerance Base
Code
Pressure

1 HAD 10 AA401 Boiler Drum Safety Valve No.1 202 Kg/CM² 200~204 161 Kg/CM²

2 HAD 10 AA402 Boiler Drum Safety Valve No.2 202 Kg/CM² 200~204 161 Kg/CM²

3 HAD 10 AA403 Boiler Drum Safety Valve No.3 200 Kg/CM² 198~202 161 Kg/CM²

4 HAD 10 AA404 Boiler Drum Safety Valve No.4 197 Kg/CM² 195~199 161 Kg/CM²

5 LBA 10AA401 Main Steam Safety Valve 185 Kg/CM² 183.2~186.8 148 Kg/CM²

6 LBB10AA401 Hot Reheat Safety Valve-1 49 Kg/CM² 48.3~ 49.70 40 Kg/CM²

7 LBB10AA402 Hot Reheat Safety Valve-2 49 Kg/CM² 48.3~ 49.70 40 Kg/CM²

8 LBC10AA411 Cold Reheat Safety Valve-1 52 Kg/CM² 51.3~52.70 40 Kg/CM²

9 LBC10AA412 Cold Reheat Safety Valve-2 52 Kg/CM² 51.3~52.70 40 Kg/CM²

10 LBC10AA413 Cold Reheat Safety Valve-3 52 Kg/CM² 48.3 ~ 49.70 40 Kg/CM²

11 LBG30AA401 Auxiliary Steam Safety Valve-A 20.2 Kg/CM² 19.50~20.90 16 Kg/CM²

12 LBG30AA402 Auxiliary Steam Safety Valve-B 20.7 Kg/CM² 19.80~21.10 16 Kg/CM²

13 HLD10AA407 SAH Back Up Steam Safety Valve 9.2 Kg/CM² 8.73~9.27 7 Kg/CM²

14 HCB10AA405 Soot Blower Steam Safety Valve 34.5 Kg/CM² 33.9~35.10 28 Kg/CM²

*All KKS codes are general, Add unit no. before KKS code for individual unit valve.

Attachment #2
HPSL/HUB/ENG/M/009-F1
 HUB POWER STATION

Procedure Compliance Record for Boiler Safety Valve Trevi Testing

No Activity Compliance
1 Area at drum level is delineated
2 Telephone and radio contact with operations confirmed
3 Calibrated standard pressure gauges installed at drum/super-
heater/re-heater level
4
5
6 Pressure of the boiler is set at 160kg/cm2 for Trevi testing
7 Take print of Trevi test pressure twice for each valve
8 KKS code for valve set for floating with appropriate gagging of
other valves
8a Valve lifting pressure
8b Valve blow down pressure
9 All gags removed and counted
10 Operations informed to take control of boiler

Valve Gagging Record (During Boiler Operation only)

No Activity Compliance
1 Confirm by calculation that adequate relief capacity shall be
provided by remaining valves
2 Communicate to DM Operations if load restriction is required
3 Supervise gagging process and inform DM Operations about it
4 Fill out temporary modification form for valve gagging
5 Close temporary modification after valve is overhauled and
tested and remove the gag

Unite No: _________________

Date: _____________________

Signed: _________________________
(Designated Engineer)

Attachment #3
HPSL/HUB/ENG/M/009-F2
 HUB POWER STATION

Date Approved by
Safety Valve Overhauling Written by
Check Sheet
WK No. KKS.

Model Set Pressure Size

No. Check Point Disassembly Time Assembly Time
1 Measure Adjusting Screw Position ("C", "A") "C" "A" “C”"C" 73.38mm “A”
Time
2 Center Throttle Position. Seizure (based on position 0) Notch Seizure "A" 80.85mm
Notch
3 Seizure of Adjusting Screw

4 Corrosion / Rust on Spring

Spring free length. (Only in case of problem for more details, Design Value Measurement
5 refer to the Instruction Manual h6.1) (Within ±1% of Design Value)

6 Measure Lift Stopper Position("D") & Lift

7 Collar Position
8 Upper Ring Position(Number of Upraise Turn)
9 Lower Ring Notches (Base Position is Seat Surface)
10 Seizure of Spindle Sliding Part
Contact Point of Spindle lip (Method refers to Instruction
11
Manual H 6.1)
12 Measure Spindle Deflection (Acceptance Criteria less than
0.15mm)
13 Disc Lip Height "E"
(Acceptance Criteria: more than 0.15mm)
14 Seizure of Sliding Part between Holder and Guide
Clearance between Sliding Parts of Holder and Guide “F” F1~ -K K2~ M P
15 mm

Measure Nozzle Seat Surface Parallelism (4 points) (Max. mm mm () mm () mm

16 Gradient: less than 0.03mm)
mm mm () mm () mm
Measure Nozzle seat dimension “G” STELITE MM
17 Acceptable /Not Acceptable
(Some step to be checked visually)
18 Color Check (Disc. Nozzle, Spindle, Tip) Acceptable /Not Acceptable
19 Measuring Instrument Numbers (Depth & Vernier)
20 Spindle, seat and nozzle checked using DPT
21 Drain connections checked for integrity and blockage

Attachment #4
HPSL/HUB/ENG/M/009-F3