Trip and

Relief Valve Testing

Chapter 6

DKK3442
PCSU
Definition
Trip is fault or error detect by the circuit breaker
which is designed to protect an electrical circuit
from damage caused by overload or short circuit.
Unlike a fuse which operates once and then has
to be replaced, a circuit breaker can be reset
(either manually or automatically) to resume
normal operation.
Circuit breakers are made in varying sizes, from
small devices which protect an individual
household appliance up to large switchgear
designed to protect high voltage circuits feeding
an entire city.
Under short-circuit conditions, a current many times
greater than normal can flow.
When electrical contacts open to interrupt a large current,
there is a tendency for an arc to form between the opened
contacts, which would allow the flow of current to continue.
Therefore, circuit breakers must incorporate various
features to divide and extinguish the arc.
In air-insulated and miniature breakers an arc chute
structure consisting (often) of metal plates or ceramic
ridges cools the arc, and blowout coils deflect the arc into
the arc chute.
Larger circuit breakers such as those used in electrical
power distribution may use vacuum, an inert gas such as
sulfur hexafluoride or have contacts immersed in oil to
suppress the arc.
Trip Testing
Vital activity prior to the introduction of organic
material to the site
Trip testing should be as realistic as possible,
involving initiation in the field to action in the
field
The trip test shall be adequate to prove that the
associated interrupting device open when the
protective device operate.
Trip testing is witnessed by owner
Instrument group are key part of the exercise
A single person should be responsible for
controlling the test
Trip Testing
Confirms the correct trip actions as detailed in
the trip schedule and logic diagrams
Confirms the correct operation of bypass
switches, both control room and maintenance
Confirms the correct operation of the sequence of
events recorder (SOER)
Demonstrates the correct set point of each
initiator
Confirm trip
SOER
Sequence of Event Recorder (SOER)
is an intelligent stand-alone micro
processor based system
SOER finds wide application in POWER
GENERATION & PROCESS PLANTS
which have some critical events to be
chronologically identified and
recorded.
SOER is integrated to real time Process
Automation System in process plants to
monitor and record digital inputs
with time stamping.
These inputs are collected from terminal
PCBs mounted on the rear end.
SOER interfaces with host Computer
which processes and stores event data
for further display and printing.
Trip Testing
All valves should be in their normal
position-check any safety considerations
Valve positions should be witnessed in the
field and in the DCS
Initiate the trip and record the actions-
field, DCS, SOER
Check resets
Check bypasses
Trip Initiation
Level
- Fill the vessel with water
- Fill the isolated level bridle
Pressure
- Pressurize the instrument with a standard
calibration pump
Temperature
- Inject a signal at the field junction
Trip Initiation
Flow
- Pressurize the diff. pressure (DP) cell with
a standard calibration pump
Hand Switch
- Push the button
Differential Pressure
Differential pressure (DP) cells are the most often used
level measuring device in the process industries.
Differential pressure cells measure the pressure difference
between two points and send a differential pressure reading
to the plant control system.
Typically, DP cells are rated in inches of water equivalent.
Standard ranges include 0 to 20, 0 to 50, 0 to 100, 0 to
200, and 0 to 500 inches of water differential pressure.
The control system converts the DP cell reading into a
liquid level based on an assumed specific gravity inside the
vessel.
Trip Testing Output Documentation
Completed log sheet recording the correct
operation each trip
Highlighted trip schedule and progress
logic diagrams
Discussion report on problems and
solutions
Relief Valve
Used to control or limit the pressure in a system.
By allowing the pressure source fluid to flow from an
auxiliary passage, away from the main flow path.
Designed or set to open at a predetermined pressure to
protect pressure vessels and other equipment from being
subjected to pressures that exceed their design limits.
When the pressure setting is exceeded, the relief valve
becomes the "path of least resistance" as the valve is
forced open and a portion of the fluid is diverted through
the auxiliary route.
The diverted fluid (liquid, gas or liquid-gas mixture) is
usually routed through a piping system known as a flare
header to a central.
Elevated gas flare where it is burned and the resulting
combustion gases are released to the atmosphere.
In some cases, a so-called bypass valve acts as a relief
valve by being used to return all or part of the fluid
discharged by a pump acts as a relief valve by being used
to return all or part of the fluid discharged by a pump or
gas compressor back to either a storage reservoir or the
inlet of the pump or gas compressor.
This is done to protect the pump or gas compressor and
any associated equipment from too high a pressure. The
bypass valve and bypass path can be internal (an integral
part of the pump or compressor) or external (installed as a
component in the fluid path).
In other cases, equipment must be protected against being
subjected to an internal vacuum (i.e., low pressure) that is
lower than the equipment can withstand.
In such cases, vacuum relief valves are used to open at a
predetermined low pressure limit and to admit air or an
inert gas into the equipment so as control the amount of
vacuum.
Relief Types
Two general categories of relief devices:
i) spring-operated
ii) rupture discs.
Spring-operated: conventional and
balanced-bellows.
Rupture disc is cheaper than spring-operated
relief valves and normally used alone or with
(series/ parallel) spring loaded relief.
3 subcategory types of spring-loaded pressure
reliefs:
1. The relief valve.
2. The safety valve.
3. The safety relief valve.
Safety valve
A safety valve is a valve is a valve mechanism
for the automatic release of a gas from a boiler is
a valve mechanism for the automatic release of a
gas from a boiler, pressure vessel is a valve
mechanism for the automatic release of a gas
from a boiler, pressure vessel, or other system
when the pressure or temperature exceeds preset
limits.
They are often called by more specific names
such as pressure relief valves, T&P valves, or
temperature and pressure relief valves.
Safety valves were first used on steam boilers
during the industrial revolution.
Early boilers without them were prone to
accidental explosion when the operator allowed
Relief Valve Testing
Visual check of any damage during pipe
erection
Clean-out inlet and outlet openings
Use tape to seal over to prevent dirt
ingress
Store in clean dry environment
Test for lift and re-seat pressure
Maintain test records
Carefully reinstall on site with permanent
gaskets.