PSVS WORKING &

MAINTENANCE

QAISAR
IQBAL
 CONTENTS

 Introduction
 Types of Safety Valves
 Parts of PSVs
 Operation
 Test Bench Calibration
 Trouble and Maintenance
INTRODUCTION
DEFINITION
PSV

“A pressure relief valve is a safety device designed to

prevent internal fluid pressure from rising above pre
determined maximum pressure in a pressure vessel exposed
to emergency or abnormal condition.”

PURPOSE
PSVs are used to protect equipment like vessel, tank,
compressors, pumps, Boilers and piping against abnormal
(high pressure) conditions as compare to pre determined
design pressure.
PSV & PRV
 PSV & PRV

1 Pressure Safety Valve:

A safety valve is a pressure relief valve actuated by
inlet static pressure and characterized by rapid
opening or pop action. Used for steam, gas and air
services.

2 Pressure Relief Valve:

A relief valve is a pressure relief valve actuated by
inlet static pressure having a gradual lift generally
proportional to the increase In pressure over opening
pressure. Used for liquid service.
PSV PRV
TYPES OF SAFETY VALVES
TYPES OF PSVS

 Spring Loaded
 Pilot Operated

 Counter Weight
 Rupture Disc
SPRING LOADED
PSV
A pressure relief valve
in which the disc is
held closed by a
spring
 BACK PRESSURE EFFECT
SAFETY RELIEF VALVE:
1 Conventional Safety Relief Valve:
This valve has its spring housing vented to the discharge side
of the valve. Operational characteristics(opening, closing
pressure and relieving capacity) are directly affected by
changes of the back pressure on the valve.

2 Balanced Safety Relief Valve:

This valve incorporates means of minimizing the affect of back
pressure on the operational characteristics(opening, closing
pressure and relieving capacity)
Bellows safety valves
PILOT OPERATED PSVS

Pilot valve

Main valve

A pressure relief valve in which

the major relieving device is
combined with and is controlled
by a self actuated auxiliary
pressure relief valve.
 COUNTER WEIGHT PSVS

 These PSVs are used with Weights instead of Spring.

 These PSVs are for low process pressure.
 Easy to check the operation of the PSV.
 Pressure Cooker is an example of Counter weight PSV
RUPTURE DISC
 A non mechanical over pressure relief device that ruptures
when its rating is attained.

 A thin diaphragm designed to burst at a designated

pressure, discharging into atmosphere or a closed system
such as a flare header.

 Its is known as “weak spot” in any pressure system

(Intentionally designed).
PARTS OF SAFETY VALVES
Parts of Safety Valves
PRINCIPLE OF OPERATION
OPERATION – SPRING LOADED
 A disc is held against the nozzle by a spring
 Adjustable nozzle ring on the nozzle, control the geometry
of the fluid exit control chamber(huddling chamber)
 Normal operation valve remain closed because spring force
is greater than the system pressure force.
 Just prior to reaching set point fluid leaks into the huddling
chamber, causing to open the valve instantaneously.
 Maximum lift attained on allowable overpressure which
may be 10% to 21%
 PILOT OPERATED PSV

 Piston lift, resulting flow through

the main valve .

 Relief demand satisfied, pilot

closes, full system pressure is
diverted to the dome and the piston
moves downward closing the main
valve.
 VALVE VALVE COIL
“A” “B” SPRING

PILOT

MAIN
MAIN VALVE
VALVE PISTON

INLET OUTLET

SEAT
Process Pressure
<
Set Pressure
  VALVE A REMAINS  VALVE B REMAINS
OPEN CLOSED

LINE 1

LINE 2 LINE 3 LINE 4

INLET OUTLET
Process Pressure
>
Set Pressure
  VALVE A IS CLOSED  VALVE B IS OPEN

LINE 1

LINE 2 LINE 3 LINE 4

COUNTER WEIGHT OPERATION
OPERATION OF PRV ( LIQUID SERVICE)
 Different dynamic as compared to gas service.
 Liquid do not expand when flowing across orifice and small
amount of liquid flow across the nozzle will produce large
local pressure drop at the nozzle orifice.
 Pressure drop causes the spring to re close the valve.
 Liquid leaking into huddling chamber can quickly drain out.
 In liquid service “chattering” occur. Rapid opening and
closing of the pressure relief valve.
PSVs Test Bench
Calibration
 CALIBRATION AND SEAT TIGHTNESS TEST

 After final spring setting an valve has popped a few times lower
the pressure of the valve to 90% of set pressure for testing of
air leakage.
 Outlet blanked off by a cover plate on which 5/16” OD tube is
fastened.
 Tube bend at 90 in to a receptacle
 End of the tube to be submerged ½” to the water in the
receptacle.
 Most manufacturers recommend that system operating
pressure should not exceed 90% of the set pressure to achieve
and maintain proper seat tightness.
 ADJUSTMENT & PERFORMANCE

 Correct spring
 Spring can be adjusted 10 % above and below the given range
 For steam and gas service POP action
 10 % above set pressure PSV full lift
 Reseat 5% to 7% below the set pressure
 Liquids service NO POP action, opening increase gradually
 In liquid service, pressure rises 25% above the set pressure the
valve will attain full lift.
 Close at 5% to 7% below the set pressure
 BLOW DOWN ADJUSTMENT
 Reseating pressure ( Blow Down)
 Adjusted by nozzle ring
 Increase blow down, nozzle ring lift up by moving notches. (lower
reseating pressure)
 Decrease blow down, nozzle ring lowered by moving notches.
( higher reseating pressure)
 BLOWDOWN RING SETTING
(NOTCHES FROM CONTACT AGIANST DISC HOLDER)

SET PRESSURE (bar)

- INLET
1 2.5 6 10 16 25 40 64 100 160 250
DN - NPS ORIF.
to 2.5 to 6 to10 to16 to 25 to 40 to 64 to 100 to 160 to250 to 400

D 3 5 6 7 8 9 10 11 - - -
1"
E 4 7 9 11 13 15 17 18 - - -

D 1 2 3 3 4 4 5 5 6 6 7

E 2 3 4 5 6 7 7 8 9 10 11

1" 1/2 F 3 5 6 8 9 10 12 13 14 15 17

G 4 8 10 13 15 17 19 21 23 - -

H 7 13 16 20 23 26 - - - - -

G 2 4 5 6 7 8 9 10 11 12 13
2"
H 3 6 8 10 11 13 14 16 18 19 -
2"1/2
J 5 10 13 16 13 21 24 26 - - -

J 3 5 7 8 9 10 12 13 15 16 -

3" K 4 7 10 11 13 15 17 19 21 23 -

L 6 11 15 18 20 23 - - - - -

L 3 6 8 9 10 12 13 15 16 18 -

M 4 7 10 11 13 15 17 19 21 - -
4"
N 5 9 12 14 16 18 20 23 25 - -

P 7 13 17 20 23 27 30 33 - - -

P 2 5 6 7 8 9 10 11 13 - -

6" Q 4 8 10 12 14 16 18 20 - - -

R 6 12 15 18 20 24 - - - - -

8" T 6 12 16 19 22 25 - - - - -

10" U 5 10 13 16 - - - - - - -

12" V 5 10 13 16 - - - - - - -

Parcol 1) DESIGNED FOR 3-5200 SERIES VALVES W ITH V SERIES

SPRINGS: APPLICABLE ALSO TO PRECEDING SPRING SERIES
 COLD SETTING
 An increase in temperature cause a reduction in set
pressure
 It is to be compensated when a valve is set at ambient
condition
 Up to 100ºC increase in spring setting NONE
 From 100ºC to 250ºC increase in spring setting 2%
 From 251ºC to 500ºC increase in spring setting 3%
 Above 500ºC increase in spring setting 5%
 Example - 1
A standard valve without balanced bellow, set pressure 20 Kg/Cm2,
temperature 260 ºC, constant back pressure 1 Kg/Cm2 service vapor.

Spring set = 20 Kg/Cm2 - 1 Kg/Cm2 = 19 Kg/Cm2

As per temp. table 3% of 19 = 0.57
Round off to 0.60
Cold setting = 19 + 0.6 = 19.60 Kg/Cm2
 Example - 2
Valve with balanced bellow, set pressure 50 Kg/Cm2, temperature 180
ºC, constant back pressure 1.5 Kg/Cm2 service vapor.

Spring set = 50 Kg/Cm2 since balanced valve is not affected by

back pressure

As per temp. table 2% of 50 = 1

Cold setting = 50 + 1 = 51 Kg/Cm2

 LAPPING / RE FACING

Light scratches
Use cast iron lapping plate or a ring lap which should be clean
and flat
Apply compound on lapping block and use figure 8 motion
Apply uniform and light pressure
Much compound can round the edges of the seat
Disc and nozzle re facing can be done maximum three times
TROUBLESHOOTING
&
MAINTENANCE
 SAFETY VALVES TROUBLES
Faulty operation
 Excessive warn
 Failure to close sharply
 Too long blow down
 Improper adjustment
 Damaged seat and sticking
 Rough handling
 Excessive gagging
 Carelessness in valve painting
 TROUBLESHOOTING
Faults Causes Solutions
Leakage 1. Presence of foreign 1. Operate the valve one or twice
matter between seat consecutively. If leakage
and disc. continue, disassemble valve
and clean the trim.
2. Scratching or pitting 2. Disassemble valve, machine
on seat surface and lap the seat.
3. Valve used with fluid
3. Lap seat and disc more finely if
other than that
specified during the valve, originally ordered for
ordering. liquid service, is used with gas.
4. Valve not mounted 4. Correct installation.
vertically.
 TROUBLESHOOTING
Faults Causes Solutions
Discharge 1. Variable back 1. For standard valves check that
at incorrect pressure. discharge takes place in piping
pressure. whose dimensions are equal to or
greater than those of the outlet
connections of the valve, and that
the discharge piping is free from
obstructions. Possibly use a
bellows type valve.
2. Back pressure 2. The valve must be recalibrated,
different from that correcting spring compression for
specified during the new back pressure value.
ordering.
3. Loosening of locknut 3. Tighten locknut after recalibrating
in spring adjusting the valve.
screw.
4. Poor trim alignment. 4. Discharge valve 2 or 3 times to
allow self-alignment of the trim.
 TROUBLESHOOTING
Faults Causes Solutions
Chatter 1.Blow down ring 1. Ensure that the blow down
(rapid incorrectly ring is in the lowest position
opening adjusted. for valves for liquid service.
and For valves used with gas
closing regulate suitably.
cycle) 2.Insufficient 2. Check that discharge tubing is
discharge not obstructed nor too long.
capacity. Check that valve is not
undersized.
3.Oversized valve. 3. Substitute valve with a smaller
one.
MAINTENANCE
Tools
 Lapping blocks for each size
 Lapping block reconditioned
 Lapping compounds coarse, medium, fine and polish
 Nozzle wrench
 Set of contour gauges
Dismantle as per procedure
 Observe and clean all the parts.
MAINTENANCE
Seat conditioning
 Disc seat and nozzle seating area should be lapped.
 Both seats should be flat and properly finished

Lapping procedure
 Never lap the disc against the nozzle
 Lap each part separately against a cast iron lapping block
of proper size.
 Seat to be kept perfectly flat
 Apply compound Coarse, medium coarse, fine and then
polish
 Dirty compound will create scratches.
MAINTENANCE

Machining
 Same template gage to be used for the
machining of nozzle and disc.
 After machining seat and nozzle to be lapped.

Reassembly
THANK YOU
 SPRING LOADED PSV

Sr # Advantages Limitations
1 Low initial cost Seat Leakage
Wide chemical compatibility Simmer and blowdown adjustment
2
interactive
3 High temperature compatibility Vulnerable to inlet pressure losses
Standardized flanged center to face Opening pressure changes with
4
dimensions superimposed back pressure
5 Accepted for ASME Section I and VIII In situ testing can be inaccurate
6 Built-up back pressure limitations
 BALANCED BELLOWS
PSV
Sr # Advantages Limitations
1 Wide chemical compatibility Seat leakage
High temperature compatibility Simmer and blowdown adjustment
2
interactive
Standardized flanged center to face Vulnerable to inlet pressure losses
3
dimensions
4 Protected guiding surfaces and spring In situ testing can be inaccurate
No change in opening pressure at any Bellows can limit amount of
5
superimposed back pressure superimposed back pressure
Withstand higher built-up back High initial cost
6
pressures
7 - High maintenance costs
 PILOT OPERATED PSVS

Sr # Advantages Limitations
Soft seat for tightness before and after High initial cost
1
relief cycle
No change in opening pressure at any High process fluid temperatures
2
superimposed back pressure
Good seat tightness before relieving Chemical compatibility
3
and after reseating
4 Remote pressure sensing Polymer or viscous fluids
5 Full lift at zero overpressure available Complexity
6 Ease of adjustment
Valve remain tight at least 95% of set
7
pressure
 Functions / Advantage
Two fold primary function:

 Provides leak tight seals until.

 A combination of conditions allow it to rupture in a predictable &

controlled manner.

Advantage:

 Used as primary protection & alternate to SR v/v.

 Used in parallel with S. relief valve as 2ry protection.

 In combination with a S. v/v to enhance performance.

PRIMARY
SECONDARY
COMBINATION
 SAFETY VALVES TROUBLES
Incorrect popping pressure

 Dirt of scale wedged between the disc holder and the guide.
 Deposit of hardened boiler compound on the nozzle under the
seat, may be causing it to stick.
 Valve pop too low, seat may have damaged.
 Low popping pressure is seldom caused by spring set.
Simmer: the audible or visible escape of fluid between the seat and
disc at an inlet static pressure below the popping pressure and at no
measurable capacity. It applies to safety or safety relief valves on
compressible fluid service.
Chatter: abnormal, rapid reciprocating motion of the moveable parts of
a pressure relief valve in which the disc contacts the seat.