EXP-MN-SM085-En-R0 - Safety Valves and Burst Discs

MECHANICAL MAINTENANCE
SAFETY VALVES
AND
BURST DISCS
TRAINING MANUAL
COURSE EXP-MN-SM085
Revision 0
Field Operations Training
Mechanical Maintenance
Safety Valves and Burst Discs
EQUIPMENT
SAFETY VALVES AND BURST DISCS
CONTENTS
1. OBJECTIVES ..................................................................................................................4
2. THE FUNCTIONS OF SAFETY VALVES ........................................................................5
2.1. INTRODUCTION.......................................................................................................5
2.2. OPERATION .............................................................................................................6
2.3. STANDARDS ............................................................................................................9
3. THE PRINCIPAL CATEGORIES ...................................................................................10
3.1. SPRING VALVE/ HIGH PRESSURE SAFETY VALVE ...........................................10
3.1.1. Different types .................................................................................................12
3.1.1.1. Screw plug valve ........................................................................................12
3.1.1.2. Thermal expansion valve ...........................................................................13
3.1.1.3. Regulator valve ..........................................................................................14
3.1.1.4. Safety valve with operating lever................................................................15
3.2. PILOT OPERATED VALVE.....................................................................................16
3.3. TANK VENT VALVE................................................................................................17
3.4. PRESSURE REDUCING VALVE ............................................................................18
3.5. BURST DISC ..........................................................................................................19
4. APPLICATIONS OF VALVES........................................................................................20
4.1. SPRING VALVE ......................................................................................................20
4.1.1. Pressure Safety Valve (PSV) ..........................................................................20
4.1.2. Pressure Relief Valve (PRV) ...........................................................................20
4.2. TANK VENT VALVE................................................................................................21
4.3. BURST DISC ..........................................................................................................22
4.3.1. Arrangement of burst discs..............................................................................22
4.3.1.1. Conventional burst disc ..............................................................................22
4.3.1.2. Back pressure or anti-vacuum mountings ..................................................23
4.3.1.3. Reversed burst disc ...................................................................................24
4.4. ADVANTAGES AND DISADVANTAGES................................................................25
5. PRINCIPLE OF OPERATION........................................................................................26
5.1. TERMINOLOGY USED...........................................................................................26
5.2. SPRING VALVE ......................................................................................................26
5.2.1. Valve installed on gases or steam. ..................................................................27
5.2.2. Valve installed on liquids .................................................................................28
5.3. VALVE WITH ADJUSTING RINGS .........................................................................29
5.4. PILOT-OPERATED VALVE ....................................................................................31
5.5. TANK VENT VALVE................................................................................................32
5.6. BURST DISC ..........................................................................................................33
5.6.1. Conventional burst disc ...................................................................................33
5.6.2. Reversed burst disc.........................................................................................33
5.6.3. Warning note ...................................................................................................33
6. REPRESENTATION AND DATA ...................................................................................35
Training Manual : EXP-MN-SM85-EN

Last Revision: 20/03/2008 Page 2 of 55
6.1. REPRESENTATION ON PID ..................................................................................35

6.2. DIAGRAMMATIC REPRESENTATION OF VALVES..............................................35
6.3. DATA SHEET..........................................................................................................36
7. OPERATION OF VALVES.............................................................................................37
7.1. PRESSURE SETTING ............................................................................................37
7.1.1. Sequence of preparation for pressure setting and pressure setting ................39
7.2. LEVEL 1 MAINTENANCE .......................................................................................40
7.2.1. Valves in general.............................................................................................40
7.2.2. Burst disc.........................................................................................................40
7.2.3. Disposal...........................................................................................................40
7.3. ASSEMBLY AND INSTALLATION ..........................................................................40
7.3.1. Assembly.........................................................................................................40
7.3.2. Installation .......................................................................................................41
7.3.3. Isolation of safety valves .................................................................................41
7.4. EXAMPLE OF MONITORING PROCEDURE .........................................................42
7.4.1. Subject ............................................................................................................42
7.4.2. Scope ..............................................................................................................42
7.4.3. Standards applicable .......................................................................................42
7.4.4. Identification and marking................................................................................43
7.4.5. Operations performed......................................................................................44
7.4.5.1. In-service valve inspections .......................................................................44
7.4.5.2. Workshop overhaul of valves .....................................................................44
7.4.5.3. Bench testing BEFORE dismantling...........................................................45
7.4.6. Inspection after triggering in service ................................................................45
7.4.6.1. Role of the Operator...................................................................................45
7.4.6.2. Role of the zone inspector..........................................................................46
7.4.7. Inspection after an overpressure without triggering.........................................46
7.4.7.1. Role of the Operator...................................................................................46
7.4.7.2. Role of the zone inspector..........................................................................46
7.4.8. Burst discs.......................................................................................................46
7.5. EXAMPLES OF LOGICAL DIAGRAMS ..................................................................47
8. EXERCISES ..................................................................................................................50
9. LIST OF FIGURES ........................................................................................................53
10. LIST OF TABLES ........................................................................................................54
11. ANSWERS TO EXERCISES .......................................................................................55

1. OBJECTIVES

2. THE FUNCTIONS OF SAFETY VALVES
2.1. INTRODUCTION
A safety valve is a safety device designed to protect capacities against overpressures or

negative pressures.
Its operation must be exceptional and its position must remain normally closed.
Industrial capacities are characterised by a maximum operating pressure which must not
be exceeded. This is the pressure used as a basis for calculating the strength of the
component materials used in the capacity.
Figure 1: Examples of valves
Adjustment:
Spring
Counterweight
Discharge:
To the open air
Channelled
2.2. OPERATION
Safety valves evacuate any excess energy from the system to be protected in order to limit
the maximum pressure in the protected device to a level which is acceptable for it.
A safety valve is a safety component whose operation is exceptional. Its normal position is
the closed position. The valve is designed to evacuate a gas flow because, for an equal
volume, more (pneumatic) energy is evacuated in the gas phase than in the liquid phase.
Figure 2: Operation of safety (relief) valves
Valve closed = rest position
When the internal pressure of the installation to be

protected is less than the calibration pressure of the
valve (i.e. of the spring), the spring presses the clapper
against its seat.
Valve open = work position
When the internal pressure of the installation to be

protected exceeds the calibration pressure of the valve,
it lifts the clapper and allows the excess energy to be
discharged. The spring is compressed and remains
compressed for as long as the internal pressure
exceeds the spring force.
Figure 3: Spring-type safety valve
By discharging the excess pressure, the internal

pressure is reduced. As soon as the internal pressure
drops below the calibration pressure of the safety valve,
the spring presses the valve against its seat.
The discharge orifice is extended by a vertical vent

which favours dilution and which, in case of ignition,

keeps the flames away from the wall of the tank protected by the valve. The top end of this
vent is also protected by a shutter, which prevents water or foreign matter from entering
the valve / vent tube assembly.
When two valves are used, they are usually installed on a twinning valve.
This enables either a single valve to be put in service (with the other valve isolated) or both
valves at the same time (index in the intermediate position).
The inlet orifice of the twinning valve is connected to the

installation, on the tapping provided for this purpose. The
valves are installed on the tapping provided for this purpose.
The safety valves are installed on the outlet orifices of the
twinning valve.
The operating principle of the twinning valve prevents both

safety valves from being isolated at the same time.
Figure 4: Example of safety valves on a twinning valve
Figure 5: Diagram of a twinning valve
It is necessary for the position of the isolated valve to be clearly indicated.

When the two valves are operated simultaneously (in which case
neither valve provides 100 % of the required flow-rate), the position of
the twinning valve (intermediate position) must be guaranteed by a
safety chain or a lead seal.
Figure 6: Safety valves on a twinning valve
The safety valves can also be installed on a manifold, in cases where

more than two safety valves are required for each tank to be protected.
When necessary, these devices enable a valve to be removed for a check, an inspection
or replacement, without completely emptying the tank.
Figure 7: 4-valve manifold

2.3. STANDARDS
Standards concerning safety valves, applicable both in France and at our subsidiaries,
must be taken into account before any operation or before carrying out any work on these
devices. The main standards concerned are listed below.
Decree dated 4 December 1998 (Arrt du 04 dcembre 1998):
Concerning the operational monitoring of safety valves and steam or gas

pressure devices.
Decree No. 99-1046 dated 13 December 1999 (Dcret no 99-1046 du 13 dcembre

1999):
Concerning equipment under pressure
Decree dated 15 March 2000 (Arrt du 15 mars 2000):
Concerning the operation of equipment under pressure
EC Directive 97-23 (Directive CE 97-23) from the European Parliament and the
Council Meeting held on 29 May 1997:
Concerning the alignment of legislation between member states for equipment

under pressure.
NF EN 14382 (October 2003):
Safety devices for gas pressure regulation stations and installations - Safety
valves for service pressures up to 100 bars
NF EN ISO 4126-1 (July 2004):
Safety devices for protection against excessive pressure - Part 1: safety valves
NF EN ISO 4126-4 (July 2004):
Safety devices for protection against excessive pressures - Part 4: controlled

safety valves
NF EN ISO 4126-7 (July 2004):
Safety devices for protection against excessive pressures - Part 7: common data

3. THE PRINCIPAL CATEGORIES
3.1. SPRING VALVE/ HIGH PRESSURE SAFETY VALVE
Figure 8: Examples of spring valves
A spring valve is composed of:
A body in cast steel connected to the capacity to be protected and to the exhaust
system.
A seat, screwed into the body, of which the upper section is carefully machined in
order to provide sealing.
An adjusting ring which is screwed to the seat and can be operated from the
exterior by a worm screw.
A lift ring which is screwed to the adjusting ring and can be operated from the
exterior by a worm screw.
A valve guide which rests on the upper part of the body through a seal.
A disc valve which slides in the valve guide and is held against the seat by the
spring, thus providing sealing.
A stop maintained against the upper side of the valve guide and against which
the disc valve stops when it opens.
A pin, the spring and its washer constituting the system which forces the plug
against the seat.
An adjusting screw and its nut, allowing the spring tension to be adjusted

A jacket, resting on the top of the valve body through a seal and fixed by bolts,
which protects the spring
A bonnet screwed to the top of the jacket and connected to it by a sealing which
prevents any modification of the valve setting.
BONNET
ADJUSTING NUT
CONVENTIONAL ADJUSTING SCREW

SAFETY VALVE SEAL
S
SEALING
SPRING WASHER
SPRING
PIN
JACKET
VALVE GUIDE
STOP
DISC VALVE
TO EXHAUST
SYSTEM LIFT RING
ADJUSTING
RING
SEAT
BODY
Figure 9: Composition of a spring valve

3.1.1. Different types
3.1.1.1. Screw plug valve
It is possible to place an interlock pin on

these valves which presses down the
disc valve and therefore inhibits the
safety function of the valve.
After lifting, the valve may leak. In such

cases we need to try to restore sealing
by using the interlock pin to press down
on the disc valve.
The interlock pin must not be left on a

valve during normal operation.
1 Bonnet
3 Plug
4 Baseplate
5 Disc valve
6 Valve carrier ring
7 Valve carrier
8 Guide
9 Stop screw
10 Retaining ring
11 Rod
15 Adjusting screw
16 Adjusting screw nut
17 Plug screw
18 Plug screw seal
19 Plug seal
20 Bonnet seal
21 Stop screw seal
22 Spring washer
23 Spring
37 Nameplate
Figure 10: Screw plug valve

3.1.1.2. Thermal expansion valve
Gradual lift type valve fitted in product lines,

particular on offsites, to ensure line expansion
on isolation, and also installed in cooling water
circuits. S
Figure 11: Thermal expansion valve
Figure 12: Example of thermal expansion

valve

3.1.1.3. Regulator valve
Placed on the discharge line of

a pump, it regulates the
pressure to a given value and
modulates the flow rate, which
can vary between the maximum
and zero.
Overpressures and pressure

surges are thus eliminated if
rapid closure occurs.
Anti-surge accumulators are

also necessary in order to avoid
pressure surges.
Figure 13: Regulator valve
Figure 14: Example of a regulator valve

3.1.1.4. Safety valve with operating lever
Fitted on the steam systems which they

protect, these valves can be recognised by
a lever which enables the disc valve to be
unstuck from its seat from time to time.
This operation, specified in the 1926

regulations, is not performed today because
it is too dangerous and has been replaced
by tests (Trvitest) on the site.
Figure 15: Valve with operating lever
Figure 16: Examples of valve with operating

lever
Two safety valves per tank are generally fitted either to a change-over valve or to a
manifold, which allows one of the valves to be isolated while ensuring that the other
operates
This arrangement allows valve maintenance to be performed without shutting down the
equipment

3.2. PILOT OPERATED VALVE
In certain applications where conventional valves do

not perform satisfactorily, it may be necessary to fit
pilot-operated valves (steam plant LPG spillage from
D5)
Figure 17: Example of pilot-operated valve
Figure 18: Pilot-operated valve

3.3. TANK VENT VALVE
The double valve is particularly recommended in

cases where an inerting system or pressurisation
system is used in the tanks.
It prevents damage to the tank if there is a lack of

inert gas or a failure in a system component, and thus
complements pressurisation systems.
It also allows atmospheric air to be admitted when the

tank is emptied or when a drop in temperature occurs.
Figure 19: Tank vent valve
ATMOSPHER
CAPACITY SIDE
FROM GAS SYSTEM
Figure 20: Diagram of a tank vent valve

3.4. PRESSURE REDUCING VALVE
A pressure reducing valve is a self-contained valve device

(requiring no external energy supply), which enables the fluid
obtained at its output to be at a pressure that is lower than the
input pressure, and to be maintained more or less at a constant
value, with or without circulation.
Figure 21: Pressure reducing valve
Note:
The designation "pressure reducing valve" refers to two types of equipment:
Pressure reducing valve reserved for compressed air; steam and gases, which
are compressible,
Pressure reducing valve used for liquids, which are incompressible.

3.5. BURST DISC
This device protects against

overpressures or underpressures.
Component which does not re-close,

designed to burst at a predetermined
pressure in order to protect systems or
isolated facilitiess against unacceptable
pressure or vacuum conditions.
Figure 22: Burst disc
Connection:
Between flanges
Advantages:
Fluid-tight
Good resistance to temperature
Withstands most acids, alkalis and organic solvents
Disadvantage:
Systematic replacement (mandatory stock)

4. APPLICATIONS OF VALVES
4.1. SPRING VALVE
4.1.1. Pressure Safety Valve (PSV)
PSV's are mainly installed on

compressible gases, including
steam
They are also used on process and

utility fluids to protect equipment
against overpressures.
The valve opens without requiring

energy other than that of the fluid
Figure 23: Examples of PSV's
4.1.2. Pressure Relief Valve (PRV)
A PRV opens under the pressure of the internal fluid, usually in proportion to the increase
in pressure
PRV's are used in liquid systems to protect the capacity and

prevent thermal expansion. They can also be used in the
pumping system to protect against overpressures.
Figure 24: Examples of PRV's
PRV's are characterised by rapid opening, or opening which is

proportional to the pressure rise, depending on the application
A PRV will in general act as a PSV when it is used in a

compressible gas system, but opens proportionally when used
in a liquid system

Mainly used on the fixed roofs of storage tanks in the

oil sector, vent valves avoid overpressures or
underpressures in a tank

4.3. BURST DISC
These are generally installed either
upstream of valves in order to isolate

them from corrosive products
or as a relief device
Figure 26: Burst disc (1)
They must be carefully fitted on special flanges

and the metal used must be determined
according to the upstream fluid.
Figure 27: Burst disc (2)
4.3.1. Arrangement of burst discs
4.3.1.1. Conventional burst disc
Capsule type mounting supports have two rings assembled by screws and fitted between
two pipe flanges which do not provide sealing between the disc and the rings. Sealing
requires the assembly to be tightened between pipe flanges.
Capsule type supports exist in two types:
The semi-nozzle type which is fitted

inside the drilling circumference of
standard flanges.
The flange of a burst disc is sufficiently ductile

to seal the assembly and act as a gasket.
Figure 28:Semi-nozzle type arrangement

The full-nozzle type whose diameter is

the same as that of the flanges and is
drilled for the insertion of bolts.
The Figure shows a full-nozzle type

arrangement for a conventional burst disc
installed between 2 pipe flanges.
Figure 29: Full-nozzle type arrangement
4.3.1.2. Back pressure or anti-vacuum mountings
A conventional burst disc is

arranged with its concave side
towards the vacuum or back
pressure, which may result in
reversal of the dome and premature
bursting.
This problem is overcome by using a

perforated mounting, which exactly
adapts to the shape of the disc that
it supports and allows the disc to
withstand an effective operating
pressure of 1 bar, preventing it from
reversing.
Figure 30: Burst disc - back

pressure and anti-vacuum support
Some discs are thick enough to tolerate a total vacuum without support.
The vacuum support, shown by the points, is always placed under the disc.

4.3.1.3. Reversed burst disc
Whereas a conventional disc is mounted

with its concave side towards the pressure,
a reversed disc has its convex side oriented
towards the pressure.
A reversed or inverted disc is always under

compression.
The reversed disc can withstand a vacuum

and therefore does not need a back
pressure mounting.
Figure 31: Arrangement of a semi-nozzle

reversed disc
The disc is mounted in a support which has, on its downstream side, a diagonal
arrangement of sharp blades.
If an overpressure occurs, the disc reverses and is cut or torn by the blades to ensure
relief.

4.4. ADVANTAGES AND DISADVANTAGES
ADVANTAGES DISADVANTAGES
Needs to be readjusted regularly

Can be re-used after use
if readjusted
Pressure setting must be performed
Spring valve by specific personnel
Simple fitting to
equipment
Weight of the valve for large
diameters
Requires somewhat more

maintenance
Pilot valve More flexible to use
Usable on clean fluid
Vent valve
Total safety for

instantaneous relief
Can only be used once, since
Absence of leaks by activation destroys it
Burst disc
virtue of construction
Replacement means shut-down of
Good resistance to the unit or isolation of the device
corrosion if valve
metallurgy is correctly
chosen
Table 1: Advantages and disadvantages of the different types

5. PRINCIPLE OF OPERATION
It is the result of 2 dynamic forces caused by the velocity of the fluid and the rise in static
pressure.
In the lifting of a valve, 2 cases must be considered:
Valve installed on gases or steam.
Valve installed on liquids
5.1. TERMINOLOGY USED
Maximum Allowable Operating Pressure (MAOP): Equipment design pressure.
Operating Pressure: Normal equipment operating pressure

.
Set Pressure: Spring adjustment pressure set on a test bench at ambient temperature -
Exhaust to Atmosphere. The Set Pressure is normally equal to the Opening Pressure.
.
Opening Pressure : Pressure at which valve starts to rise. This pressure must not be
greater than the pressure of the equipment.
Closing Pressure : Pressure at which valve is entirely closed.
5.2. SPRING VALVE
Valve closed: idle position
When the internal pressure of the tank is less than

the set pressure of the valve (the spring) the spring
keeps the disc valve against its seat.
Valve open: working position
If the internal pressure of the tank exceeds the set

pressure of the valve, the disc valve rises and allows
the excess energy to escape. The spring compresses
and remains compressed as long as the internal tank
pressure is higher.
Figure 32: Spring valve
The escape of the fluid reduces the internal pressure.

As soon as it returns to below the set pressure of the valve, the spring keeps the disc
valve against its seat.
The outlet orifice is extended by a vertical vent which helps dilution and in the case of
ignition keeps the flames away from the wall of the tank that the valve protects.
The upper part of the vent is itself protected by a cover which prevents water or foreign
objects from entering the valve/vent pipe assembly.
The weight of this cover is calibrated so that it lifts under the pressure.
The valve opens when:
D D
P1 > P2 + kx
4 4
kx: action of spring (adjustable)
P1 and P2: pressures acting on each side of the valve. Weight of parts ignored
The effect of the spring can be replaced by that of a counterweight but this is no longer
used.
5.2.1. Valve installed on gases or steam.
Normal Operation:
Valve closed:
Process pressure: P2
Spring pressure: P1
P2 is less then P1: P2 < P1
When P2 rises to equilibrium with P1 (P2 = P1):
The specific thrust of the disc valve becomes zero.
The gases succeed in entering the valve faces for Pressures < 1 to 2 % of the set
pressure.
There is a hiss and the valve is said to "fizz".
If the Pressure P2 continues to rise, the valve opens to the fully open position:

The disc valve comes against the stop and the overpressure escapes to the
exhaust system
5.2.2. Valve installed on liquids
Normal Operation:
Valve closed:
Process pressure: P2
Spring pressure: P1
P2 is less then P1: P2 < P1
When P2 rises to equilibrium with P1 (P2 = P1)
The valve remains closed
The valve only opens when
Pressure of Liquid P2 > P1 Spring
For the disc valve to lift completely:
The pressure P2 must be higher by 25%
Figure 33: Operation of a simple valve

5.3. VALVE WITH ADJUSTING RINGS
The principle is identical to the previous case as far as the "hiss" stage
The role of this type of valve is to allow rapid opening in order to avoid this phenomenon -
rapid closure in order to avoid loss of pressure in the capacity and bouncing of the disc
valve on the seat.
Figure 34: Valve with adjusting ring
Role of the adjusting ring
The disc valve having started to lift, the gases enter the chamber 1 and can only escape
through the annular space formed by the outer edge of the adjusting ring and the edge of
the disc valve. This space is adjustable by moving the ring. If the space is tightened, the
speed of the gas is reduced, while the pressure increases. The bearing area is also
increased and the pressure on it creates a force which is able to overcome the action of
the spring, promoting a sudden lifting of the disc valve.
Examples of ring adjustment
The valve set to the MAOP "fizzes". The adjusting ring is too low.
It rises distinctly but the closing is slow and results in a loss of pressure: The adjusting ring
is too high.
Role of the baffle
If we raise the baffle, its outer edge comes closer to that of the Valve Carrier and we have
the same phenomenon of pressure increase in chamber 2 as previously. If the baffle and
the ring are set "HIGH", the spring will be unable to overcome the total of the forces
exercised by P2 + chambers 1 & 2.
To create a rapid drop and return to P2 < P pressure setting, the baffle must be set lower.

5.4. PILOT-OPERATED VALVE
PHASE 1
The pressure PS < pressure PR

(adjustment
pressure), the pilot sensor is open and
the valve piston is under pressure.
P THE VALVE IS CLOSED
PHASE 2
The pressure PS rises and reaches 95% of

PR, the 3-way system hydraulically isolates
the volume 5.
The valve head remains under pressure.
THE VALVE STAYS CLOSED Volum
PHASE 3
The pressure PS reaches the value of PR,

the pilot sensor trips and the fluid contained
at the surface of the head piston is purged.
THE VALVE OPENS

Volum
PHASE 4
The opening of the valve lowers the

pressure PS to a value< PR. The pilot
sensor hydraulically isolates the purging of
the valve head.
A further lowering of the pressure causes

the pilot to flip over and:
RETURN TO PHASE 1
Volum
Figure 35: Operation of a pilot-operated valve

If the capacity pressure falls:
the disc valve on the Gas System side rises
the disc valve to Atmosphere remains pressed against its seat
gas is admitted into the capacity
If the capacity pressure rises:
the disc valve on the Gas System side is pressed against its seat
the disc valve to Atmosphere rises
the excess pressure is sent to atmosphere
2
ATMOSPHER
CAPACIT
DISC VALVE 1: PROTECTION AGAINST UNDERPRESSURE
DISC VALVE 2: PROTECTION AGAINST OVERPRESSURE

5.6. BURST DISC
This device protects against overpressures or underpressures.
5.6.1. Conventional burst disc
A conventional burst disc is a component which does not re-close. It is designed to burst at
a predetermined pressure in order to protect systems or isolated facilities against
unacceptable conditions of pressure or vacuum.
5.6.2. Reversed burst disc
A reversed disc is always under

compression.
The disc is mounted in a support which

has, on its downstream side, a diagonal
arrangement of sharp blades.
If an overpressure occurs, the disc reverses

and is cut by the blades to ensure relief.
Figure 37: Reversed burst disc
5.6.3. Warning note
For safety reasons, it is important to pay attention to the following recommendations:
Discharge from the burst disc continues until the pressure reaches equilibrium.
The discharge may include parts of the burst disc.
The products discharged must be removed to a safe place.
The sound levels caused are sometimes extremely high.
The intensity of burst can be very high and impose reaction forces.
Incorrect connection can cause overpressure in the system.
The useful life of a burst disc cannot be guaranteed.

Certain types of disc are not suitable for hydraulic applications (reversed dome
disc).
Burst disc devices are sometimes significantly heavy.
Burst discs can be fragile.
Burst discs may have sharp edges.
Alignment errors or damage can cause leaks.
The re-use of discs is not recommended after they have been removed.

6. REPRESENTATION AND DATA
6.1. REPRESENTATION ON PID
Figure 38: Representation of valves on a PID
6.2. DIAGRAMMATIC REPRESENTATION OF VALVES

6.3. DATA SHEET
Figure 39: ROSA PSV data sheet sample

7. OPERATION OF VALVES
7.1. PRESSURE SETTING
They are fitted with a

non-aging metal plate
fixed permanently to the
device bodies. The
plate specifies (at least)
the nominal pressure of
the body or of the
flange drilling template,
the nominal diameter of
the device and its
pressure setting.
Figure 40: Pressure

setting bench
Safety valves are

factory-adjusted to
within 0.1 bar of the
pressure specified in
the official engineering documents. They are designed to permit easy adjustment of the
setting.
Valve pressure setting follows very

strict rules because the valves are
SAFETY devices.
TOTAL Group Specifications require

readjustment once per year (more or
less). We must differentiate however
between readjustment and
commissioning of a valve.
When equipment is commissioned,

the valves are usually set by the
supplier, but the pressure setting
certificates are only valid for 60 to 90
days depending on the country.
Figure 41: Adjusting a valve

In all cases, an equipment must only be commissioned with these valves if the certificate
dates from less than 90 days, after which the maintenance rules take effect.
Each valve is fitted with a nameplate showing these characteristics, and an additional plate
showing the date of the last pressure setting. These plates are INDISPENSABLE.
All valves have data sheets and certificates, which must ABSOLUTELY be kept for
inspection.
The pressure setting of a valve, i.e. the pressure at which it starts to open must not be
higher than the maximum operating pressure.
When the internal pressure of the tank is less than the set pressure of the valve, the spring
keeps the disc valve against its seat.
If the pressure exceeds the set pressure of the valve, the disc valve rises and allows the
excess energy to escape.

7.1.1. Sequence of preparation for pressure setting and pressure setting
Dismounting the unit
If pressure > 110% open pressure

VERIFICATION on the bench
Stop the verification
Verify
WORKSHOP overhaul Clean
Remove
Refit
Calibration on bench Pressure gauge with maximum EM calibration

certificate
Pressure = 90 % open pressure

Leak test on bench
If one bubble in a time of < 45 s (no leaks)
Otherwise (leak): needs grinding in
Certifying body test on bench
Refitting to unit

7.2. LEVEL 1 MAINTENANCE
7.2.1. Valves in general
Check the external state of corrosion, particularly for offshore sites, and lubrication of nuts
and bolts for easier dismantling for inspection.
7.2.2. Burst disc
Burst discs do not generally require maintenance because they have no moving parts.
7.2.3. Disposal
Used components must be disposed of in accordance with local and national regulations.
It is essential to be aware of these instructions before installing a burst disc.
7.3. ASSEMBLY AND INSTALLATION
7.3.1. Assembly
Place the discharge side of the support on a bench with the throat upwards.
Check that all surfaces are clean and smooth and that the radius is not damaged.
Check the information shown on the disc label (identification no., burst pressure,
operating temperature).
Fit the pressure side part of the support into the discharge side part.
Assembly
o Standard assembly
Insert and tighten the assembly screws which fix the two parts of the support.
These screws must not be overtightened.
o Assembly to a predefined torque

Carefully turn the disc assembly over, line up the holes and insert the
assembly screws. Tighten the screws evenly and gradually according to the
specified torque.
The disc assembly can now be installed in the system.

Note: No sealing ring must be fitted between the disc and the discharge side of the
support. Sealing rings may be fitted between the disc assembly and the pressure side of
the support. If these are required, they must be supplied by MARSTON.
7.3.2. Installation
Check that the information shown on the disc and support labels is correct for the
position in question.
When installing the assembly between flanges, check the position and direction of
the disc
Sealing rings must be fitted between the support and the system flanges.
Tighten the flange bolts gradually in order to ensure that the system does not
leak.
The tightening torque of the flange bolts does not affect the performance of the
disc.
7.3.3. Isolation of safety valves
All valves connected to the flare systems can be closed, separately or in groups, by means
of an isolation valve.
An isolation valve which is always:
Open in operation.
Closed during maintenance.
This valve is equipped with a locking system (chain and padlock) which protects the safety
valve against operation.
The safety system is operated in accordance with the CGS 05-05 Instruction entitled:
"Isolation of safety valves".

7.4. EXAMPLE OF MONITORING PROCEDURE
7.4.1. Subject
The purpose of this procedure is to define the actions to be undertaken in order to check
the condition and correct operation of safety devices installed on equipment under
pressure which are monitored by the Corrosion-Inspection department.
It also deals with the intervention frequency and the management of monitoring.
It concerns in-service on-site inspections as well as workshop inspections during unit

shutdowns or special interventions.
7.4.2. Scope
This procedure applies to safety devices which are intended to protect equipment under
pressure against overpressures or underpressures:
spring valves,
pilot-operated valves,
tank vent valves,
burst discs
recirculation of treatment product injection pumps
The following valves are not monitored:
compressor lubricating oil system discharge.
7.4.3. Standards applicable
Ministerial Order of 4 December 1998: operational monitoring of safety valves on

equipment under steam or gas pressure.
French Standards NFE 29410 to 29425
CTG Rule RG TUY-F3
Ministerial Order of 15 March 2000 concerning the operation of equipment under pressure

Maintenance Procedure TECH 307-1 GS EXP 212
7.4.4. Identification and marking
Before being installed on site, all new valves must be identified by the Central File
Manager of the inspection department. He enters the manufacturing characteristics in the
CMMS.
The valve is then sent to an approved repairer who performs a triggering test and fits a
sealed metal nameplate bearing the following engraved information:
station identifier
equipment identifier
pressure setting
date of pressure setting
Figure 42: Example of identification
Burst discs are catalogued in the Central File lists.

7.4.5. Operations performed
7.4.5.1. In-service valve inspections
Nature
It is carried out by the Zone Inspector. It includes the following inspections:
check of the general condition of the valve and associated equipment (change-
over valves, pipework)
verification of sealing
verification of indications on the nameplate
verification of consistency of required pressure settings with pressures in the

equipment protected by means of the computer application
Frequency
For valves installed on equipment under the normal regulatory system, the
inspection takes place when the unit is being prepared for shutdown, during the
12 months prior to the shutdown.
For valves installed on equipment covered by a P.C.S., the inspection takes place
during the external examinations specified in the procedure.
For valves installed on common systems, inspection takes place at the same time
as the systems inspection.
7.4.5.2. Workshop overhaul of valves
valve which has been triggered in service, in accordance with 5.4.2
valve which has been subjected to an overpressure according to 5.5.2
valve delivered individually to the overhaul workshop (not during a Scheduled

Shutdown)
100% of the valve population is delivered to the workshop per batch (Scheduled
Shutdown)
Nature
Overhaul is carried out by an approved repairer of TOTAL GABON, in accordance with a

repairer procedure which meets TOTAL GABON specifications

The overhaul includes the following at least:
a preliminary bench test in accordance with 5.3.1
dismantling
check of components
return to compliance if necessary
final bench test
Overhaul report
Frequency
A workshop inspection takes place at each re-qualification and/or major intrusive

examination (RBI analysis) of the equipment protected, whether under regulations
or not.
7.4.5.3. Bench testing BEFORE dismantling
Circumstances
The specifications for workshop valve overhauls includes a systematic bench test
BEFORE any other verification
In all cases, an invitation must be sent to the inspector responsible. The test must be
monitored by an inspector or its designated representative.
7.4.6. Inspection after triggering in service
In-service triggering is taken into account in all cases except when the pressure recorded
was not more than 10% higher than the pressure setting of the valve, in which case the
incident is closed
7.4.6.1. Role of the Operator
The Operator records all cases of valve triggering: significant facts" of the control room
and issues a failure notice in SAP.

When such an incident occurs, it also notifies the inspector responsible for the site via e-
mail.
If the valve has closed again correctly, it archives the pressure recording (if the pressure
was recorded) corresponding to the incident
7.4.6.2. Role of the zone inspector
The zone inspector validates the failure notice in the SAP computer application and follows
up the work order until its closure.
If this is not the case, the inspector asks for the valve to be removed for workshop
overhaul.
If the valve continues to leak, the inspector asks for it to be removed for workshop
overhaul.
7.4.7. Inspection after an overpressure without triggering
7.4.7.1. Role of the Operator
This case is characterised by the ESP monitoring pressure transmitter threshold being
exceeded without triggering the valve. The Operator is informed by an alarm on its
management system.
The Operator records the event in the "daily log: significant events" of the control room.
When such an incident occurs, it also notifies the inspector responsible for the site via e-
mail and creates a failure notice in Unisup.
7.4.7.2. Role of the zone inspector
The zone inspector validates the failure notice in the SAP computer application and follows
up the work order until its closure.
7.4.8. Burst discs
Burst discs are replaced at each regulatory shutdown.

7.5. EXAMPLES OF LOGICAL DIAGRAMS
Figure 43: Logical diagram for removal/refitting
1) SIC issues a malfunction form to search for the causes and induced effects
2) during the daily meetings
3) the inspector attends the test
4) and countersigns the malfunction form after on-site verification that refitting was compliant
5) either in the technical dossier for the equipment, or in the file provided for that purpose for
piping

Figure 44: Logical diagram for issue from store
(1) full list of valves to be overhauled plus list of valves to be tested before removal
(2) the inspector attends testing for 10% of the designated valves
(3) by countersigning the original list
(4) either in the technical dossier for the equipment, or in the file provided for that purpose for piping

Figure 45: Logical diagram for removal in store
(1) full list of valves

(2) the inspector attends testing
(3) by countersigning the original list
(4) either in the technical dossier for the equipment, or in the file provided for that purpose for piping
As shown in the procedure and the logical diagrams, monitoring follows precise
rules with which compliance is mandatory
The valve is a SAFETY device

8. EXERCISES
1. What does PSV mean?
2. Is the safety valve a
Safety device?
Regulation device?
3. With respect to the tank which it protects, a valve is set to a value
Higher than the design pressure of the tank?
Lower than the tank pressure?
At least equal to the tank pressure?
4. What is the opening pressure?
5. When do we say that a valve fizzes?
6. If P2 > P1, what happens?
The disc valve opens
The disc valve closes
The disc valve does not move

7. What is the minimum number of valves on a tank?
8. Draw the representation of a valve on a PID
9. What information is found on a valve?
10. A check shows that the pressure is at 110% of the normal pressure setting: what
should I do?
Stop
Continue to 120%

11. If I have 10 bubbles in 45 seconds, my valve is considered to be good
Yes
No
12. What are the advantages of burst discs?
13. What are the disadvantages of burst discs?

9. LIST OF FIGURES
Figure 1: Examples of valves...............................................................................................5
Figure 2: Operation of safety (relief) valves .........................................................................6
Figure 3: Spring-type safety valve .......................................................................................6
Figure 4: Example of safety valves on a twinning valve.......................................................7
Figure 5: Diagram of a twinning valve..................................................................................7
Figure 6: Safety valves on a twinning valve .........................................................................8
Figure 7: 4-valve manifold....................................................................................................8
Figure 8: Examples of spring valves ..................................................................................10
Figure 9: Composition of a spring valve.............................................................................11
Figure 10: Screw plug valve...............................................................................................12
Figure 11: Thermal expansion valve..................................................................................13
Figure 12: Example of thermal expansion valve ................................................................13
Figure 13: Regulator valve.................................................................................................14
Figure 14: Example of a regulator valve ............................................................................14
Figure 15: Valve with operating lever.................................................................................15
Figure 16: Examples of valve with operating lever.............................................................15
Figure 17: Example of pilot-operated valve........................................................................16
Figure 18: Pilot-operated valve ..........................................................................................16
Figure 19: Tank vent valve.................................................................................................17
Figure 20: Diagram of a tank vent valve ............................................................................17
Figure 21: Pressure reducing valve ...................................................................................18
Figure 22: Burst disc ..........................................................................................................19
Figure 23: Examples of PSV's ...........................................................................................20
Figure 24: Examples of PRV's ...........................................................................................20
Figure 26: Burst disc (1).....................................................................................................22
Figure 27: Burst disc (2).....................................................................................................22
Figure 28:Semi-nozzle type arrangement ..........................................................................22
Figure 29: Full-nozzle type arrangement ...........................................................................23
Figure 30: Burst disc - back pressure and anti-vacuum support ........................................23
Figure 31: Arrangement of a semi-nozzle reversed disc....................................................24
Figure 32: Spring valve ......................................................................................................26
Figure 33: Operation of a simple valve ..............................................................................28
Figure 34: Valve with adjusting ring ...................................................................................29
Figure 35: Operation of a pilot-operated valve...................................................................31
Figure 37: Reversed burst disc ..........................................................................................33
Figure 38: Representation of valves on a PID ...................................................................35
Figure 39: ROSA PSV data sheet sample .........................................................................36
Figure 40: Pressure setting bench .....................................................................................37
Figure 41: Adjusting a valve...............................................................................................37
Figure 42: Example of identification...................................................................................43
Figure 43: Logical diagram for removal/refitting.................................................................47
Figure 44: Logical diagram for issue from store.................................................................48
Figure 45: Logical diagram for removal in store.................................................................49

10. LIST OF TABLES

Table 1: Advantages and disadvantages of the different types..........................................25

11. ANSWERS TO EXERCISES


EXP-MN-SM085-En-R0 - Safety Valves and Burst Discs

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MECHANICAL MAINTENANCE

Training Manual : EXP-MN-SM85-EN

6.1. REPRESENTATION ON PID ..................................................................................35

Training Manual : EXP-MN-SM85-EN

Training Manual : EXP-MN-SM85-EN

2. THE FUNCTIONS OF SAFETY VALVES

A safety valve is a safety device designed to protect capacities against overpressures or

Figure 1: Examples of valves

To the open air

Figure 2: Operation of safety (relief) valves

Valve closed = rest position

When the internal pressure of the installation to be

Valve open = work position

When the internal pressure of the installation to be

Figure 3: Spring-type safety valve

By discharging the excess pressure, the internal

The discharge orifice is extended by a vertical vent

Training Manual : EXP-MN-SM85-EN

The inlet orifice of the twinning valve is connected to the

The operating principle of the twinning valve prevents both

Figure 4: Example of safety valves on a twinning valve

Figure 5: Diagram of a twinning valve

It is necessary for the position of the isolated valve to be clearly indicated.

Training Manual : EXP-MN-SM85-EN

Figure 6: Safety valves on a twinning valve

The safety valves can also be installed on a manifold, in cases where

Figure 7: 4-valve manifold

Training Manual : EXP-MN-SM85-EN

Decree dated 4 December 1998 (Arrt du 04 dcembre 1998):

Concerning the operational monitoring of safety valves and steam or gas

Decree No. 99-1046 dated 13 December 1999 (Dcret no 99-1046 du 13 dcembre

Concerning equipment under pressure

Decree dated 15 March 2000 (Arrt du 15 mars 2000):

Concerning the operation of equipment under pressure

Concerning the alignment of legislation between member states for equipment

NF EN 14382 (October 2003):

NF EN ISO 4126-1 (July 2004):

NF EN ISO 4126-4 (July 2004):

Safety devices for protection against excessive pressures - Part 4: controlled

NF EN ISO 4126-7 (July 2004):

Training Manual : EXP-MN-SM85-EN

3. THE PRINCIPAL CATEGORIES

3.1. SPRING VALVE/ HIGH PRESSURE SAFETY VALVE

Figure 8: Examples of spring valves

A spring valve is composed of:

Training Manual : EXP-MN-SM85-EN

CONVENTIONAL ADJUSTING SCREW

Figure 9: Composition of a spring valve

Training Manual : EXP-MN-SM85-EN

3.1.1. Different types

3.1.1.1. Screw plug valve

It is possible to place an interlock pin on

After lifting, the valve may leak. In such

The interlock pin must not be left on a

Figure 10: Screw plug valve

Training Manual : EXP-MN-SM85-EN

3.1.1.2. Thermal expansion valve

Gradual lift type valve fitted in product lines,

Figure 11: Thermal expansion valve

Figure 12: Example of thermal expansion

Training Manual : EXP-MN-SM85-EN

3.1.1.3. Regulator valve

Placed on the discharge line of

Overpressures and pressure