INDUSTRIAL TRAINING REPORT

SAFETY VALVE UNIT

CCS/LNG DEPARTMENT
FEBRUARY

Name : Muhammad Faris B. Roslan

IPT No: 48736
Supervisors Name: En. Mohd Hanafi B. Ibrahim

ACTIVITY

DATE
15
16
17

18
19
20
21
22
23
24
25

26
27
28

29

ACTIVITY
1)Safety Induction
1)Side Visit
2)Introduction to Safety Valve
1)Pre testing P-V Valve
2) Setting the Cargo Valve
3)Pre testing Liquid Line valve
1)Surveyor (Tenaga 1)
2)Overhaul Liquid line valve
1)Lapping Process

COMMENT

1)Lapping Process
2)Popping control
1)Overhaul Training valve
2)Lapping process
1)Overhaul Training valve
2)Lapping process
1)Overhaul Training valve
2)Lapping process
3) Pre-Test
1)Assembling discharge valve
(TENAGA 1)
2)Replacing Punching Device
1)Final Test for training valve

on

board

INTRODUCTION
The pressure relief valve (PRV) or pressure safety valve (PSV), is a type of valve used to
control or limit the pressure in a system or vessel which can build up for a process upset,
instrument or equipment failure, or fire. The pressure is relieved by allowing the pressurized
fluid to flow from an auxiliary passage out of the system.
The relief valve is designed or set to open at a predetermined set pressure to protect
pressure vessels and other equipment from being subjected to pressures that exceed their design
limits. When the set pressure 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 liquidgas mixture) is usually routed through a piping system
known as a flare header or relief header to a central, elevated gas flare where it is usually burned
and the resulting combustion gases are released to the atmosphere.
As the fluid is diverted, the pressure inside the vessel will stop rising. Once it reaches the
valve's reseating pressure, the valve will close. The blow down is usually stated as a percentage
of set pressure and refers to how much the pressure needs to drop before the valve reseats. The
blow down can vary from roughly 1-20 %, and some valves have adjustable blow downs.

TYPES OF SAFETY VALVE

1. PRESSURE & VACUUM RELIEF VALVE (P-V valve)
The valve has two types which are weight or spring loaded. Direct acting P-V relief valves
(also known as breather valves, conservation vents, or safety vents) are low pressure devices
specifically designed to protect tanks, process systems and equipment from excessive pressure
and vacuum.
As well as providing the primary layer of protection for tanks and process systems, P-V
valves also minimize emission losses of gases or vapors, thus protecting the environment and
providing significant financial savings.
The range includes pressure only, vacuum only and combined P-V valves, all available with
flanged outlets or vented to atmosphere. P-V relief valves are used extensively on bulk storage
tanks, including fixed roof tanks with floating covers, to minimize evaporation loss. The valves
prevent the buildup of excessive pressure or vacuum which can unbalance the system or damage
the storage vessel.
P-V protection levels are controlled with weighted pallets or springs and can be combined to
provide the required pressure/vacuum settings. It is common to combine pallet and spring
systems in one unit i.e. pressure settings require a spring section, whilst the vacuum settings use
the pallet method.
P_V relief valves have weight-loaded or spring-loaded pallets. Flow through the valve is
controlled by the weight of the pallet or the spring force acting on the pallet to keep the device
closed. Once the pressure or vacuum in the tank reaches the pallet closing force, the pallet will
start to lift off the seat and allow flow through the valve.
Due to its air-cushioned sealing technology, the valves prevent emission losses until very
close to the set pressure, and prevents air intake until very close to the set vacuum. The geometry
of the valves has been developed in order to optimize overall performance in terms of high flow
capacity, set pressure, sealing and re-sealing.

2. CARGO TANK RELIEF VALVE

Cargo tanks are to be provided with venting systems entirely distinct from the air pipes of the
other compartments of the ship. The arrangements and position of openings in the cargo tank
deck from which emission of flammable vapors can occur are to be such as to minimize the
possibility of flammable vapors being admitted to enclosed spaces containing a source of
ignition, or collecting in the vicinity of deck machinery and equipment which may constitute an
ignition hazard.
The venting arrangements are to be so designed and operated as to ensure that neither pressure
nor vacuum in cargo tanks exceeds design parameters and be such as to provide for:
b. the flow of the small volumes of vapor, air or inert gas mixtures caused by thermal
variations in a cargo tank in all cases through pressure/vacuum valves, and
c. the passage of large volumes of vapor, air or inert gas mixtures during cargo loading and
ballasting, or during discharging,
d. a secondary means of allowing full flow relief of vapors, air or inert gas mixtures to
prevent overpressure or under pressure in the event of failure of the arrangements in (b).
The venting arrangements are to be connected to the top of each cargo tank and
are to be self-draining to the cargo tanks under all normal conditions of trim and list of
the ship. Where it may not be possible to provide self-draining lines, permanent
arrangements are to be provided to drain the vent lines to a cargo tank. Plugs or
equivalent means are to be provided on the lines after the safety relief valves.

3. LIQUID LINE RELIEF VALVE

Liquid lines are comprised of butt welded, cryogenic stainless steel pipeline connecting each
of the cargo tanks to the cargo manifolds by means of a common line. At each tank, there is a
manifold which connects to the loading and discharge lines from the tank to allow for the loading
and discharge of cargo. This manifold connects to the cargo pump discharge lines, the loading
line and the spray line. All sections of the liquid line outside the cargo tanks are insulated and
covered with a molded cover to act as a tough water and vapors tight barrier.
4. INSULATOR RELIEF VALVE

The valve is normally same with cargo valve but different in the location that being
applied where it is assembles for the secondary membrane in the tank. It acts when the
pressure in the secondary membrane increase due to the gas release from the primary tank .

PRACTICAL ASSESMENT
1. OVERHAUL AND ASSEMBLING EACH RELIEF VALVE
The first assessment that given is to learnt how to overhaul and assemble back the
components in the pressure relief valve. Most of the valve have the same steps to
be overhaul either P-V valve , Cargo valve, Liquid line valve or Insulation valve
where it is shown below :
1. Before overhaul the pre-test must be done to know the exact condition of the
valve( No need to overhaul if desired pressure can be achieve)
2. The valves components must be disassembles from top side to the bottom
3. Cargo valve, Insulator valve and P-V valve the main components that need to
be checked were main diaphragm, main pallet, pilot diaphragm and the O
ring seal.
4. Liquid line valve used the seat and spring to control the pressure.
5. The components were disassembling one by one and being checked.
6. During overhaul, the process must be carried carefully to protect the valve
from damages.

7. Pilot and seat for each type of valve must be confirmed to be in good
condition to be operating.
8. Seat used in the liquid line must be perfectly flat surface to seal the liquid
and maintain the pressure ( metal intact)
9. Pilot and diaphragm used need to be changed if not in the good conditions
where the leaking can be detected during the pre-test session.
10. The cleaning and lapping process then take over
11.The components of the valve are assemble from the bottom(inlet point) to
the top(pressure setting)
12.The valve are then test again to set the desire pressure

2. LAPPING PROCESS
The objective of this process is to get the seat in the liquid line valve flat. This
process is important and need a high concentration as the components are very
sensitive including dust. The seat is the method used to control the pressure in the
valve where metal intact is applied. The steps of the process are shown in below:
1. Clean the seat with air blower and made a hole on a paper according to the
diameter of the seat.
2. Rotate the seat upright on a sand paper and used the hole made before to fix
the position of the seat.
3. Used different grade of sand paper to get a smooth and flat surface where in
MMHE we used from grade 500 to 1600.
4. Kemet Diamond Compound is used on the seat to have shiny and flat
surface.
5. Mega Cleaner (Dye Penetrating System) was used to clean up the diamond
compound and others dirt.
6. Air blower was used again to make sure the components are clean before
assembled.

3. CLEANING PROCESS
Cleaning is a common process to have a better look for the valve but in some cases,
cleaning is essential to provide a better efficiency for the valve. The main part need
to be cleaned was inlet and outlet where the old gas cad being corrodes and cause

leakage. Power brush is used to get off the dirt and followed by Mega Cleaner.
Chemical cleaning is applied when the dirt on the valve is hard to be removed. The
process of chemical cleaning is shown below:
1.
2.
3.
4.

Put the disassemble components of the valve on the tray

Used a proper PPE (Full Face Mask & Rubber glove)
The components were then soak with Formula 1 solution at about 1 hour
Some water is added in the solution and brush is used to make sure each
surface of the components get wet with it.
5. The component then cleaned using brush before rinsed by the water.

4. PRESSURE TESTING
Pressure testing is to make sure that the valve is functioning according to the
pressure assigned. The test are repeat many times until the pressure required is
achieve where the setting can be done by changing the spring or pilot load. The
pressure is set for the main outlet to be function and then determine the closing
pressure for the inlet to close. To detect the opening pressure, in the liquid valve
Popping Setting was used while others not. To determine the closing pressure, a
beaker of water used to detect the leakage where bubbles are produce until the
inlet was completely close.