PROCEDURE FOR

OVERHAUL, REPAIR AND CALIBRATION OF PRESSURE RELIEF VALVES

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o JUNE 02, 2001 1ST ISSUE

lAM

MAS

ANAS

REV DATE DESCRIPTION

APPD

PREPD

CHKD

REVISIONS

DOCUMENT NO.

TOTAL NO. OF SHEETS (INCL. COVER)

OS

QC/PROC/01/27

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PROCEDURE FOR OVERHAUL, REPAIR AND (;Al.IBflATJlON

INDEX

1. SCOPE

2. REFERENCE

3. RESPONSIBILITY

4. PROCEDURE

5. POST TEST JOB

6. DOCUMENTATION

OLA VAN DESCON

QC/PROC/Ol/21 REV.O

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PROCeDURE FOR OVER.HAUL, REPAIR AND CAUSRATION Of PRESSURE REUEf VALVES

1. SCOPE

This procedure describes the general requirement and steps to be followed for the Overhaul, repair and calibration of pressure relief valves and other equipment of similar nature, In case of Client I Manufacturer's specific procedures, this procedure shan supplement with the specific procedure,

2. REfERENCE

2.1 Specification Sheet

2.2 Client documents

2.3 Scope of Work

2.4 Manufacturer catalogue

2.5 API 527

2.6 Olayan Descon QA Manual

3. RESPONSIBILITY

3.1 Execution Engineer I Supervisor shall be responsible for Overhaul! repair, calibration and functional test of Pressure relief valves as per the scope of work.

3.2 QC inspector shall be responsible for visual inspection, witnessing of test and calibration and documentation.

4. PROCEDURE

4. I Receipt of Valve In the Shop.

4.1. I Upon receipt of valve, the relevant data on the nameplate of valve shall be recorded in prescribed format Equipment Receiving Note "ERN" (Exhibit Q67, Attachment-I). If the specification sheet of valve is available! then the above data shall be verified I matched with the given specification. -In case of any physical damage I discrepancy the same shall be recorded and informed to client in writing I verba! as the case may be.

4.1.2 External seals shall be checked if broken. It shall be recorded under remarks on ERN

4.1.3 Bonnet (on bellow type valves) shall be checked for venting.

4.2 Pre-test

4.2.1 The relevant data on the Valve nameplate shall be recorded in the prescribed format. Safety relief valve repair and inspection report "SVR" (Exhibit Q 48,AttachmenHI). If the specification sheet of the valve is available the

OLAYAN DESCON

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PROCEDURE FOR OVERHAUL, REPAIR AND CAUBRATION Of PRESSURi: ~EUI::"f VAI,.VES

above data shall be verified, In case of any discrepancy, it shall be informed to client either verbal or in writing as the cause may be,

4.2.2 "As received" POP test on the Relief valve test bench shall be conducted as per Specification sheet! Name Plate data.

4.2.3 "As received" Leak test shall be conducted as per API 527 or other wise applicable standard. Results shall be recorded in SVR,

4.2.4 Based on the results Item 4.2.2, item 4.2.3 and the Scope of work proceed for item 4.3 (Overhaul! Repair) or Item 5 (Post Test Job.)

4.3 Overhaul I Repair

Based on the result (Item 4.2,1 to Item 4.2.3) I Scope Of work the Valve I Pilot shall be dismantled as follows:

4.3.1 The procedure is applicable for the Conventional! PlIot operated valves as the case may be. Note - Pilot is not available in conventional valves.

4.3.2 Punch marking (alphabetic I numerical) shall be done on Bodyl bonnet & bonnet lCap or any other parts of the valve ! Pilot to ensure proper re-assembly of components in proper orientation during re-assembly stage.

4.3.3 Orientation of Valve body I Pilot and other accessories by Sketch or

photograph shall be recorded as and when required. .

4.3.4 The presence of correct tools & specific instructions, if any, shall be ensured before starting the work.

4.3.5 Parts shall be removed one-by-one, as per the instruction manual of the valve manufacturer, or as per standard sequences.

4.3.6 Record measurement of the spindle screw in SVR, The same is to be utilized for re-assembly and course valve setting.

4.3.7 Pilot shall be removed if required from the main Valve.

4.3.8 Dis-assemble Valve! Pilot as required based on the scope of work.

4.3.9 The parts shall be removed one-by-one of the valve and ! Pilot as per manufacturers instruction manual or as per standard practices, A due care shall be taken to minimise the risk of any damage,

4.3.10 Any unusual damage! material on the internals shall be documented with Photograph! Sketch or other wise,

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PROCEDURE FOR OVERHAULr REPAIR AND CALIBRATION OF PRESSURE REUEF. VALVES

4.4 Preparation for Inspection.

4.4.1 All the parts shall be cleaned by solvent / abrasive to remove scale / foreign material etc. and expose bare meta! surface for inspection.

4.4.2 Extreme care shall be taken to protect the seating surfaces (Nozzle' Disc etc.) to avoid any damage during cleaning.

4.5 Inspection

4.5. I Inspection of aU the parts, as described in the SVR shall be carried out and results of inspection be noted in the report.

4,5.2 After inspection, refurbishment j replacement of parts shall be carried out, as required.

4.6 Repair I Refurbish.

4.6.1 Refurbish I replace the parts as per recommendation (Item 4.5.1),

4.6.2 In case of major repair involving Weld build-up I Machining authorisation be sought and relevant documents shall be followed.

4.7 Re- Assembly

4.7.1 Valve I Pilot shall be re-assembled, in proper sequence. It shall be ensured that the parts do not get damaged during re-assembly. Punch marking shall be matched on Body I bonnet & bonnet I Cap or other parts of the valve I Pilot to align in proper orientation during re-assembly.

4.8 Calibration I Final Pop and leak Test.

4.8.1 Adjust the valve pop test I pilot operating pressure as per specification sheet or applicable document and record the actual data in SVR

4.8.2 Perform Valve leak test as API 527 or any other specific standard applicable and record actual data in SVR.

4.8.1 After successful tests I Calibration, all adjustments shall be tag'ged, I sealed by wire, lead seal. Tag shall indicate the Set pressure, Cold set pressure, Tag number or Serial number, date of Test and SVR #.

5 POST TEST JOB

5.1 After the test, the inlet and outlet flanges of the valve shall be covered appropriately for the protection from foreign particle.

6 DOCUMENTATION

6. t QC inspector shall record all inspection data in the prescribed format SVR and sign the report. This report shari be submitted to the Client for his review & record,

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