When does the clock start on inspection and testing of relief devices?

[ReliaEng2008]

Hello,

I am working on a brand new plant that will be commissioned next year. We will be installing PRDs in about 6 months. I was questioned if we need to pop test any of the PRDs prior to installing. I don't know how long each PRD have been in storage. Some of our PRDs will be on a 12 months replacement interval (fouling service).

I tried to do my research online with little results regarding when the inspection/testing interval clock starts. My consideration is that the clock starts when the system is commissioned with its designed fluid. Somebody else could make a case that the clock starts when the valve is installed, even though the system will still go through pre-commissioning and commissioning activities after the PRD is installed with water and nytrogen.

I personally don't consider that the clock starts when the PRD was manufactured and initially tested at the manufacturer's facilities.

Anyone have opinions or resources on this issue?

 

[Compositepro]

The valves should be tested as a part of the commissioning process. I have seen plastic pipe plugs left on pipes when they were installed.

 

[ReliaEng2008]

Why should the relief devices be tested as part of the commissioning process? They have not been exposed to the process? The issue with the plugs left could happen even if they were sent to a testing facility and pop tested. That is just negligence/ignorance of the people installing them.

 

[The Obturator]

I would recommend that you consider the comprehensive observations contained within API-RP-576 - Inspection of Pressure Relief Devices.

Regarding when the clock starts - it also depends what warranty the supplier has provided. Some terms start from commissioning, but are limited from date of shipment, whatever ends first etc.

With new PRD's you also need to consider the following;-

i. Will the PRD manufacturer allow the end user to maintain warranty after testing? (you may have to break the seals to test properly eg., ring settings differ for workshop test benches).
ii. Are any 3rd parties competent (and/or certified) to test the PRD's to the manufacturers standards?
iii. Have the PRD's been adequately stored up to point of installation/commissioning?
iv. Has an ongoing maintenance programme from date of installation/commissioning been established for the future?

API-576 was (is) the original test and maintenance spec used. For ASME Certified requirements, the National Board also publishes NBIC-13 (Part 4 is PRD's)- this is based on API-576 but is used where coded PRD's are used.

Note also that there is no mandate to test factory supplied, test and certified PRD's, but most users and API do recommend to test as close to the point of installation as possible. PRD's can have their set pressures shift from handling, shipping etc.

More info can be found in the Safety Relief Valve Forum

Hope that helped.

*** Per ISO-4126, the generic term 'Safety Valve' is used regardless of application or design ***

*** 'Pressure-relief Valve' is the equivalent ASME/API term ***

 

[GD2]

It’s a very common practice to start clocking PRDs from the date of commissioning the plant when the process first goes in the system.

It’s also a very common practice to re-test the valves during commissioning.

GDD
Canada