-UNCONTROLLED DOCUMENT-
FUJI KOKI RESOURCES (M) SDN BHD
PROCEDURE FOR PRESSURE RELIEF VALVE (PRV)
SERVICE, REPAIR & TESTING (API 527 & 576)
This document is the property of Fuji Koki Resources (M) Sdn Bhd. Unless otherwise specified, no
part of this publication may be reproduced or utilized in any form or by any means, electronic or
mechanical including photocopying and microfilm, without permission in writing from Fuji Koki
Resources Sdn Bhd.
Document No:
FKR-PR-07-REV02
Last Update:
Revision No:
14/10/21
02
Prepared By
Jaafar
Reviewed By
Sugan Purusothman
Approved By
Steven Yang
Jaafar
Sugan
Steven
Senior Technician
Mechanical Engineer
Engineering HOD
*This is an electronic copy of the uncontrolled document; no original signatures are required. Please
request from Document Controller to retrieve the original controlled document.
QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 02
Title: Pressure Relief Valve (PRV) Service, Repair &
Testing Procedure (API 527 & 576)
Document No: FKR-PR-07-REV02
Date: 14/10/2021
REVISION HISTORY
Rev.
00
01
02
Effective Date
02/01/18
24/09/18
14/10/21
Affected Content
All Pages
Page 4 (Sub-section 7.2 no 3)
Description of Changes
New Issue
Specification of pressure gauge
accuracy class
Page 8 (Sub-section 7.5 no 3)
Revision of pressure gauge working
range marking
Revision of service/repair &
calibration certificate
Page 11 (Sub-section 7.6)
1|Pag e
QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 02
Title: Pressure Relief Valve (PRV) Service, Repair &
Testing Procedure (API 527 & 576)
Document No: FKR-PR-07-REV02
Date: 14/10/2021
TABLE OF CONTENTS
NO
1
2
3
4
5
6
7
DESCRIPTION
Objective
Definition
References
Policy
Scope
Application
Procedure
PAGE
3
3
3
3
3
3
3-10
Appendix 1 – Service Report Template
2|Pag e
QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 02
Title: Pressure Relief Valve (PRV) Service, Repair &
Testing Procedure (API 527 & 576)
Document No: FKR-PR-07-REV02
Date: 14/10/2021
1.
OBJECTIVE
To establish a consistent method for the inspection and testing of PRVs.
2.
DEFINITION
FKR – Fuji Koki Resources (M) Sdn Bhd
PRV – Pressure Relief Valve
PRD – Pressure Relief Device
CDTP – Cold Differential Test Pressure
3.
REFERENCES
API 510 – Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair & Alteration
API 576 – Inspection of Pressure-Relieving Devices
API 527 – Seat Tightness of Pressure Relief Valves
4.
POLICY
All inspection and testing performed on PRVs shall be in accordance to this procedure.
5.
SCOPE
This procedure covers on PRVs only and does not cover any other PRDs. Methods covered in this
procedure is narrowed to those listed below:
a. Recording PRV Specification
b. Servicing
c. Popping Test
d. Seat Tightness Test
e. Body Test
6.
APPLICATION
This procedure applies to all employees of FKR performing the scopes listed in section 5 above.
7.
PROCEDURE
7.1 SPECIFICATION RECORDING
The below specifications shall be recorded as a minimum:
a. Brand
b. Type
c. Serial Number/Heat Number
d. Model
e. Set Pressure
f. Body & Bonnet Material
g. Nozzle & Disc Material
h. Trim Material
i. Spring Material
j. Outlet Flange Size & Rating
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 02
Title: Pressure Relief Valve (PRV) Service, Repair &
Testing Procedure (API 527 & 576)
Document No: FKR-PR-07-REV02
Date: 14/10/2021
k. Inlet Flange Size & rating
l. CDTP
7.2
TESTING
1. Upon receiving the valve for servicing, record the nameplate details or details of specification
listed on section 7.1 to the worksheet.
2. Blow out test stand to remove any loose particles from the system. Clean the valve inlet
and place it on the test stand. Clamp the valve securely to the stand.
3. Select a pressure gauge where the CDTP of the valve falls in (the gauge accuracy shall be class
0.6 or better).
4. A pre-pop test can now be carried out, the information gained from this test can be used
to determine the valves frequency of inspection. For the as received pop pressure test,
the first reading of the result should be taken as as-received pop test result in accordance to
API 576 clause 6.2.9.2.
5. Apply pressure slowly to the valve, If the valve lift before 110% of C.D.T.P. and there is no
audible or visual leakage, a seat leakage test may now be carried out in accordance with API
527 standard.
6. If the valve gives an indication of lift before 110% of its C.D.T.P. then record the lift pressure.
If the valve fails to lift at a pressure of 150% of its C.D.T.P., then no more pressure should be
applied. Record the fact that the valve failed to lift then a seat leakage test may now be carried
out in accordance with API 527 standard.
7. Remove pressure from valve inlet.
8. If a bellow valve is being tested, a bellows test should now be carried out to check their
integrity. Apply a pressure of 30 P.S.I.G. through the valve outlet test flange and attach a
bubble pot to the bonnet vent hole. Any leakage through the bellows will be observed and a
new bellows must be fitted.
9. Remove valve from test stand, strip, clean and inspect valve. Consult the manufacturers
maintenance instructions.
10. Consult manufacturers maintenance instruction for information as to machining and lapping
of nozzles and disc, their tolerances, dimensions and recommended practices when
necessary.
11. Renew any worn or damaged parts with new spares.
12. Re-assemble valve and consult manufacturers maintenance instruction when necessary.
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 02
Title: Pressure Relief Valve (PRV) Service, Repair &
Testing Procedure (API 527 & 576)
Document No: FKR-PR-07-REV02
Date: 14/10/2021
13. Set nozzle ring and guide ring. This will assist when calibrating the valve and giving a good
indication of valve lift on test stand.
14. Secure valve to test stand ensuring valve inlet and test stand are clean.
15. Calibrate valve to the C.D.T.P., ensure adjusting bolt lock-nut is tight after each
adjustment
16. Set pressure is based on API 576, for any setting below 70 PSI, acceptable tolerance is +/- 2
PSI for setting above 70 PSI, tolerance is +/- 3%.
17. Seat tightness pressure is based on API 527. For any set pressure 50 psi or less, seat tightness
pressure is -5 psi of CDTP. For set pressure above 50 psi, seat tightness pressure is 90% of
CDTP. Bubbles count is being carried out for gas tight bonnet. For opened bonnet type,
Water is pour into body, above the seating contact from the outlet side. A half flange is
needed in this case to contain the water. Count the numbers of bubbles coming out.
18. Carry out seat leakage test in accordance with API 527 standard, and then remove pressure
from valve inlet.
19. Adjust nozzle ring and guide ring (if any) to the manufactures recommended setting.
20. Body test valve to check integrity of gasket and sealing faces. Conventional valves are
tested by applying pressure through the outlet test flange. Bellow valves are tested by
applying pressure of 30 PSIG through the valve outlet. No leakage should be detected by
soap test sprayed at all joints or pressure should not drop after 5 minutes.
21. If a bellow valve is being tested, then a bellows test is repeated.
22. All external adjusting points must now be sealed.
23. Cover the valve inlet and outlet flange to protect the sealing faces and to prevent
contamination of the valve.
24. Handle valve with care as it is a very sensitive instrument.
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 02
Title: Pressure Relief Valve (PRV) Service, Repair &
Testing Procedure (API 527 & 576)
Document No: FKR-PR-07-REV02
Date: 14/10/2021
7.3 SERVICING
Safety Valve Repair Process
Start
Start
·
·
·
Preparation
Preparation
Clear bench
Mount Valve
Select Gauge
Rec
Rec name
name Plate
Plate
Pre-pop/leak
Pre-pop/leak
·
·
·
·
·
110% of CDTP
150% CDTP
Adjust Bolt & Nozzle ring
measurement
API 527
API576
Disassemble
Disassemble process
process &
&
Inspection
Inspection process
process
Component
Component Check
Check
Not OK
Report
Report to
to Customer
Customer
OK
Cleaning
Cleaning
·
·
·
Wire brush
Solvent
Grit blasting
Lapping/Machining
Lapping/Machining
Measurement
Measurement
Engineering
Engineering Data
Data
Reassemble
Reassemble
Testing
Testing
Preparation
Preparation for
for Painting
Painting
Tagging
Tagging
Test
Test Cert
Cert &
& Report
Report
Approved Signatory
Customer
Customer
End
End
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 02
Title: Pressure Relief Valve (PRV) Service, Repair &
Testing Procedure (API 527 & 576)
Document No: FKR-PR-07-REV02
Date: 14/10/2021
7.4 TESTING PROCESS FLOWCHART
Safety Valve Testing Process
Start
Start
·
·
·
Clear bench
Mount Valve
Select Gauge
Seat
Seat Tightness
Tightness Test
Test with
with Air
Air
(Closed
(Closed Bonnet)
Bonnet)
NO
Preparation
Preparation
Open
Open Bonnet
Bonnet
Type?
Type?
YES
Seat
Seat Tightness
Tightness Test
Test with
with Air
Air
(Open
(Open Bonnet)
Bonnet)
Leakage
Leakage Test
Test
API
API 576
576
Bellow
Bellow Type
Type
YES
Bellow
Bellow Test
Test
NO
End
End
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 02
Title: Pressure Relief Valve (PRV) Service, Repair &
Testing Procedure (API 527 & 576)
Document No: FKR-PR-07-REV02
Date: 14/10/2021
7.5 TESTING ILLUSTRATION
1) Clear the Test Bench
2) Mount the valve vertically to the test
bench and clamp it securely.
3) Select the correct pressure gauge (within 25% to 66%)
8|Pag e
QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 02
Title: Pressure Relief Valve (PRV) Service, Repair &
Testing Procedure (API 527 & 576)
Document No: FKR-PR-07-REV02
Date: 14/10/2021
4) CDTP Tolerance (API 576)
- Apply pressure slowly to the valve.
- Set pressure less than or equal to 70 psi (±2 psi)
- Set pressure greater than 70 psi (±3%)
- Maximum pop pressure 150% of CDTP for stuck
shut valve.
5) Select correct test apparatus
- Tube outside diameter 7.9mm
- Tube wall thickness 0.89mm
- Tube end opening 12.7mm below the surface of
water.
6) Conventional Valve Leakage Test (API 527)
- Make sure all joints are tight
- Valve joints tightness and fitting should be checked with
spray liquid detergent.
- Set pressure 50 psi or less (-5 psi)
- Set pressure 51 psi and above (90%)
- Observe valve leakage test for at least 1 minute
9|Pag e
QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 02
Title: Pressure Relief Valve (PRV) Service & Testing
Procedure
Document No: FKR-PR-07-REV02
Date: 14/10/2021
7) Conventional Valve Leakage Test
(API 527)
- Make sure all joints are tight
- Valve joints tightness and fitting should be
checked with spray liquid detergent.
- Set pressure 50 psi or less (-5 psi)
- Set pressure 51 psi and above (90%)
- Observe valve leakage test for at least 1 minute.
8) Open Bonnet Valve Leakage Test
(API 527)
- Make sure all joints are tight
- Valve joints tightness and fitting should be
checked with spray liquid detergent.
- Water is poured into the body, above
the seating contact from the outlet side.
- Use a mirror to look for leakage.
- Set pressure 50 psi or less (-5 psi)
- Set pressure 51 psi and above (90%)
- Observe valve leakage test for at least 1 minute.
9) Bellow Test Pressure
- Make sure all joints are tight
- Valve joints tightness and fitting should be
checked with spray liquid detergent.
- Apply pressure of 30 psi through the
valve outlet.
10 | P a g e
QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 02
Title: Pressure Relief Valve (PRV) Service & Testing
Procedure
Document No: FKR-PR-07-REV02
Date: 14/10/2021
7.6 SERVICE/REPAIR & CALIBRATION CERTIFICATE
Each PSV that passes this procedure without failure shall have a calibration certificate valid
for 1 year and a service/repair certificate indicating works that have been performed as well
as outlining the issues and recommendation.
The certificates shall contain the below information as a minimum:
▪ FKR Job No
▪ Customer name
▪ Certificate Number
▪ Date of Issue
▪ Valve Type, Manufacturer, Size, Pressure Rating, Body & Trim Material
▪ Valve Tag Number/Identification Number
▪ Set Pressure
▪ Test pressure and type of test conducted.
i.
Service/Repair Certificate
A service/repair report shall be issued to the customer 3 working days after the
completion of the service/repair works upon request.
The report shall be of non-photo format and all-important aspects of the scope of work
including testing shall be highlighted in the report.
Refer attached template of this report in Appendix 1.
ii. Calibration Certificate
A calibration certificate not-longer than 3 days after the completion of the calibration
process shall be provided to customer. Calibration certificate will be valid for a period of
1 year exactly from the issued date.
Refer attached template of the calibration certificate in Appendix 2.
iii. Approval of Report
Each report shall be signed by the technician, engineer and/or a third party/customer
witness if requested.
iv. Certificate Number
Each individual valve shall have its own unique certificate number for recording and
tracking purpose. It shall be noted that the Service/Repair Report, NC Report (if
applicable), & Photo Report shall be of the same certificate number for a valve. The
certificate number shall be obtained from the Work Certificate Number Running No Form
(FKR-FM-20-REV00).
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 02
Title: Pressure Relief Valve (PRV) Service & Testing
Procedure
Document No: FKR-PR-07-REV02
Date: 14/10/2021
7.7 PAINTING
i. Touch-Up Painting
Touch up painting shall be performed if requested by customer only and it will be
performed according to the existing surface paint color of the valve unless otherwise
specified by customer or on the WORF.
ii. Blasting & Painting
Unless not specified by the customer in writing or documented in the WORF, blasting &
painting will not be performed.
If specified, the blasting & painting will be performed, and a subsequent blasting &
painting report shall be issued to the customer not longer than 1 working week after the
blasting & painting was performed on the valve.
7.8 PACKING & PRESERVATION
All valves shall be packed according to Handling, Storage, Packing, Unpacking &
Preservation Procedure FKR-PR-26-REV00 unless otherwise specified by customer or in the
WORF. Refer PRV section of the above-mentioned procedure for specific instructions for
handling, storage, packaging, unpacking & preservation of PRVs.
12 | P a g e
QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 02
Title: Pressure Relief Valve (PRV) Service & Testing
Procedure
Document No: FKR-PR-07-REV02
Date: 14/10/2021
APPENDIX 1 – SERVICE CERTIFICATE TEMPLATE
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QUALITY MANAGEMENT SYSTEM MANUAL
FUJI KOKI RESOURCES (M) SDN BHD
Revision: 02
Title: Pressure Relief Valve (PRV) Service, Repair &
Testing Procedure (API 527 & 576)
Document No: FKR-PR-07-REV02
Date: 14/10/2021
APPENDIX 2 – CALIBRATION CERTIFICATE