Pressure relief valves (PRVs) are essential components in industrial systems that help to protect equipment and personnel from overpressure situations. These valves operate in all types of environments and need to be routinely inspected to ensure proper performance. PRV’s are also a major component of the Layers of Protection Analysis (LOPA) which evaluates risks and protective layers. It is critical that the components used in the LOPA are maintained to ensure the safety of all those working in a facility and surrounding area. In this blog post, we will discuss some things to consider and what to expect for PRV MRO activities.
1. Scheduled Maintenance
Scheduled maintenance helps ensure the proper operation of the PRV, prevent unplanned downtime, extend equipment life, and ensure safety. For the LOPA, PRV’s are an independent layer of protection that has an average probability of failure to perform. This value is initially calculated and then maintained by completing scheduled maintenance. PRV maintenance involves periodic inspection, testing, and maintenance of PRVs to ensure that they are in good condition and functioning as intended. The frequency of maintenance is dependent on several factors, please reach out to your maintenance personnel for more details.
During scheduled maintenance, the valve will be evaluated as received. The valve will have its set pressure verified and depending on the results of this test and what is required by the customer the valve will be returned as is, repaired, or replaced if needed. If any repair or replacement is needed, the valve will undergo the following tests after it has been built.
- Set Pressure Test in accordance with ASME Section VIII Div. 1 UG-126 or ASME Section I PG-72.2.
- Seat Leakage Test in accordance with API 527
2. Repair or Replacement
PRVs will wear down over time and worn out or damaged components can lead to safety hazards and unexpected downtime. When a valve arrives in our shop, our team will determine if any components need to be repaired or replaced based on a visual examination and set pressure test. It is essential to use authorized personnel and approved replacement parts to ensure compliance with ASME and NB specifications.
3. Cleaning and Lubrication
PRVs can become clogged due to corrosion, scale buildup, or debris accumulation. Selecting the right lubricant is crucial to the valve performance. During scheduled maintenance activities, if the valve is repaired, it will be cleaned and lubricated to ensure proper operation. Our highly trained personnel can help guide you to the correct lubricant that meets your process needs.
Documentation and record keeping are other important aspects of PRV MRO activities. It involves maintaining detailed records of maintenance, repair, and testing, including the date, time, location, and personnel involved. Documentation and record keeping can help to demonstrate compliance with regulatory requirements, identify trends and issues, and facilitate continuous improvement. AWC valve experts can perform a complimentary Installed Base Analysis at your facility to aid in your documentation process. This analysis provides knowledge for ongoing maintenance, repair, and operations information to proactively schedule service. The analysis can be done on a unit, site, multi-site or company-wide level.
Our confidential, no cost, no obligation PRV supply chain analysis will require less than an hour of your time.
In conclusion, PRV MRO activities are critical for ensuring the proper functioning of PRVs and protecting equipment and personnel from overpressure situations. Scheduled maintenance and analysis of the valve’s operation from our team here at AWC are important considerations for PRV MRO activities. Our team will ensure the safe and reliable operation of your PRVs and prevent unplanned downtime and safety hazards.