SAEP-318

Previous Issue: 31 March, 2003 Next Planned Update: 1 November, 2009 Page 1 of 28 Primary contact: Fahad S. Al-Blaies on 874-6604

Engineering Procedure

SAEP-318 31 October, 2004 Pressure Relief Valve Program Authorization for Installation, Deletion and Changes Document Responsibility: Inspection Department

Saudi Aramco DeskTop Standards Table of Contents 1 Scope............................................................. 2 2 Deviation Approval......................................... 3 3 Definitions....................................................... 3 4 References..................................................... 7 5 Purpose.......................................................... 8 6 Responsibilities.............................................. 9 7 Authorization Requirements......................... 18 8 Authorization Procedures............................. 20 9 Marking and Identifying RVs........................ 21 10 Rupture Disks (RD) and Rupture Pins (RP). 21 11 Spare RVs.................................................... 22 12 Pressure Testing RVs.................................. 23 13 Mothballed RVs............................................ 24 14 Test and Inspection Interval Determination.. 24 15 Surge Relief Valves (SR)............................. 24 Chart I - Projects Authorization Procedure for RV Installation and Changes........... 26 Chart II – Operational Facilities RV Authorization Procedure for RV Installation and Changes...................... 27 Chart III – Retirement (Deletion) of RV from Service......................................... 28

Document Responsibility: Inspection Department SAEP-318 Issue Date: 31 October, 2004 Pressure Relief Valve Program Authorization Next Planned Update: 1 November, 2009 for Installation, Deletion and Changes

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1 Scope

1.1 This procedure defines the approval and authorization procedures, responsibilities, relief valve identification, in-kind replacements, and the references used to control and maintain Saudi Aramco Pressure Relieving Devices (relief/safety valves, surge relief valves, vacuum breakers, rupture pins and rupture disks). Safety valves, relief valves, safety relief valves, surge relief valves, vacuum breakers, rupture pins and disks will be referred to as a 'RV' throughout this procedure.

1.2 This procedure applies to RVs as defined as PZV in SAES-J-600 on fixed, mobile, skid mounted and packaged equipment, except as noted in 1.4. It also applies to surge relief valves as defined as SRV in SAES-J-605.

1.3 This procedure shall also apply to flow modulating, i.e., Ful-Flo or equivalent, relief valves, providing:

1.3.1 They are the sole relieving device for the system being protected.

1.3.2 They can be tested in-place when an approved In-Place Test Procedure is used.

1.4 The following are EXCLUDED from the requirements of this Procedure (Refer to Paragraph 1.6):

1.4.1 Individual residence hot water heaters

1.4.2 Water heaters of less than 100 gallon capacity

1.4.3 Turbine alarm (sentinel) valves

1.4.4 Bottled gas cylinders

1.4.5 Surge suppression valves

1.4.6 Pressure reducing and let-down valves

1.4.7 Pressure controllers and regulator valves

1.4.8 Integral pump and compressor casing RVs

1.4.9 Air compressor mounted on vehicles (portable).

1.5 A RV that is requested to be added or deleted from paragraph 1.4 exclusion list shall be reviewed and approved by the Manager of the Inspection Department.


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1.6 RVs excluded from the RV Program must be maintained or replaced periodically, in accordance with a documented maintenance program that can only be altered with Operations Manager level approval.

2 Deviation Approval

Any required deviation of the requirements of this procedure shall be reviewed and approved by the Manager, Inspection Department.

3 Definitions

3.1 Relief Valve Authorization, Form SA 3099A-ENG

Approval, by signature, of a RV design and installation into any Saudi Aramco facility. The authorizing individuals are noted on the Relief Valve Authorization, Form SA 3099A-ENG, which is the permanent record of initial use, approval, changes, and deletion of a RV in the Saudi Aramco Relief Valve Program through SAP R/3.

3.2 Instrument Specification Sheet

Data sheet, for verification of RV design for installation into any Saudi Aramco facility, which is the permanent record of initial design for approval and changes of a RV in the Saudi Aramco Relief Valve Program. The approval signatories are noted on the specific Instrument Specification Sheet (ISS). ISS used for RVs within Saudi Aramco include:

ISS 8020-611-ENG Instrument Specification Sheet – Pressure Relief Valves Conventional & Balanced Types

ISS 8020-612-ENG Instrument Specification Sheet – Safety Relief Valves Pilot Operated

ISS 8020-613-ENG Instrument Specification Sheet – Pressure – Vacuum Relief Valves

ISS 8020-614-ENG Instrument Specification Sheet – Rupture Disks

ISS 8020-605-ENG Instrumentation Specification Sheet – Surge Relief Valves

3.3 Changes that AFFECT RV Operation

Mechanical and operational changes that affect RV reliability and operation, such as: set pressure, back pressure, spring range, nozzle orifice size, service, operating temperature, design code, material, inlet and outlet pipe sizes and test intervals.


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3.4 Changes that DO NOT AFFECT RV Operation

Changes that do not directly affect valve reliability and operation, such as: RV location, installation code, disassembly indicator, mothballing/demothballing, RV type indicators, ISS drawing number, PZV tag number, and other non-mechanical changes.

3.5 SAP BW Data Warehouse

It is a SAP product that is called Business Information Warehouse (BW).

3.6 SAP- CC

SAP Computer Center

3.7 Mechanical Services Shops Department (MSSD) in Dhahran

The organization that oversees the maintenance work of Saudi Aramco RVs in Contractor Shops, In-Kingdom.

3.8 Lost RV

A safety relief device that can not be located and is verified to no longer exist in the field, yet has a database record assigned to it.

3.9 Operations

The business line department that is directly responsible for the management of the facilities with installed RVs.

3.10 Originator

An engineer who initiates a RV installation or change that requires authorization approvals by providing the design and specification information. He can be an engineer for any discipline (i.e.; Operations Engineer, Maintenance Engineer, Inspection Engineer, Projects Engineer, Plant Engineer, etc.)

3.11 Projects

Facilities that are under the management of a Project Manager, and not yet transferred to an Operations Organization by the signing of the Mechanical Completion Certificate (MCC).

3.12 RV

The generic term used in this procedure and the field when referring to pressure relieving devices, as defined in the Scope.


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3.13 RV Lead Administrator

The lead administrator of the corporate RV program assigned by the Superintendent of Operations Inspection Division, who reports to Supervisor of Inspection Engineering Unit, Dhahran.

3.14 RV Administrator

The administrator of the RV program assigned by the Superintendent of Operations Inspection Division, who reports to the Supervisor of Inspection Engineering Unit, Dhahran. He is assigned role ID number 37 in SAP Plant Maintenance module.

3.15 RV Coordinator

The local administrator of the RV Program assigned by the Operations Inspection Unit Supervisor to control local in-plant RV activities and authorizations. He coordinates activities with the RV Administrator, local Engineering, Operations, and Maintenance Divisions, as well as local Inspectors. He is assigned to role ID number 35 in SAP Plant Maintenance module.

3.16 RV Equipment Processor

An authorized person from Maintenance organization having Role ID number 04 in Plant Maintenance module of SAP.

3.17 RV Equipment Task List Processor


3.18 RV Inspection Work History Processor


3.19 Maintenance Plan Processor


3.20 CMS Master Data Maintainer

An authorized person from Corporate Maintenance System having Role ID number 64. He maintains all the entries of RV tables in SAP Plant Maintenance.


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3.21 CMS RV General Task List Processor

An authorized person from Corporate Maintenance System having Role ID number 68. He maintains the one General Task List for RV's and Master Inspection Characteristics and Sampling Procedures within the RV General Task List in SAP Plant Maintenance.

3.22 RV Program

RV administration program in SAP Plant Maintenance Module established by SAEP-318 and SAEP-319 that applies approved procedures uniformly. It utilizes a centralized database to assure proper testing and inspection of RVs at specific intervals.

3.23 Replacement "IN-KIND"

Replacement of a RV with an identical RV from the same manufacturer, i.e., same application and design code.

3.24 Spare RV

A new or used RV that is a potential replacement unit or can be used for parts. This is not to be confused with the on-line spare RV.

3.25 Test RV

A RV which is temporarily installed to protect a system being pressure tested for strength or leakage.

3.26 SAP R/3

Systems, Applications and Products in data processing. "R" means 'real-time processing.

3.27 Relief Valve Database Approval

The process of authorizing RV data (new or updated data on the Form SA 3099A-ENG) entered into the RV Program database. This approval is by the Inspection Department RV Administrator.

3.28 Relief Valve Maintenance Report Database Approval

The process of authorizing the RV maintenance test data (on the Form SA 3750-ENG) entered into the RV Program database of SAP R/3. This approval is by the local Operations Inspection Unit's RV Coordinator.


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3.29 Surge Relief (SR) Valve

The generic term used in this procedure and the field when referring to surge relieving devices, as defined in the Scope of this procedure.

4 References

The following references or associated documents are required by this SAEP.

4.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-319 Pressure Relief Valves Routine Test and Inspection

SAEP-1027 Pressure Relief Valve Conventional and Balanced Types

SAEP-1131 Use of Relief Valve Authorization, Form SA 3099A-ENG

SAEP-1134 Relief Valve Technician Certification

Saudi Aramco Engineering Standards

SAES-B-067 Safety Identification and Safety Colors

SAES-J-600 Pressure Relief Devices

SAES-J-605 Surge Relief Protection Systems

SAES-L-140 Thermal Expansion Relief in Piping

Saudi Aramco Forms and Data Sheets

PM02 Maintenance Work Order (printed out from SAP System)

SA 2760-ENG Approval Request-to Deviate from Equipment Inspection Schedule

SA 3099A-ENG Relief Valve Authorization

SA 8020-605-ENG Instrumentation Specification Sheet – Surge Relief Valves

SA 8020-611-ENG Instrument Specification Sheet - Safety Relief Valves

SA 8020-612-ENG Instrument Specification Sheet - Pilot Operated Safety Relief Valves


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SA 8020-613-ENG Instrument Specification Sheet - Pressure-Vacuum Relief Valves

SA 8020-614-ENG Instrument Specification Sheet – Rupture Disks

4.2 Industry Codes and Standards

American Petroleum Institute

API RP 520 Recommended Practice for the Design and Installation of Pressure Relieving Systems in Refineries Part II Installations

API STD 527 Commercial Seat Tightness of Safety Relief Valves with Metal-to-Metal Seats

API RP 576 Inspection of Pressure Relieving Devices

American Society of Mechanical Engineers/Boiler and Pressure Vessel Code

ASME SEC I Rules for Construction of Power Boilers

ASME SEC IV Construction of Heating Boilers

ASME SEC VII Recommended Guidelines for the Care of Power Boilers

ASME SEC VIII D1 Rules for Construction of Pressure Vessels

ASME SEC VIII D2 Rules for Construction of Pressure Vessels

ASME B31.1 Power Piping

ASME B31.3 Chemical Plant and Petroleum Refinery Piping

ASME B31.4 Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols

ASME B31.5 Refrigeration Piping

ASME B31.8 Gas Transmission and Distribution Piping Systems

ASME B31.9 Building Services Piping

NBIC NB 23 National Board Pressure Vessel and Boiler Inspection Code

5 Purpose

The purpose of this procedure is to assure that:


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• Installation, deletion, or changes are approved and accurately recorded in the corporate SAP system.

• Testing and Inspection are conducted at predetermined and repeating intervals to maintain RV reliability.

• RV installations and changes conform to ASME Code, SAES-J-600, SAES-L-140, SAES-J-605, and Manufacturer's requirements.

• RV problems are identified for resolution by engineering.

6 Responsibilities

6.1 The Operations Inspection Division in Dhahran is responsible for overall administration of the Relief Valve Program. Various phases of the program are delegated as follows:

6.2 RV Lead Administrator

6.2.1 Controls revision of RV related Engineering Procedures and reviews Deviation Requests.

6.2.2 Coordinates SAP R/3 activities with regard to RV related matters.

6.2.3 Provides guidance and consultation to RV Administrators, RV Coordinators and RV technicians.

6.3 RV Administrator

6.3.1 Approves the RV SA 3099A-ENG data entry in SAP R/3 and verifies RV numbers upon received of an authorized Relief Valve Authorization, Form SA 3099A-ENG, that is correct, as verified against the attached SA 8020-611-ENG, Instrument Specification Sheet (ISS). See paragraph 3.14.

6.3.2 Administers the security access to the RV Program in SAP for only RV Coordinators.

6.3.3 Communicates with, and assists RV Coordinators and RV users.

6.3.4 Sends monthly follow-up report, to each proponent's Manager, on overdue relief valves with overdue periods in excess of that allowed by SAEP-319, section 5.5.3.


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6.4 SAP Computer Center

Manages the implementation of the SAP R/3 system in Saudi Aramco. It is comprised of four (4) functional departments namely, SAP Applications, SAP Computing, SAP Training & Change Management and SAP Design.

6.5 Originator

6.5.1 Verifies that the RV conforms to Saudi Aramco Specifications.

6.5.2 Prepares the Relief Valve Authorization, Form SA 3099A-ENG per SAEP-1131.

6.5.3 Obtains or prepares the Instrument Specification Sheet SA 8020-611-ENG, as per SAEP-1027 and other ISS forms as applicable for each RV type.

6.5.4 Initiates the authorization procedures, using Relief Valve Authorization, Form SA 3099A-ENG with the Instrument Specification Sheet SA 8020-611-ENG for new, replaced, retired, changed, or removed RVs. For deleted RVs, only the Form SA 3099A-ENG or a letter is required with the pertinent approval signatures from Engineering, Operations Superintendent or equivalent and local Inspection Unit.

6.5.5 Requests authorization and verification signatures to complete the Relief Valve Authorization, Form SA 3099A-ENG.

6.5.6 Enters the approved RV Form SA 3099A-ENG data into the RV Program using SAP system Transaction Code IE01 with Equipment Category "R". The originator may designate someone (from Maintenance RV Shop) under his supervision to input the data, but the originator must verify the integrity of the data prior to requesting an RV number. The originator must check with the local RV Coordinator on data entry requirements prior to inputting the data in SAP system.

6.5.7 Requests a RV equipment number from the local RV Equipment Processor; or RV Coordinator if no RV Equipment Processor is assigned in the area.

6.5.8 Assures that no unauthorized RVs are installed in-site.

6.5.9 Sends a copy of the approved Relief Valve Authorization, Form SA 3099A-ENG with the new RV number and the PM02 Work Order created automatically by SAP R/3, to the RV Test Shop Unit to initiate


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the field work, or coordinate this task with the local Inspection Unit in accordance with local procedures.

6.5.10 Obtains the required installation approvals from the Project Inspection Unit, Operations Inspection Unit, Operations Foreman, and/or commissioning Supervisor, and verifications on Relief Valve Authorization, Form SA 3099A-ENG.

6.5.11 Sends the originals of all completed Forms (SA 3099A-ENG, SA 3750-ENG, and SA 8020-611-ENG) to the local RV Coordinator for filing and follow up.

6.5.12 Establishes the base intervals for RV T&I scheduling. Refer to SAEP-319, paragraphs 5.1.2 and 5.2.

6.5.13 Revises or requests as built drawing and P&ID's as required.

6.6 Senior Project Engineer or Supervisor Operations Engineering

6.6.1 Provides or approves RV design and specification.

6.6.2 Approves new RV installations, changes, replacements, retirements, or removals by signing Relief Valve Authorization, Form SA 3099A-ENG.

6.6.3 Maintains a current technical library that includes applicable relief valve documentation for the RVs used in the Operating Facility.

6.6.4 Provides In-Place RV Test Procedures.

6.6.5 Provides a review of corroded, stuck or malfunctioning RVs in cooperation with Operations Inspection Unit, as required by SAEP-319 Regulation Program, Section 12.

6.6.6 Assign an engineer for the two years physical review mentioned under paragraph 6.7.4.

6.7 Operations Superintendent

6.7.1 Approves new installations, changes, replacements, retirements, or removals by signing the Relief Valve Authorization, Form SA 3099A-ENG.

6.7.2 Approves RV in-place testing, and assures that the correct equipment pressure is strictly maintained during the test.

6.7.3 Assures that RV Work Orders are distributed for timely RV T&Is.


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6.7.4 Every two years, conducts periodic comprehensive physical review, jointly with local Inspection Unit & Engineering, on the operating facility to verify that all RV's are tracked by the Corporate SAP system.

6.7.5 Assures that a monthly RV checklist is used by the responsible Operations personnel, the checklist is maintained in the Control room cabinets and the RV Coordinator is notified of any discrepancy.

6.8 Maintenance

6.8.1 Schedules and performs the physical inspection, testing, and repair of RVs in accordance with the RV Program.

6.8.2 Receives the approved RV Authorization Form SA 3099A-ENG and enters its data in SAP system and obtains RV number to be written on Form SA 3099A-ENG.

6.8.3 Prepares/Prints a Relief Valve Maintenance Report, Form SA 3750-ENG, for each RV repair activity, for entry into the SAP system.

6.8.4 Enters the Relief Valve Maintenance Report data into the RV Program Database using SAP Transaction QE17. The RV Maintenance Supervisor may designate someone under his supervision to input the data, but he must verify the integrity of the data prior to requesting approval by the RV Coordinator. The autonomous operating Department Manager is authorized to delegate the task of Form 3750-ENG data entry to another unit.

6.8.5 Sends the original Form 3750-ENG to the local RV Coordinator for test results approval.

6.8.6 Verifies that the manufacturer's nameplate is attached, and the RV has an ASME stamp.

6.8.7 Verifies that each RV conforms to its design description on the Relief Valve Authorization, Form SA 3099A-ENG.

6.8.8 Verifies or applies RV ID tags, stamps, paints the bonnet green on bellows type RV, and adjustment seals per SAEP-318, Section 9.

6.8.9 Maintains an inventory of replacement parts.

6.8.10 Maintains "TEST" RVs for pressure testing purposes, with associated service and design records.

6.8.11 Maintains an inventory of "SPARE" RVs and their records.


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6.8.12 Provides calibrated RV testing equipment.

6.8.13 Provides certified RV Technicians, as per SAEP-1134 by setting up or coordinating a training program for all RV technicians.

6.8.14 Maintains an up to date and complete reference library for servicing RVs including the manufacturer's service manuals for each type of RV serviced, QA Manual, plus the Engineering Procedure, and related industry standards, such as ASME and API.

6.8.15 Prepares and maintains a QA manual for the RV Shop.

6.8.16 Maintains a file on each RV which consists of all RV data (SA 3099A-ENG, ISS, SA 3750-ENG), communication letters, memos, and any other related information pertaining to RVs. This includes "Test RVs".

6.9 RV Coordinator

6.9.1 Administers the RV Program for all plants and support facilities under his area of responsibility.

6.9.2 Familiarizes himself with the RV Engineering Procedures, SAES RV Standards, Industry Standards, and manufacturer requirements for RV upkeep.

6.9.3 Obtains a thorough understanding of how relief valves work and assists in trouble shooting problems associated with service conditions (corrosion), poor maintenance, or items listed in Section 12 of SAEP-319.

6.9.4 Receives and verifies the original Form SA 3099A-ENG data against the Form SA 8020-611-ENG, initials the form, obtains his supervisor's signature and submits to the RV Administrator for final data entry approval.

6.9.5 Investigates why a relief valve has not been tested within three months following the issuance of a RV number.

6.9.6 Maintains a RV master file that includes the original Form SA 3099A-ENG, any changes/updates, the original ISS Form SA 8020-611-ENG, originals of the Maintenance report, Form 3750-ENG, annual external inspection reports, any worksheet requests and other correspondence related to the RV. A copy of the SIS for the equipment that the RV is attached to should also be included.


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6.9.6.1 RV records are to be maintained for the life of an active RV.

6.9.6.2 Records for Deleted RVs are to be kept for a minimum of three years after which they may be electronically stored. A method of record retrieval must be in-place.

6.9.6.3 Maintenance reports, Form 3750-ENG, are to be maintained in the active RV file for a minimum of three test intervals, after which they may be electronically stored. A method of record retrieval must be in-place.

6.9.7 Reviews all the information on the 3099A-ENG prior to approving the data entered by maintenance on the Form 3750-ENG (see paragraph 3.19). If there is any wrong or missing information regarding the testing of the RV, the test results should not be approved.

6.9.8 Monitors overdue test status, and sends monthly memos/letters to Operation's Division management to inform them of their RV OVERDUE status, as well as RVs due to be tested.

6.9.9 Participates in internal RV Program audits, as directed by the Inspection Supervisor.

6.9.10 Assists Originating Engineers with filling out the Relief Valve Authorization, Form SA 3099A-ENG, to ensure conformance to the respective ISS and RV SAEPs.

6.9.11 Maintains or has access to current RV reference material needed to support his duties. This should include manufacturer's manuals, catalogs, and a copy of the local RV Shop Quality Assurance Manual.

6.9.12 Communicates with and assists local Inspectors and maintenance to resolve questions concerning test interval revisions, deletions, additions, change requests, test shop activity and troubleshooting RV problems as they relate to documentation or SAEP requirements and mechanical problems.

6.10 Project Inspection Supervisor

6.10.1 Reviews and signs off the Relief Valve Authorization, Form SA 3099A-ENG, using the 8020-611-ENG to verify data entered on the Relief Valve Authorization Form, for newly constructed facilities.

6.10.2 Verifies correct installation and identification marking of RVs is in accordance with this SAEP.


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6.10.3 Verifies that installed RVs are sealed, in the correct location, and properly piped to a safe location per SAES-J-600.

6.10.4 Verifies that block valves are properly installed and painted, as per SAES-J-600 and SAES-B-067.

6.10.5 Verifies that the isolation valve installed between the remote pressure gauge and the area being monitored (the area between the rupture disk or rupture pin and the relief valve) is locked open.

6.10.6 Verifies that RV bonnets are vented to a safe location, per SAES-J-600, and painted green for bellows type RVs, per SAES-B-067.

6.10.7 Signs off the verification section of the original Relief Valve Authorization, Form SA 3099A-ENG to verify that installation, deletion or a change has taken place.

6.11 Supervisor/Field Supervisor of the Operations Inspection Unit

6.11.1 For remote areas, the Inspection Field Supervisor has the authority to act on behalf of the Inspection supervisor for the following items:

6.11.2 Provides an audit of the RV T&I Program at least once a year.

6.11.3 Assigns a member of Inspection Unit as 'RV Coordinator'.

6.11.4 Provides Inspection for witnessing In-Place RV testing.

6.11.5 Provides inspection for Engineering reviews of corroded, dirty, stuck, and malfunctioning RVs, as required by the Regulation Program, Section 12 of SAEP-319.

6.11.6 Ensures that installed RVs are tagged, sealed, in the correct location, and piped to a safe location, as required by SAES-J-600, during annual external inspections.

6.11.7 Ensures that block valves are properly installed and painted, as per SAES-J-600 and SAES-B-067, during annual external inspections.

6.11.8 Signs the original Relief Valve Authorization, Form SA 3099A-ENG to verify his review and concurrence to an installation, deletion or change.

6.11.9 Investigates RVs that have been commissioned without a Relief Valve Authorization, Form SA 3099A-ENG, and reports findings to Engineering for initiation of the form.


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6.11.10 Provides written procedures for RV Program auditing for areas under his responsibilities.

6.11.11 Recommends interval updates, per SAEP-319.

6.11.12 Assigns a member of the Inspection Unit to participate in the two-year physical review mentioned under 6.7.4 and document the result of the survey.

6.12 Operations Foreman / Commissioning Supervisor

6.12.1 Verifies that the RV location and marking are correct.

6.12.2 Verifies that inlet and outlet block valves, for active RVs, are open completely and properly sealed.

6.12.3 Verifies that inlet is closed and outlet block valve is completely opened for on-line SPARE RVs, and the valves are sealed. He also verifies that the isolation valves between the remote pressure gauges and the area being monitored (the area between the rupture disk or rupture pin and the Relief Valve) is locked open, where applicable.

6.12.4 Verifies that the block valves are painted orange, as required by SAES-J-600 and SAES-B-067, Section 4.2.4.A.

6.12.5 Verifies that the block valve stems are oriented horizontally or sloping away from the valve as per SAES-J-600.

6.12.6 Signs off on the Relief Valve Authorization, Form SA 3099A-ENG verification block(s) whenever the RV is installed on site after being tested and inspected.

6.12.7 Verifies that the Maintenance Order, PM02, for RV servicing is automatically initiated and scheduled by SAP system through Maintenance Division.

6.12.8 Concurs with approval to conduct In-Place RV testing.

6.12.9 Initiates Maintenance Orders for the repairs of RVs not Due for T&I under the Preventive Maintenance system in SAP.

6.12.10 Submits Waiver, Form SA 2760-ENG, to request schedule deviation as required in compliance with the requirements of paragraph 5.5.4 of SAEP-319.

6.12.11 Verifies that bellows type RV bonnets are correctly vented.


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6.12.12 Verifies that bellows type RV bonnets are painted green.

6.12.13 Verifies that a pressure gauge is present between a reclosing RV and an in-series rupture disk.

6.12.14 Verifies that all newly installed RV have a permanently assigned RV number.

6.13 Contract Repair & Operations Unit/Dhahran Shops Division, Mechanical Services Shops Dept.

6.13.1 Performs administration of Contractor RV repair shops, and provides support to the Vendor Inspection Division, Dhahran, to ensure that Contractor's shops are approved to perform work required by SAEP-318 and SAEP-319.

6.13.2 Audits Contractor facilities annually. Copies of the Audit reports are to be sent to Operations Inspection Division/Inspection Department, Dhahran.

6.13.3 Assigns work based on Contractor's approved capabilities.

6.13.4 Performs RV T&Is in Mechanical Services Shop for Saudi Aramco facilities.

6.13.5 Notifies the valve proponent when problems are identified, such as stuck, dirty, corroded, etc., so that an Engineering decision can be made prior to release/testing of the valve.

6.13.6 Enters the Relief Valve Maintenance Report data, Form SA 3750-ENG into SAP system using the SAP transaction QE17. The original Form SA 3750-ENG is then sent to the proponent to forward to the local RV Coordinator.

6.14 Process Control Systems Division/Instrumentation Unit

6.14.1 Reviews and concurs with RV In-Place testing procedures.

6.14.2 Consults with Plant Maintenance or Operations on RV problems.

6.14.3 Evaluates and approves any new RV technology to be used in Saudi Aramco facilities.


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6.15 Loss Prevention Department

The division head of the Area Loss Prevention Division is to review and concur with RV in-place testing procedures, as well as on Form SA 2760-ENG "Approval Request to Deviate from Equipment Inspection Schedule."

6.16 Manager of Inspection Department

6.16.1 Reviews and approves RV In-Place testing procedures.

6.16.2 Reviews and approves exclusions or additions to SAEP-318.

6.16.3 Reviews and concurs on Form SA 2760-ENG "Approval Request to Deviate from Equipment Inspection Schedule".

6.17 RV Technician

6.17.1 Tests and inspects RVs according to manufacturer's requirements per SAEP-319, API and ASME requirements.

6.17.2 Records the condition of the RV on Relief Valve Maintenance Report, Form SA 3750-ENG, and any additional format needed to provide a meaningful historical record of RV condition and performance.

6.17.3 Informs RV Shop Supervisor when an Engineering Review is needed, as described in SAEP-319, Section 12.

6.17.4 Familiarizes himself with the RV SAEPs, standards, manufacturer's maintenance manuals, and Codes (ASME, API as referenced in this SAEP).

6.18 SAP Computing Center

6.18.1 Performs Computer programming, and RV program monitoring required to maintain the RV program and the database in SAP R/3 system.

6.18.2 Performs Computer operations, programming, database backup, and data input required to maintain the RV database.

7 Authorization Requirements

7.1 Authorization Responsibility is given to the Senior Project Engineer, Supervisor of Operations Engineering and the Operations Superintendent.


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7.2 Authorization IS REQUIRED for new RV installations, RV changes, "NOT IN-KIND" RV replacement, and deletion.

Examples of changes are indicated in paragraphs 3.2 and 3.3.

7.3 Changes that AFFECT RV operations require the approval of the Supervisor of Operations Engineering, Operations Superintendent, and review by the Supervisor of the Operations Inspection Unit. The local RV Coordinator must also initial each Form SA 3099A-ENG. Repetitive changes, of more than five (5) RVs, can be requested by a letter to the Inspection Department, Dhahran and signed by the above referenced personnel.

7.4 Changes that DO NOT AFFECT RV operations can be made with the approval of the Supervisor of the local Operations Inspection Unit. Repetitive changes, of more than five (5) RVs, can be requested by a letter to the Inspection Department, Dhahran and signed by the Supervisor of the local Operations Inspection Unit.

Exceptions:

A DECREASE IN THE TEST INTERVAL, for RVs with an in service history, can be authorized by the Supervisor of the Local Operations Inspection Unit and Operations Foreman. Test intervals would normally be decreased in six (6) months increments.

An INTERVAL EXTENSION, for RVs with an in service history, can only be made with the authority of the Supervisor of Operations Engineering and the Operations Superintendent.

Mothballing and demothballing can be authorized by the Supervisor of the local Operations Inspection Unit and the Supervisor of the Operations Engineering Unit.

7.5 Deletion of an existing Relief Valve number can only be authorized by the Operations Superintendent, and only when the equipment being protected has been permanently dismantled, when the existing RV is replaced "NOT IN KIND", or if the RV is lost. For replacement "NOT IN KIND" the old RV number shall be deleted.

When a deleted RV is to be replaced with another RV, authorization for the new RV should be completed and a new RV number assigned, prior to deleting the old RV or RV number.

7.6 Authorization is required for an "IN-KIND" Replacement and the RV number of the old valve can NOT be applied to the new valve.


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Authorization is required for "IN-KIND" replacement of a LOST RV. The RV number of the LOST RV shall be deleted from the RV Program Database.

7.7 All outstanding Form SA 3099A-ENG SAP requests shall be kept on "Awaiting Approval" until the authorized Form SA 3099A-ENG and the ISS sheet are received by the RV Administrator, Dhahran.

7.8 Verification Requirements

Verification responsibility is given to the Operations Foreman and Supervisor of the Local Operations Inspection Unit for on-line facilities, and to the Supervisor of Projects Inspection and the Commissioning Supervisor for new projects.

7.8.1 Verification is required to assure that a RV addition, deletion or change has actually taken place in the field. This is recorded in the verification part of the Relief Valve Authorization, Form SA 3099A-ENG.

7.8.2 Verification is required within three months of RV authorized activity. This is a follow-up requirement. The RV Coordinator shall request or perform a field verification if a Form SA 3099A-ENG has not been verified within three months.

8 Authorization Procedures

8.1 New RV Installation and change Authorization Procedures are described in Charts I and II. Use the chart that corresponds to the responsible organization, either Projects or Operations.

When updating a RV, the program requires that all missing data must be provided and authorized as described in Chart II.

8.2 RV Deletion Authorization Procedure is described in Chart III.

RV Deletion is only authorized when the equipment being protected is dismantled, the RV function will never be required, or the RV is lost. The RV database file will not be retrievable after deletion.

8.3 "IN-KIND" Replacement procedure

8.3.1 "IN-KIND" Replacement is requested through Operations Engineering by the RV Shop. The RV Shop shall verify with Operations Engineering that the replacement is identical. A new Relief Valve Authorization, Form SA 3099A-ENG, shall be initiated to update any database changes, as required, i.e., updating any missing database information or where spring numbers may have changed. IN-KIND


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Replacement documentation shall be sent to the RV Coordinator for filing.

8.3.2 Immediately remove RV number markings from the old RV. Mark the new RV with the new RV number. Test, set, seal, and tag in accordance with SAEP-319.

8.4 A NOT IN-KIND replacement for the same service requires a new RV number to be issued, i.e., a new ISS and Form SA 3099A-ENG is to be generated. The NOT IN-KIND Replacement Authorization Procedure is described in Chart I or II depending on the organization responsible.

8.5 When Authorization requirements are in question the local RV Coordinator or the RV Administrator should be consulted.

9 Marking and Identifying RVs

9.1 Each RV shall be identified by attaching a corrosion resistant metal tag FIRMLY secured by a 16 gage stainless steel wire. Tags are available from storehouse stock (SCM SAP stock # 1000168143). For rupture disks and rupture pins, attach the tag to the holder. (Galvanized metal tags should not be used).

9.2 The tag shall be die stamped with the following:

RV number ___________

Set Pressure ___________

CDTP ___________

Test Date ___/___/___

Due Date ___/___/___

Commentary Note:

The Due Date on the RV tag equals to the Planned Date which is designated automatically by SAP system. That is the date at which the next T&I is due for a RV based on the specified interval.

9.3 The RV number, as described in tag requirements, shall be die stamped on the body of screw type valves. The RV number shall be stamped on the outlet flange of flanged RVs. Stamping the mating pipe flange or installing a field RV number tag is recommended to avoid installation errors.


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9.4 The mounting flange of a rupture disk or a rupture pin holder shall be die stamped with the disk/pin RV number.

9.5 The bonnets of all bellows type RVs shall be painted GREEN, per SAES-B-067, paragraph 4.2.2.d. This is to indicate that the bonnet must be vented and the vent piping is to be directed away from other equipment or walkways.

9.6 All other RVs shall be painted with the mandatory aluminum color, as per SAES-B-067.

10 Rupture Disks (RD) and Rupture Pins (RP)

10.1 Rupture Disks and Rupture Pins installation shall be per SAES-J-600.

10.2 The Authorization Procedure for Rupture Disks and Rupture Pins is the same as for all other RVs.

10.3 The Authorization Procedure for Series Rupture Disk requires approval by submittal of an authorized Form SA 3099A-ENG for both the Rupture Disk and the reclosing Relief Valve. Both Relief Valve Authorization Forms shall be accompanied by the approved Instrumentation Specification Sheets, Forms SA 8020-611-ENG and SA 8020-614-ENG, showing the capacity calculations, and conformance to ASME SEC VIII D1, UG-127, 128, as per SAES-J-600.

11 Spare RVs

11.1 The RV program recognizes the following (RV SPARE types).

11.1.1 An In-Service Isolated spare RV (entry code INIS on Form SA 3099A-ENG).

11.1.2 An Off-line spare RV that is used for a specific location (to be moved to the designated "spare" Functional Location, entry code is OFSP).

11.1.3 A General use spare RV that can be used in different locations. See 11.5.

11.1.4 A Cannibalized spare RV used for parts replacements. See 11.3.

Commentary Note:

The entry codes (i.e., INIS, OFSP) for INSTALLATION/SPARE CODE shall be selected from the User Status menu for spare RV in SAP system.


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11.2 SPARE RVs may serve as extra open stock, assigned replacement RVs (e.g., an extra superheater replacement safety valve), or for parts. The use determines how it is controlled in the database.

11.3 SPARE RV which is cannibalized for parts shall be deleted from the computer database, i.e., SAP system. The SPARE PARTS RV shall be stored in the RV Shop inventory, and a complete file maintained on the SPARE PARTS accurately describing the material, and condition of the parts. Use of spare parts shall be contingent upon verification by Engineering that materials, tolerances, process conditions and design match the parts being replaced.

11.4 An assigned Replacement SPARE RV shall be set and maintained to replace a particular RV, as per SAES-J-600 paragraph 8.15. It shall meet the manufacturer's, Code, and Saudi Aramco specifications for the service intended. The design shall be identical to the in-service RV being replaced.

11.4.1 The SAP system shall reflect the Installation/Spare Code status by entering the appropriate spare code in the SA 3099A-ENG INSTALLATION/SPARE CODE field (i.e.; INIS, OFSP). See SAEP-1131.

11.4.2 The Assigned Replacement SPARE RV shall have: it's own RV number, the T&I interval shall be the same as the RV that it replaces and a shop test conducted within one week prior to the SPARE RV being placed in service.

11.4.3 A Relief Valve Authorization, Form SA 3099A-ENG shall be authorized by the Operations Superintendent and Supervisor of Operations Engineering Unit for the SPARE to be activated. This will update its status from SPARE (entry codes INIS, OFSP) to ACTIVE (code INON), as well as update the new location and service.

11.5 SPARE RVs in open stock (General use) are used RVs that are maintained in the Shop inventory with no service assigned. The Data Base record and number are kept current, the RV is put on Mothball status, and the RV should be moved to the designated spare Functional Location. The Relief Valve Authorization, Form SA 3099A-ENG is completed as a "change" authorization.

When an open stock SPARE is to go into service it shall meet all the requirements of Section 11.4.3 above.

12 Pressure Testing RVs

Pressure Testing RVs shall be administered as follows:


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12.1 Each RV shall be assigned with a serial number for tracking and record purposes.

12.2 Each RV shall have a history log file. This file should include the RV Engineering data, and components (i.e.; spring), changes and updates.

12.3 TEST RVs used for PRESSURE TESTING shall be identified with a corrosion resistant metal tag, as described by Section 9, and stamped as follows:

"TEST RV"

Spring Number _______________

Set Pressure _______________

Test Date _______________

12.4 The TEST RV must not be stamped.

12.5 The TEST RV shall not have a data base RV number assigned to it.

13 Mothballed RVs

13.1 A RV in a mothballed facility shall remain in SAP system under Relief Valve equipment category.

13.2 The SAP system RV data is put on "MOTH status" by the RV Administrator under the User Status. Test and inspection are not required provided the facility is properly mothballed. The condition of the mothballed facility shall be periodically reviewed in order to determine if RV inspection and preventive maintenance is needed.

13.3 The Maintenance Plan (Maintenance Order) shall be put on "INAK" status, i.e., Inactive, by the responsible Plant Maintenance Plan Processor.

13.4 The SAP system RV data of a mothballed RV can not be changed/updated as long as the RV is in the "mothballed" status. The maintenance data records can not be updated if the RV is mothballed.

13.5 To reactivate mothballed RVs, use an Authorization Form SA 3099A-ENG or formal correspondence (if more than 5 RVs) to put the SAP system for RVs on "Active" status.

13.6 When a MOTHBALLED RV is to be reactivated, it shall be inspected, tested, and the Maintenance Plan in the SAP system status "activated" and the RV


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master record shall be put as "Approved" in the User Status by the RV Administrator prior to the RV use.

14 Test and Inspection Interval Determination

Testing, inspection and interval determination shall be performed according to the requirements found in Section 5 of SAEP-319, Pressure Relief Valves Routine Tests and Inspection.

15 Surge Relief Valves (SR)

15.1 The selection, sizing and installation of surge relief valves shall be in accordance with SAES-J-605.

15.2 The Authorization procedure for surge relief valves is the same as for all other RVs. Surge Relief valve is tracked as a RV in SAP system under "R" category and is identified as "SR" in the equipment data record of SAP and on the RV Authorization Form SA 3099A-ENG.

15.3 The Authorization procedure for single or multiple installations of surge relieving devices requires approval by submitting an authorized Form SA 3099A-ENG. The relief Valve Authorization Forms shall be accompanied by a certified and approved Instrumentation Specification Sheet, Form SA 8020-605-ENG, showing the capacity calculations as stipulated in SAES-J-605.

Revision Summary 31 October, 2004 Major revision.


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Originator Supervisor Operations Engineering & Operations SuperintendentReviews and approves SA-3099A-ENG.

Prepares SA-3099A-ENG. Includesreason(s) for deletion in the form remarks Assures that the equipment being protected is permanentlysection. dismantled or the RV is lost.

Operations Inspection Supervisor/RV CoordinatorRequests authorization approvals. Reviews and signs SA-3099A-ENG.

Verifies that the RV has been removed from service.

Operations ForemanRequests names and signatures in the Verifies that the RV has been removed from service.Verification section of SA-3099A-ENG.

Signs off the Verification section of SA-3099A-ENG.

Maintenance, RV Test Shop or Contractor ShopVerifies RV against SA-3099A-ENG.

Initiates RV removal (use PM02 Order). Performs RV work by removing the RV from service and removesFollows RV master data records all identification tags and stamping.deletion. Dismantles the functional location of the RV from SAP system.

Sets the RV Maintenance Plan to INACTIVE "INAK" status inRequests RV master data records SAP system.approvals. Reports work to Originator and RV Coordinator.

If the RV can be used for SPARE parts, then the records are Follows RV field deletion/removal. manually maintained by the RV Shop.

RV AdministratorSends copy of the approved SA-3099A- Reviews SA-3099A-ENG DELETION REQUESTS.ENG to the RV Administrator for deletion Checks RV Maintenance Plan for "INAK" in SAP system.from SAP system. Sets Deletion Flag for the RV record in SAP system.

Reports action to the Originator and RV Coordinator.

Local RV CoordinatorSends original, approved & verified Assists Originators in RV work flow and issues.SA-3099A, and 3750-ENG forms to Maintains RV data record in SAP system.local RV Coordinator. Verifies that the RV record has been deleted from SAP system.

Files the Deleted RV documents in the RV DELETION FILE.

Chart III - Retirement (Deletion) Of RV From Service

1

2

3

4

9

10

7

8

5

6

11

12

Documents

SAEP-318