UIC QP INS - 011

Revision: 1
Date: J un 27,05
Unocal Indonesia Co.
PROCEDURE FOR
CALIBRATION &
CERTIFICATION OF
PRESSURE SAFETY
VALVE

Page 1 of 12









PROCEDURE
FOR
CALIBRATION & CERTIFICATION
OF
PRESSURE SAFETY VALVE

UIC QP INS - 011






APPROVAL
Description N a m e Signature D a t e

Approved by


Reviewed by Iman Sugihartoto

June 27, 2005
Revision 1 Suhartono

June 27, 2005

Originator Dedi Iskal
Dec 31, 2002


UIC QP INS - 011

Revision: 1
Date: J un 27,05
Unocal Indonesia Co.
PROCEDURE FOR
CALIBRATION &
CERTIFICATION OF
PRESSURE SAFETY
VALVE

Page 2 of 12



TABLE OF CONTENT

1.0 SCOPE.

2.0 CODE AND STANDARD.

3.0 GENERAL.

4.0 CALIBRATION PREPARATION.

5.0 INSPECTION, TESTING,
MAINTENANCE & SETTING OF PSV IN
THE SHOP.

6.0 INSPECTION, TESTING & SETTING OF
PSV ON EQUIPMENT IN THE SITE.

7.0 CALIBRATION STEP PROCEDURE.

8.0 REPORTING, RECORD &
RECOMMENDATION.

9.0 ATTACHMENT.


UIC QP INS - 011

Revision: 1
Date: J un 27,05
Unocal Indonesia Co.
PROCEDURE FOR
CALIBRATION &
CERTIFICATION OF
PRESSURE SAFETY
VALVE

Page 3 of 12



1.0 SCOPE

This standard covers the procedure for calibration and Migas certification of
Pressure Safety Valve (PSV). It defines as a minimum requirement for inspection,
calibration and certification procedure.

2.0 CODE AND STANDARD

2.1 This procedure shall refer to the latest edition of the following standards
and specification:
API RP 520 part-I Sizing, Selection and Installation of Pressure
Relieving Devices in Refineries.
API STD 526 Flange Steel Pressure Relief Valve.
API STD 527 Seat Tightness of Pressure Relief Valve.
API RP 576 Inspection of Pressure Relieving Devices.
ASME Section VIII Div.1 Boiler & Pressure Vessel Code.
Manufacture guide line for Calibrating and Testing
Migas Regulation No. 84.K/38/DJ M/1998.

3.0 GENERAL

3.1 Purpose of Calibration & Certification.
All Pressure Safety Relief Valve (PSV) operating in Unocal Indonesia
Co. shall be covered by a valid certificate issued by Directorate
General of Oil and Gas of Indonesia Government (MIGAS). Pressure
Safety Valve (PSV) shall be re-inspected, re-calibrated every three
years utilization cycle for maintaining validity of certificate and also to
ensure that the overall mechanical integrity condition of PSV is
reliable and good condition.
If there is any anomalies or alteration should be done during PSVs
services (certificate still valid), which require seal break, the MIGAS
seal break report shall be filled and submitted to MIGAS authority at
least 24 hours afterwards.

3.2 Safety Precaution
PPE shall be worn when required by regulation or by owner and user.
Prior to remove PSV from the system, personal shall report to Control
Room (Production Control Room).
Prepare job safety analysis, work permit, obtain permission to work
from operation personnel responsible in the area to be inspected.


UIC QP INS - 011

Revision: 1
Date: J un 27,05
Unocal Indonesia Co.
PROCEDURE FOR
CALIBRATION &
CERTIFICATION OF
PRESSURE SAFETY
VALVE

Page 4 of 12


4.0 CALIBRATION PREPARATION.

4.1 Data & Documents.
The following datas shall be prepared before performing calibration and
re-certification. The data are as follows:
List of PSVs to calibrated.
Previous Migas certificate (for existing PSV).
Data sheet.
P&ID drawing.
Sizing calculation (orifice area & required capacity).

4.2 Re-Calculation.
Each PSV shall be recalculated for its orifice area and capacity. The
purpose of re-calculation is to determine weather PSV still capable to
handle the current condition equipment operation. Re-calculation shall
conform to API RP 520 Part-I latest edition.

4.3 Equipment and Tools.
Equipment & tool shall be prepared properly prior to calibration the PSV.
Minimum list equipment shall be provided to perform calibration and
recertifications are as follows:
Test Bench complete with valid certificate.
Test Gauge complete with certificate and calibration report.
Tools such as various wrenches, etc.
High pressure hose and pressure regulator.
Tubing and its connections.
Precision lapping & polishing kit.
etc

Consumable goods are as follows:
Teflon (soft seal threaded).
Test Media (Nitrogen gas, Air).
Rust Remover.
Stainless steel wire for sealing.
Identifying plate.
Seal material (lead).
Soft good kit.
etc

4.4 Personnel Qualification.
Personnel who handle the calibration shall be qualified PSV Inspector
certified by Migas or Authorized agency.

UIC QP INS - 011

Revision: 1
Date: J un 27,05
Unocal Indonesia Co.
PROCEDURE FOR
CALIBRATION &
CERTIFICATION OF
PRESSURE SAFETY
VALVE

Page 5 of 12


Personnel who handle re-calculation of orifice area, required capacity
shall be qualified Instrument Expert or Instrument Engineer.
At least 3 (three) years experience for personnel and shall posses a
valid certificate for each qualification.

5.0 INSPECTION, TESTING, MAINTENANCE & SETTING OF PSV IN THE
SHOP.
After a PSV removed from the system, visual inspection shall be conducted
immediately especially deposit, debris, or corrosion product and analyze the
sample for next evaluations.
The PSV shall be handled carefully during transportation to the shop. Rough
handling shall be avoided during the PSV lifted from plant to the shop, because it
can influence at set pressure, leaking, and part deformation that can cause serious
damage.

5.1 Visual Inspection
Visual inspection shall be conducted immediately after the PSV arrive in
shop. Some of important thing should be inspected during dismantling of
the PSV are as follows:
- Condition of flange from pitting, roughness, surface reduction of seat
etc.
- Corrosion and cracking of spring.
- Inspection of bellows at bellows balanced type.
- Set screw position (adjusting bolt, locked nut) and opening at bonnet
too.
- Deposit/corrosion or foreign material at inlet and outlet nozzles.
- Outside condition from atmospheric corrosion or mechanical damage,
check of name plate tag, also seal in still good condition or not.
- Wall thickness measurement of body (if necessary).
- Condition of pilot and associated parts.

5.2 Pressure Testing
Before dismantling, the PSV shall be checking of its pressure popping.
If PSV popping at right pressure the re-popping is not required. But if the
popping pressure higher than set pressure, the PSV is required for re-
popping. Normally the PSV was stuck due to corrosion product.
If the PSV is not popping in its set pressure, the setting pressure may be
improper before or its setting pressure was change during operation. The
setting pressure change can be caused by spring weak.

5.3 Popping test and Tightness test
After dismantling, cleaning, checking all PSV part, recondition or
replacement (if any), and re assembling was conducted, the PSV shall be

UIC QP INS - 011

Revision: 1
Date: J un 27,05
Unocal Indonesia Co.
PROCEDURE FOR
CALIBRATION &
CERTIFICATION OF
PRESSURE SAFETY
VALVE

Page 6 of 12


tested, adjusted, and tighten tested as per required by code, standart, or
government regulation.

6.0 INSPECTION, TESTING AND SETTING OF PSV AT SITE.
Popping test and adjustment can be carried out by using inert gas with bleeder or
special devices.
When the test complete and meet with requirement in code, standard, or
government regulation, the PSV can be seal and operated.

6.1 At Process Unit.
Generally, it is more effective and cheap if performs inspection, services
and testing at shop periodically. But if PSV was installed on clean
operation, low temperature and low pressure, the inspection can be
performed safely and practically at site. The popping test and set pressure
adjustment can be carried out by using inert gas with bleeder or special
devices connection.

6.2 At Boilers.
According to Section I of the ASME Code, the block valve is not
permitted to be installed on safety valves. The inspection, calibration, and
testing must be conducted on site by raising the steam pressure until
popping at it setting pressure.

7.0 CALIBRATION STEP PROCEDURE.

7.1 Prepare all data sheet, P&ID drawing, previous Migas certificate for all
PSVs which be calibrated.

7.2 Prepare PSV test report or Migas form (Laporan Pemeriksaan Teknis
Katup Pengaman).

7.3 Prepare test bench, test gauge, test media, tools and wrenches as required
(test bench, test gauge shall be equipped by valid certificate).

7.4 Report to control room and prepare work permit before commencing the
job. PPE shall be used when required.

7.5 Determine the PSV which will be removed in plant.

7.6 Isolated the PSV by closing the block valve at up stream and down stream
of the PSV (the job shall be conducted by authorized personnel).

7.7 Vent the remaining fluids between PSV and block valve to safe area.

UIC QP INS - 011

Revision: 1
Date: J un 27,05
Unocal Indonesia Co.
PROCEDURE FOR
CALIBRATION &
CERTIFICATION OF
PRESSURE SAFETY
VALVE

Page 7 of 12


7.8 If the block valve is not be installed at down stream, where the down
stream is common header, the discharge line shall be installed blind flange
to avoid spill if the other PSV popping into the header.

7.9 Dismantle all bolts and nuts and lift up the PSV to the Shop.

7.10 Handle PSV with care in straight position as it is a very sensitive
instrument.

7.11 Upon receipt of the valve from service, record the nameplate details.

7.12 Blow out test stand to remove any loose particles from the system. Clean
the valve inlet and place on a test stand. Clamp the valve securely.

7.13 Select a pressure gauge where the Cold Differential Test Pressure (CDTP)
of the valve falls in the middle third of the gauge.

7.14 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.

7.15 Apply pressure slowly to the valve, if the valve gives an indication to lift
before 110% of its CDTP then record the lift pressure. If valve fails to lift
at a pressure of 110% of its CDTP, then no more pressure should be
applied. Record the fact that the valve failed to lift.

7.16 If the valve lifts before 110% of its CDTP and there is no audible or visual
leakage, a seat leakage test may now be carried out in accordance with
API 527 standard.

7.17 Remove pressure from valve inlet.

7.18 If a below 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. though 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.

7.19 Remove valve from test stand, strip, clean and inspect valve consulting the
manufacturers maintenance instructions.

7.20 Test the spring in accordance with A.S.M.E. Section VIII, Division I, UG
136, if adequate test equipment is available. Record spring dimensions.

UIC QP INS - 011

Revision: 1
Date: J un 27,05
Unocal Indonesia Co.
PROCEDURE FOR
CALIBRATION &
CERTIFICATION OF
PRESSURE SAFETY
VALVE

Page 8 of 12


7.21 Consult manufacturers maintenance instructions for information as to
machining and lapping of nozzles and disc, their tolerances, dimensions
and recommended practices.

7.22 Renew any worn or damaged parts with original manufacturers spares.

7.23 Re-assemble valve consulting manufacturers maintenance instruction,
lubricate only as instructed.

7.24 Set nozzle ring to 2-notches and guide ring (if any) level. This will assist
when calibrating the valve giving a good indication of valve lift on the test
stand.

7.25 Secure valve to test stand ensuring valve inlet and test stand are clean.

7.26 Calibrate valve to the CDTP; ensure adjusting bolt lock-nut is tight after
each adjustment.

7.27 Carry out seat leakage test in accordance with API 527 standard, then
remove pressure from valve inlet.

7.28 Adjust nozzle ring and guide ring (if any) to the manufacturers
recommended setting.

7.29 Body test valve to check integrity of gaskets and sealing faces. This is
done in accordance with A.S.M.E Section VIII, Division 1, and UG 136.
Conventional valves are tested by applying pressure through the outlet test
flange. Bellows valves are tested by applying equal pressure through the
outlet test flange and bonnet vent hole at the same time. Inspection carried
out by applying leak detector solution to all gaskets and sealing faces.
There must be no visible sign of leakage. Test pressure to be a minimum
of 30 P.S.I.G.

7.30 If a bellows valve is being tested then a bellows test is repeated.

7.31 All external adjusting points must now be sealed.

7.32 Cover the valve inlet and outlet flanges to protest the sealing faces and to
prevent contamination of the valve.

7.33 Handle valve with care as it is a very sensitive instrument.

7.34 All external adjusting points must now be sealed, and equipped with
identified name plate.

UIC QP INS - 011

Revision: 1
Date: J un 27,05
Unocal Indonesia Co.
PROCEDURE FOR
CALIBRATION &
CERTIFICATION OF
PRESSURE SAFETY
VALVE

Page 9 of 12



7.35 Re-install the PSV which have been sealed by Migas at previous location,
and tighten bolts and nuts on inlet and outlet nozzle.

7.36 Re- Open the block valve at inlet slowly, until fully open, then does the
same for at outlet.

7.37 Calibration is finish


8.0 REPORTING, RECORD AND RECOMMENDATION.

8.1 Reporting.
Each PSV shall has one set of report include P&ID, data sheet, previous
Migas certificate, and include Migas test report ( Laporan Pemeriksaan
Teknis Katup Pengaman ).All report shall be approved by production,
MIQA, and Migas officer for submission to MIGAS for issuing new
certificate.

8.2 Records.
Use computer base system in Microsoft Access or Excel for storing all
data of PSV.

8.3 Recommendations.
Recommendation will be issued if any anomalies finding during
inspection, calibration and re-certification.


















UIC QP INS - 011

Revision: 1
Date: J un 27,05
Unocal Indonesia Co.
PROCEDURE FOR
CALIBRATION &
CERTIFICATION OF
PRESSURE SAFETY
VALVE

Page 10 of 12


9.0 ATTACHMENT.

9.1 Migas Calibration Report.


DEPARTEMEN ENERGI DAN SUMBER DAYA MINERAL
DIREKTORAT JENDERAL MINYAK DAN GAS BUMI

LAPORAN PEMERIKSAAN TEKNIS KATUP PENGAMAN
Nomor :



Perusahaan Pemilik / Pemakai (user/owner) :
Lokasi/ Unit Instalasi (Location/Unit Installed) :

DATA KATUP PENGAMAN/PSV DATA
Nomor Item(PSV Tag No.) :
Pabrik Pembuat (Manufacturer) :
Tipe (Type) Konvensional / Bellows / Pilot :
Model / Ukuran (Model No. / Size) :
Nomor Seri (Serial Number) :
Orifice Area (Calculated / Selected / Designation) :
Tahun Dibuat / Digunakan ( Year Built/Used ) :
Kapasitas Yang Disyaratkan (Required Capacity) :
Kapasitas Katup Pengaman (PSV Capacity) :
Nomor P & ID (P & ID No.) :
Nomor Data Sheet (Data Sheet No.) :
No. SKPP Lama & Tgl. Berakhir (Exp. Date) :

DATA PERALATAN YANG DILINDUNGI
Jenis Peralatan yang dilindungi (Eq. Protected) :
Nomor Item(Tag No.) :
Tekanan Design Peralatan (Design Press/MAWP) :
Tekanan Operasi (Operation Pressure) :
Temperatur Operasi (Operation. Temperature) :
Fluida :

PENGUJIAN KATUP PENGAMAN / PSV TEST
Tekanan Buka (Setting Pressure) :
Back Pressure :
Temperatur Koreksi (Temperature Correction) :
Cold Diff. Test Pressure (Popping Test) :
Uji Kebocoran (Leak Test Pressure) :
Media Untuk Pengujian (Test Media) :
Pengukur Tekanan (Pressure Indicator) :
Kalibarasi Oleh/Tgl. (Calibration By/Date) :
Nomor / Tgl. SKPP Test Bench :
Tempat Pengujian ( Test Location ) :
Tanggal Pengujian (Test Date) :
Pengujian Berikutnya (Exp. Date) :

Diuji oleh Disaksikan oleh
Unocal Indonesia Co. Pelaksana Inspeksi Tambang Migas





Diverifikasi oleh
Kepala Seksi Keselamatan Instalasi


UIC QP INS - 011

Revision: 1
Date: J un 27,05
Unocal Indonesia Co.
PROCEDURE FOR
CALIBRATION &
CERTIFICATION OF
PRESSURE SAFETY
VALVE

Page 11 of 12


9.2 Seal Breaker Report

KEPADA YTH.
DIREKTUR DIREKTORAT TEKNIK
PERTAMBANGAN DAN MINYAK DAN GAS BUMI
J AKARTA

BERITA ACARA
PEMUTUSAN SEGEL MIGAS
NO: / UNOCAL /INS

Pada hari ini, _______________________ tanggal ____________________,
Segel Migas pada Katup Pengaman (PSV) berikut telah diputus.

PSV Tag No : __________________________________
Sertifikat Migas :
Type : Pilot / Conventional/Bellows
Type seat : Metal to Metal / resilient
Set pressure : Psig
Back Pressure : Psig

VESSEL Tag no/ Service : /
M.A.W.P. : Psig
Normal working press : Psig
Normal Working Temp :
o
F

COLD SET Popping pressure : Psig
Reseat pressure : Psig
Leak Test Pressure : Psig
Bubble Count : Per Minute

Alasan pemutusan segel adalah :


Perbaikan / Maintenance yang dilakukan :


Balikpapan, _____________________2005

Seal Breaker Head of Maintenance




( ) (________________)


UIC QP INS - 011

Revision: 1
Date: J un 27,05
Unocal Indonesia Co.
PROCEDURE FOR
CALIBRATION &
CERTIFICATION OF
PRESSURE SAFETY
VALVE

Page 12 of 12