Saudi Aramco Standards

Engineering Procedure
SAEP-1132 30 June 2014

Instructions for Using the Relief Valve Test Stand
Document Responsibility: Inspection Engineering Standards Committee
Saudi Aramco DeskTop Standards

Table of Contents
1 Scope................................................................. 2
2 Purpose.............................................................. 2
3 Conflicts and Deviation..................................... 3
4 Applicable Documents....................................... 3
5 Definitions & Acronyms.................................... 4
6 Instructions......................................................... 9
Figure I - Typical Safety Relief Valve Test Facility

Using Air or Nitrogen as Test Medium......... 17
Figure II - API STD 527 Test Apparatus
for RV Metal to Metal Seat Leak Testing..... 18
Figure III - Test Apparatus for Pilot RV
Adjustment and Testing............................... 19
Figure IV - Test Apparatus for Tank Breather
Adjustment and Testing............................... 20
Table I - Tolerances for Set Pressure

of Pilot/Safety Relief Valves......................... 21
Table II - Leakage Rates for Pilot/Safety
Relief Valves with Set Pressures
to 1000 psig (6895 kPa)............................... 21
Table III - Maximum Seat Leakage Rate
(Bubbles Per Minute) for Set
Pressure Over 1000 psig............................. 22
Appendix A – RVTS Minimum Requirements … 23
Previous Issue: 1 July 2008 Next Planned Update: 30 June 2019

Page 1 of 23
Primary contact: Kakpovbia, Anthony Eyankwiere on 966-13-8801772
Copyright©Saudi Aramco 2014. All rights reserved.

Document Responsibility: Inspection Engineering Standards Committee SAEP-1132
Draft Date: 30 June 2014
Next Planned Update: 30 June 2019 Instructions for Using the Relief Valve Test Stand
1 Scope
1.1. This Saudi Aramco Engineering Procedure (SAEP) defines the instructions and
requirements for using Relief Valve Test Stands (RVTS) during testing and
maintenance of Pressure Relief Devices (PRD) in Saudi Aramco operating
facilities.
1.2. This procedure applies to shop testing of all pressure relief devices defined in
SAEP-318.
1.3. RVs in Saudi Aramco operating facilities which are to be tested by third party
RV Shop shall be tested according to the requirements of this SAEP.
1.4. RVs which are on or a part of equipment owned and operated by Contractors
within Saudi Aramco Operating Units shall be tested and inspected in
accordance with this Procedure.
1.5. Buckling Pin and Surge Relief Valves which have an approved separate In-
Place Test Procedure as per SAEP-319 are excluded from this procedure.
2 Purpose
2.1 The test stand shall have a volume large enough to provide reliable RV
adjustment and pressure testing at the specified, Cold Differential Test Pressure
(CDTP) within the tolerances set by the applicable Code.
2.2 For gas service, a test stand must be able to cause a sharp pop of the RV for the
test to be valid. Simple opening and passing of air or nitrogen is not acceptable.
The gas service test stand design described in this Procedure is intended to
provide a sharp pop action with minimum altering of the blowdown ring
adjustment. However, the blowdown ring may be adjusted to assist in achieving
a valid pop action for the test. Upon these occasions it is essential that the
blowdown ring be returned to its original operating position upon completion of
the test.
2.3 The RV test stand shall provide sufficient capacity to adequately verify the
pressure at which the RV pops without damaging the valve trim. Insufficient
volume, poor pressure control, inaccurate gauges or contaminated test media
may cause unreliable testing and/or additional maintenance. Test stand design is
intended to produce a pop action, because a pre-simmer action is not the true
opening pressure of a gas service RV, by manufacturer's definition. This pre-
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simmer test method can result in a 10-15% difference in the actual popping
pressure. RV manufacturers have recommended that "lift restrictors" be used
for testing even with the Saudi Aramco test stand.
2.4 To ensure RVs remain in good physical condition and comply with all
requirements of this procedure for external condition as specified in Appendix
E.
2.5 To ensure roles and responsibilities for RV Testing and Maintenance are
outlined and auditable.
2.6 It is not the purpose of a Saudi Aramco test stand to adjust blowdown for boiler
valves because the test stand volume is too low. Blowdown adjustments shall be
made with an approved RV IN-PLACE Procedure. See SAEP-319.
3 Conflicts and Deviations
3.1 Waivers
Direct all requests to waive the requirements of this Procedure in writing

according to internal company procedure SAEP-302 to the Manager, Inspection
Department of Saudi Aramco, and Dhahran.
3.2 Deviations
Any required deviation from the requirements of this procedure shall be

reviewed and approved by the Inspection Department Manager.
4 Applicable Documents
The requirements contained in the following documents apply to the extent specified in
this procedure.
4.1 Saudi Aramco References
Saudi Aramco Engineering Procedures

SAEP-20 Equipment Inspection Schedule
SAEP-318 Pressure Relief Valve Program Authorization for
Installation, Deletion and Changes
Page 3 of 23
SAEP-319 Pressure Relief Valves - Routine Test, Inspection,

Quality Assurance & Regulation
SAEP-1134 Relief Valve Technician Certification
Saudi Aramco Engineering Standards

SAES-D-001 Design Criteria for Pressure Vessels
SAES-J-600 Pressure Relief Devices
Definitions & Acronyms
4.2 Industry Codes and Standards
American Petroleum Institute

API STD 527 Seat Tightness of Pressure Relief Valves
American Society of Mechanical Engineers

ASME SEC VIII D1 Rules for Construction of Pressure Vessels
5 Definitions & Acronyms

Car seal - A locking seal that when placed in position and closed, locks and must be cut
or physically broken to be removed.
Galling - A condition whereby excessive friction between high spots results in localized
welding with subsequent splitting and a further roughening of rubbing surfaces of one
or both of two mating parts.
Non-reclosing pressure-relief device - A pressure-relief device, which remains open

after operation. A manual resetting means may be provided.
Pin-Actuated Device - A non-reclosing pressure-relief device actuated by static

pressure and designed to function by buckling or breaking a pin which holds a piston or
a plug in place. Upon buckling or breaking of the pin, the piston or plug instantly moves
to the full open position.
Effective Discharge Area - A nominal or computed area used with an effective

discharge coefficient to calculate the minimum required relieving capacity for a
pressure-relief valve per the preliminary sizing equations contained in API 520. Refer to
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API 520-1 for the preliminary sizing equations. API 526 provides effective discharge
areas for a range of sizes in terms of letter designations, “D” through “T.”
Huddling Chamber - An annular pressure chamber located downstream of the seat of a

pressure-relief valve, for the purpose of assisting the valve to achieve lift.
Inlet Size - The nominal pipe size (NPS) of the relief device at the inlet connection,
unless otherwise designated.
Lift - The actual travel of the disk away from the closed position when a pressure-relief
valve is relieving.
Outlet size - The nominal pipe size (NPS) of the relief device at the discharge
connection, unless otherwise designated.
Accumulation - The pressure increase over the MAWP of the vessel allowed during
discharge through the pressure-relief device, expressed in pressure units or as a
percentage of MAWP or design pressure. Maximum allowable accumulations are
established by applicable codes for emergency, operating, and fire contingencies.
Design pressure - The design pressure of the vessel along with the design temperature
is used to determine the minimum permissible thickness or physical characteristic of
each vessel component, as determined by the vessel design rules. The design pressure is
selected by the user to provide a suitable margin above the most severe pressure
expected during normal operation at a coincident temperature. It is the pressure
specified on the purchase order. This pressure may be used in place of the MAWP in all
cases where the MAWP has not been established. The design pressure is equal to or less
than the MAWP.
Maximum Allowable Working Pressure (MAWP) - The maximum gauge pressure

permissible at the top of a completed vessel in its normal operating position at the
designated coincident temperature specified for that pressure. The pressure is the least
of the values for the internal or external pressure as determined by the vessel design
rules for each element of the vessel using actual nominal thickness, exclusive of
additional metal thickness allowed for corrosion and loadings other than pressure. The
MAWP is the basis for the pressure setting of the pressure-relief devices that protect the
vessel. The MAWP is normally greater than the design pressure but can be equal to the
Page 5 of 23
design pressure when the design rules are used only to calculate the minimum thickness
for each element and calculations are not made to determine the value of the MAWP.
Maximum Operating Pressure - The maximum pressure expected during normal

system operation.
Overpressure - The pressure increase over the set pressure of a pressure relief of a
relieving device allowed achieving rated flow. Overpressure is expressed in pressure
units or as a percentage of set pressure. It is the same as accumulation only when the
relieving device is set to open at the MAWP of the vessel.
Rated Relieving Capacity - The relieving capacity used as the basis for the application
of a pressure-relief device. This capacity is determined in accordance with the
applicable code or regulation and is provided by the manufacturer. NOTE the capacity
marked on the device is the rated capacity on steam, air, gas, or water as required by the
applicable code.
Stamped Relieving Capacity - The rated relieving capacity that appears on the device
nameplate and based on the rated relieving capacity determined at the specified set
pressure or burst pressure plus the allowable overpressure.
Backpressure - The pressure that exists at the outlet of a pressure-relief device as a

result of the pressure in the discharge system. It is the sum of the superimposed and
built-up backpressures.
Blowdown - The difference between the set pressure and the closing pressure of a
pressure-relief valve, expressed as a percentage of the set pressure or in pressure units.
Built-Up Backpressure - The increase in pressure at the outlet of a pressure-relief

device that develops as a result of flow after the pressure relief device opens.
Burst Pressure - The burst pressure of a rupture disk at the specified temperature is the
value of the upstream static pressure minus the value of the downstream static pressure
just prior to when the disk bursts. When the downstream pressure is atmospheric, the
burst pressure is the upstream static gauge pressure.
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Burst-Pressure Tolerance
The variation around the marked burst pressure at the specified disk temperature in
which a rupture disk will burst.
Closing Pressure - The value of decreasing inlet static pressure at which the valve disc
reestablishes contact with the seat or at which lift becomes zero, as determined by
seeing, feeling or hearing.
Cold Differential Test Pressure (CDTP) - The pressure at which a pressure-relief

valve is adjusted to open on the test stand. The CDTP includes corrections for the
service conditions of backpressure or temperatures or both.
FAT- Factory Acceptance Test
SAT- Site Acceptance Test
Leak-Test Pressure - The specified inlet static pressure at which a seat leak test is
performed.
Manufacturing Design Range - The pressure range at which the rupture disk shall be
marked. Manufacturing design ranges are usually catalogued by the manufacturer as a
percentage of the specified burst pressure. Catalogued manufacturing ranges may be
modified by agreement between the user and the manufacturer.
Marked Burst Pressure Or Rated Burst Pressure - The marked burst pressure or
rated burst pressure of a rupture disk is the burst pressure established by tests for the
specified temperature and marked on the disk tag by the manufacturer. The marked
burst pressure may be any pressure within the manufacturing design range unless
otherwise specified by the customer.
The Marked Burst - pressure is applied to all the rupture disks of the same lot.
Opening Pressure - The value of increasing inlet static pressure whereby there is a
measurable lift of the disk or at which discharge of the fluid becomes continuous, as
determined by seeing, feeling or hearing.
Set Pressure - The inlet gauge pressure at which a pressure-relief valve is set to open
under service conditions.
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Simmer - The audible or visible escape of compressible fluid between the seat and disc,
which may occur at an inlet static pressure below the set pressure prior to opening.
Specified Burst Pressure - The specified burst pressure of a rupture disk is the burst
pressure specified by the user. The marked burst pressure may be greater than or less
than the specified burst pressure but shall be within the manufacturing design range.
The user is cautioned to consider manufacturing range, superimposed backpressure and
specified temperature when determining a specified burst pressure.
Superimposed Backpressure - The static pressure that exists at the outlet of a

pressure-relief device at the time the device is required to operate. It is the result of
pressure in the discharge system coming from other sources and may be constant or
variable.
Pressure-Relieving Devices - Pressure-relieving devices protect equipment and

personnel by automatically opening at predetermined pressures and preventing the
adverse consequences of excessive pressures in process systems and storage vessels. A
pressure-relief device is actuated by inlet static pressure and designed to open during
emergency or abnormal conditions to prevent a rise of internal fluid pressure in excess
of a specified design value. The device may also be designed to prevent excessive
internal vacuum. The device may be a pressure-relief valve, a non-reclosing pressure
relief device, or a vacuum-relief valve.
Common examples include direct spring-loaded pressure-relief valves, pilot-operated

pressure-relief valves, rupture disks, weight-loaded devices, and pressure- and/or
vacuum-vent valves.
Pressure-Relief Valve - A pressure-relief valve is designed to open for the relief of

excess pressure and reclose thereby preventing further flow of fluid after normal
conditions have been restored. A pressure-relief valve opens when its upstream pressure
reaches the opening pressure. It then allows fluid to flow until its upstream pressure
falls to the closing pressure. It then closes, preventing further flow. Examples of
specific types of pressure-relief valves include: safety valve, relief valve, conventional
safety-relief valve, balanced safety-relief valve, and pilot-operated pressure-relief valve.
Safety Valve - A safety valve is a direct spring-loaded pressure-relief valve that is

actuated by the static pressure upstream of the valve and characterized by rapid opening
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or pop action. When the static inlet pressure reaches the set pressure, it will increase the
pressure upstream of the disk and overcome the spring force on the disk. Fluid will then
enter the huddling chamber, providing additional opening force. This will cause the disk
to lift and provide full opening at minimal overpressure. The closing pressure will be
less than the set pressure and will be reached after the blowdown phase is completed.
The spring of a safety valve is usually fully exposed outside of the valve bonnet to
protect it from degradation due to the temperature of the relieving medium. A typical
safety valve has a lifting lever for manual opening to ensure the freedom of the working
parts. Open bonnet safety valves are not pressure tight on the downstream side.
6 Instructions
6.1 Pre-Test Requirements
6.1.1 Relief Valve Test Stand (RVTS) General Requirements:-

a) The RVTS must be adequately sized to ensure RV action is consistent
with the set pressure and tolerances required for reliable RV performance.
b) The RVTS used in Saudi Aramco Facilities shall be approved by

Inspection/OID/IEU.
c) The RVTS shall have an assigned Saudi Aramco equipment number.
d) As built drawings, Safety Instruction Sheet, and Design Data Form shall
be available and entered into the SAO drawing system by the User.
e) If a test drum is included in the RVTS design, the test drum shall have an
approved Equipment Inspection Schedules (EIS) per SAEP-20 with a
maximum of 60 months interval.
6.1.2 Relief Valve Test Stand (RVTS) Pressure Gauges:-

a) The test gauges shall have a range of 1.25 to 2.0 times the RV CDTP set
pressure.
b) Gauges shall have scale markings in the same measurement units as those
of the RV set pressure shown on the. Conversions between units shall not
be made. The gauge scale definition shall be adequate to determine the
pressure tolerances.
c) All gauges must have evidence of calibration within three months.
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d) Re-calibrate gauge if it appears to be functioning improperly.
e) New gauges shall be calibrated before use.
f) Gauge calibration procedures shall be included or referenced in the QA

document, as required in SAEP-319. The procedure shall include
calibration stickers and a calibration log for scheduling to assure the task
is performed and the responsibility is defined.
g) Units for installed gauges shall be Standard Units (Refer to SAEP-1131).
6.2 Test Stand Requirements
6.2.1 Test stand control valve configuration and/or regulators shall be

designed for the necessary control needed for leak testing and low set
pressures.
6.2.2 A Vacuum pump shall be included in the Test Facility where vacuum
type breather valves are maintained.
6.2.3 All fabricated flange adapters shall be approved by RVTS manufacturer

prior to use.
6.2.4 Adapter plates and special fixtures shall be readily available for
mounting and testing the various types of RVs being maintained.
6.2.5 The pilot of Pilot RVs may be adjusted using the gas test stand or a
specialized pilot test stand.
6.2.6 A single unit with capacity to test multiple services (gas and liquid) is
acceptable provided purging capacity is built in.
6.2.7 Accumulator tank size specification and other design specification shall
be adequate to prevent RV seat hammering.
6.2.8 Computerized test bench is an optional requirement.
6.2.9 Any modification to the original design of the RVTS shall include:
a) proponent approved engineering package
b) MOC document.
Page 10 of 23
c) OID re-validation, if the modification exceeds the maximum design

pressure limit.
6.3 Safety Requirements

6.3.1 RVTS shall be installed in safe location away from shop traffic with
adequate barrier to protect personnel not involved with the RV testing.
6.3.2 RVTS shall be equipped with an anchor nut and specification of

recommended anchor bolt provided in the design package.
6.3.3 The Test Stand shall be rigid/safe on the appropriate holders.
6.3.4 A safety RV to protect the piping from overpressure.
6.3.5 T-claws and hydraulic clamping mechanism are installed.
6.3.6 Interlock device is installed to prevent release of the clamping pressure

unless test pressure is first released.
6.3.7 Safe venting and pressure release system installed.
6.3.8 Safety shatter resistant screen between the RV Test Technician and the
clamp bench installed.
6.3.9 An approved Equipment Inspection Schedule (EIS) exist for the RV Test
Stand.
6.3.10 Noise suppression shall be used when necessary to maintain safe

working conditions, as required by Industrial Hygiene measurement of
sound levels. Exhaust piping, mufflers or hose shall be large enough to
prevent back pressure rise, and shall be vented to a safe location. Noise
suppression may be by vertical upward venting, venting to a large
insulated baffle chamber, or any other method acceptable to local Loss
Prevention.
6.3.11 Ensure visual and audible safety alarms in the RVTS are available.
6.4 Preventive Maintenance

6.4.1 Annual external inspection checklist shall be developed by the proponent
in accordance with RVTS manufacturer recommendation and Appendix
A.
Page 11 of 23
6.4.2 Preventive maintenance plan shall meet the RVTS manufacturer

recommendation.
6.4.3 Minimum Spare parts for the test stand shall be maintained.
6.5 Test Stand Operation

a) A test stand operating procedure shall be prepared and included in the
RV Shop QA Manual. The procedure shall be based on the RVTS manufacturer
recommended operating procedure and shall be approved by the facility
manager. The procedure shall include safety requirements such as eye and ear
protection, safe tool operation, and installation of air compressor filters. Refer
to the testing requirements of SAEP-319, and RV manufacturer repair manuals
to prepare a complete procedure.
b) A Certified RV Technician, as defined by SAEP-1134, shall operate the

Test Stand or be present.
c) RVs in liquid service can be tested with gas or liquid.
d) RV's in vapor, air, gas, or a combination of liquid and gas service shall
only be tested with gases (air or nitrogen).
e) RVs in boiler steam service may have the initial pop pressure set
in the Test Shop using air, but the final pressure and blow-down setting shall be
made with steam, on the boiler using an approved In-place Procedure, as defined
in SAEP-319 Section.
f) The following is an example instruction for testing a gas service

spring actuated RV on the typical RV Test Stand illustrated in Figure I of this
SAEP.
g) Before using the RV test stand eliminate loose particles in the system by
air blowing. These is done by closing valves V4 and V5, open valve V2 and
V6, and to alternately open and close valve V1 until no particles are visually
seen. Close test nozzle valve (V2) after flushing.
h) Testing begins with mounting the RV to the test nozzle flange.
i) Attach noise suppression line to RV outlet.
j) Open test nozzle valve (V2) and close the bleed valve.
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k) Open the pressure gauge valve for the appropriate pressure range.
l) Close all other pressure gauge isolation valves.
m) Increase pressure in test drum to 90% of cold differential test pressure

(CDTP)
n) by opening valve V1. WARN Shop personnel of high noise level test.
o) Close valve V1 and use small bypass valve V8 to increase pressure

smoothly and continuously until the RV pops or CDTP tolerance is reached;
BUT NEVER HIGHER THAN 10% OVER THE CDTP.
p) Close valve V8 and record pop pressure/results. Compare to allowable

tolerances, shown in Table 1 of this Procedure.
q) Based on test results and Work Order, either disassembles, accept,

rework or readjust the RV. Perform a final verification test. Proceed with the
leak testing; see Section 5 for a representative procedure.
r) Remove the RV when testing is completed by first closing test nozzle

valve (V2).
s) Reduce stand pressure to 75% of the CDTP of the next valve.
t) Open bleed valve on test nozzle valve (V2) outlet and release pressure
under tested RV.
u) Remove tested relief valve and install next valve to be tested.
v) Go to operation for next test.
w) After ALL testing is complete, shut in the test stand by blowing down
the drum through valve V6. After verifying there is no pressure in the drum,
close the test gauge valve that was in use.
x) While the test stand is not in use, close valves V1, V2, V4, V5 and V8.
Open valve V6 or designate one valve that remains open when the test stand is
not in use.
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6.6 Seat Leakage Testing
6.6.1 Leak testing is mandatory, and is conducted as required in SAEP-319.

Leakage is measured through the seat to disk seal while the RV is at 90% of
CDTP. The test is conducted on the RV test stand.
6.6.2 The seat leakage test shall be conducted in accordance with API STD
527.
6.6.3 Attach the special flange and water bubbler (it shall be designed with a
rupture seal that will vent full flow in the event the RV should open), as per
Figure II, and seal all other RV body outlets or vents.
6.6.4 Hold 90% of CDTP for the required test period as follows:
 One minute for 0.5" to 2" RV inlet size
 Two minutes for 2.5" to 4" RV inlet size
 Five minutes for all other larger inlets sizes
6.6.5 Compare BUBBLES PER MINUTE leakage rate to the acceptance

criteria, as follows:
 Appendix Table II for RV's with CDTP up to 1000 psig.
 Appendix Table III for RV's with CDTP over 1000 psig.
6.6.6 When the RV body can not be sealed for the API STD 527 test method
(such as an open bonnet RV design) then use the Half Gasket Dam Leak Test
Method.
 Cover the lower half of the outlet flange with a half gasket or a
fabricated device that allows the body cavity to be partially filled with
water.
 Fill the body cavity with water to cover the seating joint.
 Raise the test bench pressure to 90% of the CDTP set pressure and look
for evidence of bubbling from the seating joint. Use a mirror to observe
the activity; NEVER LOOK DIRECTLY INTO A RV OUTLET
Page 14 of 23
WHILE IT IS UNDER PRESSURE. No bubbles are acceptable with

this method.
6.6.7 For small screwed RVs, attach an elbow on the outlet, and fill the body
cavity and the elbow with water. Raise the test bench pressure to 90% of the
CDTP set pressure and look for evidence of bubbling at the open elbow. Never
look directly into the elbow while it is under pressure. No bubbles are
acceptable with this method.
6.6.8 The maximum test pressure for RVs tested in the RVTS shall be
specified and included in the Quality Assurance (QA).
6.6.9 Dryness procedure for RVs tested in liquid shall be available and
included in the Quality Assurance (QA).
6.7 Post-Test Requirements

All post tests shall comply with SAEP-319 and SAEP-1133.
6.8 Special Considerations
6.8.1 Use a lift restrictor to limit the disk travel when momentum forces cause
hammering damage to the disk. Dresser Consolidated recommends 1900 Series
valves with orifice sizes D and greater be tested with lift restrictors. Crosby also
state that their valves should be tested with lift restrictors. Contact OID/ID,
Dhahran for fabrication and adjustment details.
6.8.2 Avoid testing with incorrect test equipment. Contact OID or Dhahran
Shops, Planning and Coordinating Unit, Dhahran, if assistance is needed in
locating a RV Shop with a larger capacity or specialized test equipment.
6.8.3 Steam boiler safety valves shall not have the blow down adjusted on a
test bench.
6.9 Specialty RV Testing Devices
6.9.1 Specialized RV testing Devices, such as direct spring assist units, shall
be ASME stamped. Inspection Department and P&CSD approval is required and
concurrence by Loss Prevention prior to using the equipment.
6.9.2 A direct spring assist device should incorporate precise, accurate and
repeatable pressure recording, as a minimum.
Page 15 of 23
6.9.3. An approved written Operating Procedure shall be developed by the

User's Engineering Unit that includes calibration details, limitations, Operator
training, and tolerance requirements. Approval shall be required by the
Manager of the Inspection Department, Process & Control Systems Department,
and concurrence from Loss Prevention.
Revision Summary
30 June 2014 Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued
with no other changes as major revision.
Page 16 of 23
gauges and/or digital read out

discharge pipe/hose
00000
MULTIFIT TEST FLANGE

WITH 2" ORIFICE AND
V5
ADAPTERS
vent/drain
V4
bleed
valve
V1
V2 2"
2"
TEST DRUM 2"

min. 5 cubic feet 1/2"
12” min. diameter or
RV for more
vessel V8
V6
V6
drain
flanged ends for

internal coating PRESSURE SOURCE
Figure I – Typical Safety Relief Valve Test Facility Using Air or Nitrogen as Test Medium
Page 17 of 23
blind/plate
pressure blowout
hole in plate
tube
water cup
Leak tester
for
screwed
connection
Figure II – API STD 527 Test Apparatus for RV Metal to Metal Seat Leak Testing
Attach the blind/plate to the RV outlet and seal all other body ports so that the only available
gas exit from a seat leak is through the water trap.
Use the half gasket leak test method if body ports can not be sealed. With this method, the
outlet is partially covered or an elbow is attached to permit filling of the body cavity with
water. Leaking seats will cause bubbles in water. With this method NO LEAKAGE IS
PERMITTED.
Page 18 of 23
vent
set pressure adjustment
Dome pressure
indicator
Pilot valve
Exhaust vent
Support Blowdown
adjusment
Accumulator, 5 cu. ft.
Inlet supply
pressure indicator
Pressure supply
Figure III – Test Apparatus for Pilot RV Adjustment and Testing
Page 19 of 23
Manometer
Multi-fit test flange on legs

with 0.75" orifice; connected
to pressure and vacuum sources
Vent
Pallet Access
T a n k B re a th e r
Vacuum Port
L o w P r e s s u r e S u p p ly
V a cuum S ource
Figure IV – Test Apparatus for Tank Breather Adjustment and Testing
Mount breather on test flange after disassembly, cleaning and repairs are complete.
1. Replace all soft goods, and restore seating surfaces.
2. Pallets should be checked for free movement before testing.
3. Verify that weighted pallets have not been altered. Apply the correct pressure, and verify pressure when
pallets opens.
4. Isolate pressure source, and apply vacuum. Verify vacuum pressure when pallet lifts.
Page 20 of 23
Table I – Tolerances for Set Pressures of Pilot/Safety Relief Valves
(In English Units to Conform to ASME Code Requirements)

Set Pressure (CDTP) POP Pressure OK if
0 to 100 psi (0-690 kPa) ± 2 psig (14 kPa)
over 200 psi (1379 kPa) ± 3 psig (21 kPa)
for every hundred psig
Steam Safety Valves

Set Pressure (CDTP) POP Pressure OK if
0 to 70 psi (0-483 kPa) ± 2 psi (14 kPa)
71 to 300 psi (490-2068 kPa) ± 3%
301 to 1000 psi (2075-6895 kPa) ± 10 psi (70 kPa)
over 1000 psi (6902 kPa) ± 1%
NOTES: 1. NEVER CONDUCT A TEST HIGHER THAN 10% OVER THE CDTP.
2. NEVER CONDUCT A TEST ABOVE THE TEST STAND MAWP.
Table II – Leakage Rates for Pilot/Safety Relief Valves

with Set Pressures to 1000 psig (6895 kPa)
Standard Standard Cubic

Type of Manufacturer's Bubbles Cubic Ft. Meters Per
Valve Orifice Size Per Min. Per 24 Hrs 24 Hrs.
Conven- F & smaller 40 0.60 0.017
tional G & larger 20 0.30 0.0085
Page 21 of 23
Table III – Maximum Seat Leakage Rate (Bubbles Per Minute)

for Set Pressure Over 1000 psig
300
250
200
150
BUBBLES PER MINUTE, MAX.
100
90
80
ER
70
LL
A
SM
60
&
F"
."
IF
R
50
O
40
ER
G
R
LA
30
&
"
G
."
IF
R
O
20
1000 1500 2000 2500 3000 4000 5000 6000
(6.9) (10.3) (13.8) (17.2) (20.7) (27.6) (34.5) (41.4)
SET PRESSURE , PSIG (MPa)
Page 22 of 23
APPENDIX A
RVTS Minimum Requirements of Approval
1) Annual External Inspection Plan:
Availability of the annual external inspection and preventive maintenance plan for
the test stand according to the manufacturer’s FAT Check and Test Plan checklist.
The following safety features of the test stand shall be included in the annual
external inspection check list:
 T-claws and hydraulic clamping mechanism.

 Venting and pressure release system.
 Safety screen between the RV Test Technician and the clamp benches.
 Liquid and gas reservoir tanks.
2) Equipment Inspection Schedule (EIS):
Obtain the approved EIS for the RV Test Stand including the liquid and gas
reservoir tanks based on a maximum of 60 months inspection interval.
3) Test Stand Pressure Safety:
 The RVs for protecting the test stand shall either be tracked in SAP or included
in the test stand preventive maintenance (PM) program.
 The RV testing cycle shall not be greater than 12 months.
4) Pressure Gages’ Specification and Calibration:
 Pressure gauges installed shall have the same units as the tested RVs at all times,
with a range of 1.25 to 2.0 times the RV Cold Differential Test Pressure (CDTP).
 Pressure gauges shall be calibrated every 3 months.
Page 23 of 23

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Engineering Procedure

SAEP-1132 30 June 2014

Saudi Aramco DeskTop Standards

Figure I - Typical Safety Relief Valve Test Facility

Table I - Tolerances for Set Pressure

Previous Issue: 1 July 2008 Next Planned Update: 30 June 2019

Copyright©Saudi Aramco 2014. All rights reserved.

3 Conflicts and Deviations

Direct all requests to waive the requirements of this Procedure in writing

Any required deviation from the requirements of this procedure shall be

4.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-319 Pressure Relief Valves - Routine Test, Inspection,

Saudi Aramco Engineering Standards

4.2 Industry Codes and Standards

American Petroleum Institute

American Society of Mechanical Engineers

5 Definitions & Acronyms

Non-reclosing pressure-relief device - A pressure-relief device, which remains open

Pin-Actuated Device - A non-reclosing pressure-relief device actuated by static

Effective Discharge Area - A nominal or computed area used with an effective

Huddling Chamber - An annular pressure chamber located downstream of the seat of a

Maximum Allowable Working Pressure (MAWP) - The maximum gauge pressure

Maximum Operating Pressure - The maximum pressure expected during normal

Backpressure - The pressure that exists at the outlet of a pressure-relief device as a

Built-Up Backpressure - The increase in pressure at the outlet of a pressure-relief

Cold Differential Test Pressure (CDTP) - The pressure at which a pressure-relief

FAT- Factory Acceptance Test

SAT- Site Acceptance Test

Superimposed Backpressure - The static pressure that exists at the outlet of a

Pressure-Relieving Devices - Pressure-relieving devices protect equipment and

Common examples include direct spring-loaded pressure-relief valves, pilot-operated

Pressure-Relief Valve - A pressure-relief valve is designed to open for the relief of

Safety Valve - A safety valve is a direct spring-loaded pressure-relief valve that is

6.1 Pre-Test Requirements

6.1.1 Relief Valve Test Stand (RVTS) General Requirements:-

b) The RVTS used in Saudi Aramco Facilities shall be approved by

c) The RVTS shall have an assigned Saudi Aramco equipment number.

6.1.2 Relief Valve Test Stand (RVTS) Pressure Gauges:-

c) All gauges must have evidence of calibration within three months.

d) Re-calibrate gauge if it appears to be functioning improperly.

e) New gauges shall be calibrated before use.

f) Gauge calibration procedures shall be included or referenced in the QA

g) Units for installed gauges shall be Standard Units (Refer to SAEP-1131).

6.2 Test Stand Requirements

6.2.1 Test stand control valve configuration and/or regulators shall be

6.2.3 All fabricated flange adapters shall be approved by RVTS manufacturer

6.2.8 Computerized test bench is an optional requirement.

a) proponent approved engineering package

c) OID re-validation, if the modification exceeds the maximum design

6.3 Safety Requirements

6.3.2 RVTS shall be equipped with an anchor nut and specification of

6.3.3 The Test Stand shall be rigid/safe on the appropriate holders.

6.3.4 A safety RV to protect the piping from overpressure.

6.3.5 T-claws and hydraulic clamping mechanism are installed.

6.3.6 Interlock device is installed to prevent release of the clamping pressure

6.3.7 Safe venting and pressure release system installed.

6.3.10 Noise suppression shall be used when necessary to maintain safe

6.4 Preventive Maintenance

6.4.2 Preventive maintenance plan shall meet the RVTS manufacturer

6.5 Test Stand Operation

b) A Certified RV Technician, as defined by SAEP-1134, shall operate the

c) RVs in liquid service can be tested with gas or liquid.