Professional Documents
Culture Documents
References
The American Society of Mechanical Engineers (ASME) Pressure Relief Devices Performance Test Code 25-2001 (PTC 25-2001) The National Board Inspection Code (NBIC) Plant testimonials
A special thanks to J. Alton Cox (Vice Chairman, NBIC Sub-Group Pressure Relief Devices) for his contributions in guidance, and experience.
Definitions NOTE: For the purpose of this paper we are going to define the following as: High Volume test bench PRV Test device with at a minimum capacity volume of 28 Liter [1 cubic foot] test vessel and a minimum piping (between the Test Vessel and the Test Connection for the Valve being tested) diameter of 5 cm [2 inches]. Low Volume test bench PRV Test device with a test vessel less than 28 Liter [1 cubic feet] and a piping diameter (between the Test Vessel and the Test Connection for the Valve being tested) of less than 5 cm [2 inches]. Set Pressure The value of increasing inlet static pressure at which a pressure relief device displays one of the operational characteristics as defined under opening pressure, popping pressure, start-to-leak pressure, burst pressure, or breaking pressure. (The applicable operating characteristic for a specific device design is specified by the device manufacturer.) PTC 25-2001 Opening Pressure The value of increasing inlet static pressure of a PRV at which there is a measurable lift, or at which the discharge becomes continuous as determined by seeing, feeling, or hearing. (For liquid Service) PTC 25-2001 Popping Pressure The value of increasing inlet static pressure at which the disk moves in the opening direction at a faster rate as compared with corresponding movement at higher or lower pressures. PTC 25-2001 Start-to-Leak Pressure The value of increasing inlet static pressure at which the first bubble occurs when a PRV is tested by means of air under a specified water seal on the outlet. PTC 252001 Chatter abnormal rapid reciprocating motion of movable parts of a pressure relief valve in which the disk contacts the seat. PTC 25-2001 First Steady Stream Set pressure for liquid Service Pressure Relief Valves. When gravity overcomes cohesion the water drops straight off the Pressure Relief Valve outlet; an observable, repeatable Phenomenon. NB 18 Cohesion the attraction of like molecules Note: For the purposes of this paper Test Bench, Test Device, Test Stand, and/or Test Unit are interchangeable.
Definitions
Introduction
Testing methods and devices vary widely within the industry when testing for the set point of Pressure Relief Valves. Testing devices within Nuclear Plants range from:
Shop built devices Hand Pumps Manufacturer built test devices Others
Purpose
To discuss some of the different design characteristics and how those design characteristics can affect your set point when testing for the set point of Pressure Relief Valves in both gas and liquid service.
Overview
Importance of following NBIC and ASME PTC-25-2001 recommendations on Internal Contours of Fittings, Adapters, and Reducers between Test Vessel and Test Device Recommended Volume Capacity
PRV Seat Alignment
Air Evacuation
Internal Contours of Fittings, Adapters, and Reducers between Test Vessel and Test Device
ASME PTC 25-2001 states that The pressure relief device to be tested shall be installed on a test vessel with adapter fittings (flanged, screwed, welded, etc.). The NBIC also states that any intervening piping between the test vessel and the pressure relief valve should be as short and straight as possible and be of adequate size to minimize inlet pressure drop. ASME PTC 25-2001 goes on to state that Other adapter fittings may be used provided the accuracy of the test is not affected. ASME PTC 25-2001 and the NBIC recommend that when testing a PRV on a test bench the piping, adapters, and fittings leading up to the test valve need be taken into account in order to minimize the pressure drop as well as minimize the affect of flow turbulence on the final test results.
PTC 25-2001 Recommended Arrangements for Testing Valves with Incompressible fluids
Tapered Inlet
Adaptor
Test Plate
Sharp Corner
Adaptor
Test Plate
Sharp Corner on Inlet may cause turbulence in flow path and result in poor performance from SRV including Flutter or Chatter.
Sharp
Corner
Test Plate
Air Flow
Radius on Inlet eliminates turbulence in flow path and results in consistent performance from SRV without Flutter or Chatter.
Tapered
Test Plate
INLET
Preleak
When Gravity overcomes Cohesion, the Water drops Straight off the PRV outlet. This is Set Pressure. It is an observable, repeatable Phenomenon. Opening Pressure
Gary Caudill with VC Summer is also a strong proponent of high volume testing:
Has seen improved results by using his high volume test bench (3 inch diameter piping along with a 4 cubic foot Stainless Steel test vessel) when compared to the previous method of testing with a low volume test bench.
Accuracy and repeatability of new relief valve test equipment (High Volume) exceeds the capabilities of the old equipment (low volume test unit). A three (3) inch test bench port and accumulator now provides the volume to control relief valve lift at set point more accurately versus the previous reciprocating pump test bench and 3/8 inch tube. The low volume test bench could in some instances only burp the valve before dropping below the lift point. Determination of manufacturers set points (i.e. first steady stream) was subjective, susceptible to inconsistencies and sometimes not achievable.
Air Evacuation
The Air Bubble trapped in the nozzle between the disc and the water Causes the first Test to give an inaccurate reading The trapped air beneath the seat of a PRV installed on a test bench skews the first As Found test Goal: Utilize the first pop as an actual documented Set Point Reading Eliminate the Air pocket Compressed Air generates a burp of compressible fluid just ahead of the liquid which follows it out of the PRV (Pre Conditioning) Has the effect of yielding something other than a steady stream as required by PTC 25 As Found set point may be different from expected
Air Evacuation
There are a couple methods commonly used to evacuate the compressed air out of the PRV prior to initiating the test.
One of these methods is to literally rotate the entire valve and clamping station 180 degrees in order to allow the air to escape, sometimes referred to as pre-conditioning the valve.
This method is effective but can be tedious and time consuming.
Another method commonly used is to implement a test plate adapter with a bleed valve that is placed in between the test plate itself and the test valve. One then would pressurize the system with the bleed valve open until all of the air is evacuated. After all air is evacuated one would then close the bleed valve and initiate the test. DeLuca incorporates a standard air evacuation tube design developed by Gary Caudill at VC Summer
Air Evacuation Incorporates a standard Air Evacuation tube design Completely eliminating the air pocket Saves time Validates the first As Found test
Method 3:
*Gary Caudill developed idea of the Air Evacuation method currently used by DeLuca to validate the As Found Set Pressure Test
J-Tube Vent
Conclusion
The National Board Inspection Code along with The ASME PTC 25-2001 provide input and recommendations in regards to bench testing Pressure Relief Valves and gives a basic guide on test bench layout and characteristics. Although these recommendations provide a base to follow they can still be open to interpretation. These interpretations will be evident in the differences in both the designs and capabilities of PRV test benches found throughout the industry. PRV test bench users should be at least aware of these differences and the impact they could have on the accuracy of their set point results.
Acknowledgements
Richard Booth, Vermont Yankee Gary Caudill, V.C. Summer J. Alton Cox, Vice Chairman, NBIC SubGroup Pressure Relief Devices Curt Dupill, Dupill Group / DeLuca Test Equipment Dean Mathews, DeLuca Test Equipment
Questions
Test & Reconditioning Equipment for Industrial valves Tel: 724-468-3271 Fax: 724-468-5896 Email: solutions@dupillgroup.com Internet: www.delucatest.com