Everything You Need to Know About Safety Valves: Inspection, Testing, and Maintenance.

What Are Safety Valves?

Safety valves, including Pressure Relief Valves (PRV) and Pressure Safety Valves (PSV), are critical components in any pressure equipment system. These valves play a vital role in maintaining the safety and integrity of steam vessels and electric steam generators by preventing excessive pressure buildup that can lead to equipment failure or catastrophic events. Ensuring their proper function through regular inspection, testing, and maintenance is crucial for safe and efficient operation.

Safety Valve Maintenance

Safety valves are essential for a variety of facilities such as hospitals, pharmaceutical plants, research centres, and process industries that rely on steam for sterilisation and processing. Regular maintenance and formal testing of these valves are necessary to ensure they operate correctly and adhere to safety standards.

Key Requirements for Safety Valve Inspection and Testing

1. Inspection and Testing Standards: Safety valves should be inspected and tested in accordance with standards such as AS/NZS 3788. These standards specify the intervals and procedures for ensuring valve integrity and performance.
   

2. Functional Checks: During routine maintenance, safety valves should be visually inspected and physically tested to verify that they lift off their seats and re-seat properly without leaking. This check is critical for confirming that the valve can handle the pressure it is designed to relieve.
   

3. Replacement Criteria: If a valve fails to perform satisfactorily during testing, it should be replaced immediately. Routine replacement should occur at intervals not exceeding four years, ideally in conjunction with internal equipment inspections.
   

4. Service Intervals: The inspection and testing intervals for safety valves vary depending on the equipment and its service environment. For example, valves on steam boilers require more frequent checks than those on less critical systems.
   

Common Challenges with Safety Valves

1. Deterioration in Dirty Environments: Safety valves exposed to dirty or corrosive environments are more likely to suffer from performance issues due to material buildup and wear. Regular maintenance is crucial in these conditions to prevent failure.
   

2. Operational Failures: If a valve does not operate within the specified pressure range, it must be replaced or repaired. The device should be tagged out and removed from service until a replacement is installed.
   

3. Logistical Challenges: Coordinating the replacement and inspection of safety valves can be challenging, particularly in facilities with numerous pressure systems. It requires careful scheduling and coordination with qualified inspectors.
   

Inspection and Testing Process

1. Visual Inspection: Conduct regular visual inspections to ensure there are no signs of damage, tampering, or blockages that could impair valve function. This includes checking for corrosion, mechanical damage, and ensuring proper installation.
   

2. Operational Testing: Perform physical tests to verify that the valve lifts at the correct pressure and reseats properly. This test should be conducted at least annually and more frequently if the valve is subject to harsh conditions.
   

3. Reassembly and Adjustment: After testing and any necessary repairs, reassemble the valve and adjust it to the correct settings. Ensure that it is tested under operational conditions to confirm it functions correctly.

Regular inspection, testing, and maintenance of safety valves are vital for the safe and efficient operation of pressure equipment. Adhering to industry standards and conducting timely replacements can prevent catastrophic failures and ensure compliance with safety regulations. For all of your safety valve needs, chat to the team at Safety Valve Supplies – call 08 8276 9254 or email admin@svinspections.com.au