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Engineering Procedure

SAEP-318 29 March 2008


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) & Rupture Pins (RP).... 21
11 Spare RVs.................................................... 22
12 Pressure Testing RVs.................................. 23
13 Mothballed RVs............................................ 24
14 Test & 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



Previous Issue: 2 February 2008 Next Planned Update: 2 February 2013
Page 1 of 28
Primary contact: Ajaji, AbdulAziz O on 966-3-8746604

CopyrightSaudi Aramco 2008. All rights reserved.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 2 of 28

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.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 3 of 28
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 SA 8020-605-ENG Instrumentation Specification Sheet Surge Relief
Valves
ISS SA 8020-611-ENG Instrument Specification Sheet Pressure Relief
Valves Conventional & Balanced Types
ISS SA 8020-612-ENG Instrument Specification Sheet Safety Relief
Valves Pilot Operated
ISS SA 8020-613-ENG Instrument Specification Sheet Pressure
Vacuum Relief Valves
ISS SA 8020-614-ENG Instrument Specification Sheet Rupture Disks
ISS SA 8020-615-ENG Instrument Specification Sheet Rupture Pin
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, disassembly indicator, mothballing/demothballing,
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 4 of 28
design code, material, inlet and outlet pipe sizes and test intervals.
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, 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
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 5 of 28
relieving devices, as defined in the Scope.
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
An authorized person from Maintenance organization having Role ID number
07 in Plant Maintenance module of SAP.
3.18 RV Inspection Work History Processor
An authorized person from Maintenance organization having Role ID number
19 in Plant Maintenance module of SAP.
3.19 Maintenance Plan Processor
An authorized person from Maintenance organization having Role ID number
32 in Plant Maintenance module of SAP.
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.
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
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 6 of 28
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.
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.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 7 of 28
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 3750-ENG Relief Valve Maintenance Report
SA 3099A-ENG Relief Valve Authorization
SA 8020-605-ENG Instrumentation Specification Sheet Surge Relief
Valves
SA 8020-611-ENG Instrument Specification Sheet - Conventional &
Balanced Relief Valves
SA 8020-612-ENG Instrument Specification Sheet - Pilot Operated
Safety Relief Valves
SA 8020-613-ENG Instrument Specification Sheet - Pressure-Vacuum
Relief Valves
SA 8020-614-ENG Instrument Specification Sheet Rupture Disks
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 8 of 28
SA 8020-615-ENG Instrument Specification Sheet Rupture Pin
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:
Installation, deletion, or changes are approved and accurately recorded in the
corporate SAP system.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 9 of 28
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 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 Coordinators and RV
technicians.
6.2.4 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.
6.2.5 Administers the security access to the RV Program in SAP for only RV
Coordinators.
6.2.6 Communicates with, and assists RV Coordinators and RV users.
6.2.7 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. Response to overdue report must be made
within thirty (30) days and returned to the inspection Department. If
the response is not provided within the thirty days, the Inspection
Department Manager will follow up with the client Admin Area Head,
informing him the SAEP-319, section 5.5 requirements are not adhered
to by the relief valve proponent.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 10 of 28
6.3 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.
6.4 Originator
6.4.1 Verifies that the RV conforms to Saudi Aramco Specifications.
6.4.2 Prepares the Relief Valve Authorization, Form SA 3099A-ENG per
SAEP-1131.
6.4.3 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.
6.4.4 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.
6.4.5 Requests authorization and verification signatures to complete the
Relief Valve Authorization, Form SA 3099A-ENG.
6.4.6 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.
6.4.7 Requests a RV equipment number from the local RV Equipment
Processor; or RV Coordinator if no RV Equipment Processor is
assigned in the area.
6.4.8 Assures that no unauthorized RVs are installed in-site.
6.4.9 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
the field work, or coordinate this task with the local Inspection Unit in
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 11 of 28
accordance with local procedures.
6.4.10 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.
6.4.11 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.
6.4.12 Establishes the base intervals for RV T&I scheduling. Refer to
SAEP-319, paragraphs 5.1.2 and 5.2.
6.4.13 Revises or requests as built drawing and P&ID's as required.
6.5 Senior Project Engineer or Supervisor Operations Engineering
6.5.1 Provides or approves RV design and specification.
6.5.2 Approves new RV installations, changes, replacements, retirements, or
removals by signing Relief Valve Authorization, Form SA 3099A-ENG.
6.5.3 Maintains a current technical library that includes applicable relief valve
documentation for the RVs used in the Operating Facility.
6.5.4 Provides In-Place RV Test Procedures.
6.5.5 Provides a review of corroded, stuck or malfunctioning RVs in
cooperation with Operations Inspection Unit, as required by SAEP-319
Regulation Program, Section 12.
6.5.6 Assign an engineer for the two years physical review mentioned under
paragraph 6.6.4.
6.6 Operations Superintendent
6.6.1 Approves new installations, changes, replacements, retirements, or
removals by signing the Relief Valve Authorization, Form SA 3099A-
ENG.
6.6.2 Approves RV in-place testing, and assures that the correct equipment
pressure is strictly maintained during the test.
6.6.3 Assures that RV Work Orders are distributed for timely RV T&Is.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 12 of 28
6.6.4 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.
6.6.5 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.
6.7 Maintenance
6.7.1 Schedules and performs the physical inspection, testing, and repair of
RVs in accordance with the RV Program.
6.7.2 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.
6.7.3 Prepares/Prints a Relief Valve Maintenance Report, Form SA 3750-
ENG, for each RV repair activity, for entry into the SAP system.
6.7.4 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 SA
3750-ENG data entry to another unit.
6.7.5 Sends the original Form SA 3750-ENG to the local RV Coordinator for
test results approval.
6.7.6 Verifies that the manufacturer's nameplate is attached, and the RV has
an ASME stamp.
6.7.7 Verifies that each RV conforms to its design description on the Relief
Valve Authorization, Form SA 3099A-ENG.
6.7.8 Verifies or applies RV ID tags, stamps, paints the bonnet green on
bellows type RV, and adjustment seals per SAEP-318, Section 9.
6.7.9 Maintains an inventory of replacement parts.
6.7.10 Maintains "TEST" RVs for pressure testing purposes, with associated
service and design records.
6.7.11 Maintains an inventory of "SPARE" RVs and their records.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 13 of 28
6.7.12 Provides calibrated RV testing equipment.
6.7.13 Provides certified RV Technicians, as per SAEP-1134 by setting up or
coordinating a training program for all RV technicians.
6.7.14 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.
6.7.15 Prepares and maintains a QA manual for the RV Shop.
6.7.16 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".
6.8 RV Coordinator
6.8.1 Administers the RV Program for all plants and support facilities under
his area of responsibility.
6.8.2 Familiarizes himself with the RV Engineering Procedures, SAES RV
Standards, Industry Standards, and manufacturer requirements for RV
upkeep.
6.8.3 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.
6.8.4 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.
6.8.5 Investigates why a relief valve has not been tested within three months
following the approval of a RV.
6.8.6 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.
6.8.6.1 RV records are to be maintained for the life of an active RV.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 14 of 28
6.8.6.2 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.
6.8.6.3 Maintenance reports, Form SA 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.
6.8.7 Reviews all the information on the SA 3099A-ENG prior to approving
the data entered by maintenance on the Form SA 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.
6.8.8 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.
6.8.9 Participates in internal RV Program audits, as directed by the
Inspection Supervisor.
6.8.10 Assists Originating Engineers with filling out the Relief Valve
Authorization, Form SA 3099A-ENG, to ensure conformance to the
respective ISS and RV SAEPs.
6.8.11 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.
6.8.12 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.
6.9 Project Inspection Supervisor
6.9.1 Reviews and signs off the Relief Valve Authorization, Form SA
3099A-ENG, using the 8020-6XX-ENG to verify data entered on the
Relief Valve Authorization Form, for newly constructed facilities.
6.9.2 Verifies correct installation and identification marking of RVs is in
accordance with this SAEP.
6.9.3 Verifies that installed RVs are sealed, in the correct location, and
properly piped to a safe location per SAES-J -600.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 15 of 28
6.9.4 Verifies that block valves are properly installed and painted, as per
SAES-J -600 and SAES-B-067.
6.9.5 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.
6.9.6 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.
6.9.7 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.
6.10 Supervisor/Field Supervisor of the Operations Inspection Unit
6.10.1 For remote areas, the Inspection Field Supervisor has the authority to
act on behalf of the Inspection supervisor for the following items:
6.10.2 Provides an audit of the RV T&I Program at least once a year.
6.10.3 Assigns a member of Inspection Unit as 'RV Coordinator'.
6.10.4 Provides Inspection for witnessing In-Place RV testing.
6.10.5 Provides inspection for Engineering reviews of corroded, dirty, stuck,
and malfunctioning RVs, as required by the Regulation Program,
Section 12 of SAEP-319.
6.10.6 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.
6.10.7 Ensures that block valves are properly installed and painted, as per
SAES-J -600 and SAES-B-067, during annual external inspections.
6.10.8 Signs the original Relief Valve Authorization, Form SA 3099A-ENG
to verify his review and concurrence to an installation, deletion or
change.
6.10.9 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.
6.10.10 Provides written procedures for RV Program auditing for areas under
his responsibilities.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 16 of 28
6.10.11 Recommends interval updates, per SAEP-319.
6.10.12 Assigns a member of the Inspection Unit to participate in the two-year
physical review mentioned under 6.6.4 and document the result of the
survey.
6.11 Operations Foreman / Commissioning Supervisor
6.11.1 Verifies that the RV location and marking are correct.
6.11.2 Verifies that inlet and outlet block valves, for active RVs, are open
completely and properly sealed.
6.11.3 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.
6.11.4 Verifies that the block valves are painted orange, as required by
SAES-J -600 and SAES-B-067, Section 4.2.4.A.
6.11.5 Verifies that the block valve stems are oriented horizontally or sloping
away from the valve as per SAES-J -600.
6.11.6 Signs off on the Relief Valve Authorization, Form SA 3099A-ENG
verification block(s) or operation check list whenever the RV is
installed on site after being tested and inspected.
6.11.7 Verifies that the Maintenance Order, PM02, for RV servicing is
automatically initiated and scheduled by SAP system through
Maintenance Division.
6.11.8 Concurs with approval to conduct In-Place RV testing.
6.11.9 Initiates Maintenance Orders for the repairs of RVs not Due for T&I
under the Preventive Maintenance system in SAP.
6.11.10 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.
6.11.11 Verifies that bellows type RV bonnets are correctly vented.
6.11.12 Verifies that bellows type RV bonnets are painted green.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


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6.11.13 Verifies that a pressure gauge is present between a reclosing RV and
an in-series rupture disk.
6.11.14 Verifies that all newly installed RV have a permanently assigned RV
number.
6.12 Contract Repair & Operations Unit/Dhahran Shops Division, Mechanical
Services Shops Dept.
6.12.1 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.
6.12.2 Audits Contractor facilities annually. Copies of the Audit reports are
to be sent to Operations Inspection Division/Inspection Department,
Dhahran.
6.12.3 Assigns work based on Contractor's approved capabilities.
6.12.4 Performs RV T&Is in Mechanical Services Shop for Saudi Aramco
facilities.
6.12.5 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.
6.12.6 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.
6.13 Process Control Systems Division/Instrumentation Unit
6.13.1 Reviews and concurs with RV In-Place testing procedures.
6.13.2 Consults with Plant Maintenance or Operations on RV problems.
6.13.3 Evaluates and approves any new RV technology to be used in Saudi
Aramco facilities.
6.14 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 deviation request Form SA
2760-ENG "Approval Request to Deviate from Equipment Inspection
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


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Schedule." Deviation request excluded in SAEP-319 Pararagraph 5.5.5 do not
require LPD review.
6.15 Inspection Department OID Division Head
6.15.1 Reviews and approves RV In-Place testing procedures.
6.15.3 Reviews and concurs on Form SA 2760-ENG "Approval Request to
Deviate from Equipment Inspection Schedule".
6.16 RV Technician
6.16.1 Tests and inspects RVs according to manufacturer's requirements per
SAEP-319, API and ASME requirements.
6.16.2 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.
6.16.3 Informs RV Shop Supervisor when an Engineering Review is needed,
as described in SAEP-319, Section 12.
6.16.4 Familiarizes himself with the RV SAEPs, standards, manufacturer's
maintenance manuals, and Codes (ASME, API as referenced in this
SAEP).
6.17 SAP Computing Center
6.17.1 Performs Computer programming, and RV program monitoring
required to maintain the RV program and the database in SAP R/3
system.
6.17.2 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.
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.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 19 of 28
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.
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.
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
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 20 of 28
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.
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
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.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 21 of 28
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.
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.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 22 of 28
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.
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.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 23 of 28
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:
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.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 24 of 28
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
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.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Page 25 of 28
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
2 February 2008 Major revision.
29 March 2008 Editorial revision.
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Chart I Projects Authorization Procedure for RV Installation and Changes




Page 26 of 28
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes


Chart II Operational Facilities RV Authorization Procedure
for RV Installation and Changes




Page 27 of 28
Document Responsibility: Inspection Dept. SAEP-318
Issue Date: 29 March 2008 Pressure Relief Valve Program Authorization
Next Planned Update: 2 February 2013 for Installation, Deletion and Changes



Chart III Retirement (Deletion) of RV from Service

Origi nator Supervi sor Operati ons Engi neeri ng & Operations Superi ntendent
Reviews and approves SA-3099A-ENG.
Prepares SA-3099A-ENG. Includes
reason(s) for deletion in the form remarks Assures that the equipment being protected is permanently
section. dismantled or the RV is lost.
Operati ons Inspecti on Supervi sor/RV Coordi nator
Requests authorization approvals. Reviews and signs SA-3099A-ENG.
Verifies that the RV has been removed from service.
Operati ons Foreman
Requests 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.
Mai ntenance, RV Test Shop or Contractor Shop
Verifies RV against SA-3099A-ENG.
Initiates RV removal (use PM02 Order). Performs RV work by removing the RV from service and removes
Follows 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 in
Requests 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 Admi ni strator
Sends 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 Coordi nator
Sends 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.
1
2
3
4
9
10
7
8
5
6
11
12




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