What to Do If a Pressure Relief Valve Is Leaking

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Pressure relief valves ensure efficiency and safety in many chemical, oil, and gas plants,
but they’re susceptible to leaks. If a pressure relief valve is leaking, systems can become
overpressurized and even fail, especially if the valve isn’t addressed or repaired quickly.

To help you prevent system issues and dangerous overpressure conditions, here’s your
guide to what to do if a pressure relief valve is leaking.

Shut Down the System When a Valve is Leaking

When a pressure relief valve is leaking,
the first and most important thing you
need to do is shut down the system.
Leaking pressure relief valves can’t
regulate the overall pressure within the
pipelines. This can cause overpressure
conditions, which can lead to system
failure and, in some cases, system
explosions and fires.

So make sure that you shut down the

system when you detect a leaking pressure relief valve to prevent serious system issues
and dangerous conditions.

Determine the Cause of the Leak

When you shut down the system, carefully examine the pipelines and the valve itself to
determine the cause of the leak. This will help you figure out exactly what you need to
do to repair it.

Pressure relief valve leaks usually occur when the valve isn’t properly seated or when the
seal is broken or damaged. Leaks can also happen when the pressure relief valve is
operating too closely to the set point.

Perform the Necessary Repairs

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After you’ve determined the cause of the
leak, you can start repairing the valve.
According to federal leak detection and
repair standards, companies have five
days to perform the first repair attempt.

For the first repair, you should tighten or

replace the bonnet bolts and tighten the
packing gland nuts. You want to make
sure that you follow manufacturer repair
guidelines for the first repair.

If the valve isn’t completely repaired after your first attempt, you have up to 15 days to
perform any additional repairs according to the EPA. If the valve still isn’t fixed, then
you can either replace the pressure relief valve or wait until the next shutdown cycle to
do more repairs.

Prevent a Leaking Pressure Valve

When the pressure relief valve has been fixed or replaced, it’s important to take the
necessary steps to avoid leaks in the future. To do that, consider implementing a leak
detection and repair (LDAR) program for your company.

An LDAR program will help to train workers on everything they need to know about
detecting and repairing a leak before system damage can occur. It will also help you
monitor valves more efficiently so you can spot leaks faster and spend less money on
overall valve repair and maintenance costs.

To learn more about pressure relief valves for your company, read our post on how to
choose the right pressure relief valve.

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