Cover Page

Mechanical - Test and Inspection - Pressure Relief Device

PACKAGE CONTENT
1 Cover Page
2 Task List
3 Schedule of Results
4 Authentication
5 Condition Score Matrix

EQUIPMENT COVERED BY THIS TASK LIST

1 Digester Pressure Safety Valve

INSTRUCTIONS
1 Load button to start and save form.
2 Complete a Risk Assessment before starting work.
3 If an approved alternative risk assessment is used, record the reference number
under observations.
4 Complete the top section of each page of the Equipment Schedule of Results.
5 Add additional equipment as required to the Equipment Schedule of Results.
6 Perform the Inspection listed at the top of the Task List.
7 Select the equipment specific section from the Task List.
8 Complete the remaining tasks listed for that equipment.
9 Refer to the work order for possible special job instructions.
10 Record Results and Condition Score on the Equipment Schedule of Results.
11 Fields not completed shall be marked with line (---) unless greyed out.
12 Items that cannot be tested shall be marked a (3) in condition score
and noted in limitations as not tested.
13 Provide comments on form for all equipment with a score of 2,3,4, or 5.
14 Include photographs for all equipment with a score of 4 or 5.
15 Records shall be submitted by the end of each week from date of completion.
16 Submit record.

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 Task List

Pressure Relief Device Test & Inspection

Ensure pressure relief devices are in suitable condition to protect pressurised devices from over or under pressure.

To access valves fitted to Digester Gas Compressors purging between the inlet and outlet valves will be required.

Spare tested Digester PSV's are kept in store. Retest spare and fit in place of installed unit. Test and Inspect
removed unit. Place remaining retested unit in store as a spare.

Bursting discs
Replace bursting discs 2 yearly

Bursting discs should be replaced, rather than tested or overhauled.

Pressure relief valves

On-line external visual inspection (as per the requirements of AS3788 Section 4.7.3)

Inspection shall examine each device to ensure the following:

The correct device is installed

Identification provides means to establish the correct set pressure for the equipment
protected by the device
There is no unacceptable external mechanical damage.
The bonnets of non-balanced valves are plugged
The bonnets of balanced valves are vented to a safe location, and the vent is clear and
not discharging process fluid
The device is leak-tight
External corrosion is not excessive
There is no evidence of device tampering
Vent Pipework
Vent stacks, discharge piping and receiving vessels are properly supported
Upstream and downstream block valves (where applicable) are secure, and interlocks
are managed appropriately
No gags, blinds or closed valves would prevent the device functioning correctly
Adequacy and condition of weather protection (where applicable)
Blockage in the outlet or discharge piping or in any drains fitted to
the relief valve or its discharge piping (where possible)
Where discharge piping terminates outdoors, or where ingress of water, dust, debris
or vermin is possible, control measures are in place to prevent ingress, accumulation,
damage, fouling or blockage

Where weather protection has failed, the device should be externally examined, and
assessed for continued service

Pressure relief devices with easing gear should be manually operated, unless there is
significant risk that this will—
(I) compromise plant integrity;
(ii) damage the device; or
(iii) create a hazard for personnel in the vicinity.

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 Task List

Where a pressure relief device is found to be not functioning correctly, it shall be repaired
and tested in accordance with AS3788

Scheduled Testing and Maintenance (as per the requirements of AS3788 Section 4.7.4)

Test safety relief valve to verify functionality in accordance with AS1271. If safety relief valve fails
testing, valve to be overhauled and re-tested in accordance with AS1271

Carry out all other inspections covered in the "On-line external visual inspection" (as per the
requirements of AS3788 Section 4.7.3), not covered by the "Scheduled Testing and Maintenance"
activity
Details of the valve testing shall be recorded on documentation, which meets the requirements of
AS1271 Appendix B, C & D

Where maintenance/overhauls are required details of the as-received valve condition, repairs and work
carried out on the valve shall be recorded on documentation, which meets the requirements of AS 3788
Appendix P

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 Reset

Equipment Schedule of Results

1. Load
Work Order
Equipment Ref: MST No:
Equipment Description:
Reference Documents
Maintenance Manual: Drawing No:
Test Equipment (Type,
Model & Serial):
Special Instructions
Nameplate Details Results

Condition
Manufacturer

Vent Stack

Calibrated

Score
Replaced
Description

Leakage

Isolation
Installed
Correct
Device
Model

Valve
Make
1-5
Plant No.
Serial Number
Plant No.
Serial Number
Plant No.
Serial Number
Plant No.
Serial Number
Plant No.
Serial Number
Plant No.
Serial Number
Plant No.
Serial Number
Plant No.
Serial Number

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 Equipment Schedule of Results

Work Order
Equipment Ref: MST No:
Equipment Description:
Authentication Of Results
The results recorded in the Schedule of Results verifies, subject to the specified level of maintenance or inspection and any limitations & observations listed below, the condition of the
equipment listed.

Limitations & Observations (Technician to detail limitations and items requiring attention. Condition Score 2,3,4,5):

Inspected and Tested by

___________________ _____________________ ___________________ 2. Crossout _________________________

Work Order License/Qualification Type & Number Signature
3. Check

___________________ _____________________ _____________________

Print Name Employee Number Date

Planned Corrective (For Office Use. Receiving Officer to record reference numbers and comments):

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 Condition Score

Condition Score
Very Good Condition.
1 It is stable, no additional work required.
Advise normal or extended maintenance interval.
Good Condition.
Only used where repair/replacement work is completed as per job instructions
2
Now it is stable and safe.

Fair Good Condition. Signs of degradation or uncompleted tasks.

Schedule for re-inspection is recommended; or
3 Part repair/replacement is required (Planned Corrective in 3-9 months); or
Whole asset renewal/rehabilitation is recommended within a timeframe of 3-5 years.
Work request notification shall be submitted.

Poor Condition. Likely to fail.

Part repair/replacement is required (Planned Corrective in 1-3 months); or
4
Whole asset renewal/rehabilitation is recommended within a timeframe of 1-3 years.
Work request notification shall be submitted.

Unserviceable or breach of regulation or business requirement -

requires URGENT attention.
Repair/replacement is required as soon as possible (Planned Corrective in 1-4 weeks); or
5
Whole asset renewal/rehabilitation is recommended within a timeframe of 6-12 months.
Work request notification shall be submitted; or
Make safe and report ASAP (arrange Responsive or Urgent Planned Corrective work order).

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