Online safety valve testing - Expertise - cost savings | METRUS

2.4. The potential use of ultrasound

Recently, ultrasound technology has gained traction in the domain of online safety valve testing, particularly for detecting set points when standard diagrams are difficult to interpret. With the increasing complexity of industrial processes, more operators are adopting ultrasound as a reliable solution for liquid service safety valve testing.

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Many vendors today promote ultrasound as a foolproof solution to resolve ambiguities in standard diagrams, showcasing substantial reactions that lift and force data might not reveal. Recent studies have corroborated that ultrasound can effectively bridge gaps in testing methodologies.

In a collaborative research initiative with Sweden's premier nuclear power station, Ringhals AB, METRUS conducted an extensive benchmark test utilizing ultrasound for set point determination. Of the 55 valves tested, it became apparent that ultrasound detection correlated closely with seat conditions; specifically, while it effectively identified leak points, it did not align precisely with the set point unless the valve was newly serviced. In a typical online safety valve testing environment where a valve hasn’t been serviced for over a year, using ultrasound can yield misleading results.

Nonetheless, ultrasound proves beneficial in two significant ways in online safety valve testing. Firstly, it can compare sound levels before and after tests, providing immediate feedback regarding whether the valve has returned to its original state post-testing. This presents initial insights into whether the valve resealed successfully after lifting. You can find more in our White Paper on online safety valve testing METRUS Valve Test Bench Excellence.

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3. Operational aspects

Understanding the rationale behind online safety valve testing and its theoretical application is one thing, but gaining insight into the practical challenges encountered daily is invaluable.

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3.1. The valve disk must lift

Surprisingly, plant operators often express concern when online testing engineers inquire about valve openings. To reliably assess the initial moment when the disk lifts – defining the set point – the valve must activate, albeit the mechanics of how widely it opens will depend on the test equipment used.

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3.2. Valve types that can be tested

Testing a safety valve necessitates the ability to lift the disk and measure the corresponding force. In 95% of cases, safety valves with spindles can undergo online testing, possibly requiring modest spindle modifications based on specific configurations. Non-spindle valves, however, cannot be tested.

Additionally, valves exposed to particularly dirty fluids, such as bituminous crude oil, must be fitted with rupture disks to maintain seat cleanliness to prevent improper sealing post-testing. Maintenance teams must make informed decisions regarding the feasibility of lifting valves.

Hazardous areas housing safety valves demand specialized testing equipment aligning with EEx regulations to operate effectively. Suppliers should ensure that the certifications match the requisite classes and operational zones.

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3.3. Operational range

An enduring inquiry in the industry is: What are the limitations regarding the highest set point and the largest nominal diameters for testing? The interplay among line pressure, seat area, and test force determines the feasibility of lifting safety valve disks. Suppliers may claim their apparatus can handle any safety valve, but such assertions must be regarded cautiously, as practical testing conditions heavily influence results.

Conversely, while larger valves typically demand more force, small and medium valves form the majority in the field. Accurate sensors must align with the operational scope established for these tests.

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3.4. Working efficiency

Online safety valve testing fosters significant cost savings. When measuring direct testing costs against workshop testing, online testing generally proves more economical. However, this necessitates that the testing equipment is adept in swift handling and operational flexibility.

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The operational dynamics of safety valves dictate testing across various plant locations, often necessitating equipment relocation multiple times during a testing day. Essential retuning of the test rig is required as different valve types may demand alterations. The practicality of the equipment hinges on its portability and robust mechanical design. Rapid rigging and unpacking contribute directly to the efficiency of testing times.

Frequently, valves will require adjustments post-testing, influencing the time taken between tests. Systems where adjustments necessitate significant manual intervention can impede overall efficiency, with ideal average handling-to-testing ratios ranging around 1:5 indicative of optimal equipment performance.

Additionally, a streamlined software or control system is crucial for managing the considerable test data generated and drafting comprehensive reports. The TESON® system provides an efficient means for technicians to oversee the entire testing process, minimizing manual data retrieval complexities.

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3.5. Working safety

Instances where safety valves remain open post testing can jeopardize plant operations, underscoring the importance of having a protocol for remotely closing these valves using the test rig.

Conducting online safety valve tests isn’t inherently dangerous if executed with precision. Nevertheless, plant disturbances could arise in rare scenarios, particularly if a valve fails to close or sustains damage.

Modern testing equipment operates either manually or electronically; automated systems can significantly mitigate human error, though they remain vulnerable to power outages and potential software failures. A well-designed digital system bolsters both operational safety and efficiency, ensuring technicians can track numerous parameters throughout the online safety valve testing process.

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4. Costs of ownership

When assessing initial investments in testing technology, purchase price often captures attention. However, considering cost-saving potentials tied to online safety valve testing indicates a broader view on ownership costs is warranted.

From the outset, trained personnel must be proficient in using the equipment; worker turnover necessitates ongoing training. Suppliers should provide thorough documentation and training materials to empower internal, self-guided training programs.

Ongoing support by equipment suppliers is vital. In scenarios where time-sensitive testing must occur, timely responses to equipment malfunctions or intricate inquiries are essential for minimizing operational delays.

Calibration for testing equipment must also be factored in, typically requiring biennial services aligned with ISO quality standards. It’s advantageous if suppliers offer calibration services locally to mitigate transport overheads.

The vast varieties of valves encountered in industrial settings require tailored strategies; suppliers will provide solutions covering common testing needs, with rental options for uncommon extensions enhancing cost efficiency.

We hope this exploration provides insights into online safety valve testing. For more information, please visit What Is Beveling In Welding.