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SAFETY VALVE TESTING & CALIBRATION
SAFETY VALVE TESTING BY VALTEST® TECHNOLOGY
NESL’s Valtest® Technology enables you to test if each and every valve is functioning properly, without plant shut-down. With our unique electronic system you get a record of the valve’s performance under pressure and a certification as to whether it is working as intended. Our process is approved by various authorities including Central Boiler Board. The test is quick, is done in situ, and does not require a drop in pressure or an expensive shutdown.
Valtest® has been acknowledged as an energy-saving device by a host of major plants owners who also value plant safety as the topmost priority. So far more than 40,000 Safety Valves have been tested and calibrated by the online Valtest method in India and abroad by NESL.
The PROCESS OF TESTING
Hydraulic power pack is used with laptop recorder linked through electronic transducer that applies force to the valve spindle, to overcome spring tension. The set pressure is regulated by combining recorded data, knowledge of valve seat area and line pressure of the valve. Valtest system tests the valve without interrupting plant production.
HOT TESTING
Hot testing involves testing the safety valve while the system is operating at normal or elevated temperatures and pressures. This method is typically used for safety valves that are designed to operate at high temperatures or are exposed to high-temperature environments. During hot testing, the system is brought up to its normal operating temperature and pressure, and the safety valve is tested to ensure that it opens and closes correctly and can handle the flow of fluid or steam.
COLD TESTING
Cold testing involves testing the safety valve at ambient temperature and pressure. This method is typically used for safety valves that are not designed to operate at high temperatures or are not exposed to high-temperature environments. During cold testing, the safety valve is disconnected from the system and subjected to a controlled flow of air or water to test its opening and closing characteristics and its ability to handle the flow of fluid.
Safety Valve Testing is an essential aspect of any comprehensive maintenance and safety program.
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WHY SAFETY VALVE NEEDS TESTING?
Ensuring safety and reliability
The primary advantage of safety valve testing is that it helps ensure the safe and reliable operation of pressure vessels and pipelines. By testing safety valves regularly, operators can help prevent equipment failures, leaks, and other potentially hazardous incidents.
Early detection of potential problems
Regular safety valve testing can help detect potential problems early on, before they become more serious issues. This allows for prompt repairs and maintenance, which can help prevent equipment failures and other issues.
Compliance with regulations and standards
Many jurisdictions require regular testing and certification of safety valves, and failure to comply can result in fines and other penalties. Safety valve testing helps operators comply with regulatory requirements and industry standards.
Cost savings
By preventing equipment failures and other issues, safety valve testing can help save operators money on repairs and maintenance costs. It can also help prevent downtime and lost productivity, which can result in significant cost savings over time.
Increased equipment lifespan
Regular safety valve testing can help extend the lifespan of pressure vessels and pipelines by identifying potential problems early on and allowing for prompt repairs and maintenance.
application of valtest®
Steam Service Valves
Valtest® is capable of testing safety valves at normal operating pressure. It also tests online safety valves which cannot be tested by increasing system pressure – for example, reheater valves and primary side reactor valves.
Clean Service Process Valves
Valtest® can be used to diagnose safety and relief valves that require maintenance while the plant is running normally – prior to the scheduled shut down. Valves that were found to require overhaul can be tested after they have been returned to the line in order to verify the bench test set pressure.
VALTEST® ADVANTAGES
Regular testing of safety valves is critical to ensuring the safe and reliable operation of pressure vessels and pipelines.
Fuel Cost & testing time reduced, as during Valtest no need to over-pressurize the boiler/system.
Hydraulic power pack, which is operated by plant air pressure of 5 to 7 bar supply hydraulic oil pressure to the Ram located in the pulling device.
Valve seat erosion will be reduced.
Welded in-valves can be tested without removal from the line.
No need for temperature compensation to set pressure during hot testing.
The possibility of tube leakage for old boiler during conventional testing, can be avoided using Valtest.
Sound Polution can be reduced by Valtest.
Valtest is faster, quicker and economical.
