Pressure Relief Valve Inspection and 5-Year Overhaul Record

Estimated duration: ~20 min (annual visual) / ~2-4 hours (5-year bench test) • Full bench test is required every 5 years

Important: Annual visual inspections confirm PRV external condition and basic operability. The full 5-year bench test requires removal from service, disassembly, set pressure verification, and overhaul of internals. Only qualified personnel with appropriate test equipment should perform bench testing. Set pressure tolerances per AS 1271 are +/-3%.

Equipment and Inspection Details

Plant/Facility Name

PRV Tag Number

PRV Serial No.

Manufacturer

Model

Size (DN)

Set Pressure (kPa)

Protected Equip. Tag

Protected Equip. MAWP (kPa)

Service Medium

Last Inspection Date

Last Overhaul Date

Inspection Type

#	Inspection Item	Method
1. Documentation Review
1	PRV data sheet available and current	REVIEW
2	Previous inspection/test records reviewed	REVIEW
3	Piping and instrumentation diagram (P&ID) reference confirmed	VERIFY
4	Maintenance history reviewed	REVIEW
2. Annual Visual Inspection
5	Body and bonnet condition (corrosion, erosion)	INSPECT
6	Inlet/outlet piping condition	INSPECT
7	Discharge piping unobstructed	INSPECT
8	Body drain clear	INSPECT
9	Cap/lever guard intact	INSPECT
10	Lock wire/seal intact	VERIFY
11	No evidence of leakage (weeping)	INSPECT
12	Isolation valve position correct (locked open)	VERIFY
3. Operational Checks - Annual
13	Lifting lever operates freely	TEST
14	Valve reseats after manual lift	TEST
15	No audible seat leakage	INSPECT
16	Inlet pressure reading within normal range	VERIFY
4. 5-Year Bench Test - Disassembly
17	PRV removed from service (isolation confirmed)	VERIFY
18	Inlet/outlet blanked on vessel	VERIFY
19	Visual condition of internals	INSPECT
20	Spring condition and free length	MEASURE
21	Seat and disc condition (lapping marks, erosion, corrosion)	INSPECT
5. 5-Year Bench Test - Set Pressure Verification
22	Test medium appropriate (air/nitrogen/water as applicable)	VERIFY
23	Set pressure achieved within tolerance (+/-3% per AS 1271)	TEST
24	Blowdown within acceptable limits	TEST
25	Reseat pressure verified	TEST
26	Repeat test (minimum 3 lifts for consistency)	TEST
6. 5-Year Overhaul - Repair/Replace
27	Seat lapped or replaced	INSPECT
28	Spring replaced if corroded or fatigued	INSPECT
29	O-rings and soft goods replaced	VERIFY
30	Body cleaned and inspected (NDT if suspect)	NDT
7. Post-Overhaul Certification
31	Final set pressure test passed	TEST
32	Valve tag updated with new test date	VERIFY
33	Calibration certificate issued	VERIFY
34	Valve reinstalled correctly (torque values applied)	VERIFY
35	Isolation valve returned to locked-open position	VERIFY

Inspection Item

Method

P / F / NA

Notes

1. Documentation Review

PRV data sheet available and current

REVIEW

Previous inspection/test records reviewed

REVIEW

Piping and instrumentation diagram (P&ID) reference confirmed

VERIFY

Maintenance history reviewed

REVIEW

2. Annual Visual Inspection

Body and bonnet condition (corrosion, erosion)

INSPECT

Inlet/outlet piping condition

INSPECT

Discharge piping unobstructed

INSPECT

Body drain clear

INSPECT

Cap/lever guard intact

INSPECT

Lock wire/seal intact

VERIFY

No evidence of leakage (weeping)

INSPECT

Isolation valve position correct (locked open)

VERIFY

3. Operational Checks - Annual

Lifting lever operates freely

TEST

Valve reseats after manual lift

TEST

No audible seat leakage

INSPECT

Inlet pressure reading within normal range

VERIFY

4. 5-Year Bench Test - Disassembly

PRV removed from service (isolation confirmed)

VERIFY

Inlet/outlet blanked on vessel

VERIFY

Visual condition of internals

INSPECT

Spring condition and free length

MEASURE

Seat and disc condition (lapping marks, erosion, corrosion)

INSPECT

5. 5-Year Bench Test - Set Pressure Verification

Test medium appropriate (air/nitrogen/water as applicable)

VERIFY

Set pressure achieved within tolerance (+/-3% per AS 1271)

TEST

Blowdown within acceptable limits

TEST

Reseat pressure verified

TEST

Repeat test (minimum 3 lifts for consistency)

TEST

6. 5-Year Overhaul - Repair/Replace

Seat lapped or replaced

INSPECT

Spring replaced if corroded or fatigued

INSPECT

O-rings and soft goods replaced

VERIFY

Body cleaned and inspected (NDT if suspect)

NDT

7. Post-Overhaul Certification

Final set pressure test passed

TEST

Valve tag updated with new test date

VERIFY

Calibration certificate issued

VERIFY

Valve reinstalled correctly (torque values applied)

VERIFY

Isolation valve returned to locked-open position

VERIFY

Set Pressure Test Results

Test No.

Set Pressure Target (kPa)

Actual Pop Pressure (kPa)

Deviation (%)

Blowdown Pressure (kPa)

Reseat Pressure (kPa)

PASS / FAIL

Defects, Recommendations and Corrective Actions

Next Inspection Due

Next Annual Inspection

Next 5-Year Overhaul

Inspector / Technician

Name

Trade Qualifications

Signature

Date

Plant Engineer / Manager

Name

Organisation

Signature

Date