1. Meeting and purpose

This training manual is a practical guide for manufacturing technicians to perform safety valve testing. It covers checking set pressure, leak testing and resetting the safety valve. This manual is intended for on-site performance of planned or required repair work on a safety valve used in industrial pressure systems.

2. Safety net

It is important to stop and attach to the workplace. Before performing any work on the safety valve, shut down and secure with power sources to prevent unexpected failure or leakage of potentially hazardous media.

Protection against working conditions is required. Use appropriate equipment to protect against harmful substances, high pressure and temperature, such as gloves, goggles, special clothing.

The importance of using tools. Use only the appropriate tools specified in the "Tools and Materials" section for the job to avoid damage to the machine or personal injury.

3. Tools and materials needed

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Name of the tool	Specification	Quantity	Comment
Torque screw handle	The range is 10–100 Nm	1	To perform pressure measurement
Multimeter	Function for pressure measurement	1	To measure pressure or electrical parameters
Laser for measurement	Accuracy ±0.01 mm	1	To measure distances or eccentricity
Pressure booster	Maximum 100 bar	To perform pressure testing
Pressure transmitter	Maximum 100 bar	1	To measure the set pressure
Valve holder	Maximum 100 bar	1	To perform valve testing
Oil paper	To discard old liquids	5	To reject oil

4. Before the repair inspection

Item	Verification	Acceptance/rejection criteria	Notes
1	Checking the availability of energy sources	Power sources are turned off	Perform stop and attach
2	Checking the availability of tools	All tools are in place	All tools are as listed
3	Checking the condition of the valve	No peeling, wear or damage	Use the laser to measure
4	Checking the availability of relevant documents	The documents are available, according to the requirements	Use DSTU, ISO, EN standards
5	Checking of measuring equipment	The measuring equipment works	Use a multimeter

5. Step by step procedure

Set pressure measurement

Use a pressure transmitter to measure the set pressure of the safety valve. Connect the transducer to the appropriate valve port.

Measurement: 50 bar

Visual indication: The readings of the sensor correspond to the set pressure

Error: Bad sensor connection
Leak testing

Use a valve holder and pressure booster to test for leaks. Pressurize the valve, measure the pressure, and check for leaks.

Measurement: 50 bar

Visual indication: No leakage

Error: Incorrect valve holder connection
Valve recovery

Use a torque wrench to take the pressure measurement. Take a pressure measurement and check if it meets the set pressure.

Measurement: 50 bar

Visual indication: Valve pressure corresponds to the set one

Error: Incorrect use of torque wrench
Measuring eccentricity

Use a laser to measure valve eccentricity. Measure the eccentricity and check that it does not exceed the specified standard.

Measurements: ±0.01 mm

Visual indication: The eccentricity corresponds to the established norm

Error: Incorrect use of laser
Temperature measurement

Use a multimeter to measure the temperature. Measure valve temperature after testing.

Measurement: 60°C

Visual indication: The temperature of the valve corresponds to the set norm

Error: Incorrect use of multimeter
Flow measurement

Use a pressure intensifier to measure flow. Pressurize the valve and check that the flow rate is within the specified range.

Measurement: 50 bar

Visual indication: Consumption corresponds to the established norm

Error: Incorrect use of pressure booster

6. Inspection after completion of work

Test	Expected result	Actual result	Pass/Fail
Set pressure	50 bar	50 bar	Pas
Leak test	No leakage	No leakage	Pas
Centeredness	±0.01 mm	±0.01 mm	Pas
Temperature	60°C	60°C	Pas
Spending	50 bar	50 bar	Pas

7. Debugging table

Symptom	A possible reason	Corrective action
leakage	Incorrect installation of the valve	Check valve installation
Increased pressure	Incorrect pressure setting	Check the pressure setting
Low pressure	Incorrect pressure setting	Check the pressure setting
Incorrect centering	Incorrect centering setting	Check the centering setting
High temperature	Incorrect temperature setting	Check the temperature setting
Low consumption	Incorrect cost setting	Check the cost setting

8. Recommended maintenance schedule

Task	Frequency	Estimated duration	Skill level
Safety valve testing	Annual	2 hours	Average
Valve restoration	Annual	3 hours	Tall
Pressure measurement	Annual	1 hour	Average
Measurement of eccentricity	Annual	1 hour	Average
Temperature measurement	Annual	1 hour	Average
Flow measurement	Annual	1 hour	Average

9. Reference to spare parts

Description of the spare part	Typical specification	UNITEC-D category
Safety valve	Maximum 100 bar	Category 3
Pressure transmitter	Maximum 100 bar	Category 4
Pressure booster	Maximum 100 bar	Category 5
Valve holder	Maximum 100 bar	Category 6
Torque screw handle	The range is 10–100 Nm	Category 7
Multimeter	Function for pressure measurement	Category 8
Laser for measurement	Accuracy ±0.01 mm	Category 9

Visit our e-catalog for matching spare parts: https://www.unitecd.com/e-catalog/

10. Links

The implementation of this manual complies with the following standards:

DSTU 2489:2017 — Standard for requirements for safety valves
ISO 4126:2017 — Standard for safety valves
EN 12981:2017 — Standard for safety valves
CE / UkrSEPRO — Certification of products

Additionally, you can use the safety valve manufacturer's documentation.