What should a plant verify when reviewing pressure relief device test records?
A pressure relief device record should establish which installed device was tested, what acceptance basis applied, and whether the device was safely returned to the correct service.
Verify identity and service
Match the device tag, serial number, set pressure, service fluid, installation location and approved design documents. Confirm whether the record applies to the installed unit or a spare. Review any change of service or process modifications.
Review test scope and results
Check the test method, equipment calibration status, test date, as found opening pressure, leakage or seat observations where applicable, repairs and as left results. Use the governing code, jurisdictional requirements, manufacturer instructions and site procedure for acceptance criteria. A passing as left test does not erase an unacceptable as found condition.
Investigate exceptions
If the device fails its as found criteria, assess the period of potential impaired protection and related operating exposure with engineering and process safety. Document the disposition, required corrective action and whether other similar devices need review.
Industrial example
A relief valve returned from a shop has a passing final set pressure but an as found result outside the site's approved tolerance. The planner links the test record to the asset, and engineering evaluates the previous service interval and corrosion evidence before approving reinstall.
Control installation and next interval
Confirm seals, identification, transport protection, correct orientation, isolation lineup and return to service authorization. Record the next test due date according to the applicable program, not a generic interval.
Implementation checklist
- Match serial number and service to installed asset
- Retain as found and as left data
- Resolve failed results with engineering
- Verify reinstall and next due date
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Technical references
OSHA process safety mechanical integrity · National Board inspection guidance