Engineering Procedure

SAEP-29 27 November 2014

General Instructions and Guidelines
for Online Valve Preventive Maintenance
Document Responsibility: Valves Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 Purpose.......................................................... 2
3 Applicable Documents.................................... 2
4 Safety Precautions......................................... 3
5 General Instructions....................................... 4
6 Inspection and Preventive Maintenance
General Guidelines................................. 5

Appendix A......................................................... 10

Previous Issue: 20 November 2010 Next Planned Update: 23 November 2019

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Primary contact: Al-Jarallah, Bader Mohammed (jarallbm) - on +966-13-8809621

Copyright©Saudi Aramco 2014. All rights reserved.

Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 27 November 2014 General Instructions and Guidelines
Next Planned Update: 27 November 2019 for Online Valve Preventive Maintenance

1 Scope

This document presents general instructions and guidelines for valves online preventive
maintenance. Valves within the intention of the scope are metallic gate, globe, angle,
check, needle, ball, plug, and butterfly.

2 Purpose

The objective of this document is to maintain the performance of valves. It shall be

noted that this document is intended as a complementary to existing guidelines only,
and cannot cover all possible variations and combinations of specific equipment type.
Manufacturer's instructions take precedence in the event that they conflict with these
guidelines.
Commentary Note:

A preventive maintenance program is not intended to cover re-conditioning or major

repair, but should be designed to reveal, if possible, the need for such actions in time to
prevent malfunctions or unsafe conditions during operation.

3 Applicable Documents

The requirements contained in the following documents apply to the extent specified in
this procedure:

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-20 Equipment Inspection Schedules
SAEP-351 Bolted Flange Joints Assembly

Saudi Aramco Engineering Standards

SAES-B-058 Emergency Shutdown, Isolation and Depressuring
SAES-B-061 Protective Shields for High Health Hazard Piping
and Equipment
SAES-H-001 Selection Requirements for Industrial Coatings
SAES-H-002 Internal and External Coating of Steel Piping
System
SAES-J-601 Emergency Isolation and Shutdown System
SAES-L-108 Selection of Valves

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Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 27 November 2014 General Instructions and Guidelines
Next Planned Update: 27 November 2019 for Online Valve Preventive Maintenance

Saudi Aramco Materials System Specifications

04-SAMSS-001 Gate Valves
04-SAMSS-035 General Requirements for Valves

Saudi Aramco General Instructions

GI-0002.100 Work Permit System
GI-0002.711 Fire and Safety Watch
GI-0006.012 Isolation, Lockout and Use of Hold Tags
GI-0006.021 Safety Requirements for Abrasive Blast Cleaning

3.2 Industry Codes and Standards

American National Standards Institute/Fluid Controls Institute

ANSI/FCI 70.2 Control Valve Seat Leakage

American Petroleum Institute

API SPEC 6D Specification for Pipeline Valves
API RP 574 Inspection Practices for Piping System Components
API STD 598 Valve Inspection and Testing

American Society of Mechanical Engineers

ASME B16.5 Steel Pipe Flanges and Flanged Fittings
ASME B31.3 Code for Process Piping

Manufacturers Standardization Society of the Valve and Fittings Industry, Inc.

MSS SP-45 Bypass and Drain Connection Standard

4 Safety Precautions

Certain precautionary steps must be addressed clearly and adhered to prior to and
during the performance of maintenance & inspection of valves such as, but not limited
to the following:
i) All required work permits shall be obtained prior to starting any work in
compliance with GI-0002.100.
ii) Maintenance personnel should be adequately trained.
iii) Tools must be inspected to be fit for service.

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Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 27 November 2014 General Instructions and Guidelines
Next Planned Update: 27 November 2019 for Online Valve Preventive Maintenance

iv) Work Area must be prepared; accessibility must be fully provided and inspected,
especially where scaffolding erection is required.
v) Gas/H2S test must be performed prior to and during the job execution (for
potential toxic/hazardous services). In case venting or draining is required, a
procedure must be developed for isolation and safe venting & draining steps.
Make sure that all isolations, lockout and tags are performed in accordance with
GI-0006.012.
vi) A fire watch person shall be available for all auto-ignition services in compliance
with GI-0002.711.
vii) Never try to open any pressurized part (such as plug, drain, vent, etc.) of the valve
before verifying the valve is not subjected to line pressure.
Note: Trapped pressure is expected. Thus, cautions must be taken when opening
valve plugs/drains/vents or fittings.

viii) For valves in-situ repairs, engineering procedure must be developed to include
depressurizing, isolation, draining and venting as per SAES-B-058. The procedure
shall also include disconnecting from any electrical equipment and addressing all
work location preparation. Make sure that all safety related standards and
requirements are well addressed and followed.
ix) Use adequate torque when trying to turn a seized valve, bolts or grease fitting.
Excess stem torque may cause the valve stem to bend or break.

5 General Instructions
i) Preventive Maintenance (PM) of all valves, except, shall be performed once annually.
Longer or shorter PM intervals can be assigned by the proponent based on:
Valve Operational Criticality
Risk of potential failure and associated consequence
Frequency of operation
Maintenance and operational historical records
Service hazards and flowing medium severity
ii) Intervals for Preventive Maintenance (PM) of ZV and EIV shall be in accordance
with SAES-J-601.
iii) Critical valves identified by the proponent shall be included in the T&I activities
for complete overhauling.
iv A specific checklist of routine preventive maintenance requirements shall be
developed accordingly (Appendix A shows a sample checklist).

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Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 27 November 2014 General Instructions and Guidelines
Next Planned Update: 27 November 2019 for Online Valve Preventive Maintenance

v) Maintenance and Inspection data shall be logged at all times.

vi) During the PM, any abnormalities in the valve performance shall further
evaluated/diagnosed and scheduled for maintenance.

6 Inspection and Preventive Maintenance General Guidelines

6.1 Valve Body Visual Inspection and Maintenance

i) Clean and remove any dust, dirt or other deposits.
Notes: In case blasting to be performed, all safety aspects shall be complied with
as per GI-0006.021.

Valve’s identification data (tags and nameplates) shall be adequately

preserved during blasting and painting.

ii) Inspect the valve general conditions by checking the integrity of the paints,
and inspecting for signs of rust, external corrosion, oxidation, external
leakages or cracks. Check the required coatings and applications as stated
in SAES-H-001 and SAES-H-002.
iii) Clean and check grease fittings, and ensure their compliance to SAES-L-108
and 04-SAMSS-035 for the types and materials of fittings.
iv) Check and inspect the general conditions of all accessories, tubes and other
associated connections as recommended by API RP 574.
v) Examine the tightness of bolting such as body-bonnet, flange-line. Refer to
SAEP-351.
Note: Bolts can get loose due to frequent thermal cycles or vibration.
Also, different bolting materials have different torque as demonstrated
in manufacturer’s manuals and ASME B31.3 and ASME B16.5).

6.2 Stem and Packing Condition Inspection and Maintenance

i) Clean the stem (exposed parts), check stem/threads conditions and
lubricate accordingly.
Note: For rising stem in harsh environment, stem protections (covers) should
be provided. In addition, the selection of the lubrication type shall be
compatible with the service conditions.

ii) Check packing system integrity and inject lubricants/sealant accordingly

(refer to 04-SAMSS-001 for the types of packing).
Caution: For rising stem valves, online packing replacement shall be performed
only when full assurance of the backseat integrity can be verified.

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Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 27 November 2014 General Instructions and Guidelines
Next Planned Update: 27 November 2019 for Online Valve Preventive Maintenance

6.3 Valve Body/Seats Lubrications

i) Valves equipped with grease fittings shall be lubricated accordingly.
Note: The type of lubricants/sealant to be used shall be compatible with the
service conditions. Refer to Manufacturer recommendations.

ii) Cleaning and flushing chemical injection shall be used whenever needed
such as when back pressure buildup is observed during the lubrication
activities or for contaminant removal.
Caution: Always operate the lubrication equipment in accordance with the
manufacturer instruction.

6.4 Stroking

Valves shall be cycled/stroked at least once during the PM activity.

Commentary Notes:

Stroking must be coordinated with the Operations. If full stroking is not possible,
partial stroking must be carried out.

Valve to be stroked should be equalized during stroking to avoid valve stroking

difficulties, which might cause some parts or seals damage.

6.5 Draining of Body Cavity

Sealing capabilities of double block and bleed valves must be checked by

draining. Check whether the leakage is within the acceptable limit (refer to
API STD 598, and/or API SPEC 6D).

The draining must be handled with extreme cautions as high pressure maybe
released. Also; hazardous (toxic and/or otherwise poisonous, flammable or
explosive) materials might be drained, and thus draining must be contained
through a safe system in an environmentally responsible manner.

Check the compliance of drain and vent connections with 04-SAMSS-035 and
MSS SP-45).

6.6 Valve Gearbox Inspection and Maintenance

i) Check for any leak sign from the gearbox cover; replace any damaged
seals and O-rings to prevent water from entering the gearbox causing
corrosion problems.
ii) Top off the gearbox with lubricants as needed.
Notes:

The selection of the gearbox lube type shall be in accordance with the

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Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 27 November 2014 General Instructions and Guidelines
Next Planned Update: 27 November 2019 for Online Valve Preventive Maintenance

specifications of the manufacturer.

Gearbox shall not be overfilled as to avoid getting weather seal blown out.

iii) If sound or vibration is noticed in the gearbox during the valve stroking,
remove the gearbox cover to inspect gear drives condition. Remove any
dirt, sludge and corrosion. Replace damaged parts if any. Finally, top off
the gearbox with lubricant.

6.7 Actuator Inspection and Maintenance

a) Visual Inspection
i) Remove dust and dirt build up surfaces.
Note: Dirt build up can inhibit cooling thus, rising the temperature of the
actuator above the maximum allowable level.

ii) Inspect the actuator body for any cracks or paint work damage.
Touch up as required to ensure continued corrosion protection.
iii) Check all actuator to valve mounting bolts conditions. Tighten/replace
as necessary.
iv) Check actuator for lubricant leaks. Remove covers to inspect gear
drive conditions, and replace covers gaskets. Then, report finding.
Note: When refitting or replacing bolts, enclosure covers and fasteners in
corrosive environments apply applicable lubricant to threads, hinges
in order to prevent seizure or damage from corrosion.

b) Additional Requirements for Motor Operated Valve

i) Check condition for all cables, conduits, fittings, earth connections
and fasteners.
ii) Inspect and clean all relays, push button assembly, and contactors.
Check fuses for correct rating. (Refer to Manufacturer Data).
iii) Check Torque switch setting and operation.
iv) Check limit switch settings & adjust if necessary.
v) Check the motor starter contacts/interlocks.
vi) Check the signal indicator for correct indication during the valve
cycling.
vii) For the digital MOV's, check all cards from sign of damage or
discoloration, check the display screen.

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Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 27 November 2014 General Instructions and Guidelines
Next Planned Update: 27 November 2019 for Online Valve Preventive Maintenance

viii) Check the Actuator 9V/Lithium battery and record the reading,
replace if needed.
Caution: All maintenance activities of the actuator must be carried out
only after having isolated the actuator from the electrical supply
to prevent hazard.

c) Additional Requirements for Gas Operated Valve

i) Check actuator mechanism for visible hydraulic leaks & audible gas
leak during static and operation modes.
ii) Check and clean inside cabinets, flow valves, equipment and piping.
Inspect and rectify any gas or oil leaks on valves, hand pumps, oil
reservoirs and tubing connections. Replace any damaged tubing and
check security of all piping clamps.
ii) Check the regulators and pressure switches functionality.
Caution: Extreme caution needs to be taken while working with any
pressurized system. Always isolate, vent & depressurize prior
to disconnection of any part.

iii) Check gas supply filters. Drain, strip and clean/replace if necessary.
iv) Check Hydraulic System: check oil levels in accumulator bottles and
tanks. Clean filters, check pump couplings and top up oil level.
vi) Check pressure gauges conditions and functionality.
vii) Ensure the cabinet door seals are undamaged to prevent dust/sands
ingress.
viii) Check the Solenoid functionality.
ix) Check the limit switch and the external indicator and adjunct if
necessary.
d) Functional Test

The functional test procedure of each individual valve needs to be prepared

by the operational department based on the valve specific, plant experience
and vendor recommendation. The following steps might be included:
i) Check manual operation of actuator engagement and disengagement
for smoothly easy operation. Check if mechanical valve position
indicators and the actuator stops are correctly set.
ii) Check power operation of the valve both locally and remotely,
preferably fully stroking valve or to maximum possible stroke

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Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 27 November 2014 General Instructions and Guidelines
Next Planned Update: 27 November 2019 for Online Valve Preventive Maintenance

depending upon system flexibility.

iii) iii) Check the stroking speed if required.
Caution: Stop the motor immediately if any sign of incorrect operation.
It is vital that toque/limit switches are set correctly; incorrect
setting may cause damage to the valve internals. Readjust the
setting if necessary, per manufacturer’s guidelines. Do not
operate the actuator continually to avoid overheating.

Revision Summary
27 November 2014 Major revision as relevant SA General Instructions were clearly addressed in a safety
precaution section to ensure safety during performing Valve PM.

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Document Responsibility: Valves Standards Committee SAEP-29
Issue Date: 27 November 2014 General Instructions and Guidelines
Next Planned Update: 27 November 2019 for Online Valve Preventive Maintenance

Appendix A

VALVE NUMBER:____________
********************************************************
* *
* ENSURE SAFETY PROCEDURES ARE FOLLOWED AT ALL TIMES. *
* *
********************************************************
SAFETY: Does this job require electrical disconnection.
(if so, make sure that the breakout is done for the same valve).
EQUIPMENT: Make sure that all tools are checked and fit for service.

1. Inform operations of PM and obtain cold/hot work permit.

And the work area is accessible and safe for work. _____
2. Compare the information above of the work order against
the valve tag number (equipment name plate). _____
3. Clean and check the body appearance and ensure no rust, external
corrosion, oxidation, leakages, and cracks. _____
4. Examine the tightness of bolting such as body-bonnet,
flange-line. _____
5. Check stem seal and gland packing for oil leaks. _____
6. Clean/grease the valve stem. _____
7. Stroke the valve from fully open to fully close
and return back to open (or vice versa). _____
8. Ensure that the valve operates smoothly
and there are no abnormal sounds/motion/vibrations. _____
9. Clean area of any materials, tools, etc. _____
10. Inform operations that the PM has been completed
and close the work permit. _____
If any additional work was done or required, please give
details below or on the back of this sheet.

Comments:__________________________________________________
___________________________________________________________
___________________________________________________________
___________________________________________________________

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