Analysis of safety relief valve proof test data to optimize lifecycle maintenance costs

Proof test results were analyzed and compared with a proposed life cycle curve or hazard function and the limit of useful life. Relief valve proof testing procedures, statistical modeling, data collection processes, and time-in-service trends are presented. The resulting analysis of test data allows for the estimation of a probability of failure on demand (PFD). Extending maintenance intervals to the limit of useful life as well as methodologies and practices for improving relief valve performance and reliability are discussed. A generic cost-benefit analysis and an expected life cycle cost reduction concludes that $90 million maintenance dollars might be avoided for a population of 3000 valves over 20 years.