GE EVT-Pro User manual

EVT-Pro Technical Manual
Version 1.0
Release date: 1-May-2012
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GE Energy
The Next Generation Valve Testing Device for Pressure and Safety ReUef Valves
• imagination at work
Consolidated EVT -Pro
Rev - 1.0 / Page 1 / 10/10/2012
The Next Generation Valve Testing Device for Pressure Relief Valves

How to Use This Manual
This manual is equipped with hot links which enable the reader to instantly jump to a desired location in this manual. Also.
There are comments and attachments which can be viewed by clicking on the appropriate icon. Below is an explanation of
the various icons used in this manual.
•The Menu icon will take the reader to the first page of the Table of Contents.
•The Back Arrow will take the reader back one page.
•The Forward Arrow will take the reader to the next page.
•The Chart icon is found on pages which relate directly to the EVT-Pro Software Quick Reference Guide. Click on
this icon to be taken to the first page of the EVT-Pro Software Quick Reference Guide.
•Click on the comment icon to view additional comments.
•Click on the red thumbtacks to view attachments to this manual.
Rev - 1.0 / Page 2 / 10/10/2012

LEGAL NOTICE
To maintain the design, accuracy, safety, and regulatory integrity of the EVT-Pro, a Green Tag
Center (GTC) is NOT authorized to make any changes to the EVT-PRO unit unless approval to
make changes is provided in writing by an authorized person within GE Energy.Specifically, the
following changes are not authorized:
•Modifications of any sort to the test fixture, cabling, mounting, or other changes related to
the test fixture
•Modifications to any software which will alter any setting critical to the accurate testing of
the pressure relief valve
•Modifications to any seat areas of the EVT-PRO which are stored in databases.
•Modifications and/or use of the GE or Consolidated logos in any form other than as
approved for use on the GE website.
*Trademark of General Electric Company 2011 General Electric Company, All rights
reserved Other company names and product names used in this document are the
registered trademarks or trademarks of their manufacturer owners
Rev - 1.0 / Page 3 / 10/10/2012

TABLE OF CONTENTS – Page 1
AUTHORIZED USE AND RESPONSIBILITIES
•Authorized use
•Technician Responsibilities
IN SITU PRV TESTING, TECHNICAL DESCRIPTION
•Overview
•Explanation of graph
•Mathematics of In Situ PRV Testing
•EVT-Pro Physics
•Influence of PRV Geometry on Accuracy
•Influence of Process Pressure on Accuracy
•Transducer Accuracy
•Overall Accuracy
Rev - 1.0 / Page 4 / 10/10/2012

TABLE OF CONTENTS – Page 2
EVT-Pro Technical Components
•Hand Pump with Electronics
•Hardware Assembly
•Hydraulic/Electronic Cable Assembly
•Laptop Computer
Explanation of Functional (Effective) Valve Seat Area
Functional Effective Seat Areas
Using the EVT-Pro Software
How to Test a Valve
Certificate Management
Rev - 1.0 / Page 5 / 10/10/2012

TABLE OF CONTENTS – Page 3
Options
•Hardware Settings
•Software Settings
•Graph Settings
•Category Settings
•Unit Settings
•Back-up database settings
•Report Generator
•Miscellaneous Settings
Calibration Requirements of EVT-Pro
EVT-Pro Calibration Requirements
EVT-Pro Troubleshooting Guide
EVT-Pro Troubleshooting Guide
Rev - 1.0 / Page 6 / 10/10/2012

TABLE OF CONTENTS – Page 4
•ValvKeep IMPORT
•Valvkeep EXPORT
•Quick Reference Guide / Flowchart
•Part Number Listing
•EVT-Pro Marketing Presentation
•EVT-Pro Fact Sheet
EVT-Pro Contacts at General Electric
•
•
Rev - 1.0 / Page 7 / 10/10/2012

AUTHORIZED USE AND RESPONSIBILITIES
.
Rev - 1.0 / Page 8 / 10/10/2012

Authorized Use:
The EVT-Pro is constructed using state of the art technology and according to established technical safety regulations.
Improper use of the EVT-Pro can result in injury or death.
Technicians must adhere to the following guidelines in order to prevent personnel accidents or cause damage to the EVT-
Pro or other equipment.
•Consolidated® restricts the use of the EVT-Pro to technicians certified by the Consolidated® Product Training
Department.
•Prior to initial operation, read this technical manual carefully. Ensure all technicians operating the EVT-Pro understand
the functions and controls, the hardware assembly, and the computer.
•Prior to operation, ensure all components of the EVT-Pro are operational. Immediately correct any faults that may
impair testing.
•Do not attempt to make any software changes to the computer system. Do not load any additional software with the
exception of printer drivers to the laptop computer.
•Consolidated®, or its designee, is the only authorized repairer of the EVT-Pro. IN FIELD REPAIRS ARE NOT
AUTHORIZED
Rev - 1.0 / Page 9 / 10/10/2012

Technician Responsibilities
•Keep this technical manual available at all times.
•Observe and comply with recognized safety measures and obligatory regulations regarding accident prevention
and environmental protection.
•Consider additional factors including, but not limited to, organization of work, plant production schedule, and use
of additional personnel when using the EVT-Pro.
•Thoroughly inspect the EVT-Pro periodically during operation to ensure safe operation and accurate test results.
•The EVT-Pro system contains two batteries. The average battery-life for both the computer battery and the
pump battery is eight hours. Ensure the batteries are charged prior to use.
•Always wear appropriate PPE when using the EVT-Pro.
•Do not use the EVT-Pro during periods of inclement weather, i.e., dense fog, rain, sleet, snow, etc. Immediately
abort the use of the EVT-Pro if lightning occurs.
Rev - 1.0 / Page 10 / 10/10/2012

Additional Technician Safety Concerns
Ensure all personnel adhere to the following additional safety precautions during EVT-Pro testing:
•Do not stand in front of the discharge side of a pressure relief valve when testing.
•Exercise extreme care when examining a pressure relief valve for visible or audible leakage.
•Know the points of possible media exhaust or leakage for the valve being tested. Some valves exhaust media at
locations other than the valve outlet.
•Ensure installed pressure relief valves provide adequate access around the valve to include overhead clearance for
equipment mounting. Per Consolidated drawings, the minimum overhead clearance is 18 inches.If an overhead
obstruction is present, check if the valve can be tested using the reduced height bracket kit.
•Use caution when testing pressure relief valves installed in flammable or toxic environments. Ensure appropriate
protective measures are being implemented.
DO NOT OPERATE THE EVT-PRO IF SAFETY IS QUESTIONABLE!
“GE Energy/Consolidated® is not responsible for damage or personal injury caused by failure to follow the instructions
contained in this manual, poor maintenance of the EVT-Pro, or improper use of the equipment. Consolidated® emphasizes
that working with high pressure media is dangerous and can cause serious injury or death. The operator of the EVT-Pro must
be aware of this danger and operate the equipment accordingly.”
Rev - 1.0 / Page 11 / 10/10/2012

In Situ PRV Testing / Technical Description
.
Rev - 1.0 / Page 12 / 10/10/2012

1
GE Title or job number
9/18/2012
In Situ PRV Testing, Technical Description
Overview
In Situ PRV testing enables the technician to accurately
determine the PRV’s set pressure without removing the PRV
from the installation. The test result obtained during in situ
testing is considered the ‘hot set pressure’, not the ‘cold set
pressure’, given that normal operating conditions are present
during testing.
During in situ testing, hydraulic force is applied to the PRV
spindle, fractionally lifting the disc off the seat. An installed
force transducer, records the hydraulic force necessary to lift
the disc from the seat. The EVT-Pro combines this
measurement with an indication of lift and an increase in
sound produced by flow through the PRV to determine the PRV
set pressure.
Graphic evaluation of the hydraulic force, lift, and sound
enables the technician to accurately determine the PRV set
pressure (Fig. 1).
Rev - 1.0 / Page 13 / 10/10/2012
Set Pressure (Green)
Hydraulic Force (Red)
Lift Indication (Blue)
Inlet Pressure (Brown)
Sound Indication
(Orange)

1
GE Title or job number
9/18/2012
In Situ PRV Testing, Technical Description
Explanation of Graph
Rev - 1.0 / Page 14 / 10/10/2012

Mathematics of In-Situ PRV Testing
.
Rev - 1.0 / Page 15 / 10/10/2012

Mathematics of In-Situ Testing
The ability to accurately determine PRV set pressure during in situ testing relies on three known factors:
•Hydraulic force generated by test equipment
•Inlet pressure resulting from process pressure
•Effective seat area of PRV
Rev - 1.0 / Page 16 / 10/10/2012

Influence of PRV Geometry on Accuracy
.
Rev - 1.0 / Page 17 / 10/10/2012

Influence of PRV Geometry on Accuracy
The point of contact between the disc and the seat determines the effective seat area of the PRV. As
indicated in Fig. 2, the effective area is somewhere between the inner and outer diameter of the seat. In
order to accurately measure set pressure, it is extremely important that this data be accurately
determined using proven engineering methods.
Rev - 1.0 / Page 18 / 10/10/2012

Influence of Process Pressure on Accuracy
During in situ testing, accuracy increases when the difference between process pressure and PRV set
pressure is minimal. However, technicians and plant personnel must realize that the possibility of
putting a PRV into full lift also increases when process pressure is close to PRV set pressure.Do not
conduct in situ testing when the process pressure is less than 50% or greater than 90% of the PRV
set pressure.
Transducer Accuracy
The transducers provided with the EVT-Pro are calibrated in a dedicated test facility and are delivered
with a certificate of calibration. The accuracy of the force transducers is higher than 0.1% F.S. To
maintain this high level of accuracy, GE Energy/Consolidated® requires the EVT-Pro be calibrated on
an annual basis. They are to be returned for calibration per instructions found under the EVT-Pro Tab
on GTC.Net Overall Accuracy
The overall accuracy of in situ testing is based upon the accuracy of the test equipment used, the
accuracy of the gauged inlet pressure, and the accuracy of the effective seat area. Of the three,
effective seat area is the most critical element in determining an accurate set pressure. Typically the
accuracy of the EVT-Pro is within 1% of expected set pressure.
Rev - 1.0 / Page 19 / 10/10/2012

EVT-Pro Parts Lists / Drawings
Bracket Tool Case
Load Cell / Sensor case
Rev - 1.0 / Page 20 / 10/10/2012