Pressure Relief Valve (PSV) Set Pressure Test Record Template
Every relief valve that comes through a test shop needs a record that shows what it popped at when received and when released. This template captures the identification, set pressure data, as-found and as-left results and repairs on a single page.
Fill in
Pressure Relief Valve Set Pressure Test Record Template
Pressure Relief Valve Test Record
Facility: Gulf Valve Repair and Test Tag: PSV-2041A Serial: SV-883712 Manufacturer / model: Spring-loaded conventional, 2J3 Size / orifice: 2 in x 3 in, orifice J Test date: 2026-10-19
Test Basis
Set pressure: 285 psig Cold differential test pressure: 285 psig Tolerance: +/- 3 psi up to 70 psig, +/- 3% above Test medium: Air
Results
As-found popping pressure: 296 psig As-left popping pressure: 286 psig
Seat Tightness and Condition
| Check | As found | As left | Notes |
|---|---|---|---|
| Seat tightness at 90% of set | |||
| Visual condition (corrosion, deposits) | |||
| Spring and guide condition | |||
| Blowdown ring setting |
Repairs and Adjustments
Disassembled, cleaned, lapped seat and disc, replaced spring washers, reset blowdown ring, resealed adjusting screw.
Approval
Use the tolerance and seat tightness criteria from your repair procedure, the customer's requirement or the applicable code such as API 527. The 90 percent test point above is a common convention, not a universal rule. Gauges used for testing must be calibrated and traceable.
Track PSV due dates against your maintenance system
Optional: a short review of how test intervals and tags could be monitored from your ERP.
Optional. The tool and every export work without this. No spam.
How to use this template
Enter the tag, serial number, manufacturer and orifice. Fill in the set pressure and cold differential test pressure, which accounts for back pressure or service temperature on the nameplate. Record the as-found popping pressure before any cleaning or adjustment, then the as-left value after repair. Complete the seat tightness table, describe the work done, and export the record for the valve tag and the plant's PSV register.
Understanding as-found versus as-left
The as-found result tells the operator whether the valve would have protected the equipment while in service, so a high as-found pop is a reliability finding, not only a repair detail. The as-left result proves that the valve now meets its set pressure within tolerance. Set pressure on the nameplate is the service value, while the cold differential test pressure compensates for back pressure and operating temperature when the bench test runs at ambient conditions.
- Record as-found first, before touching the valve
- Never discard an as-found reading that is out of tolerance
- Use the same gauge for as-found and as-left tests where possible
- Seal the adjusting screw and tag the valve after the final test
Common mistakes
The common errors are testing at the service set pressure instead of the cold differential test pressure, recording only the final result, and issuing a record with no gauge calibration reference. Another is mixing up tags when several identical valves are in the shop at once. Use a physical tag at receiving, and photograph the nameplate as part of the record.
Frequently Asked Questions
What is a cold differential test pressure?
It is the pressure at which the valve is set on the bench so that it opens at the correct set pressure in service. It adjusts for back pressure and for the difference between ambient and operating temperature.
Why record the as-found pressure?
Because it shows how the valve behaved in service. If it opened well above set pressure, the plant should evaluate whether the protected equipment was at risk and whether the test interval should be shortened.
What medium should I use?
Use the medium specified by your procedure and the valve type. Gas and vapor valves are normally tested with air or nitrogen, steam valves with steam, and liquid valves with water.
How often are PSVs tested?
The interval depends on the code, jurisdiction and the plant's risk-based inspection program. Your inspection authority or API 510 and related practices set the maximum, so use the interval from your own program.
If PSV test dates and due dates live in spreadsheets, we can help connect them to your ERP or maintenance system so overdue relief valves surface automatically.
Related Tools
Wellhead and Christmas Tree Factory Acceptance Test Template
Record assembly details, pressure tests, function tests and witness sign-off for a wellhead or tree FAT, then export it for the data book.
Industry TemplatesHydrostatic Test Pressure and Water Volume Calculator
Compute test pressure from MAWP and lowest stress ratio, recommended gauge range, and the fill volume and water weight of a cylindrical vessel.
Maintenance & ReliabilityFlange Bolt-Up Torque Sequence Log Worksheet
Log each flanged joint with target torque and calculated pass values at 30, 60 and 100 percent. Edit rows and export to Excel.
Quality & InspectionPositive Material Identification PMI Record Template
Document XRF alloy verification by heat number and component, with instrument details, acceptance basis and sign-off. Exports to PDF or Word.
More Maintenance & Reliability tools
See all- MTBF and MTTR Worksheet
- TPM Autonomous Maintenance CIL Standard Template
- TPM Autonomous Maintenance Standard Template
- TPM Pillars and Autonomous Maintenance 7 Steps Reference
- Preventive Maintenance Schedule Template
- Maintenance Work Order Template
- Inherent vs Operational Availability Calculator (MTBF, MTTR)
- Spare Parts Criticality Scoring Worksheet
- Maintenance Backlog Calculator (Weeks of Work and Crew Size)