PSV In-Situ Testing (Online Safety Valve Verification)
Advanced PSV Testing Services
Tenova Synergy provides non-intrusive, in-situ testing for spring-loaded Pressure Safety Valves (PSVs) using a portable and advanced system – allowing full performance verification without removing the valve or stopping operations.
In-situ testing, also known as hot testing, simulates actual process pressure conditions and ensures the valve opens (cracks) at its designated set point. This method allows plant owners to maintain full productivity while verifying that PSVs are in compliance with safety and regulatory standards.
Key Advantages of In-Situ PSV Testing
Maximize safety assurance while minimizing downtime and cost.
In-situ testing is a game-changing method that enables safety valves to be tested under actual process conditions without removal or shutdown. This approach not only enhances operational reliability but also supports efficient plant maintenance planning. Below are the key benefits that make in-situ PSV testing a preferred choice for modern facilities:
✅ No Plant Shutdown Required
Testing can be done while the system is live — no need to isolate, drain, or shut down the process, which minimizes disruption to operations.
✅ No Dismantling of Valves
Valves are tested in place, eliminating the need for removal, transport, or reinstallation. This reduces manpower, downtime, and risk of mechanical damage.
✅ Maintains Production Uptime
Since testing is performed during normal operations, there’s zero loss in production. This ensures full continuity of supply and output, especially for critical systems.
✅ Instant Digital Test Reports
Real-time data is captured, analyzed, and displayed through intuitive software — providing immediate visual confirmation of valve condition, set pressure, and performance.
✅ Complies with International Standards
The system complies with safety and testing norms (API, ASME), and can be used in ATEX-certified zones, ensuring both safety and regulatory alignment.
✅ Cost-Effective Maintenance Strategy
By reducing the need for full plant outages and valve handling, in-situ testing lowers both operational cost and maintenance turnaround time.
Certified for hazardous zones. Tested for performance. Trusted for uptime.
Tenova’s in-situ PSV testing uses ATEX-compliant portable systems to deliver accurate safety valve performance validation directly on-site — even in explosive atmospheres (Zone 1 & 2). By eliminating the need for shutdowns or valve removal, we help clients ensure safety, compliance, and productivity — all at once.
How the System Works
Tenova’s in-situ PSV testing system uses a lightweight, ATEX-certified test bracket that is mounted directly onto the safety valve. Once in position, it applies a precisely controlled lifting force to the spindle, simulating actual process pressure without disrupting operation.
As the valve begins to crack open, high-precision sensors capture real-time performance metrics, including:
Set pressure (cracking point)
Re-seat pressure
Valve movement consistency across multiple test cycles
Spring stiffness & lift profile
Acoustic feedback and actuation force
All test data is immediately visualized on-screen through specialized software and stored digitally for traceability and future audits.
Core Features & Certified Outcomes
Tenova’s in-situ PSV testing delivers a complete safety assurance package — enabling predictive maintenance, operational continuity, and compliance with global safety standards — all without the cost and hassle of valve removal.
Safety & Technical Highlights
Built-in Lift Restrictor
Prevents unintentional full-lift or extended discharge during testing.
Emergency Shutdown Function
Allows quick force release and valve closure in case of anomaly or risk.
ATEX Certified (Zone 1 & 2)
Safe to operate in explosive environments — bracket rated for Zone 1, control unit for Zone 2.
Valve Management System Integration
Enables seamless data sync, tagging, and recordkeeping within your digital maintenance ecosystem.
Standard Power Supply
Operates on single-phase 100–240V, compatible with site utilities.
Comprehensive Deliverables
Certified PSV Test Report (PDF)
Generated instantly with result summary and tolerances.
Digital Graph Analysis
Clear graphical insights of valve behavior across test cycles.
Historical Data Logging
Full performance traceability stored in the valve database.
Verification Certificate
Including set pressure accuracy, re-seat confirmation, and compliance tolerances.
Ensure Safety and Efficiency with Tenova Today
Tenova’s in-situ PSV testing delivers a complete safety assurance package — enabling predictive maintenance, operational continuity, and compliance with global safety standards — all without the cost and hassle of valve removal.