Nov 2019

Slides marked “Skip” provide additional

information for Relief System sizing
engineers
Introduction
Codes & Standards
Relief Devices

Relief Systems - Introduction

Acknowledgment
API STD -RP 520/ 521/ 526/ 537
Various Client/ Project Standards/ Specifications
DEDICATED TO:
Pictures from many sources, suppliers, internet
My friend Winston Yeo, KBR, Singapore/ Chevron, Thailand

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PRV
PAHH
PIC/PAH
NOP

Control system: Maintains stable operation Relief devices - key Layer of Protection
Trip / shutdown system: Provides primary protection, when  Protect plant and personnel. Avoid production loss
control system fails  Avoid loss of containment and environmental release
Relief system: Provides secondary or ultimate protection - or Relief devices are required by national codes and
last line of defence, when control and trip systems fail standards, mandated under national and local laws
PRV
PIC
Community Emergency Response. Evacuation

T0 Flare Plant Emergency Response. Containment/ Evacuation

PAHH
PALL
T0 Compressor Mechanical Mitigation. Relief System
SDV Operator Action Mitigation
SIS Trips. Operator Response Prevention
Fluids Separator
SDV Controls & Monitoring
SDV Alarms
SDV Operator Supervision
Oil/ Light Liquid
RV lifting: A serious incident Water/ Heavy Liquid Process Design

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Tank drained with vent

closed. Pulled vacuum

Fast chemical reactions

 Very high pressure propagation. Loss of containment
occurs before PRV pops
 “Hot spots,” decompositions, detonation or fire
Plugged PRV
Air freshener can in a closed
Plugging, polymerization or deposition block PRV car - Thermal
High relieving rate. Large relief area Column internals - Pyrophoric fire
Use Rupture Discs
Multi-phase relief: Rate difficult to predict
Relief creates hazards due to stack location
Relief requires very large vent/ flare system
Use HIPPS
HIPPS = High Integrity Pressure Protection. 2 separate SDVs closed by 2 independent PAHH Vacuum column fire Surge rupture of FW piping.
Semi sub tilted and sank

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Vessels under 15
psig excluded
Codes
 ASME Sec I - Steam Boilers. Sec VIII - Unfired Pressure Vessels
 ANSI B31.1 Power Plant Piping. B 31.3 Refinery Piping
 ASME B16.5 / Flanges & Flanged Fittings
 IBR Indian Boiler Regulations

Recommended Practices/ Standards. API

 RP 520 Pressure Relieving Devices in Refineries
▪ Part I Sizing and Selection. Part II Installation
 STD 521 Pressure Relief and Depressuring Systems
 STD 526 Flanged Steel Pressure Relief Valves
 RP 2000 Relief load calculations for Storage Tanks

ASME is a Code. Compliance is mandatory

API is a recommended practice. Getting adopted as a National / International Standard

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Operating Pressure = Normal plant operation PRV Relieving Pressure

 + margin = Alarm PAH or PCV Dump Set Point  Full capacity at Relieving Pressure
 + margin = Trip PAHH Set Point  Set pressure + margin as below
 + margin = Design Pressure  Non-fire 10%. Fire 21%. [Min 3 psig MAWP 15 to 30 psig]
 16% with multiple PRVs. [Min 4 psig MAWP 15 to 30 psig]
Design Pressure  Europe: 10% for all the cases
 Min 2 bar or PAHH + 10%. Min 3 barg (50 psig) for HC Relieving Pressure
vessels to flare or vent against an internal explosion  Set pressure + Overpressure or
 MAWP + Accumulation
PRV set at DP. May be set below DP if gap is high Why 21% for fire? Infrequent event (10% above 10%). Higher % gives a
 >1 PRV in service. Non-fire at 105% DP. Fire at 110% smaller PRV size. No practical use as PRVs come in standard sizes with step
change in area 20-80%. Helps avoid going for a bigger PRV in borderline cases

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Vessel
Pressure Vessel Requirements Pressure PRV Characteristics
Max Allowable Accumulated 121 Relieving Pressure - Fire Case
Pressure - Fire Case
1. MAWP = Maximum Allowable Working Pressure > DP. Multiple PRDs - Relieving
Standard thickness plate for vessel fabrication. Wall Multiple PRDs - Max Allowable
Accumulated Pressure -non-fire cases
116 Pressure - non-fire cases
thicker than required/ calculated Multiple PRDs - Max Set Pressure
- additional fire case PRD
2. MAWP is known late in engineering. PRV is set per Single PRD - Max Allowable
110 Single PRD - Relieving
Accumulated Pressure - non-fire cases
DP Pressure - non-fire cases

Overpressure
3. For revamp: MAWP OK. Caution: Corroded walls! 105
Multiple PRDs - Set Pressure for
additional PRD - non-fire case

Max Allowable Working Pressure

4. Hydrotested to 130% of MAWP or Design Pressure
100
Simmer
Single PRD - Max Set Pressure

Blowdown
5. PRVs can be set below DP or MAWP
6. PRVs reseat after a lift at a pressure 3-7% below set 95

point (=blowdown). So PRVs set 3-7% above PAHH Single PRD - Closing Pressure
Expected Max Operating Pressure 90 Leak Test
7. Overpressure is above Set Pressure. Accumulation is Pressure
Where PRD is set below MAWP, overpressure
above MAWP can be higher to match MAWP + Accumulation,
85
subject to manufacturers guidance

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Contingency Single Device Multiple Devices

Unit: MAWP Max Set Max Accumulated Max Set Max Accumulated API 520 Non-Fire Fire
Press, % Pressure, % Press, % Pressure, % Single Multiple Single Multiple Supplement
Non-Fire Case MAWP 100 100 100 100 100
First PRD 100 110 100 116 (16% OP) Accumulated Press 110 116 121 121 121
Additional PRD 105 116 (10% OP) First - Set At 100 (90) 100 100 (90) 100 100
Fire Case First - Over Press 10 (20) 16 21 (31) 21 21
First PRD 100 121 100 121 (21% OP) First - Relief 110 116 121 121 121
Additional PRD 105 121 (16% OP)
Supplement PRD 110 121 (10% OP) Additional - Set At 105 105 110

Accumulation / ASME - Relieving Pressure, as % MAWP Additional - Over Pr 11 16 11

 Single Device: 3 psi (21 kPa) when MAWP 15-30 psig (103-207 kPag) Additional - Relief 116 121 121
 Multiple Device: 4 psi (28 kPa) when MAWP 15-30 psig (103-207 kPag)

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Relief Valve: Opens in proportion to overpressure.

Liquid / incompressible fluids service
Safety Valve: Opens rapidly. Pop action. Vapour/
compressible fluids service
Safety Relief Valve: Either Relief or Safety valve

Pressure Relief Valve- PRV: Generic term for above

Pressure Relief Device - PRD: Generic term for PRV,

Rupture Disk and Rupture Pins

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V-002

Design Pressure: Design pressure at design temperature Backpressure: Pressure at PRD outlet E-001
MAWP: Max Allowable Working Pressure on vessel
top at coincident temperature ≈> Design Pressure Superimposed: Pressure at PRD outlet before it
Set Pressure: Pressure at which PRD opens. ≤ MAWP opens. Adds to spring load and increase set
pressure
Burst Pressure: Pressure at which Rupture Disk opens  Constant: Always present and remains the same. PRD
discharges to a closed system. Can be high ~ 50% of SP.
 Upstream static pressure minus downstream static pressure
PRV spring adjusted
Relieving Pressure: Set pressure + Overpressure or
 Variable: Due to on flow from other sources when
MAWP + Accumulation discharging to a common header. Don’t adjust the
Why?
spring to avoid premature opening
As supplier adjusts the spring for superimposed BP, do not give
Where PRD is set below MAWP, overpressure can be higher to a superimposed constant BP in a data sheet unless one exists
match MAWP + Accumulation, subject to manufacturers guidance

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Flare
V-002

Built-up: Pressure at PRD outlet as a E-001

Normal Operating Press = 0.3 U Header
∆P = 10 U due to flow from PRDs
result of PRD flow. ΔP in discharge
SP = 100 U ∆P = 5 U
 Does not affect PRD opening but reduces capacity Flare KOD
Relief valve Care needed while
 Should be less than overpressure viz, 10%, 16% and specifying constant BP

21%
Total backpressure = Superimposed + Built-up Superimposed Constant Backpressure = 0.3 U
BP Built-up Backpressure = 10+5 = 15 U
Total Backpressure = 15.3 U
Spring set at: 100-0.3 = = 99.7 U
PRD Sizing ∆P Non-Fire = 110-15.3 Fire 121-15.3

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Rupture Disk

Rupture Pin Buckling Pin

Relief Valve

PVRV

Explosion Door Blow-off Hatch

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Backpressure adds
to the spring force

Widely used Bellows isolate backpressure from

100
 Simple, cheap and reliable
spring. No change in opening pressure
 Maximum backpressure 30% on all
Back Pressure, BP 0
Backpressure 
50
except smaller sizes. Up to 50% with
 Reduces capacity capacity correction
Manual lever, to
 Backpressure adds to spring  Beyond 30% backpressure, lift and hence
blowup solids
capacity affected
load. Increases PRV opening build-up on seat
pressure. Vessel under risk Bellows
Built-up BP Fragile. Mechanical pressure limit
 ≤ overpressure 10/ 16/21% Movement gets restricted in plugging
Large springs limit Set and polymerizing service
Pressure of bigger PRV Get sealed in hydrate, solid, foaming
150# Set Press, psig at 100°F and coking services
150# Flange 285 psig @ 100°F D – P Q R T Keep foreign matter out of bonnet
285 165 100 65

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Bellows Pilot: A small external PRD. Routes process

Prone to fatigue and pin-hole leaks. pressure to dome - top of valve seat
[Leaks take away ability to handle Same (process) pressure on top and bottom
backpressure. Hence bonnet is of seat balances it and keeps it closed
vented. As long vent is bigger than Larger top area Vs smaller bottom area.
“holes”, OK] Higher downward force, keeps valve shut c.f.
opposite of spring loaded PRV, that may simmer
Bonnet vent routed to safe location
in toxic service Can operate close to set pressure, say 98%
Potential freezing of atmospheric At set pressure, Pilot vents source pressure
moisture in cold ambient or in cold from top and PRV opens. No backpressure
service due to auto-refrigeration impact
Original purpose to protect spring Instead of a piston, a diaphragm in low
from corrosive fluids pressure service
Piston top area > bottom area. For the same pressure, force on top > force on bottom, keeping the seat TIGHTLY closed

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No heavy spring load to overcome. Full lift and capacity Pilot is a small PRV!
near set pressure 1. As process pressure reaches set
Larger PRV can have higher set pressure. Not limited by pressure, the spring is compressed.
spring force. c.f. opposite of spring loaded PRV Lower feeding seat closes, isolating
process gas
2. Upper drain seat opens, venting
Pop pilot: full lift at set pressure. One shot venting. Rapid dome gas and opening RV.
relief of gas. Spring loaded pilot. Not recommended in As process gas is isolated during a
liquid service to avoid instability relief - this is a non flow pilot
Modulating pilot: full lift at relieving pressure. Gradual  avoids hydrate and solids/ dirt in
venting. Opens with a small pressure rise. Relieves what is lading fluid issues
reqd. Diaphragm
Flowing pilot: Process gas
 ∆P on relieving rate and not on valve capacity discharged before, during and after
relief. Not recommended
Pilot: If vented to atmosphere, backpressure has no effect  May lead to freezing or particulates
on SP. If vented to valve outlet, use balanced pilot Spindle travel - decides into the pilot
blowdown. 3% blowdown possible

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Remote sensing: Pilot intake need not During start-up, blowdown, and
be at PRV inlet. Removes inlet line
pressure loss effect. shutdown, vessel pressure may be
Non-flow sensor ≈ 0.4”/ 8mm φ) lower than flare header pressure
 In Pop: avoids cycling/ chattering
In Modulating: full lift at required OP
 Sense static pressure. ∆P will lower SP.
Higher backpressure can lead waste
Dampener to reduce pulsating effects in gas reaching dome, open the seat,
pilot line allowing waste gas into vessel+
Corrosion, polymerizing, plugging product contamination, E.g. LPG
service: Sensing line can plug. Non-
Typical PRV: No-flow, pop action
service.
flow or filtered sensing line in dirty
service elastomer seat/ seal type
 Filter plugging: Purge system may be Check valves or Back flow preventer
Pilot PRV:
required
Less commonly used
in pilot lines will stop waste gas into
 Inert fluid isolation for polymerization,
viscous, dirty and corrosive May require prior approval vessel

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Nozzle/ orifice
- flow decided by:
 Sonic: Upstream pressure
 Subsonic: ∆P = (P1-P2)
Sonic to Subsonic
100
Orifice Formula
80  Flow α P1 for sonic
 α (P1-P2) for subsonic
Flow, % 
60
Perfect Nozzle 
40

20

0
0 20 40 60 80 100
Built-up Backpressure, % Pinlet 
PRV Flow Characteristics

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Backpressure adds to spring Cold differential test pressure: Bellows nullify backpressure effect
force. Increases Set Point Set pressure with correction on set pressure, to an extent
Reduces lift, flow area and for backpressure and/or
capacity. Unstable operation. temperature service condition Bellows fixed at upper end. High
Unable to deliver nozzle flow  Temp at PRV inlet at normal backpressure lengthens the bellows
operating conditions. May not at the lower end, restricting seat lift
At 15% valve fully closed be the same as process due to At 35% Capacity reduced
100 rupture disk or heat tracing 100 Backpressure mechanical limit
Why? decided by bellows. Bigger the PRV
80 If the superimposed 80 lower is allowable backpressure.
Balanced backpressure is not constant, Balanced
 Affects non-flowing PRVs too.
Flow, % 

Flow, % 
60 do NOT adjust the spring - cold 60
Forgotten by Process Engineers. See
Perfect Nozzle  differential pressure Perfect Nozzle  RP 526
40 40

20 Conventional 20 Conventional Difficult to have small bellows. Size

Pilot PRV Pilot PRV
D & E, may be a ‘modified’ F !!
0 0
0 20 40 60 80 100 0 20 40 60 80 100
Built-up Backpressure, % Pinlet  Built-up Backpressure, % Pinlet 
PRV Flow Characteristics PRV Flow Characteristics

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 University of Milan Test on 5 Balanced Flow follows closely nozzle flow

PRV
 Bellows OK to 40% is a myth For k = 1.3 & BP = 70%.
100
 Capacity at BP Remarks Flow: Nozzle = 92% Pilot = 78%
Lost, % %
A 10 50 80
A 100
B 30 40
Flow, % 

B
C 40 30 60 80
Balanced
D 20 30 0% at 32%
Flow, % 
60
E 60 18 bellow ruptured 40 C Perfect Nozzle 
D 40
E
20 20 Conventional
Pilot PRV
0
0 0 20 40 60 80 100
0 20 40 60 80 100 Built-up Backpressure, % Pinlet 
Built-up Backpressure, % PRV Flow Characteristics

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Outlet: PRV Area Ratio

Area, in2
Size (Ao/A)
Backpressure reduces lift/ area/ flow
1½ D 2 0.110 (31)
 As flow reduces, backpressure is reduced.
Valve opens again and then closes 1½ E 2 0.196 (17)
 Rapid open/ close cycling or chattering. Seat & 1½ F 2 0.307 (11)
bellows damage. [Fluttering: Similar, but seat 2G3 0.503 (15)
untouched]
2H3 0.785 (9)
P2, backpressure at valve outlet flange is known 3J4 1.287 (10)
and NOT PB inside at nozzle outlet 3K4 1.838 (7)
Bigger PRV. Smaller is outlet. Higher is PB
PB, controls flow in sub-sonic cases 3L4 2.853 (5)
4M6 3.600 (8)
Vendors apply correction factor to Nozzle Coefft - 4N6 4.340 (7)
based on body / nozzle geometry 4P6 6.380 (5)
6Q8 11.050 (5)
P2
PB 6R8 16.000 (3)
8 T 10 26.000 (3)

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PRD starts simmering - as in kitchen Pressure PSV pop action:

Cooker
As initial flow starts, pressure builds up in  Small area disk in a larger diameter
Huddling Chamber B, increasing area below
spring, overcoming spring inertia chamber
Additional pressure build-up at C. Disk lifted up  Above setpoint as stem lifts, process
 When lift ≈ ¼ Nozzle dia, flow decided by bore than
curtain fluid flows to the chamber
 Larger chamber area  uplifting force
Liquid PRDs: No expansion forces as in gas
 Gas PRDs in liquid service need 25% overpressure. larger than spring force and PSV pops
PRV PRV
With 10% OP, K = 0.6  bigger PRD and instability (opens completely)
 Surge to 50-100% lift at 2-6% OP
 Now liquid certified PRDs available and
recommended for liquid and 2 Phase < 50%V
PSV  PRV Operation  PRV Vs PSV  PRV Pops PSV

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Boiler Board Formula with Lift

S Overpressure
As the seat lifts, flow is thru Pressure
Seat
Pop Pressure
(i) curtain at partial lift and Blowdown
Disk Set Pressure

Curtain
(ii) nozzle at full lift Reseat Pressure

Lift, L
P
Nozzle Area = πD²/4
Curtain Area = πDL. L = D/4 Skirt Increases
Usual L = 0.3 - 0.4 D Nozzle Decrease
Diameter, D Stage 1 Stage 2 Stage 3 Stage 4
Blowdown
At PRV opening point, Ring
pressure * area = spring load Lift
For full lift, additional overpressure Set Pressure Vs Lift - Conventional
required to overcome spring inertia. 100
10% not enough. Simmer

Lift, % 
Solution? Add a skirt to seat, to add
‘area’ and redirect flow to add to lift
Blowdown Ring, controls blowdown
93 100 110
Top: Short Simmer. Long blowdown 0
 BlowdownOverpressure 
PRD Closes PRD Opens Relieving
Pressure Set Point Popping Point Full Lift Reseat Pont

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Set Pressure Vs Lift - Conventional

100
Blowdown: Difference Chattering:
Lift, % 

between set pressure and  Rapid opening and closing of PRV in quick succession.
reseating pressure, % of set  Wear and tear of seating surfaces  leak in normal
pressure. Usually 3% 0 93 100
 BlowdownOverpressure 
110
operation. Bellows may burst - local HC release
PRD Closes PRD Opens Relieving Caused by:
Simmer: Audible or visual Lift: Rise of the disc to open the PRV
Pressure
 Oversized PRV. Different relieving cases may have
release of fluid across the PRV Set Pressure Vs Lift – Pilot differing rates, X, 2X and 3X
just prior to opening at set ▪ Use multiple n+1 PRVs with staggered setpoints. A smaller PRV
pressure 100 for the smallest load
Lift, % 

 Excessive simmering is
Pop Action  Inlet loss > 3%
detrimental to valve seating Modulating  Hi back-pressure
surfaces. May result in solids on 0 95 100 110  Broken or leaking balanced bellows
seat Blowdown Overpressure
RV Closes PRV Opens Relieving
Pressure

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For large or Instantaneous and PRV Upstream:

unrestricted relief, say FCC reactor  In valuable/ toxic fluids. Avoids leaks/ fugitive emission
For sudden release. HX tube rupture  In viscous, high melting point, slurry or polymerization
 Opening time: RD: 5 milli s. PRV 25 ms services. Liquids that may freeze on depressurization.
Plugging, gumming and polymerization on seat
Non-reclosing:
 In corrosive services. RDs can be made of high alloy
 Unlike a PRV that closes once pressure is below set and corrosion resistant materials. Not possible with
pressure, RD remains open and discharge the contents PRV Vent
PG/PAH
 It has to be replaced after an event. Loss of full vessel RD
content Space between RD and RD/ PRV - vent +
RD - up/down orientation important PG + PAH to alert about RD leak Note: Max distance
between RD and PRV = 5D
 - otherwise bursting pressure goes up  Leak will equalize pressure across RD. RD will not
In parallel to or in series with a PRV or 2 RDs in series open/burst
 In parallel: For a larger relief. PRV for a smaller one
Note: Mount RD flush or protruding into vessel to avoid inlet
 HX Thermal: PRV HX Tube Rupture: RD solids accumulation. N2 or liquid flushing of inlet may not
reduce solids accumulation in inlet pipe, a dead pocket

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Downstream of PRV Conventional: Forward Acting,

 Protects PRV internals from corrosion - save
tension loaded and domed
 Op pressure <70% of burst pressure
money using standard MOC. Prevents fouling and
 Reverse flexing. Provides support
gumming of PRV. Cushions against variable BP
against vacuum or backpressure
▪ Note: You need a RD u/s of PRV too. Otherwise leakage
 Pressure on concave side. Flat or
via PRV may burst the d/s RD
angular seat
PRV Upstream and downstream:  Solid metal. Fragments. Not used
 Corrosive and slurry (no exposed seat/ spring). under PRV
Slurry: fluid directed across RD inlet to prevent
 Rupture Disk
 Scored Metal - Can be used under PRV
Reverse: Snap back action reqd to
solid build-up ▪ Op pressure <85-90% of burst pressure
move the disc thru knife blade. May
Design Tip: RD + PRV requires Combined Capacity Factor ≈ 0.9 factor on PRV area. Combined inlet ∆P <3%. not be reliable in liquid service.
RD burst pressure ≈ 90-100% PRV set pressure (ASMEVIII Div 1 UG-127 foot note 52 + UG132 (a)(4)(a)) Scored design instead of knife-cut

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Reverse acting. Buckling disk Electrical/ Mechanical signal to

 Op pressure <90% of burst pressure infer opening or leakage
 Pressure on convex side. Knife blades/ Hi Temp units: Heat shields u/s of
tooth rings RD What is the gauge pressure?.
 Dull or damaged knife blades may
hinder opening Rupture disk at PRV inlet should What it tells you?

 Can withstand pressures in excess of obey the <3% rule. RD at inlet may Leakage thru RD can increase
the pressure in the cavity
burst pressure on the outlet. be 1 size larger than PRV inlet. between RD and PRV, reduce
 Thicker material. Long service life Outlet 1 size larger than PRV outlet dP across RD and hinder RD
opening
 Non-fragmenting. Can be used under
Provide a PG/PAH/vent line d/s
PRV Caution: +ive manufacturing range of RD discharging to PRV
▪ PAH @ >10% set point - between RD & PRV outlet to keep cavity pressure
+tolerance increases burst low
pressure. U/L ≤ MAWP
49 50

Backpressure
Caution: +ive Manufacturing Range + Burst impact
Tolerance increases burst pressure  Same as
conventional
Upper Limit U/L ≤ MAWP PRV
 Constant or
Case: RD, Set at 100. Manufacturing range superimposed
backpressure
+8/-4%. And Burst Tolerance 5%. 70% Op Ratio increases burst
pressure on a 1
for 1 basis
Max Burst P +BT 113.4 + 5% Burst Tolerance  Another RD (2 in
Burst Press U/L 108 +8% Manufac range series) may
Burst Press Specified 100 -4% Manufac range cushion variable
Burst Press L/L 96 - 5% Burst Tolerance backpressure
Min Burst P with -BT 91.2 + 70% Operating Ratio
Operating Pressure 67.2 (0.7* 96) ‘Combining RDs with PRVs’,
Roger Bours, ChE, June 2014

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As a replacement for relief valves. Non reclosing type. As a replacement for relief valves. Non reclosing type
Instead of relieving, isolates the high pressure source.
Good for large loads. Low replacement cost Eliminates flaring
Usually in alternative paths to staged flares Clapper, disk, piston or plunger valve held in place by a
Pin not in wetted part or at process temperature pin
When the pin buckles, the valve is instantly closed.
Not Approved by ASME. OK for Pipelines under Dept of
Transportation Code

Open
Pin

Closed

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PVRV - Conservation Vents

 Low set pressure - from few mm of H2O to 1 bar( 15 psig)
 Generally for Storage Tank protection
Emergency Vents. Blow-off Hatches.
Explosion Doors
 For infrequent large releases
 Used generally for Storage Tank protection
 In furnace fire boxes (“Explosion Doors”)

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Type of relief valve Weighted Pallet Balanced Bellows - Metal Seat

Low Cost Set Press constant with
 Based on backpressure and service Very Low Set Pressure backpress
Set Press, not adjustable Good Chemical & Temp
 Steam service: direct spring loaded “pop action” High over pressure 100%++ compatibility
Seat can be frozen
type.
Seat Leakage = Product Loss
As backpressure on the valve rises Conventional PRV - Metal Seat
Long simmer or blowdown
Lowest Cost
 Conventional  Balanced bellows  Pilot Good Chemical & Temp Limited bellows life
compatibility Affected by inlet press loss
Rupture disks: Rapid rise in pressure, corrosive Seat Leakage = Product Loss Affected by higher
services or for very large relieving areas Long simmer or blowdown backpressure
Affected by inlet press loss Difficult to check Set Press
 E.g. Heat Exchanger Tube Rupture, Reactor Affected by backpressure in-place
Difficult to check Set Press in-
 RD + PRV to avoid emissions or in corrosive service place
Soft Seat: Good tightness. But elastomer
will limit chemical & temp capability

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Pilot - Soft Seat - Piston Type Pilot - Soft Seat - Diaphragm or

Bellows
Pilot - Metal Seat Rupture Disks
Smaller & Lighter
Good for Low Press operation 3” WC
Excellent Seat Tightness Good tightness, if disk is
Excellent Seat Tightness Excellent Seat Tightness Set Pressure can be intact
Pop or Modulating Action tested in-situ
In-line maintenance of main valve
Pop or Modulating Action Wide choice in material
In-line maintenance of main valve
Set Pressure can be tested in-situ. Set Pressure can be tested in-situ. Adaptable for remote Minimum space
Only pilots are tested Only pilots are tested press sensing For high capacity relief as
Adaptable for remote press Adaptable for remote press sensing Excellent Chemical & in FCCU
Remote unloading possible
sensing Fully opens at Set Pressure Temp Compatibility For secondary relief in
Remote unloading possible Not OK in polymerizing or dirty parallel to a PRV
Not OK in polymerizing or dirty service Only pop action available
service Limited Chemical & Temp
Limited Chemical & Temp Compatibility Pressure limited to 1,200 Wide tolerance in burst
Compatibility Limited High Press Setting <50 psig psig (83 barg) pressure
Liquid service limitations Temperature limited
Limited Low Press Setting >15 psig Non-reclosing
Not Allowed under ASME Sec I 1000°F (538°C) Premature rupture, with
pressure pulsations

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Type Conventional Bellows Pilot

Default Selection  Design Note: In high pressure service, large size
Backpress ≤ 10% ≤ 30% (Note 1) No limit
valves may not be available. Instead of waiting to
Max Op Press 90% SP 90% SP 90% SP (Note 2)
ASME Sec I    find out at AFC stage, it helps if Process
Remote Pressure Sensing/ Unloading  Engineers do a quick sizing and select multiple
Plugging, Polymer, Dirty Service  
valves, if required, for right piping runs
1. Up to 50% with capacity correction 2. Up to 95% of set in revamp or high pressure situation

Rupture Disk RD/RV Combination For heat exchangers, one may need a small PRV
• Rapid pressure rise
• Corrosive, fouling polymerization services
• Prevent atmospheric emissions
• Reduce PRV cost in corrosive service
for thermal and a bigger RD for tube rupture. Set
• Very large relieving area • Not allowed for ASME Sec I PRV low so that on thermal demand, RD is not
• Always use non-fragmenting RD
• Derate PRV capacity by 10% ruptured

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Your every action in a day, considering its

impact on you, your family, your colleagues
and friends, will make it a way of life!

Additional Reading
GPSA Databook Volume 1 Section 5 Relief Systems
API STD - RP 520/ 521/ 526/ 537

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