Pressure Relief Devices

Rev. # – Mmm YYYY

Table of Contents

 Course Learning Objectives

 Relief Events
 Pressure Relief Devices
 Codes & Standards
 Terminology
 Types of Pressure Relief Valves
 Sizing of Pressure Relief Valves
 Rupture Disks
 Pressure & Vacuum Relief Valves
 Inspection & Shop testing
 Review

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Course/Learning Objectives

 To understand what are Relief events and what is the purpose of

Pressure Relief devices.
 To identify the codes & standards used in selection & sizing of Pressure
Relief Devices
 To learn about the terminologies used
 To understand what is Backpressure
 To learn about the types of Pressure Relief Devices
 To learn about the types of pressure relief valves
 To learn how pressure relief valves are sized
 To understand what are Rupture disks and its types
 To understand what are Pressure & Vacuum Relief valves
 To learn about the various testing and inspection requirements.

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WHAT IS A RELIEF EVENT?

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What is a Relief Event?

 Relief event is the process of de-pressurization to prevent

excessive overpressure in a system.

 Following are some of the causes that can produce overpressure in

a system:
• External fire
• Flow from high pressure source
• Heat input from associated equipment
• Pumps and compressors trips
• Ambient heat transfer
• Liquid expansion in pipes and surge
• Blocked outlet
• Instrument Air failure
• Gas Blow by
• Runaway reactions

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WHAT IS A PRESSURE RELIEF DEVICE?

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Pressure Relief Devices
 A device actuated by inlet static pressure and designed to open during emergency or
abnormal conditions to prevent a rise of internal fluid pressure in excess of a specified
design value. The device also may be designed to prevent excessive internal vacuum.

 The device may be a pressure relief valve, a non-reclosing pressure relief device –
Rupture disc, or a vacuum relief valve.

 It is the final mechanical device to safeguard Over/ Under pressure to prevent Hazard.

 The function of relief devices is to:

• Prevent an overpressure scenario in the plant (equipment / piping)
• Protect equipment & piping (from damage / loss of containment)
• Protect personnel
• Prevent loss of production time
• Prevent an environmental release/De-escalate fire related damage /Prevent loss of
containment

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CODES & STANDARDS

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Codes & Standards
 API Std 520, Sizing, Selection, and Installation of Pressure-relieving Devices in
Refineries Part I—Sizing and Selection
 API RP 520, Sizing, Selection, and Installation of Pressure-relieving Devices in
Refineries, Part II—Installation
 API Std 521/ISO 23251, Guide for Pressure-relieving and Depressurizing
Systems
 API Std 526, Flanged Steel Pressure Relief Valves
 API Std 527, Seat Tightness of Pressure Relief Valves
 API Std 2000, Venting Atmospheric and Low-pressure Storage Tanks: Non-
refrigerated and Refrigerated
 ASME Boiler and Pressure Vessel Code , Section I—Power Boilers
 ASME Boiler and Pressure Vessel Code, Section VIII—Pressure Vessels,
Division 1
 PED-97 23 EC

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TERMINOLOGY

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Terminology
 Maximum allowable working pressure
(MAWP):
The maximum gauge pressure permissible
at the top of a completed vessel in its normal
operating position at the designated
coincident temperature specified for that
pressure.

 Set Pressure:
The inlet gauge pressure at which the
pressure relief device is set to open under
service conditions.

 Burst Pressure:
Burst Pressure of rupture disks at a specified
temperature is the value of the upstream
static pressure minus the value of
downstream static pressure prior to when
the disk bursts.
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Terminology
 Accumulation:
• The pressure increase over the
maximum allowable working pressure of
the vessel, expressed in pressure units
or as a percentage of maximum
allowable working pressure (MAWP) or
design pressure.
• Maximum allowable accumulations are
established by applicable codes for
emergency operating and fire
contingencies.
• Relieving pressure shall not exceed
MAWP by more than following values i.e.
overpressure shall be within these
values (As per ASME codes):
− 3% for fired and unfired steam boilers
− 10% for vessels equipped with a single
pressure relief device
− 16% for vessels equipped with multiple
pressure relief devices
− 21% for fire contingency 12
Terminology
 Overpressure:
The pressure increase over the set pressure
of the relieving device. Overpressure is
expressed in pressure units or as a
percentage of set pressure.
Overpressure is the same as accumulation
only when the relieving device set pressure
is the maximum allowable working pressure
of the vessel.
 Closing Pressure:
The value of decreasing inlet static pressure
at which the valve disc reestablishes contact
with the seat or at which lift becomes zero.
 Blow down:
It is the difference between the actual
pressure at which the pressure relief valve
pops and reseating pressure expressed in
percentage of set pressure or in pressure
units.
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Terminology
 Simmer :
It is the visible or audible escape of fluid between seat and nozzle at an inlet static
pressure below the set pressure. It applies for compressible fluids.

 Chattering:
It is the abnormal rapid reciprocating motion of the movable parts of a pressure relief
valve in which the disc contacts the seat.

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WHAT IS BACKPRESSURE?

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Backpressure

 The pressure that exists at the outlet of a pressure relief device as a

result of the pressure in the discharge system.

 Backpressure is the sum of the superimposed and built-up

backpressures.

 Total back pressure = Superimposed + Built-up back-pressures

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Superimposed Backpressure
 Pressure in discharge header before the valve opens.
 It is the result of pressure in the discharge system coming from other
sources
 It may be constant or variable

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Built-up Backpressure

 The pressure that develops (builds up) in the discharge header when the
relief valve opens.

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CLASSIFICATION OF PRESSURE RELIEF DEVICES

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Classification of Pressure Relief Devices

Pressure Relief Devices

Reclosing Devices Non-reclosing Devices

• Rupture Disc
Loading Principle

Direct-load Controlled

Spring Loaded Safety Valves Pilot-Operated Safety Valve

•
Function

Conventional Balanced Bellow Pressure &

Pressure Relief Pressure Relief Vacuum Relief Snap-acting Modulating
Valve Valve Valve
• *acc. to ASME
•

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TYPES OF PRESSURE RELIEF VALVES

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Conventional Spring Loaded PRV
 Self-actuated spring-loaded PRV.
 Designed to open at a predetermined
pressure and protect a vessel or system
from excess pressure by removing or
relieving fluid from that vessel or
system.
 Basic elements include
• an inlet nozzle connected to the
vessel or system to be protected,
• a movable disc which controls flow
through the nozzle,
• and a spring which controls the
position of the disc.

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Conventional Spring Loaded PRV
 Advantages
• Most reliable type if properly sized and operated
• Versatile -- can be used in many services

 Disadvantages
• Relieving pressure affected by back pressure
• Susceptible to chatter if built-up back pressure is too high

 Selection Criteria
• The superimposed backpressure is not variable (otherwise the pressure at
which the valve will open will vary)
• Built-up backpressure should not exceed 10 % of the set pressure at 10 %
allowable overpressure.
• When the superimposed backpressure is constant, the spring load may be
reduced to compensate for the superimposed backpressure.
• Material for spring and bonnet shall be suitable for service fluid
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Balanced Bellow Spring Loaded PRV
 A balanced PRV is a spring-loaded PRV
which incorporates a bellows or other
means of balancing the valve disc to
minimize the effects of backpressure on
the performance characteristics of the
valve.
 A balanced bellows valve is used where
the built up back pressure is too high for
conventional relief valves or where the
superimposed back pressure varies
widely compared to the set pressure.
 For conventional relief valve,
backpressure should not exceed 10% of
the set pressure at 10% allowable
pressure. However, it is possible to get
relief valve with balanced bellows if total
back pressure (superimposed + built-up)
is up till 50% of the set pressure.

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Balanced Bellow Spring Loaded PRV
 Advantages
• Relieving pressure not affected by back pressure
• Can handle higher built-up back pressure
• Protects spring and guiding surface from corrosion

 Disadvantages
• Bellows susceptible to fatigue/rupture
• Will release flammables/toxics to atmosphere in case of
bellows rupture
• Requires extended venting system for Bonnet vent to
safe location

 Selection Criteria
• Where the total backpressure (superimposed plus built-
up) does not exceed approximately 50 % of the set
pressure.
• Back pressure is within the limit of Bellows Mechanical
limit.
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Pilot Operated PRV
 A pilot-operated PRV consists of the
main valve, which encloses a floating
unbalanced piston assembly, and an
external pilot.
 The piston is designed to have a larger
area on the top than on the bottom. Up
to the set pressure, the top and bottom
areas are exposed to the same inlet
operating pressure.
 As the operating pressure increases,
the net seating force increases and
tends to make the valve tighter.
 At the set pressure, the pilot vents the
pressure from the top of the piston; the
resulting net force is now upward
causing the piston to lift, and process
flow is established through the main
valve.
 After the overpressure incident, the pilot
will close the vent, and the net force will
cause the piston to reseat. 26
Pilot Operated PRV

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Types of Pilot Operated PRVs
Mainly Classified in Two types of Pilot:
Snap Acting type or Pop Action type Modulating type
 The Pop action pilot causes the main valve to  The modulating pilot opens the main valve
lift fully at Set pressure without overpressure. only enough to satisfy the required relieving
This immediate release of pressure provides capacity and can be used in gas, liquid or two-
extremely high opening and closing forces on phase flow applications. In contrast to a pop
the main valve seat. action valve, it limits the amount of relieving
fluid to only the amount required to prevent the
pressure from exceeding the allowable
accumulation.

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Pilot Operated PRV
 Advantages
• Relieving pressure not affected by backpressure
• Can operate at up to 98% of set pressure
• Less susceptible to chatter (some models)
• Zero Leakage
• Reduced loss of inventory for modulating type
• Smaller, lighter valves at higher pressure and/or with larger orifice size

 Disadvantages
• Pilot is susceptible to plugging by fouling fluids, hydrate formation etc.
• Limited chemical and high temperature use due to “O-ring” seals
• Vapor condensation and liquid accumulation above the piston may cause
problems

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Pilot Operated PRV
 Selection Criteria and Concerns
• When back pressure can not be met by Bellows type
• Very low margin between Max operating pressure and Set pressure
• To optimize line size and reduce inventory loss
• Provide high capacity and one valve can replace multiple conventional valves
• Limited availability of soft goods for seat & seal limits Pilot selection in high
temperature and certain service chemicals
• Not to be used when pilot or pilot line can be choked due to solid particles /
condensates

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RUPTURE DISKS

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Rupture Disk
 Rupture Disks are used in single & multiple relief
device installations.
 With no moving parts, rupture disks are simple,
reliable & faster acting than other pressure relief
devices. They can be specified for vapor (gas) or liquid
application.
 They are Temperature sensitive devices. Hence
rupture disks must be specified at the Pressure &
temperature the disk is expected to burst.
 Based on the construction, Rupture disks can be
classified into:

• Conventional Disks (Forward acting Rupture disks)

• Reverse Acting (also known as Reverse Buckling disks)
• Composite disks

P&ID symbol
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Rupture Disk
 Conventional Disks
(Forward acting Rupture disks):

• A forward-acting rupture disk is a formed

(domed), solid metal disk designed to burst at
a rated pressure applied to the concave side.
• The disks in this case bursts in the forward
direction as indicated in the figure.
• These disks perform satisfactorily when the
operating pressures are up to 70% of the
marked burst pressure of the disks.
• If vacuum or backpressure conditions are
present, the disk can be furnished with a
support to prevent reverse flexing.

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Rupture Disk
 Reverse- Acting Rupture disks:
• A reverse-acting rupture disk is a formed
(domed), solid metal disk designed to reverse
and burst at a rated pressure applied to the
convex side.
• The performance of these disks is satisfactory
when operating pressures are 90% or less of
the marked burst pressure.
• These disks do not require vacuum support.

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Rupture Disk
 Composite Disks:
• These disks are either flat or dome shaped
multi piece construction disks.
• The dome shaped rupture disks are designed
to burst at rated pressure applied to the
concave side of the disc.
• This type of rupture disk consists of a slotted
metal top section, a metallic or non metallic
bottom seal membrane. Due to the seal
membrane this type of rupture disk offers
better corrosion resistance.
• This type of rupture disk performs
satisfactorily when the operating pressure is
80% or less of the marked burst pressure.
• If vacuum or back pressure condition exists
then a vacuum support is generally provided.

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Rupture Disks used in conjunction with PRV
 A rupture disk can be installed either on the inlet or
outlet side of the safety valve.
 If installed on the inlet, it isolates the contained
media from the PRV. When there is an
overpressure situation; the rupture disk bursts
allowing the fluid to flow into the PRV, which will
then subsequently lift. This arrangement is used to
protect the internals of the safety valve from
corrosive fluids.
 Alternatively, if the PRV discharges into a manifold
containing corrosive media, a rupture disk can be
installed on the safety valve outlet, to protect the
internals of the safety valve in normal use.
 When a rupture disk is used between the PRV &
the vessel, the space between them shall have a
free vent, pressure gauge. This is required
because if this space is not vented & back
pressure builds up in this non vented space, the
rupture disk will not burst with in tolerance limits.

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PRESSURE & VACUUM RELIEF VALVES (PVRV)

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Pressure & Vacuum Relief Valve (PVRV)
 The primary function of PVRV is to protect the tank
from physical damage or permanent deformation
caused by increases in internal pressure or
vacuum encountered in normal operations.
 Pressure / vacuum relief valves are used
extensively on bulk storage tanks, including fixed
roof tanks with floating covers, to minimize
evaporation loss.
 They are used on low pressure storage tanks at
pressures from vacuum through 15 pounds per
square inch gauge (1.034 barg), to prevent the
excessive build up of pressure and vacuum which
can unbalance the system and damage the tanks.
 Pressure and vacuum protection levels are
controlled with springs or weighted pallets and can
be combined to provide the required
pressure/vacuum settings. It is common to
combine pallet and spring systems in one unit i.e.
pressure settings require a spring section, whilst
the vacuum settings use the pallet method.
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Pressure & Vacuum Relief Valve (PVRV)
 The primary function of PVRV is to protect the tank
from physical damage or permanent deformation
caused by increases in internal pressure or
vacuum encountered in normal operations.
 Pressure / vacuum relief valves are used
extensively on bulk storage tanks, including fixed
roof tanks with floating covers, to minimize
evaporation loss.
 They are used on low pressure storage tanks at
pressures from vacuum through 15 pounds per
square inch gauge (1.034 barg), to prevent the
excessive build up of pressure and vacuum which
can unbalance the system and damage the tanks.
 Pressure and vacuum protection levels are
controlled with weighted pallets or springs and can
be combined to provide the required
pressure/vacuum settings. It is common to
combine pallet and spring systems in one unit i.e.
pressure settings require a spring section, whilst
the vacuum settings use the pallet method.
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INSPECTION AND TESTING

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Inspection & Shop Testing
 Inspection and testing for relieving devices shall be as per the following standards.
1. API 526
2. API 527
3. ASME VII, DIV-1

 Following tests are mandatory for ‘UV’ stamped valves as per ASME.
• Hydro test of individual parts as applicable
• Bellows subassembly test
• Set pressure test on fully assembled valve
• Outlet pressure test on fully assembled valve
• Seal leak test on fully assembled valve as per API 527

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REVIEW

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Review
 We have understood what are Relief events and what is the purpose of
Pressure Relief devices.
 We have identified the codes & standards used in selection & sizing of Pressure
Relief Devices
 We have learned about the terminologies used
 We have understood what is backpressure and the types
 We have learned about the types of Pressure Relief Devices
 We have learned about the types of Pressure Relief Valves
 We have learned how pressure relief valves are sized
 We have understood what are Rupture disks and its types
 We have understood what are Pressure & Vacuum Relief valves
 We have learned about the various testing and inspection requirements.

43
QUESTIONS?

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SIZING OF PRESSURE RELIEF VALVES

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Sizing of Pressure Relief Valves
 Sizing Pressure relief valves involves determining the correct orifice for
the specific valve type to be used to support a required relieving
capacity. The typical method used for sizing pressure relief valves is as
follows:
1. Establish a set pressure at which PRV is to operate based on pressure limits
and applicable vessel code like ASME.
2. Establish various scenarios and determine the required relieving capacity.
Establish all other process parameters.
3. Calculate the discharge area required to relieve the “required relieving
capacity” using the equations based on API520 given on the next slide.
4. With this calculated discharge area, refer the “Orifice Area & Designation”
table in API526 and select higher size of orifice with respect to the
calculated discharge area.
5. Establish valve type required, conventional, bellows, Pilot.
6. Select valve size from vendor catalogues or API 526 tables. Verify rated
capacity in catalogue is higher than required relieving capacity.
• (In step-3, use vendor specific rated coefficient of discharge if vendor is
known)
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Sizing of Pressure Relief Valves
 For Gas/Vapour Service,

Where,
A= required effective discharge area in mm 2
W= required relieving capacity in kg/h
T= Temperature in Kelvin
Z= Compressibility
C= Gas Constant (SI unit)
Kd= Discharge coefficient obtained from the valve manufacturer
P1= Upstream relieving pressure in KPa; this is the set pressure + allowable over pressure+
atmospheric pressure
Kb= Backpressure correction factor, this is applied to valves with bellows only. For
conventional and pilot-operated valves, use a value for Kb equal to 1.0
Kc= is the combination correction factor for installations with a rupture disk upstream of the
PRV); Kc equals 1.0 when a rupture disk is not installed. Kc equals 0.9 when a rupture disk
is installed in combination with a PRV and the combination does not have a certified value.
M= Molecular weight
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Sizing of Pressure Relief Valves
 For Liquid Service,

Where,
A= required effective discharge area in mm 2
Q= flow rate in liters/min
Kd= Discharge coefficient obtained from the valve manufacturer
Kw=Backpressure correction factor, this is applied to valves with bellows only. For
conventional and pilot-operated valves, use a value for Kw equal to 1.0
Kc=combination correction factor for installations with a rupture disk upstream of the PRV);
Kc equals 1.0 when a rupture disk is not installed. Kc equals 0.9 when a rupture disk is
installed in combination with a PRV and the combination does not have a certified value.
Kv= correction factor due to viscosity,
Gl= specific gravity of the liquid at the flowing temperature
P1=upstream relieving pressure, psig (kPag); this is the set pressure plus allowable
overpressure.
P2= total backpressure, psig (kPag).

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Sizing Pressure Relief Valves

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