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A relief system is an emergency system for discharging gas during abnormal conditions, by manual or
controlled means or by an automatic pressure relief valve from a pressurized vessel or piping system, to the
atmosphere to relieve pressures in excess of the maximum allowable working pressure (MAWP).
Contents
1 Components
2 Design considerations
3.4.2 Backpressure
4 References
Components
The relief system may include:
Flashback protection
A gas outlet
A scrubbing vessel should be provided for liquid separation if liquid hydrocarbons are anticipated. The relief-
system outlet may be either vented or flared. If designed properly, vent or flare emergency-relief systems from
pressure vessels may be combined.
Some facilities include systems for depressuring pressure vessels in the event of an emergency shutdown. The
depressuring-system control valves may be arranged to discharge into the vent, flare, or relief systems. The
possibility of freezing and hydrate formation during high-pressure releases to the atmosphere should be
considered.
Design considerations
There are three main engineering considerations when designing or modifying a relief system:
Determining the relief requirements of individual pieces of equipment and selecting the appropriate
devices to handle the imposed loads.
Designing a relief header system that will handle the imposed loads or expansion modifications.
Defining reasonable total relief loads for the combined relief header or disposal system and designing
an appropriate disposal system with minimum adverse impact to personnel safety, plant-process system
integrity, and the environment.
These considerations are interrelated in such a way that makes it impossible to establish a procedural guideline
that would be valid for most cases. The design of one portion of a relief system must be considered in light of
its effects on the relief system.
Causes of overpressure
The most common causes of overpressure in upstream operations are blocked discharge, gas blowby, and fire.
When the worst-case relief load is caused by a control valve failing to open (blocked discharge), the relief
device should be sized with full-sized trim in the control valve, even if the actual valve has reduced trim. When
the worst-case relief load is caused by gas blowby, the relief device should be sized with full-sized trim in the
smallest valve in the liquid-outlet line, even if the actual valve has reduced trim. Many vessels are insulated for
energy savings. Thermal insulation limits the heat absorption from fire exposure as long as it is intact. It is
essential that effective weather protection be provided so that insulation will not be removed by high-velocity
fire-hose streams.
Relief valves
The three basic types of pressure-relief valves are conventional spring loaded, balanced spring loaded, and the
pilot operated.
Conventional spring loaded. In the conventional spring-loaded valve (Fig. 1), the bonnet, spring, and
guide are exposed to the released fluids. If the bonnet is vented to the atmosphere, relief-system
backpressure decreases the set pressure. If the bonnet is vented internally to the outlet, relief-system
backpressure increases the set pressure. The conventional spring-loaded valve is used in noncorrosive
services and where backpressure is less than 10% of the set point.
Balanced spring-loaded. The balanced spring-loaded valve incorporates a means to protect the
bonnet, spring, and guide from the released fluids and minimizes the effects of backpressure. The disk
area vented to the atmosphere is exactly equal to the disk area exposed to backpressure. These valves
can be used in corrosive or dirty service and with variable backpressure.
Pilot operated. The pilot-operated valve is combined with and controlled by an auxiliary pressure pilot.
The resistance force on the piston in the main valve is assisted by the process pressure through an orifice.
The net seating force on the piston actually increases as the process pressure nears the set point.
Fig. 1Conventional spring-loaded pressure-relief value
The rupture-disk device is a non-reclosing differential-pressure device actuated by inlet static pressure. The
rupture disk is designed to burst at set inlet pressure. The device includes a rupture disk and a disk holder. The
rupture disk may be used alone, in parallel with, or in conjunction with pressure-relief valves. They are
manufactured in a variety of materials with various coatings for corrosion resistance.
The entire relief system must be considered before selecting the appropriate relief device. The relief headers
should be designed to minimize pressure drop, thus allowing for future expansion and additional relief loads.
Pilot-operated-valve considerations. Pilot-operated valves should be considered for all clean services
within their temperature limitations. They are well suited for pressures below 15 psig and are available with
the pilot-pressure sensing line connected to either the valve inlet or to a different point. Pilot-operated
valves provide tight shutoff with very narrow margins between operating pressure and set pressure.
Special considerations
When selecting the appropriate relief devices to handle the imposed loads, several issues must be considered.
Set pressure
Relief devices are normally set to relieve at the MAWP. The greater the margin between the set pressure and
the operating pressure, the less likelihood there is of leakage. Aside from the requirements to compensate for
superimposed backpressure, there is no reason to set a relief device at less than the MAWP.
Backpressure
The backpressure at the outlet of every relief device should be such that the device can handle its design
capacity with the calculated backpressure under the design relief conditions.
It is common practice to install two relief valves in critical process applications where a shutdown cannot be
tolerated. The intent is that if the first relief valve lifts and fails to reseat, a second relief can be switched into
service before the first valve is removed for maintenance, without shutting down or jeopardizing the process.
This is accomplished by piping the relief valves in parallel and by putting a "car sealed" full-port ball or gate
block valve on the inlet and outlet of each relief valve. One set of block valves is sealed open and the other
sealed closed. ASME-approved selector valves are available, which simplify relief-valve switching. This
provides an interlock of parallel inlet and outlet block valves and ensures full protection for the process
equipment.
Multiple relief valves are required when the relief load exceeds the capacity of the largest available relief valve.
It is good practice to install multiple relief valves for varying loads to minimize chattering on small discharges.
ASME Sec. VIII, Division 1, 3 and RP 520, Part 1,[2] both stipulate a 10% accumulation above the MAWP for a
single relief valve and a 16% accumulation above the MAWP for multiple relief valves. The primary relief valve
must be set at or below the MAWP. Supplemental relief valves should have staged pressures. The highest
pressure may be set no higher than 105% above the MAWP. If different-sized relief valves are used, the
smallest relief valve should be set to the lowest pressure.
Blocked discharge
One design condition for the sizing of a relief valve is to assume that it must handle the total design flow rate
(gas plus liquid) into the component. It is possible to isolate a process component or piping segment for
maintenance by blocking all inlets and outlets. On startup, all outlet valves could be left closed inadvertently. If
the inlet source can be at a higher pressure than the MAWP of the process component, only a properly sized
relief valve could keep the process component from rupturing as a result of overpressure.
Gas blowby
On tanks and low-pressure vessels normally receiving liquids from higher-pressure upstream vessels, the
maximum flow rate through the relief valve often is determined by gas blowby. This situation occurs when the
level controller or level control valve of the upstream vessel fails in the open position or a drain valve from an
upstream vessel fails in the open position, allowing liquid and/or gas to flow into the component evaluated.
Under blowby conditions, both the normal liquid and gas outlets on the component being evaluated are
functioning properly. However, the gas flow into the component could greatly exceed the capacity of the normal
gas outlet. This excess gas flow must be handled by the relief valve to keep from exceeding the components
MAWP. Gas-blowby conditions also can occur when a pressure regulator feeding a component fails in the open
position, creating a higher than designed inlet flow rate of gas.
Gas-blowby rate is the maximum that can flow given the pressure drop between the upstream component and
the component being evaluated. In computing the maximum rate that can flow because of pressure drop,
consideration should be given to the effects of control valves, chokes, and other restricted orifices in the line. A
more conservative approach would be to assume that these devices have been removed or have the
maximum-sized orifice that could be installed in the device.
The pressure in process components exposed to the heat from a fire will rise as the fluid expands and the
process liquid vaporizes. For tanks and large low-pressure vessels, the need to vent the liberated gas may
govern the size of the vent or relief valve. Fire sizing a relief valve only keeps pressure buildup to less than
120% of the MAWP. If the component is subjected to a fire for a long time, it may fail at a pressure less than the
MAWP because a metals strength decreases as temperature increases.
On components that can be isolated from the process, it is possible for the process fluid contained in the
component to be heated. This is especially true for cold (relative to ambient) service or when the component is
heated (such as a fired vessel or heat exchanger). It is also true for compressor cylinders and cooling jackets.
The relief valves on such components should be sized for thermal expansion of the trapped fluids. This
normally will not govern the final size selected unless no relief valve is needed for the other conditions.
Installation considerations
The installation of a relief device requires careful consideration of the inlet piping, pressure-sensing lines
(where used), and startup procedures. Poor installation may render the relief device inoperable or severely
restrict the valves relieving capacity. Either condition compromises the safety of the facility. Many relief-valve
installations have block valves before and after the relief valve for in-service testing or removal; however, these
block valves must be car sealed or locked open.
Inlet piping
RP 520, Part 2,[3] and ASME code[1] limit the inlet pressure loss to a PSV of 3% of set pressure where the
pressure loss is the total of the inlet loss, line loss, and block-valve loss (if used). Loss is calculated with the
maximum rated flow through the relief valve. To minimize the inlet pressure drop to a relief valve, a
conservative guideline is to keep the equivalent length-to-diameter ratio of the inlet piping to the relief valve at 5
or less. For pressure-drop limitations and typical piping configurations, refer to RP 520, Part 2.[3]
Discharge piping
The discharge piping should be designed so that the backpressure does not exceed an acceptable value for
any relief valve in the system. Piping diameters generally should be larger than the valve-outlet size to limit
backpressure. Lift and set pressures of pilot-operated relief valves with the pilot vented to the atmosphere are
not affected by backpressure; however, if the discharge pressure can exceed the inlet pressure (e.g., tanks
storing low-vapor-pressure material), a backflow preventer (vacuum block) must be used. The set pressure for
balanced spring-loaded relief valves will not be as affected by backpressure as conventional spring-loaded
relief valves are. Balanced relief valves will suffer reduced lift as backpressure increases.
Reactive forces
On high-pressure valves, the reactive forces during relief are substantial and external bracing may be required.
Refer to the formulas in RP 520, Parts 1[2] and 2[3] for computing these forces.
Tailpipe considerations
Relief valves that are not connected to a closed relief system should have tailpipes to direct the relieving gases
to a safe area away from personnel. The tailpipe should be sized for a maximum exit velocity of 500 ft/s. This
ensures that the gas/air mixture is below the lower flammable limit or lower explosive limit at approximately 120
pipe diameters away from the tailpipe. Tailpipes should be supported at the bottom of the elbow. A small hole or
a "weep hole" (minimum of in. in diameter) should be installed in the bottom of the elbow to drain liquids that
enter through the tailpipe opening. The weep hole should be pointed away from process components,
especially those classified as an ignition source.
Rapid cycling
Rapid cycling can occur when the pressure at the valve inlet decreases at the start of the relief valve flow
because of excessive pressure loss in the piping upstream of the valve. Under these conditions, the valve will
cycle rapidly, a condition referred to as "chattering." Chattering is caused by the following sequence. The valve
responds to the pressure at its inlet. If the pressure decreases during flow below the valve reseat point, the
valve will close; however, as soon as the flow stops, the inlet-pipe pressure loss becomes zero and the
pressure at the valve inlet rises to vessel pressure once again. If the vessel pressure is still equal to or greater
than the relief-valve set pressure, the valve will open and close again. An oversized relief valve may also
chatter because the valve may quickly relieve enough contained fluid to allow the vessel pressure to
momentarily fall back to below set pressure, only to rapidly increase again. Rapid cycling reduces capacity and
is destructive to the valve seat in addition to subjecting all the moving parts in the valve to excessive wear.
Excessive backpressure also can cause rapid cycling, as discussed previously.
Resonant chatter
Resonant chatter occurs when the inlet piping produces excessive loss at the valve inlet and the natural
acoustical frequency of the inlet piping approaches the natural frequency of the valves moving parts. The
higher the set pressure, the larger the valve size, or the greater the inlet-pipe pressure loss, the more likely
resonant chatter will occur. Resonant chatter is uncontrollable, that is, once started it cannot be stopped unless
the pressure is removed from the valve inlet. In actual practice, the valve can break down before a shutdown
can take place because of the very large magnitude of the impact force involved. To avoid chattering, the
pressure drop from the vessel nozzle to the relief valve should not exceed 3% of the set pressure. RP 520, Part
2 covers the design of relief-valve inlet piping. 5 Pilot-operated relief valves with remote sensing pilots can
operate with higher inlet-piping pressure drops.
Installation of full open isolation (block) valves upstream and downstream of relief valves. Isolation
valves should be car sealed open (locked open), and a log should be kept. These valves should be
discouraged where the potential overpressure is twice the maximum allowable pressure. A test connection
should be provided on all spring-loaded relief valves. The installation of two relief valves (100% redundant)
should be considered so that one relief valve can be left in service at all times.
Installation of pilot-operated valves without isolation valves. This configuration allows for the testing of
pilot set pressure only and requires full plant shut-in for relief-valve repair and maintenance.
Installation of three-way valves with one port open to a tailpipe or a vent stack. This configuration
allows for valve maintenance and repair without requiring plant shut-in and ensures a path to the
atmosphere if the three-way valve is left in the wrong position.
Installation of two two-way valves, connected by mechanical linkage, and two relief valves. This
configuration provides all the advantages of isolation valves. In addition, it is impossible to isolate a
process component by mistake. The only disadvantage of this configuration is the initial cost.
Installation of a check valve in lieu of an isolation valve. This configuration is not allowed by the ASME
Pressure Vessel Code because the check valve may fail or cause excessive pressure drop. [1]
Fig. 3Relief-valve configurations.
Some companies install two relief valves on all critical installations so that plant shutdowns are not required
during testing and maintenance. If the secondary relief device is being counted on to provide any portion of any
required relieving capacity (blocked discharge, gas blowby, fire, etc.), then the secondary device should be set
in accordance with the rules of RP 520, Parts 1[2] and 2,[3] (i.e., ASME Sec. VIII, Division 1, paragraph UG-134).[1]
References
1. Jump up to:1.0 1.1 1.2 1.3 1.4 1.5 Pressure Vessels. 2001. In Boiler and Pressure Vessel, Code, Sec. 8, Divisions 1
and 2. New York City: ASME.
2. Jump up to:2.0 2.1 2.2 2.3 2.4 API RP 520, Design and Installation of Pressure Relieving Systems in Refineries, Part
I, seventh edition. 2000. Washington, DC: API.
3. Jump up to:3.0 3.1 3.2 3.3 3.4 3.5 API RP 520, Design and Installation of Pressure Relieving Systems in Refineries,
Part 2, fifth edition. 2003. Washington, DC: API.
4. Jump up API RP 521, Guide for Pressure-Relieving and Depressuring Systems, fourth edition. 1999.
Washington, DC: API.
5. Jump up Occupational Safety and Health Standards, regulations, 29 CFR Part 1910. 1999.
Washington, DC: US Dept. of Labor.