Self-Study Notes

API 520 – Dec 2008

Sizing, Selection, and Installation of Pressure-relieving Devices
in Refineries
 Scope
• SIZING & SELECTION of pressure relief devices
• Used in refineries & other related industries
• Max allowable working pressure of 15psig (103kPag) or greater
• The pressure relief devices in this API are intended to protect unfired
PV & related equipment against overpressure from operating & fire
contingencies
• Pressure relief devices protect a vessel against overpressure only, not
against structural failure
• Not covered in this API:
– Atmospheric & low-pressure storage tanks covered in API 2000
– PV used for transportation of products in bulk or shipping containers
– Rules for overpressure protection of FIRED vessels per ASME I & ASME B31.1
 Pressure Relief Devices (PRDs)
• Basic principle
• Operational characteristics
• Applications
• Selection of pressure relief devices used
independently or in combination
 PRD – Pressure Relief Valves (PRVs)
Spring-loaded PRVs
Conventional PRVs
Basic principle • Self-actuated spring-loaded (Fig 1 & Fig 4)
• Available in small sizes
• Designed to open at PREDETERMINED PRESSURE
• Protect vessel or system from excess pressure  removing / relieving fluid from the vessel or systems
• Also known as
• Safety valves  for GAS / VAPOR service
• Relief valves  for LIQUID service
• Safety relief valves  for MULTI-SERVICE applications
• Generic term, PRV  applicable to all 3 above
Operational • Under normal system operating conditions
characteristics • Inlet pressure < Set pressure
• Disc is seated on nozzle  no flow through the nozzle
• Operates based on FORCE BALANCE (Fig 5)
• Preset / Initial spring load = Force exerted on closed disc by system pressure
• Inlet pressure < Set pressure  Disc remain seated on nozzle (closed position) (Fig 5, A)
• Inlet pressure > Set pressure  Pressure force on disc > spring force (open position)
• When inlet pressure = closing pressure  valve re-closes
Applications • Thermal relief applications

Basic elements • Inlet nozzle  connected to vessel or system to be protected

• Movable disc  controls flow through the nozzle
• Spring  controls disc’s position
Selections
(independent /
combination)
 PRD – Pressure Relief Valves (PRVs)
Spring-loaded PRVs
Conventional PRVs – GAS / VAPOR SERVICE
Basic principle • Safety valves  for GAS / VAPOR service

Operational • Valve may “SIMMER” before “POP”

characteristics • When vessel pressure near to set pressure
• Fluid will audibly move past the seating surface into HUDDLING CHAMBER B (Fig 5, B)
• Pressure builds up in the huddling chamber B
• Pressure now acts over LARGER AREA  creating additional force (expansive force)  overcome the spring force
• Valve will POP open
• Once the valve open
• Additional pressure build-up at C occurs (Fig 5, C)
• Why?
• Sudden flow increase
• Flow restriction through another annular orifice formed btw 1) inner edge of disc holder skirt, and 2)
outside dia of adjusting ring
• Cause the disc to LIFT SUBSTANTIALLY at pop
• Flow restricted by opening btw nozzle & disc until disc has been lifted ¼ of nozzle dia
• Afterwards, flow is controlled by bore area
• Valve closes
• When inlet pressure < set pressure  spring force > summation of forces at A, B, & C
• Pressure at which valve re-seats  CLOSING PRESSURE
• Set pressure (minus) closing pressure = BLOWDOWN
• Fig 6
Basic elements Adjusting Ring • Adjust to alter opening in annular orifice
• Control pressure build-up in huddling chamber B
A – Set Pressure
B – Maximum Relieving Pressure
C – Closing Pressure
 PRD – Pressure Relief Valves (PRVs)
Spring-loaded PRVs
LIQUID SERVICE
Basic principle • Relief valves  for LIQUID service
• Capacity certified in accordance with ASME Code
Operational • Do NOT pop  no expansive forces
characteristics • Rely on REACTIVE FORCE to achieve lift
• When valve is closed
• Forces acting on disc < spring force
• Until FORCE BALANCE is reached  net force holding the seat closed = 0
• At initial opening
• Escaping liquid forms a VERY THIN SHEET of fluid (Fig 7, A)
• It expands RADIALLY btw the seating surfaces
• The liquid strikes the reaction surfaces & is DEFLECTED DOWNWAD  creates REACTIVE(turbine) FORCE tending
to move the disc upward
• The forces build VERY SLOWLY during first 2% - 4% of overpressure
• As flow gradually increases
• Liquid’s velocity head moving through nozzle also increases  MOMENTUM FORCES
• Momentum forces + reactive forces  enough to cause LIFT
• Valve surge to 50% - 100% lift
• 2% - 6% overpressure
• Overpressure increases  momentum forces & reactive forces increases until valve FULL LIFT
• As per ASME Code, valves are required to reach FULL RATED CAPACITY at 10% OR LESS overpressure
• Valve closes
• Overpressure decreases  momentum & reactive forces decreases
• Spring force to move disc back to seat
 PRD – Pressure Relief Valves (PRVs)
Spring-loaded PRVs
LIQUID SERVICE
• Rules per ASME Code & other international
standards
– Valves in liquid service
• At 10% overpressure  to achieve full lift, stable operation, &
rated capacity
– Blowdown is adjustable in some designs
– Valves in both liquid AND gas services, or set on liquid
but required to operate on gas or vice versa
• Different operational characteristics
• Depends on flow stream (liquid, gas, or combination)
• Many PRVs designed for liquid service have longer blowdown
(~20%) on gas than on liquid
• Some variation in set pressure may occur
 PRD – Pressure Relief Valves (PRVs)
Spring-loaded PRVs
LIQUID SERVICE
• Sizing rules for
– Liquid service  section 5.8
– Gas service  section 5.6.2 & 5.6.3
• 2 phase applications (maybe liquid, gas or multiphase
mixture)
– Use PRVs designed for liquid (or liquid & gas)
– Mfr recommends to use above PRVs if mass % at valve inlet is
50% vapor or less
• PRVs designed for liquid & gas service should be specified
for the fluid to which the valve is normally exposed
 PRD – Pressure Relief Valves (PRVs)
Spring-loaded PRVs
Balanced PRVs
• Have bellows (or other means of balancing the
valve disc) to minimize backpressure of valve
performance – Fig 2 & Fig 3
 PRD – Pressure Relief Valves (PRVs)
Spring-loaded PRVs
Balanced PRVs
• Fig 8
– Pressure force applied to valve disc = spring force + superimposed
backpressure
– Pressure for unbalanced PRV to open will increase
– If superimposed backpressure is variable  pressure for PRV to open
will vary as well
 PRD – Pressure Relief Valves (PRVs)
Spring-loaded PRVs
Balanced PRVs
• Fig 9 – balanced-bellows PRV
– Bellows attached to disc holder
– Effective bellows area (AB) ≈ or > Seating area of disc (AN)  isolate area on the disc from
the backpressure
– If AB = AN  the variable backpressure will not effect PRV opening pressure
 PRD – Pressure Relief Valves (PRVs)
Spring-loaded PRVs
Balanced PRVs
• Fig 9 – balanced-bellows PRV
– Normal practice, AB > AN  backpressure will not increase PRV’s opening pressure
– Adding bellows  1) PRV’s opening pressure will remain constant, 2) decrease with
increase of backpressure
– Reduced opening pressure, closing pressures will also be reduced  longer blowdown
 PRD – Pressure Relief Valves (PRVs)
Spring-loaded PRVs
Balanced PRVs
• Fig 9 – balanced-bellows PRV
– Bellows’ internal area is referenced to atm pressure in valve bonnet
– Valve bonnet shall be vented to atm for the bellows to work properly
– Other means of balancing a spring-loaded PRV (using sealed piston), perform similarly to
the balanced bellow design
 PRD – Pressure Relief Valves (PRVs)
Spring-loaded PRVs
Balanced PRVs
• When the balanced valve is not required?
– When superimposed backpressure is constant
– You can reduce the spring load to compensate for the effect of backpressure on set
pressure
• When to consider balanced PRVs?
– When built-up backpressure (backpressure caused by flow through the downstream
piping after the PRV lifts) is TOO HIGH for conventional pressure relief
– When you want to isolate guide, spring, bonnet & other top works parts from relieving
fluid  avoid corrosive damage
• Important to remember?
– Bonnet of a balanced PRV shall be VENTED TO ATM at all times
– Caution on potential of freezing of atm moisture inside the bonnet in cold service due to
auto-refrigeration or cold ambient temp
 PRD – Pressure Relief Valves (PRVs)
Pilot-operated PRVs
• What is this?
– Consists of 1) main valve (with floating unbalanced piston assembly), 2) external pilot
– Piston design  top area > bottom area
– F = P.A, operating pressure increases  net seating force increases (valve is tighter)
• When to use?
– When max expected operating pressure is higher than % shown in Fig 15
• What happen at different pressures?
– Set pressure  pilot vents pressure from the top of the piston, piston lifts
– After overpressure  pilot closes the vent, re-establish pressure, piston reseats
• Alternative than piston  use flexible diaphragm
 PRD – Pressure Relief Valves (PRVs)
Pilot-operated PRVs
• What is the main difference between Pilot-operated & Conventional or
balanced spring-loaded?
– It is NOT AFFECTED by built-up backpressure  allows higher pressure in relief discharge
manifolds
• Other feature?
– Pilot vent can be to atm OR to main valve outlet
• Backflow prevention
– Required when possibility exists
– Provide net downward force on diaphragm
– Insuring no flow reversal in valve
 PRD – Pressure Relief Valves (PRVs)
Pilot-operated PRVs
Pilot Types
Pop-action • Fig 16
• Main valve fully lift at set pressure WITHOUT overpressure
• Provides extremely HIGH opening & closing forces on the main valve
seat
• Typically NOT RECOMMEND FOR LIQUID services, to avoid valve
instability
Modulating-action • Fig 17
• Opens main valve for required relieving capacity
• Use in GAS, LIQUID, or 2-PHASE FLOW applications
• Limits amount of relieving fluid
• Calculation of built-up backpressure may be based on required
relieving rate instead of rated relieving capacity of the valve
• Reduces
• Interaction with other pressure control equipment
• Unwanted atm emissions
• Noise level

• Pilots maybe either

• Flowing type  allows process fluid to continuously flow through the pilot when the main valve is open
• Non-flowing type  does not allow; recommended for most services to reduce hydrate formation or
solids affecting pilot’s performance
 PRD – Pressure Relief Valves (PRVs)
Pilot-operated PRVs
Application and Limitation
Application • For liquid & vapor services
• Some are unaffected by fluid state  recommended for 2-phase flow

Limitation • Contain NON-METALLIC components  limited use in certain process

temp and fluid compatibility
• Consider susceptibility to:
• Fouling
• Viscosity
• Solid presence
• Corrosiveness
 PRD – Pressure Relief Valves (PRVs)
Pilot-operated PRVs - Accessories
Accessories
Field test • May be readily tested for verification of set pressure during normal operation
connection • How to do?
• Flow nitrogen from bottle through metering valve
• Pressurize pilot & main valve dome
• The field test pressure will actuate pilot, and may or may not actuate the main valve
Backflow • Prevents reverse flow when the superimpose backpressure > current system pressure
preventer • Should be used for the following situations:
(vacuum • Protected eqpmt can be depressured & isolated (for maintenance)
block) • Vacuum may present at inlet connection due to unusual operating conditions or
during startups
• Valve connected to downstream pressure vessel, where pressure may vary in excess
of pressure in upstream system
• Discharge of multiple PRVs is combined into single manifold or vent system
Pilot supply • Protects pilot from particulate matter
filter • Frequent maintenance may be required
• For application with excessive particulate matter, other methods such as addition of purge
system may be required
 PRD – Pressure Relief Valves (PRVs)
Pilot-operated PRVs - Accessories
Accessories
Pressure • Recommended for compressible or incompressible lading fluid
spike • Where instantaneous pressure spikes / pulsations approach or exceed the simmer or set
snubber pressure may cause valve wear & actuation (downstream of positive displacement rotating
eqpmt)
• Dampens transient pressure rises
Remote • Allow pilot to sense system pressure at location that accurately reflect the actual operating
pressure pressure
sense • Can be used to eliminate the false system pressure indication (happen during relief due to
connection pressure losses in inlet piping)
• Avoid rapid cycling or chattering
Manual or • Allow to open main valve either manually or remotely to depressurize the system
remote • No effect on sealed pressure settings
unloader • Either manual, pneumatic, or solenoid operated valve is connected to the main valve
dome
• When permitted by code, the manual unloader can be replaced with mechanical lift lever
Pilot lift • To be used where pilot’s mechanical lifting is required for verification of the valve
lever operation  Lifting the pilot’s spindle will lift main valve (system pressure is AT LEAST ≥
75% of set pressure
• ASME Code requires this for air, hot water over 60degC, steam application
• Unless ASME Code Case 2203 is used to eliminate the requirement
 PRD – Pressure Relief Valves (PRVs)
Cold Differential Test Pressure (CDTP)
• Why CDTP?
– Actual service condition may be different from test stand
– CDTP is specified to adjust the set pressure on test stand
– CDTP may include correction of actual service’s backpressure and/or
temperature

• When to have temperature correction factor?

– When relieving temp is expected TO EXCEED 120degC at the relief (Why? To
compensate spring load’s variations due to thermal growth & spring material
properties
– When relieving temp is below -60degC (PRV mfr to provide correction factor)

• How to determine CDTP? When CDTP to include correction

for backpressure and temp
– Calculate differential pressure
– Then, multiply with temperature correction
 PRD – Pressure Relief Valves (PRVs)
Cold Differential Test Pressure (CDTP)
• Why CDTP for conventional PRV?
– PRV operating with constant superimposed backpressure
– Need correction factor to compensate the backpressure
– CDTP = REQUIRED set pressure – superimposed backpressure

• Why no CDTP for balanced spring-loaded PRV?

– The change in closing force due to superimposed backpressure is NEGLIGIBLE

• When CDTP is required for pilot-operated PRV?

– When used in high temp or backpressure service
 Rupture Disk Devices
• What is Rupture Disk?
– Non-reclosing PRDs
– Protect vessels, piping & others from excessive pressure and/or vacuum
– Used in single and multiple relief device installations
– Used as redundant PRDs
– Can be made from high alloy & corrosion resistant materials  due to light weight
• Which system does it used for?
– Vapor
– Liquid
– Highly viscous fluids
• Temperature sensitive device
– Burst pressures vary with temp
– Temp at disk increase  burst pressure decrease
– Effect of temp depends of design & material
– Need to specify the pressure & temperature the disk is expected to burst
• Important
– Avoid damaging the disk
– Ensure disk & holder are properly oriented
– Follow mfr’s bolt torque & tightening procedures
 Rupture Disk Devices
Application of Rupture Disks
Single, • Where non-reclosing device is suitable
Multiple, • As specified in UG-134 of ASME Code
& Fire • Fig 18
Rupture • As per ASME Code (Fig 19)
disk • Why?
device at • To meet emission standards
INLET of • To provide corrosion protection for valve
PRV • To reduce valve maintenance
• Considered to be CLOSE COUPLED  reduce
shock loading on valve (especially for liquid
service)
• Burst pressure = Set pressure
• UG-127 of ASME Code requirements
• Free vent
• Pressure gauge PG
• Trycock
• Suitable telltale indicator
• Non-vented space with PG WITHOUT alarms
or other devices is NOT recommended
 Rupture Disk Devices
Application of Rupture Disks
Rupture disk • To protect the valve from atm or downstream fluids
device at • Valve design to consider that it WILL OPEN at proper pressure setting regardless of any
OUTLET of PRV backpressure accumulated between the valve and rupture disk
• See UG-127 of ASME Code for others
Highly corrosive • Often use of 2 rupture disks together
applications • Consists of
• 2 rupture disks mounted in special holder
• Vapor space between them  to have free vent, pressure gauge, trycock, or
suitable telltale indicator  for monitoring of pressure build-up & indicate when
to replace the disk
Highly viscous • Fluid flow is directed across the rupture disk inlet
applications • To prevent product build-up  may adversely affect rupture disk performance
 Rupture Disk Devices
Forward acting, tension loaded
Forward-acting • Formed (domed) • Have random opening pattern
solid metal • Provides service life when operating pressures • Considered fragmenting
rupture disk are up to 70% of marked burst pressure (70% • NOT SUITABLE FOR UPSTREAM OF PRV
operating ratio)
• If have issue with vacuum or backpressure,
can install support to prevent reverse flexing
Forward-acting • Formed (domed) • Can be non-fragmenting
scored rupture • Operating ratio = 85% to 90% • SUITABLE FOR UPSTREAM OF PRV
disk • Withstand vacuum without support • Scored vs non-scored
• If backpressure, can install support to prevent • Have thicker material than non-scored
reverse flexing • With same burst pressure
• Have additional resistance to
mechanical damage
Forward-acting • Flat or domed multi-piece • Flat ones
composite • Flat design allow to burst in either or both • Used for low-pressure vessels or
rupture disk directions equipment isolation
• Some are non-fragmenting  SUITABLE FOR • Complete with gaskets & designed to
UPSTREAM OF PRV be installed between companion
• Domed ones flanges
• Have flat seat or angular seat design • Operating ratio = 50% or less
• Lower burst pressure than forward-
acting non-scored
• Offer longer service life  corrosion
resistant properties of seal material
• Operating ratio = 80% or less
 Rupture Disk Devices
Reverse-acting, compression loaded
Feature • Formed (domed) solid metal disk

What can it do • Reverse & burst at rated pressure on the CONVEX side
• Opening methods by shear knife blades, tooth rings, scored lines
Specials • Non-fragmenting  SUITABLE FOR UPSTREAM PRV
• Operating ratio = 90% or less, some type = 95%
• The pressure applied on convex side allows these advantages
• Thicker disk material
• Less corrosion effect
• No need vacuum support
• Longer service life under pressure / vacuum cycling conditions & pressure
fluctuations
• Knife blades
• Corrosion-resistant material
• Inspected periodically to ensure sharpness
 Rupture Disk Devices
Graphite, shear loaded
Feature • Machined from fine graphite + sealing compound
• Have armoring (metallic ring outside dia of disk)  support loads, reduce potential
cracking
What can it do • Used in both liquid and vapor service
• Operates on pressure differential across the center diaphragm / web portion
• Random opening pattern
• Fragmenting design  NOT SUITABLE FOR UPSTREAM OF PRV
Specials • Operating ratio = 80%
• Can install support to avoid reverse flexing due to vacuum or backpressure
 Rupture Disk Devices
Rupture Disk Holders

• To clamp rupture disk in place

• Effect a leak-tight, metal-to-metal seal
• Config – full bolting, weldneck, threaded, etc
• Most common config – insert type (fits
between standard pipe flanges)
 Rupture Disk Devices
Rupture Disk Accessories
Rupture • Provide electrical or mechanical SIGNAL
indicators & • Indicate opening and/or leakage of rupture disk or PRV
sensors
Alarm • Monitor rupture disk indicators or sensors
monitors • Available with intrinsically safe circuits
Heat shields • Installed upstream of disk in high temp processes
• To reduce temp
Baffle plates • To deflect process discharge away from personnel and equipment,
during venting to atm
• To assist in absorbing recoil forces of an activating rupture disk
 Rupture Disk Devices
Rupture Disk Selection & Specification
Purchaser to specify:-
• MAWP of vessel or piping
• Fluid state (vapor, liquid, multiphase)
• Range of operating pressures & operating temperature
• Cyclic or pulsating service
• Required relieving capacity or max resistance coefficient
• Corrosiveness of upstream & downstream environment
• Vacuum or backpressure conditions
• Location upstream or downstream of PRV
• Single or multiple devices

Based on above, the following parameters are selected or determined:-

• Burst pressure and temperature (Fig 26)
• Operating ratio, mfg design range and burst tolerance (Fig 27)
• Disk type, material and construction
• Disk & holder size (based on required flow)
 Rupture Disk Devices
Rupture Disk Selection & Specification

• Fig 26 – relationship btw system pressures & operating

characteristics
• Ensure upper limit of mfg design range does NOT
EXCEED the MAWP of protected eqpmt
• Fig 28 – if disk has positive mfg design range, actual
burst pressure > specified pressure
• Upper limit  max pressure marked to burst
• Lower limit  min pressure marked to burst
• Fig 27 – relationship btw burst pressure, mfg design
range, burst tolerance, operating pressure
 Rupture Disk Devices
Rupture Disk Selection & Specification

• Superimposed backpressure has SIGNIFICANT IMPACT in

design & selection
• For closed systems,
– Superimposed backpressure varies btw some min & max pressure
– Superimposed backpressure does not include pressure caused by
other relief devices venting, unless the pressure exceed the code
allowed accumulated pressure
– Consider backpressure caused by other relief devices venting, disk
may require vacuum or backpressure support to protect the disk
• Annex A – rupture disk device specification sheet &
guideline for completing the spec sheet
 Pin-actuated Devices

• Non-reclosing device
• Consists of
– Moving disc exposed to pressure system
– External mechanism housing a pin
– Pin
• Is mechanically linked to disc
• May be loaded in tension (breaking pins) or in compression
(buckling pins, Fig 29)
• Restrains movement of disc until set pressure is reached
• At set pressure, the pin fails, and the disc opens
 Pin-actuated Devices
Buckling Pin Devices

• Fig 29
– Compression-loaded, most extensively used
– Very stable and well suited for:-
• Cyclic operating conditions, and
• Operating pressure to set pressure ratio ≥ 90%
• Sensitive to differential pressures
• ASME Code Case 2901-3
 Pin-actuated Devices
Buckling Pin Devices - Requirements
Set pressure • User to determine the set pressure, & establish set pressure tolerance on either side of
& the nominal set pressure
temperature • Wetted parts shall meet the process temperature
• Pin shall meet the external ambient temperature
• For compression-loaded buckling pins
• Have low sensitivity to temperature
• Recommended to perform specific temperature testing of pins
Leak • Typically uses ELASTOMER SEALS
tightness of • Seal material to satisfy chemical conditions & anticipated service temperature
seal material • Leak tightness test per API 527
• Consider vacuum and/or backpressure services
Marking & • On device: • On pin:
tagging • Flow direction • Manufacturer
• Set pressure • Lot number (checked against mfr’s
• Nominal size certification report)
• Serial number (checked against • Device model or type
mfr’s certification report) • Set pressure
• Model or type designation • Pin / device identifier (checked
• Materials against mfr’s certification report)
• Manufacturer
 Pin-actuated Devices
Breaking Pin Devices
• Non-reclosing
• Consists of
– Movable disc held in closed position by pin
– Pin
• Loaded in tension
• At set pressure, the pin breaks, the disc opens
• Used in combination with PRV that have concern with valve tightness (corrosive or
vibrating conditions; e.g. fluid transport vessels)
• Operate at specified differential pressure  install gauge, trycock, free vent or suitable
telltale indicator in between the PRV and breaking pin device  to detect build-up
pressure

• ASME
– ASME Code  Breaking pin devices SHALL BE USED IN COMBINATION with PRVs
– ASME Code Case 2487 allows to use breaking pin device as single relief device, with additional
requirements.