Understanding Pressure Relieving Devices PDF

API-RP-576
Inspection of Pressure-relieving Devices

My Self Study Notes
Fion Zhang/ Charlie Chong
API-RP-576
2013-
Speaker: Fion Zhang

2013/March/15
1 Scope
2 Normative References
3 Terms and Definitions
3.1 General
3.2 Dimensional Characteristics of Pressure-relief Valves
3.3 Operational CharacteristicsSystem Pressures
3.4 Operational CharacteristicsDevice Pressures
4 Pressure-relieving Devices
4.1 General
4.2 Pressure-relief Valve
4.3 Safety Valve
4.4 Relief Valve
4.5 Safety-relief Valve
4.6 Conventional Safety-relief Valve
4.7 Balanced Safety-relief Valve
4.8 Pilot-operated Pressure-relief Valve
4.9 Pressure- and/or Vacuum-vent Valve
4.10 Rupture Disk Device
5 Causes of Improper Performance

5.1 Corrosion
5.2 Damaged Seating Surfaces
5.3 Failed Springs
5.4 Improper Setting and Adjustment
5.5 Plugging and Sticking
5.6 Misapplication of Materials
5.7 Improper Location, History, or Identification
5.8 Rough Handling
5.9 Improper Differential Between Operating and Set Pressures
5.10 Improper Discharge Piping Test Procedures
5.11 Improper Handling, Installation, and Selection of Rupture Disks.
6 Inspection and Testing
6.1 Reasons for Inspection and Testing
6.2 Shop Inspection/Overhaul
6.3 Visual On-stream Inspection
6.4 Inspection Frequency
6.5 Time of Inspection.
7 Records and Reports

7.1 Objective
7.2 The Need to Keep Records
7.3 Responsibilities
7.4 Sample Record and Report System
Annex A (informative) Pressure-relief Valve Testing
Annex B (informative) Sample Record and Report Forms
1 Scope
1 Scope.
This recommended practice (RP) describes the inspection and repair practices for
automatic pressure-relieving devices commonly used in the oil and petrochemical
industries. As a guide to the inspection and repair of these devices in the users plant,
it is intended to ensure their proper performance.
This publication covers such automatic devices as;
1. pressure-relief valves,
2. pilot-operated pressure-relief valves,
3. rupture disks, and
4. weight-loaded pressure vacuum vents.
The scope of this RP includes the inspection and repair of automatic pressure-relieving
devices commonly used in the oil and petrochemical industry.
The recommendations in this publication are not intended to supersede requirements

established by regulatory bodies.
This publication does not cover;
weak seams or sections in tanks,

explosion doors,
fusible plugs,
control valves, and
other devices that either depend on an external source of power for operation or
other devices that are manually operated.
Inspections and tests made at manufacturers plants, which are usually covered by
codes or purchase specifications, are not covered by this publication.
The recommendations in this publication are not intended to

supersede requirements established by regulatory bodies.
Table 9.1.1 Approval authorities

http://www.spiraxsarco.com/resources/steamengineering-tutorials/safety-valves/introductionto-safety-valves.asp
This publication does not cover training requirements for mechanics involved in the
inspection and repair of pressure relieving devices. Those seeking these requirements
should see API 510, which gives the requirements for a quality control system and
specifies that the repair organization maintain and document a training program
ensuring that personnel are qualified.
This publication does not cover training requirements for

mechanics involved in the inspection and repair of pressure
relieving devices.
pressure-relief valves
pressure-relief valves
Safety Valve.
Relief Valve.
Safety-relief Valve.
Conventional Safety-relief Valve.
Balanced Safety-relief Valve.
pilot-operated pressure-relief valves
pilot-operated
pressure-relief
valves
rupture disks
weight-loaded pressure vacuum vents
The following referenced documents are indispensable for the application of this document.
For dated references, only the edition cited applies. For undated references, the latest
edition of the referenced document (including any amendments) applies.
API 510, Pressure Vessel Inspection Code: In-service Inspection, Rating, Repair, and
Alteration
API Standard 520 (All Parts), Sizing, Selection, and Installation of Pressure-relieving
Devices in Refineries
API Standard 521, Pressure-relieving and Depressuring Systems
API Standard 526, Flanged Steel Pressure-relief Valves
API Standard 527, Seat Tightness of Pressure Relief Valves
API Recommended Practice 580, Risk-Based Inspection
API Recommended Practice 581, Risk-Based Inspection Technology
API Standard 620, Design and Construction of Large, Welded, Low-pressure Storage Tanks
API Standard 2000, Venting Atmospheric and Low-pressure Storage Tanks (Nonrefrigerated and Refrigerated)
ASME PTC 25, Pressure Relief Devices

ASME Boiler and Pressure Vessel Code (BPVC), Section I: Power Boilers
ASME Boiler and Pressure Vessel Code (BPVC), Section IV: Heating Boilers
ASME Boiler and Pressure Vessel Code (BPVC), Section VI: Recommended Rules for the
Care and Operation of Heating Boilers
ASME Boiler and Pressure Vessel Code (BPVC), Section VII: Recommended Guidelines for
the Care of Power Boilers
ASME Boiler and Pressure Vessel Code (BPVC), Section VIII: Pressure Vessels; Division 1,
Division 2 and Division 3
ISO 4126-6, Safety devices for protection against excessive pressurePart 6: Application,
selection and installation of bursting disc safety devices
NACE MR 0175, Petroleum and Natural Gas IndustriesMaterials for Use in H2SContaining Environments in Oil and Gas Production.
NACE MR 0103, Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum
Refining Environments.
NB-18, Pressure-relief Device Certifications.
NB-23:2004, National Board Inspection Code.
3 Terms and Definitions
3.1 General
For the purposes of this document, the following terms and definitions
apply.
3.1.1 car seal
A locking seal that when placed in position and closed, locks and must
be cut or physically broken to be removed.
3.1.2 galling
A condition whereby excessive friction between high spots results in
localized welding with subsequent splitting and a further roughening of
rubbing surfaces of one or both of two mating parts.
3.1.3 non-reclosing pressure-relief device

A pressure-relief device, which remains open after operation. A manual
resetting means may be provided.
3.1.4 pin-actuated device
A non-reclosing pressure-relief device actuated by static pressure and
designed to function by buckling or breaking a pin which holds a piston
or a plug in place. Upon buckling or breaking of the pin, the piston or
plug instantly moves to the full open position.
galling
car seal
3.2 Dimensional Characteristics of Pressure-relief Valves

3.2.1 effective discharge area
A nominal or computed area used with an effective Dimensional
Characteristics of Pressure-relief Valves discharge coefficient to calculate
the minimum required relieving capacity for a pressure-relief valve per the
preliminary sizing equations contained in API 520. Refer to API 520-1 for
the preliminary sizing equations. API 526 provides effective discharge
areas for a range of sizes in terms of letter designations, D through T.
3.2.2 huddling chamber
An annular pressure chamber located downstream of the seat of a pressurerelief valve, for the purpose of assisting the valve to achieve lift.
3.2.3 inlet size

The nominal pipe size (NPS) of the relief device at the inlet connection,
unless otherwise designated.
3.2.4 lift
The actual travel of the disk away from the closed position when a
pressure-relief valve is relieving.
3.2.5 outlet size
The nominal pipe size (NPS) of the relief device at the discharge
connection, unless otherwise designated.
inlet size
outlet size
huddling
chamber
huddling chamber
huddling
chamber
lift
outlet size
inlet size
Basic Function of a
Spring Loaded Safety Valve
http://www.leser.com/en/tools/safety-valve-tutorial/spring-loaded-safety-valve-from-leser.html
http://www.spiraxsarco.com/resources/steam-engineering-tutorials/safety-valves/introduction-to-safety-valves.asp
http://www.scrmymail.net/TR/products/SRVOperation.htm
Force & pressure, area relations.
Valve Closed.
In a direct spring loaded safety valve the closing force or spring force is
applied by a helical spring which is compressed by an adjusting screw.
The spring force is transferred via the spindle onto the disc. The disc
seals against the nozzle as long as the spring force is larger than the
force created by the pressure at the inlet of the valve. The figure shows
the enlarged nozzle and disc area of a safety valve with the forces acting
on the disc.
Valve Opening.
In an upset situation a safety valve will open at a predetermined set
pressure. The spring force Fs is acting in closing direction and Fp, the
force created by the pressure at the inlet of the safety valve, is acting in
opening direction. At set pressure the forces Fs and Fp are balanced.
There is no resulting force to keep the disc down on the seat. The safety
valve will visibly or audibly start to leak (initial audible discharge).
The pressure below the valve must increase

above the set pressure before the safety valve
reaches a noticeable lift. As a result of the
restriction of flow between the disc and the
adjusting ring, pressure builds up in the so called
huddling chamber. The pressure now acts on an
enlarged disc area. This increases the force Fp so
that the additional spring force required to further
compress the spring is overcome. The valve will
open rapidly with a "pop", in most cases to its full
lift. Overpressure is the pressure increase above
the set pressure necessary for the safety valve to
achieve full lift and capacity. The overpressure is
usually expressed as a percentage of the set
pressure. Codes and standards provide limits for
the maximum overpressure. A typical value is
10%, ranging between 3% and 21% depending
on the code and application.
Fp = p*Ah = Force by pressure

where
Ah = seat area affected by pressure
p on huddling chamber
Valve Reclosing.
In most applications a properly sized safety valve will decrease the pressure in the vessel
when discharging. The pressure in the vessel will decrease at any subsequent point, but
not later than the end of the upset situation. A decreasing pressure in the vessel will
lower the force Fp. At set pressure however the flow is still acting on the enlarged disc
area, which will keep the valve open. A further reduction in pressure is required until the
spring force Fs is again greater than Fp and the safety valve begins to reclose. At the so
called reseating pressure the disc will touch the nozzle again and the safety valve
recloses. Blowdown is the difference between set pressure and reseating pressure of a
safety valve expressed as a percentage of set pressure. Typical blowdown values as
defined in codes and standards are -7% and -10%, ranging from -4% to -20% depending
on the code and service (steam, gas or liquid).
Blowdown is the difference between set pressure and

reseating pressure of a safety valve expressed as a
percentage of set pressure.
Functional Diagram.
The following diagram shows a typical functional curve of a spring loaded safety valve.
Operation of
a Series 526
API safety
valve with
adjusting
ring and
initial
audible
discharge set
pressure
definition
It is important to understand that the operating pressure of the protected equipment should
remain below the reseating pressure of the valve. Most manufacturers and codes and
standards recommend a difference of 3-5% between reseating pressure and operating
pressure to allow proper reseating of the valve and achieve good seat tightness again.
1. Set pressure.
2. Popping pressure.
(over-pressure)
3. Relieving pressure.
4. Max. overpressure.
5. Reseating pressure.
6. Max. blowdown
7. Operating pressure.
3.3 Operational CharacteristicsSystem Pressures

3.3.1 accumulation
The pressure increase over the MAWP of the vessel allowed during discharge
through the pressure-relief device, expressed in pressure units or as a percentage of
MAWP or design pressure. Maximum allowable accumulations are established by
applicable codes for emergency, operating, and fire contingencies.
3.3.2 design pressure
The design pressure of the vessel along with the design temperature is used to
determine the minimum permissible thickness or physical characteristic of each
vessel component, as determined by the vessel design rules. The design pressure is
selected by the user to provide a suitable margin above the most severe pressure
expected during normal operation at a coincident temperature. It is the pressure
specified on the purchase order. This pressure may be used in place of the MAWP in
all cases where the MAWP has not been established. The design pressure is equal to
or less than the MAWP.
design pressure
This pressure may be used in place of the MAWP
in all cases where the MAWP has not been
established. The design pressure is equal to or less
than the MAWP.
3.3.3 maximum allowable working pressure

MAWP
The maximum gauge pressure permissible at the top of a completed vessel in its;
(1) normal operating position at the
(2) designated coincident temperature specified for that pressure.
The pressure is the least of the values for the internal or external pressure as determined
by the vessel design rules for each element of the vessel using actual nominal thickness,
exclusive of additional metal thickness allowed for corrosion and loadings other than
pressure.
tMAWP = tactual - tcorrosion

The MAWP is the basis for the pressure setting of the pressure-relief devices that protect
the vessel. The MAWP is normally greater than the design pressure but can be equal to
the design pressure when the design rules are used only to calculate the minimum
thickness for each element and calculations are not made to determine the value of the
MAWP.
The MAWP is the basis for

the pressure setting of the
pressure-relief devices that
protect the vessel.
The MAWP is normally
greater than the design
pressure but can be equal
to the design pressure.
3.3.4 maximum operating pressure

The maximum pressure expected during normal system operation.
3.3.5 Overpressure
The pressure increase over the set pressure of a pressure relief of a relieving device
allowed to achieve rated flow. Overpressure is expressed in pressure units or as a
percentage of set pressure. It is the same as accumulation only when the relieving device
is set to open at the MAWP of the vessel.
3.3.6 rated relieving capacity
The relieving capacity used as the basis for the application of a pressure-relief device.
This capacity is determined in accordance with the applicable code or regulation and is
provided by the manufacturer. NOTE The capacity marked on the device is the rated
capacity on steam, air, gas, or water as required by the applicable code.
3.3.7 stamped relieving capacity
The rated relieving capacity that appears on the device nameplate and based on the rated
relieving capacity determined at the specified set pressure or burst pressure plus the
allowable overpressure.
Keywords:
Overpressure
Accumulation (pressure)
Designed lift
achieve
rated flow
P<Pset
P>Pset, , P = Poverpressure
Keywords:
Set pressure
Overpressure
Accumulation (pressure)
3.4 Operational CharacteristicsDevice Pressures

3.4.1 backpressure
The pressure that exists at the outlet of a pressure-relief device as a result of the
pressure in the discharge system. It is the sum of the superimposed and built-up
backpressures.
3.4.2 blow-down
The difference between the set pressure and the closing pressure of a pressure-relief
valve, expressed as a percentage of the set pressure or in pressure units.
3.4.3 built-up backpressure
The increase in pressure at the outlet of a pressure-relief device that develops as a
result of flow after the pressure relief device opens.
3.4.4 burst pressure
The burst pressure of a rupture disk at the specified temperature is the value of the
upstream static pressure minus the value of the downstream static pressure just prior to
when the disk bursts. When the downstream pressure is atmospheric, the burst pressure
is the upstream static gauge pressure.
3.4.5 burst-pressure tolerance

The variation around the marked burst pressure at the specified disk temperature in which a
rupture disk will burst.
3.4.6 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, as determined by seeing, feeling or hearing.
3.4.7 cold differential test pressure CDTP
The pressure at which a pressure-relief valve is adjusted to open on the test stand. The
CDTP includes corrections for the service conditions of backpressure or temperatures or
both.
3.4.8 leak-test pressure
The specified inlet static pressure at which a seat leak test is performed.
3.4.9 manufacturing design range
The pressure range at which the rupture disk shall be marked. Manufacturing design ranges
are usually catalogued by the manufacturer as a percentage of the specified burst pressure.
Catalogued manufacturing ranges may be modified by agreement between the user and the
manufacturer.
cold differential test pressure CDTP

The pressure at which a pressure-relief valve is adjusted to open on the test stand. The
CDTP includes corrections for the service conditions of;
backpressure or
temperatures or both.
3.4.10 marked burst pressure or rated burst pressure.

The marked burst pressure or rated burst pressure of a rupture disk is the burst pressure
established by tests for the specified temperature and marked on the disk tag by the
manufacturer. The marked burst pressure may be any pressure within the manufacturing
design range unless otherwise specified by the customer. The marked burst pressure is
applied to all the rupture disks of the same lot.
3.4.11 opening pressure.
The value of increasing opening pressure inlet static pressure whereby there is a measurable
lift of the disk or at which discharge of the fluid becomes continuous, as determined by
seeing, feeling or hearing.
opening pressure
3.4.12 set pressure.

The inlet gauge pressure at which a pressure-relief valve is set to open under service
conditions.
3.4.13 simmer.
The audible or visible escape of compressible fluid between the seat and disc, which may
occur at an inlet static pressure below the set pressure prior to opening.
3.4.14 specified burst pressure
The specified burst pressure of a rupture disk is the burst pressure specified by the user. The
marked burst pressure may be greater than or less than the specified burst pressure but shall
be within the manufacturing design range. The user is cautioned to consider manufacturing
range, superimposed backpressure and specified temperature when determining a specified
burst pressure.
3.4.15 superimposed backpressure
The static pressure that exists at the outlet of a pressure-relief device at the time the device is
required to operate. It is the result of pressure in the discharge system coming from other
sources and may be constant or variable.
4 Pressure-relieving Devices
Fion Zhnag/ Charlie Chong
4.1 General
Pressure-relieving devices protect equipment and personnel by automatically opening at
predetermined pressures and preventing the adverse consequences of excessive
pressures in process systems and storage vessels. A pressure-relief device is 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
may also be designed to prevent excessive internal vacuum. The device may be a
pressure-relief valve, a non-reclosing pressure relief device, or a vacuum-relief valve.
Common examples include:
direct spring-loaded pressure-relief valves,

pilot-operated pressure-relief valves,
Rupture disks,
weight-loaded devices, and
pressure- and/or vacuum-vent valves.

A pressure-relief valve is designed to open for the relief of excess pressure and reclose
thereby preventing further flow of fluid after normal conditions have been restored. A
pressure-relief valve opens when its upstream pressure reaches the opening pressure. It
then allows fluid to flow until its upstream pressure falls to the closing pressure. It then
closes, preventing further flow.
Examples of specific types of pressure-relief valves include:
safety valve,
relief valve,
conventional safety-relief valve,
balanced safety-relief valve, and
pilot-operated pressure-relief valve.
4.3 Safety Valve.
Type
Characteristics
Mediums
Limitations
Safety Valve.
valve that is actuated

by the static pressure
upstream of the valve
and characterized by
rapid opening or pop
action.
normally used with

compressible fluids
(air, steam,
gaseous)
should not be used in/where;

(1) corrosive services.
(2) the escape of process fluid around.
blowing valves.
(3) in liquid service
(4) impose any backpressure
(5) as pressure control or bypass valves.
Relief Valve.
The valve opens

normally in proportion
to the pressure
increase over the
opening pressure.
normally used for

incompressible
fluids
should not be used in;

(1) steam, air, gas, or other vapor services
Relief valves usually reach full lift at either 10% or 25% overpressure. Valves have closed
bonnets to prevent the release of corrosive, toxic, flammable, or expensive fluids. Better
degree of tightness than conventional valves.
4.3.1 General.
A safety valve is a direct spring-loaded pressure-relief valve that is actuated by the static
pressure upstream of the valve and characterized by rapid opening or pop action. When the
static inlet pressure reaches the set pressure, it will increase the pressure upstream of the
disk and overcome the spring force on the disk. Fluid will then enter the huddling chamber,
providing additional opening force. This will cause the disk to lift and provide full opening
at minimal overpressure. The closing pressure will be less than the set pressure and will be
reached after the blow-down phase is completed. The spring of a safety valve is usually
fully exposed outside of the valve bonnet to protect it from degradation due to the
temperature of the relieving medium. A typical safety valve has a lifting lever for manual
opening to ensure the freedom of the working parts. Open bonnet safety valves are not
pressure tight on the downstream side. Figure 1 illustrates a full-nozzle, top-guided safety
valve.
4.3.2 Applications
A safety valve is normally used with compressible fluids. Safety valves are used on steam
boiler drums and superheaters. They are also used for general air and steam services in
refinery and petrochemical plants. Safety valve discharge piping may contain a vented
drip pan elbow or a short piping stack routed to the atmosphere.
4.3.3 Limitations
Safety valves should not be used:
in corrosive services (unless isolated from the process by a rupture disk),

in installations that impose any backpressure unless the effects of the backpressure have
been accounted for in the installation,
where the escape of process fluid around blowing valves is not desirable,
in liquid service,
as pressure control or bypass valves.
4.4 Relief Valve.
Type
Characteristics
Mediums
Limitations
Safety Valve.
valve that is actuated

by the static pressure
upstream of the valve
and characterized by
rapid opening or pop
action.
normally used with

compressible fluids
(air, steam,
gaseous)
should not be used in/where;

(1) corrosive services.
(2) the escape of process fluid around.
blowing valves.
(3) in liquid service
Relief Valve.
The valve opens

normally in proportion
to the pressure
increase over the
opening pressure.
normally used for

incompressible
fluids
should not be used in;

(1) steam, air, gas, or other vapor services
Relief valves usually reach full lift at either 10% or 25% overpressure. Valves have closed
bonnets to prevent the release of corrosive, toxic, flammable, or expensive fluids. Better
degree of tightness than conventional valves.
4.4.1 General.
A relief valve is a direct spring-loaded pressure-relief valve actuated by the static pressure
upstream of the valve. The valve opens normally in proportion to the pressure increase over
the opening pressure. A relief valve begins to open when the static inlet pressure reaches its
set pressure. When the static inlet pressure overcomes the spring force, the disk begins to lift
off the seat, allowing flow of the liquid. The value of the closing pressure is lower than the
set pressure and will be reached after the blowdown phase is complete. Relief valves usually
reach full lift at either 10 % or 25 % overpressure, depending on the type of valve and trim.
These valves have closed bonnets to prevent the release of corrosive, toxic, flammable, or
expensive fluids. They can be supplied with lifting levers, balancing bellows, and soft seats
as needed. Figure 2 illustrates one type of relief valve. The ASME BPVC requires that liquid
service relief valves installed after January 1, 1986 have their capacity certified and stamped
on the nameplate.
Some relief valves are manufactured with resilient O-rings or other types of soft seats to
supplement or replace the conventional metal-to-metal valve seating surfaces. Usually,
the valves are similar in most respects to the other pressure-relief valves, with the
exception that the disks are designed to accommodate some type of resilient seal ring
to promote a degree of tightness exceeding that of the usual commercial tightness of
conventional metal seats. Figure 3 illustrates one type of O-ring seat seal as installed in
a safety-relief valve.
4.4.2 Applications
Relief valves are normally used for incompressible fluids (see API 520, Part 1).
4.4.3 Limitations
Relief valves should not be used:
in steam, air, gas, or other vapor services;
in installations that impose any backpressure unless the effects of the backpressure
have been accounted for;
4.5 Safety-relief Valve.
4.5 Safety-relief Valve.

A safety-relief valve is a direct spring-loaded pressure-relief valve that may be used as
either a safety or relief valve depending on the application. A safety-relief valve is
normally fully open at 10 % overpressure when in gas or vapor service. When installed
in liquid service, full lift will be achieved at approximately 10 % or 25 % overpressure,
depending on trim type.
Safety Valve: Compressible fluid (steam, air, gas, or other vapor

services)
Relieve valve: Incompressible fluids
Safety relieve valve: Both compressible and incompressible fluids.
Types
Mediums Limitations
Safety-relief Valve
Full lift; Liquid 10% or 25% overpressure, Gas/Vapor phase 10% overpressure
Conventional
All phases
Valves should not be used; :

1. total built-up backpressure exceeds the allowable overpressure.
2. (CDTP) cannot be reduced to account for the effects of variable
backpressure.
3. ASME BPVC Section I steam boiler drums & superheaters.
4. as pressure control or bypass valves.
Whose operational characteristics are directly affected by changes in the backpressure.

Bonnet is pressure-tight cavity and is vented to the discharge side of the valve.
Balanced Safetyrelief Valve.
All phases
valves should not be used:

1. on ASME BPVC Section I steam boiler drums or ASME BPVC Section I
superheaters, and
valve that incorporates a bellows or other means for minimizing the effect of backpressure
on the operational characteristics of the valve. The bonnet may or may not be pressure
tight. Used where high backpressures are present at the valve discharge.

4.6.1 General
A conventional safety-relief valve is a direct spring-loaded pressure-relief valve whose
operational characteristics (opening pressure, closing pressure, and relieving capacity) are
directly affected by changes in the backpressure (see Figure 4). A conventional safetyrelief valve has a bonnet that encloses the spring and forms a pressure-tight cavity. The
bonnet cavity is vented to the discharge side of the valve.
4.6.2 Applications
Conventional safety-relief valves can be used in refinery and petrochemical processes that
handle flammable, hot, or toxic material. The effect of temperature and backpressure on
the set pressure is considered when specifying conventional safety-relief valves.
4.6.3 Limitations
Conventional safety-relief valves should not be used in the following applications:
a) where the total built-up backpressure exceeds the allowable overpressure;
b) where the cold differential test pressure (CDTP) cannot be reduced to account for the
effects of variable backpressure (see API 520, Part 1);
c) on ASME BPVC Section I steam boiler drums or ASME BPVC Section I superheaters;
d) as pressure control or bypass valves.
http://www.leser.com/en/products/download/brochures-catalogs.html
Conventional safety valves
Fig. 9.2.1 Schematic diagram of safety valves with bonnets

vented to (a) the valve discharge and (b) the atmosphere
http://www.spiraxsarco.com/resources/ste
am-engineering-tutorials/safetyvalves/types-of-safety-valve.asp
4.7 Balanced Safety-relief Valve
Types
Mediums Limitations
Safety-relief Valve
Full lift; Liquid 10% or 25% overpressure, Gas/Vapor phase 10% overpressure
Conventional
All phases
Valves should not be used; :

1. total built-up backpressure exceeds the allowable overpressure.
2. (CDTP) cannot be reduced to account for the effects of variable
backpressure.
3. ASME BPVC Section I steam boiler drums & superheaters.
Whose operational characteristics are directly affected by changes in the backpressure.

Bonnet is pressure-tight cavity and is vented to the discharge side of the valve.
Balanced Safetyrelief Valve.
All phases
valves should not be used:

1. on ASME BPVC Section I steam boiler drums or ASME BPVC Section I
superheaters, and
valve that incorporates a bellows or other means for minimizing the effect of backpressure
on the operational characteristics of the valve. The bonnet may or may not be pressure
tight. Used where high backpressures are present at the valve discharge.
4.7.1 General
A balanced safety-relief valve is a direct spring-loaded pressure-relief valve that
incorporates a bellows or other means for minimizing the effect of backpressure on the
operational characteristics of the valve. Whether it is pressure tight on its downstream
side depends on its design. See Figure 5 and Figure 6.
4.7.2 Applications
Balanced safety-relief valves are normally used in refinery and petrochemical process
industries that handle flammable, hot, or toxic material, where high backpressures are
present at the valve discharge. This typically occurs where material from the valve is
routed to a collection system. They are used:
in gas, vapor, steam, air, or liquid services;
in corrosive service to isolate the spring and the bonnet cavity of the valve from process
material;
when the discharge from the valves is piped to remote locations.
4.7.3 Limitations
Balanced safety-relief valves should not be used:
on ASME BPVC Section I steam boiler drums or ASME BPVC Section I superheaters,
and
Balanced type valves require vented bonnets. A bellows failure allows process media from
the discharge side of the valve to discharge from the bonnet vent. Consider the nature of
the process media (e.g. liquid/vapor, toxicity, and flammability) when evaluating the
bonnet vent disposition. Bonnet vents are typically routed to a drain or atmosphere
depending on the process media involved.
The internal area of the bellows in a balanced-bellows spring-loaded pressure-relief valve is

referenced to atmospheric pressure in the valve bonnet. The bonnet of a balanced pressurerelief valve shall be vented to the atmosphere at all times for the bellows to perform
properly. In the case of a bellows failure, the absence of the vent (i.e. if the bonnet were
closed), will allow the bonnet pressure to rise to the valve discharge pressure, defeating the
balanced design of the valve, and effectively converting it to a conventional valve. The
bonnet vent ensures nearly balanced performance even in the event of a bellows failure, and
therefore shall be kept open. If the valve is located where atmospheric venting would
present a hazard or is not permitted by environmental regulations, the vent should be piped
to a safe location that is free of backpressure that may affect the pressure-relief valve set
pressure.
Balanced safety-relief valves may have a backpressure limitation based on the mechanical
strength of the bellows. Consult the individual valve manufacturer to assure the allowable
backpressure is not exceeded.
Fig. 9.2.2 Schematic

diagram of a piston type
balanced safety valve
Fig. 9.2.3 Schematic diagram

of the bellows balanced safety
valve
Pdown
Pup
https://controls.engin.umich.edu/wiki/index.php/ValveTypesSelection
Type
Characteristics
Mediums
Limitations
Pilot-operated
safety-relief valves
This type of safety valve

uses the flowing medium
itself, through a pilot
valve, to apply the
closing force on the
safety valve disc. The
pilot valve is itself a
small safety valve.
Clean,
non-viscous
mediums.
should not be used in service;

(1) Dirty, fouling mediums causing blockage to the
small bore piping..
(2) Viscous mediums increase the operation time.
(3) Corrosive mediums that cause blockage, impair
actuation.
(4) Chemical compatibility and temperature limits
that affect the pilot valve seating.
1.
2.
3.
4.
5.
6.
7.
8.
large relief area and/or high set pressures are required.

Back pressure is high and balance design is required.
low differential exists between the normal vessel operating pressure and the set pressure of the
valves.
Pilot operated safety valves offer good overpressure and blowdown performance (a blowdown
of 2% is attainable).
Pilot operated valves are also available in much larger sizes, making them the preferred type of
safety valve for larger capacities.
Remote sensing & control at different locations.
inlet or outlet piping frictional pressure losses are high.
In-situ, in-service, set pressure verification is required.
http://www.spiraxsarco.com/resources/steam-engineeringtutorials/safety-valves/types-of-safety-valve.asp
What is a Pilot operated safety valve

This type of safety valve uses the flowing medium itself, through a pilot valve, to apply the
closing force on the safety valve disc. The pilot valve is itself a small safety valve. If the inlet
pressure were to rise, the net closing force on the piston also increases, ensuring that a tight
shut-off is continually maintained. However, when the inlet pressure reaches the set pressure,
the pilot valve will pop open to release the fluid pressure above the piston. With much less
fluid pressure acting on the upper surface of the piston, the inlet pressure generates a net
upwards force and the piston will leave its seat. This causes the main valve to pop open,
allowing the process fluid to be discharged.
https://controls.engin.umich.edu/wiki/index.php/ValveTypesSelection
Ftop = Area top x P
F bottom = Area bottom x P

4.8.1 General
A pilot-operated safety-relief valve is a pressure-relief valve in which the major
relieving device or main valve is combined with and controlled by a self-actuated
auxiliary pressure-relief valve (pilot).
Depending on the design, the pilot valve (control unit) and the main valve may be
mounted on either the same connection or separately. The pilot is a spring-loaded valve
that operates when its inlet static pressure exceeds its set pressure. This causes the main
valve to open and close according to the pressure. Process pressure is either vented off
by the pilot valve to open the main valve or applied to the top of the unbalanced piston,
diaphragm, or bellows of the main valve to close it. Figure 7 illustrates a low-pressure
diaphragm-type pilot-operated valve. Figure 8 and Figure 9 show a high-pressure pilotoperated valve that uses an unbalanced piston with an integrally-mounted pilot. Figure
9 also illustrates optional remote pressure sensing from the vessel and optional dual
outlets to equalize thrust.
Figure 7Low-pressure Diaphragm-type

Pilot-operated Valve
Figure 8High-pressure Pilotoperated Valve
Figure 9High-pressure Pilot-operated Valve with Optional Dual Outlets
4.8.2 Applications
Pilot-operated safety-relief valves are generally used:
a) where a large relief area and/or high set pressures are required, since pilotoperated valves can usually be set to the full rating of the inlet flange;
b) where a low differential exists between the normal vessel operating pressure and
the set pressure of the valves;
c) on large low-pressure storage tanks (see API 620);
d) where very short blowdown is required;
e) where backpressure is very high and balanced design is required, since pilotoperated valves with the pilots either vented to the atmosphere or internally
balanced are inherently balanced by design;
f) where process conditions require sensing of pressure at one location and relief of
fluid at another location;
g) where inlet or outlet piping frictional pressure losses are high;
h) where in-situ, in service, set pressure verification is desired.
4.8.3 Limitations
Pilot-operated safety-relief valves are not generally used as follows:
a) in service where fluid is dirty, or where there is a potential for fouling or
solidification (e.g. hydrates, wax, or ice) in the pilot or sensing line unless
special provisions are taken (such as filters, sense line purging, etc.);
b) in viscous liquid service, as pilot-operated valve operating times will increase
markedly due to flow of viscous liquids through relatively small passages
within the pilot;
c) with vapors that will polymerize in the valves;
d) in services where the temperature exceeds the safe limits for the diaphragms,
seals, or O-rings selected;
e) where chemical compatibility of the loading fluid with the diaphragms, seals,
or O-rings of the valves is questionable;
f) where corrosion buildup can impede the actuation of the pilot.
4.9 Pressure- and/or Vacuum-vent Valve
Types
Mediums Limitations
Pressure- and/or
Vacuum-vent
Valve
Liquid
phase
Pressure- and/or vacuum-vent valves are generally not used for

applications requiring a set pressure greater than 15 lbf/in.2 (103 kPa).
Atmospheric storage materials with a flash point below 100F (38C). may also be
used on tanks storing heavier oils.
4.9.1 General.
A pressure- and/or vacuum-vent valve (also known as a pressure- and/or
vacuum-relief valve) is an automatic pressure or vacuum-relieving device
actuated by the pressure or vacuum in the protected equipment. A pressure
and/ or vacuum-vent valve falls into one of three basic categories:
pilot-operated vent valve, as shown in Figure 7;
weight-loaded pallet-vent valve, as shown in Figure 10;
spring- and weight-loaded vent valve, as shown in Figure 11.
Figure 7Low-pressure Diaphragm-type Pilot-operated Valve
When internal pressure

is high pressure
overcome the loaded
pallet and bleed out.
Figure 10Weight-loaded Pallet Vent Valve

When internal pressure

is low outside air is
drawn in
Figure 10Weight-loaded Pallet Vent Valve
Figure 11Spring and Weight-loaded Vent Valve

Figure 11Spring and Weight-loaded Vent Valve
4.9.2 Applications
Pressure- and/or vacuum-vent valves are normally used to protect atmospheric and
low-pressure storage tanks against a pressure large enough to damage the tank. Single
units composed of both pressure-vent valves and vacuum-vent valves are also known
as conservation-vent valves, and are normally used on atmospheric storage tanks
containing materials with a flash point below 100F (38C). However, they may also
be used on tanks storing heavier oils (see API 2000).
4.9.3 Limitations
Pressure- and/or vacuum-vent valves are generally not used for applications requiring a
set pressure greater than 15 lbf/in.2 (103 kPa).
5 Causes of Improper
Performance
Figure 22Sulfide Corrosion on Carbon Steel

Disk from Crude Oil Distillation Unit
Figure 25Monel Rupture Disks Corroded in Sour Gas Service
Figure 35Disk Frozen in

Guide Because of Buildup of
Products of Corrosion in Sour
Oil Vapor Service
Figure 36Rough Handling of Valves Should be Avoided
5.1 Corrosion
Acid attack on carbon steel due to a leaking

valve seat
Acid attack on a stainless steel inlet nozzle
Chloride corrosion on a stainless steel nozzle
Sulphide corrosion on a carbon steel disc
Chloride corrosion on a stainless steel disc
Pitting corrosion on stainless steel bellows
Sour gas (H2S) attack on a monel rupture
disc
Corrosion is a basic cause of many of the difficulties

encountered with pressure-relief devices.
Mitigations:
Material selections.
Using rupture disks at inlet and / or outlet.
Use of O ring to prevent leakages into moving parts.
Bellow seal of balanced pressure relieve valve.
http://www.valveworld.net/safetyequipment/Sho
wPage.aspx?pageID=640
Fig. 2 Spring-loaded relief valve

fitted with a bellows and a
balanced piston.
Fig. 1 Spring-loaded
pressure relief valve.
5.2 Damaged Seating Surfaces
Because there is metal-to-metal contact between the

valve disc and nozzle, this area must be extremely flat, as
any imperfections will lead to a process leak. The seating
surfaces must be lapped to produce a finish of two to
three light bands (0.000 034 8 in). Figure 8.6 shows
the principle.
What is optical flat?
Basic interferometry
The interference technique
enables you to measure
differences in orders of half
a wave length of the light
used by just counting
fringes! and a bit of simple
math. These fringes are the
result of constructive and
destructive interference
patterns created
when wavelengths having the same frequency but a phase difference are
superimposed. In its simplest form it uses a Optical Flat and a
monochromatic light source
Optical Flats and Slip Gauges
If the bands are straight, parallel and

evenly spaced, the surface is flat. If
the bands are curved or are unevenly
spaced, the surface is not flat.
The number of bands which appear is
not an indication of the flatness of
the surface but relates only to the
steepness of the wedge. The bands
may be made fewer and father apart
by pressing on the optical flat until
they are most conveniently spaced for
evaluation.
http://www.gagesite.com/docum
ents/Metrology%20Toolbox/Ho
w%20to%20Measure%20Flatne
ss%20with%20Optical%20Flats.
pdf
As light travels through the

Optical Flat the ray is 'split' into
two rays one is reflected
internally off the inner bottom
surface and the other continuing
through the air gap to be
reflected off the specimen
surface.
The extra distance this ray has to travel before being reflected back will
cause a phase displacement; if it is out of phase by 180so when it's at
maximum the internally reflected is minimum they will destructively
interfere and no light will be seen resulting in a dark fringe; every time
the gap changes by a multiple of this distance a dark fringe will be the
result.
In the above example the fringes

appear as a series of rings which
indicate the surface under test is
either concave or convex the
simple way to determine which, is
to apply finger pressure to the
center fringe, if fringes reduce in
number then the surface is concave
The two Slip Gages above are of

notionally the same length, both
show a series of fringes indicating
there is a variation in height in the
direction at right angles to the
fringes http://philipgee.com/OptFlt-01.html
Example: 1
a series of fringes indicating

there is a variation in height
in the direction at right
angles to the fringes
Total 12 fringes counts. Hg yellow
monochromatic light of say 578 nm
Closer fringes
indicate higher
variations.
Monochromatic Light Source used typically a

Mercury vapor lamp Hg yellow wave length 577.0 579.0 nm (say 578 nm)
1 fringe = variation of say 578.0 nm = 0.000 000
578 x 12 fringes = 0.000 006 936 m
A total variation of = 6.936 m (micron) (x 10 -6)
( or /2?, 578/2 x 12?)
Note: although there were height variations in both sample, the equal parallel
spacing contour suggest that both the work pieces were totally flat.
Example: 2
The bands are to be interpreted as contour lines on a map, the interval

being 0.000 01 157 inch (293.8 nm). Thus the total flatness error is
equal to half the band count between points of contact. In the figure
shown the 12 bands between high spots indicate a valley 6 bands or
0.000 069 42 in. deep.
Causes of damaged valve seats;

1.
2.
3.
4.
Corrosion
Debris.
Careless handling.
Valve leakage causing erosion corrosion;
Improper maintenance.
Improper installation.
Improper valve assembly.
Operating at near the valve setting.
5. Valve chattering;
Chattering due to wrong blowdown setting.
Chattering due to lengthy pipe length at inlet.
Chattering due to obstruct inlet.
6. Severe over-sizing of pressure relieve valve resulting in
abrupt closing of valve.
5.3 Failed Springs
Spring failures.
2 modes of failures;
Weakening.
Complete fracture.
Causes of failures;
Improper material selection for high temperature services.
Corrosion;
General corrosion and pitting corrosion.
Stress corrosion cracking
Mitigations';
Material selection.
Isolation by O ring and bellow.
Isolation by rupture disks at inlet and/or outlet.
Coating of parts.
5.4 Improper Setting and Adjustment
The size of the test

stand is important since
insufficient surge volume
might not cause a
distinct pop, and may
cause an incorrect set
pressure.
The size of the test

stand is important
since insufficient surge
volume might not
cause a distinct pop,
and may cause an
incorrect set pressure.
Incorrect calibration of pressure gauges is a frequent cause of

improper valve setting.
Adjustment of the ring or rings controlling the valve is

frequently misunderstood
How to adjust a PSV

The spring determines the pressure at which the
PSV will lift, and the blowdown ring setting
determines when it will reseat (blowdown)
http://www.controlglobal.com/articles/2013/ate-valve-blowdown-rings-dp-runs/
Overpressure
Accumulation
http://www.cicpro.com/products/safety-relief-valves/
Reseating (blowdown)
Once normal operating conditions have been restored, the valve is required to close again,
but since the larger area of the disc is still exposed to the fluid, the valve will not close until
the pressure has dropped below the original set pressure. The difference between the set
pressure and this reseating pressure is known as the 'blowdown', and it is usually specified as
a percentage of the set pressure. For compressible fluids, the blowdown is usually less than
10%, and for liquids, it can be up to 20%.
Fig. 9.1.7 Relationship
between pressure and lift
for a typical safety valve
http://www.spiraxsarco.com/resources/stea
m-engineering-tutorials/safetyvalves/introduction-to-safety-valves.asp
The design of the shroud must be such that it offers both rapid opening and relatively small
blowdown, so that as soon as a potentially hazardous situation is reached, any overpressure
is relieved, but excessive quantities of the fluid are prevented from being discharged. At
the same time, it is necessary to ensure that the system pressure is reduced sufficiently to
prevent immediate reopening.
The blowdown rings found on most ASME type safety valves are used to make fine
adjustments to the overpressure and blowdown values of the valves (see Figure 9.1.8). The
lower blowdown (nozzle) ring is a common feature on many valves where the tighter
overpressure and blowdown requirements require a more sophisticated designed solution.
The upper blowdown ring is usually factory set and essentially takes out the manufacturing
tolerances which affect the geometry of the huddling chamber.
The lower blowdown ring is also factory set to achieve the appropriate code performance
requirements but under certain circumstances can be altered. When the lower blowdown
ring is adjusted to its top position the huddling chamber volume is such that the valve will
pop rapidly, minimising the overpressure value but correspondingly requiring a greater
blowdown before the valve re-seats. When the lower blowdown ring is adjusted to its
lower position there is minimal restriction in the huddling chamber and a greater
overpressure will be required before the valve is fully open but the blowdown value will be
reduced.
Adjustment pin affect the characteristic of

huddling chamber by reducing or increasing
the curtained area during release.
http://patentimages.storage.googleapi
s.com/EP0760067B1/00260001.png
http://patentimages.storage.goog
leapis.com/EP0760067B1/00240
001.png
5.5 Plugging and Sticking
Plugging and sticking (galling) may be caused by;
Foreign particle entrapped in the moving parts.

Corrosion.
Polymer formation of entrapped process fluid.
Chattering.
Poor alignment of valve disk due to debris.
Poor alignment of parts (incl. gasket) during assemblies.
Mitigations;
Rupture disk at the inlet.

Rupture disk at the outlets.
Bellow.
O ring.
5.6 Misapplication of Materials
Material Selections
Manufacturers can usually
supply valve designs and
materials that suit special
services. Catalogs have a
wide selection of special
materials and accessory
options for various chemical
and temperature conditions.
Addition of a rupture disk device at
the inlet or outlet may help prevent
corrosion.
Typical ball valve material selection
http://www.instreng.com/selection-calculations/435-typical-ball-valve-material-selection.html
Seating material
A key option is the type of seating material used. Metal-to-metal seats,
commonly made from stainless steel, are normally used for high
temperature applications such as steam. Alternatively, resilient discs can
be fixed to either or both of the seating surfaces where tighter shut-off
is required, typically for gas or liquid applications. These inserts can be
made from a number of different materials, but Viton, nitrile or EPDM
are the most common. Soft seal inserts are not generally recommended
for steam use.
Table 9.2.2 Seating materials used in safety valves
5.7 Improper Location, History, or Identification
A comprehensive set of
specification and historical
records should be
maintained and referred to
when valves are removed for
inspection and repair.
V-203
5.8 Rough Handling
Rough handling can occur during;

shipment,
maintenance, or
installation.
5.9 Improper Differential Between Operating and

Set Pressures
The following table summarises the performance of different types of safety

valve set out by the various standards.
Table 9.2.1 Safety valve performance summary
Blowdown Recommendations
Table 1: ASME Blowdown Recommendations for Fired Boilers and
Associated Tanks Operating at up to 375 PSIG.
Pressure Relief Valve Set
Pressure in PSIG
Maximum Blowdown
Recommended
<67
4 PSI
<67 to <250
6% (of set pressure)
>250 to <375
15 PSI
Greater differentials between

operating and set pressures
promote trouble-free
operation,
Overpressure
Accumulation
MAWP
Greater differentials between

operating and set pressures
promote trouble-free
operation,
they may also

increase the cost
of the equipment.
5.10 Improper Discharge Piping Test Procedures
the disk, spring, and body area on the discharge side

of the valve are fouled;
the bellows of a balanced relief valve are damaged
by excessive backpressure;
the dome area and/or pilot assembly of a pilotoperated pressure-relief valve are fouled and
damaged by the backflow of fluid;
exceeding the design pressure of the discharge side
of spring-loaded pressure-relief valves in some of the
larger sizes.
When
hydrostatic
tests of
discharge piping
are performed,
blinds shall be
installed.
Otherwise,
results such as
the
following might
occur:
dome area and/or

pilot assembly of a
pilot-operated
pressure-relief valve
are fouled and
damaged by the
backflow of fluid
the bellows of a balanced relief

valve are damaged by excessive
backpressure
exceeding the design

pressure of the
discharge side of
spring-loaded pressurerelief valves in some of
the larger sizes
5.11 Improper Handling, Installation, and Selection of

Rupture Disks
Rupture disk problems are often associated with improper

handling, installation, and selection. The following should
be considered.
proper orientation.
Once a rupture disk is removed should not be reinstalled.
An improper torque could affect the opening pressure of
the disk
Touching the rupture disk surface could lead to localized
corrosion
Appropriate burst temperature should consider ambient
heating or cooling.
installed away from unstable flow patterns to avoid
premature failures
Rupture disc installed on the Nitrogen circuit
6 Inspection and Testing
6.1 Reasons for Inspection and Testing

PSV is to release excess pressure
The principal reason for inspecting pressure-relieving devices is to ensure

that they
will provide this protection.
In making this determination ,two types of inspections can be used. They are;
1. shop inspection/overhauls,
2. visual on-stream inspections.
6.2 Shop Inspection/Overhaul

6.2.1 What is Shop Inspection/Overhaul
Periodically, pressure-relief devices will be removed, disassembled, and

inspected.
6.2.2 Safety
1. proper authority and permits for the work should be obtained.

2. Take precaution to avoid pressurizing PSV exceed their outlet flange
rating.
3. Physical supports on adjacent piping and PSV valve.
4. Decontamination of hazardous fluid inside valve.
6.2.3 Identifications
Proper stenciling, tagging and traceability.
6.2.4 Operating Conditions Noted
Historical records during operation, servicing, part changes and abnormal

conditions.
Marking
Safety valve standards are normally very specific about the information which must be
carried on the valve. Marking is mandatory on both the shell, usually cast or stamped,
and the name-plate, which must be securely attached to the valve. A general summary of
the information required is listed below:
On the shell
Size designation.
Material designation of the shell.
Manufacturer's name or trademark.
Direction of flow arrow.
On the identification plate:
Set pressure (in bar g for European valves and psi g for ASME valves).
Number of the relevant standard (or relevant ASME stamp).
Manufacturer's model type reference.
Derated coefficient of discharge or certified capacity.
Flow area.
Lift and overpressure.
Date of manufacture or reference number.
http://www.spiraxsarco.com/reso
urces/steam-engineeringtutorials/safety-valves/safetyvalve-installation.asp
National Board approved ASME stamps are applied as follows:

V
UV
UD
NV
VR
ASME I approved safety relief valves.

ASME VIII approved safety relief valves.
ASME VIII approved rupture disc devices.
ASME III approved pressure relief valves.
Authorised repairer of pressure relief valves.
Table 9.5.1 details the marking system required by TV and Table 9.5.2 details the
fluid reference letters.
Table 9.5.1 Marking system used for valves approved by TV to AD-Merkblatt A2, DIN
3320 and TRD 421
The Kdr or aW value can vary according to the relevant fluid and is either suffixed or
prefixed by the identification letter shown in Table 9.5.2.
Table 9.5.2 Fluid types defined as steam, gas or liquid
Preinspection Documentation Reviews:

Operating Conditions Noted
Historical records during operation, servicing, part changes and abnormal

conditions.
6.2.5 Removal of Device from System in Operation
Only an authorized person should isolate a relief device.

This may require providing or identifying alternate relief protection.
Isolations (blinds/relieving).
Ensure safe discharges.
The disassembled PSV to be blind to prevent debris entering.
Seriously consider replacing the disturbed rupture disks.
Re-commissioning on reinstallations.
Removal of Device from System in Operation

Key
1. safety-relief valve
2. car-seal valve in open
position and install
horizontally
3. to blowdown header
4. plug
5. short nipple
6. car-seal valve in the
open position
7. vessel
Note: a
Block valves should have
full port area and be at
least the size of the
inlet and outlet of the
relief valve.
Exercise;
Dismantling of
PSV
6.2.6 Initial Inspection

Examination of fouling.
Sampling for analysis prior to
transportation.
Safety precautions on;
Pyrophoric acid (FeS).
Acid/caustic.
Rupture disk inspection may be
included as part of the program.
Highly Reactive Materials

Water-Reactives
When water-reactive chemicals come into contact with water, one or more
of the following reactions can occur:
Release of heat and potential ignition of the chemical or other materials
Release of flammable, toxic or oxidizing gas
Release of metal oxide fumes (reactive metals only)
Formation of acids
These materials must be stored away from any source of water or moisture.
Some examples include: alkali metals (lithium, potassium, sodium), silanes,
magnesium, phosphorous, aluminum chloride, acetyl chloride.
http://www.safetyoffice.uwaterloo.ca/hse//lab
_safety/chemicals/highly%20reactive.html
Highly Reactive Materials

Air-Reactives (Pyrophorics)
Pyrophoric chemicals will ignite spontaneously upon contact with air due to
the extreme rate of oxidation. These must be stored under inert gas or
mineral oil or other hydrocarbon liquids. Metals, when finely divided are
pyrophoric. Some examples of pyrophoric materials are: manganese,
phophorous, chromium, nickel, titanium, iron, calcium, cobalt, boron,
cadmium and phosphine.
http://www.safetyoffice.uwaterloo.ca/hse//lab
_safety/chemicals/highly%20reactive.html
6.2.7 Inspection of Adjacent Inlet and Outlet Piping
Visual inspection
here on closing the
inlet block valve.
Radiographed may be used

here to provide early
detection prior to turn-over.
6.2.8 Transportation of Valves to Shop

Lifting levers
should be wired or
secured
Valve inlet and outlet
protected to avoid
internal contamination
Flanged valves
should be
securely bolted
to pallets in the
vertical
position
avoid damage to
threaded
connections
Rupture disks
should be handled
by the disk edges.
6.2.9 Determining As Received Pop Pressure

Observations
Action
Retest observation
Pop at set pressure No more

action
Pop at higher than
set pressure
Pop 2nd
time
Conclusions could be make

Satisfactory (API510 testing interval on safety
relieve valve requirements.)
Pop near/at set

pressure
Originally popped at the CDTP because of

deposits affecting as received pop.
Pop exceed ASME

BPVC limits
valve setting was originally in error

It changed during operation.
Pop at >150%
MAWP
No more
action
Stuck shut.
Pop at less than

set pressure
No more
action
The spring has become weakened,

the valve was set improperly at its last
testing, or
the setting changed during operation.
Extremely fouled
and dirty
No test
reduce the inspection interval.
6.2.10 Visual Inspection

This inspection should be made by the shop's pressure-relief valve
repair mechanic on;
a) General valve conditions including seating.
b) the springs.
c) The bellows.
d) the positions of the set screws and
openings in the bonnet.
e) the inlet and outlet nozzles.
f) the external surfaces.
g) the body wall thickness;
h) valve components and materials.
i) the pilots and associated parts.
Caution 1When unusual corrosion,

deposits, or conditions are noted
in the pressure-relief valve, an
inspector representing the user
should assist in the inspection.
Caution 2If the pressure-relief
valve is from equipment handling
hazardous materials, caution
should be exercised during the
inspection.
6.2.11 Dismantling of Valve.

Dismantling is not necessary when;
1. Valve has been tested at the appropriate interval ( API 510 the
guidance in 6.2.9) for determining the as received
2. the results of the as received test show that the valve tests
properly
Unless restoration of the valve to the as new condition is required.
Pressure relief devices
Five years for typical process services; and

Ten years for clean (non-fouling) and noncorrosive services.
Non- E&P Vessel

External Inspection
five (5) years or the required internal/on-stream inspection

whichever is less.
Internal & On-stream Inspection
(one half) the remaining life of the vessel or 10 years,

whichever is less.
Five years for typical process services; and Ten years for clean
(non-fouling) and non-corrosive services.
E&P Vessel
High Risk
External
Inspection
When an internal inspection or on-stream is performed or at

shorter intervals at the owner or users option.
High Risk
Internal & Onstream Inspection
(one half) the remaining life of the vessel or 10 years,

whichever is less.
Low Risk
External
Inspection
When an internal inspection or on-stream is performed or at

shorter intervals at the owner or users option.
Low Risk
Internal & Onstream Inspection
(three quarter) remaining corrosion-rate life or 15 years

whichever is less.
Portable Test
Separator
Internal & OnStream Inspection
At least every 3 years.
Air Receiver
Portable Test
Separator
Internal & On-Stream

Inspection
Portable Test
Separator
Air Receiver
The pilot assembly and

dome area could be
filled with process fluid,
precautions should be
taken during
disassembly.
thoroughly clean the

valve to avoid a flash due
to sparks created by the
dismantling operations.
6.2.12 Cleaning and Inspection

of Parts
The valve parts should be;
Properly marked, segregated, and

cleaned thoroughly.
Measuring valve dimensions with
reference to the drawings and
literature.
Each components should be
checked for wear, tear, corrosion,
deformations, visual & dimensions.
6.2.13 Reconditioning and Replacement of Parts

Parts that are worn beyond tolerance or damaged should be replaced
or reconditioned.
The valve body, flanges, and bonnet nozzle, seating surfaces may be
reconditioned by repairs.
single-use components, even those that are apparently undamaged,
should be replaced.
All soft goods, even those that are apparently undamaged, should be
replaced.
Spare parts for a particular pressure-relief valve should be obtained
from its manufacturer. Follow the manufacturers recommendations
when reconditioning valve parts.
6.2.14 Reassembly of Valve
it should be reassembled in accordance with the manufacturers

instructions.
The nozzle and disk seating surfaces should not be oiled.
The spring should be adjusted to pop at set pressure.
Blowdown rings should be set in accordance with the manufactures
recommendations for the appropriate vapor or liquid service.
the blowdown settings should be noted for future reference.
Most test blocks do not have enough capacity to measure the actual
blowdown, manufacturers recommendations and past performance
should be evaluated to estimate any necessary adjustment.
Most test blocks do not

have enough capacity to
measure the actual
blowdown, manufacturers
recommendations and past
performance should be
evaluated to estimate any
necessary adjustment.
6.2.15 Setting of Valve Set Pressure

The manufacturers recommendations or NB-18 should be used to
guide the adjustment of the spring to the correct
Setting CDTP.
If a new set pressure is required, the manufacturers limits for
adjustment of the spring must not be exceeded and
applicable code requirements must be observed.
If necessary, a different spring should be provided.
Table 2 Safety Valve Standards
After the valve has been adjusted,

it should be popped at least once to
prove the accuracy of the setting.
Some manufacturers recommend a valve
be popped at least three times, as the
first pop helps align all of the
components after the overhaul while the
successive pops verify the set pressure.
Normally, the deviation of the pop pressure from the set

pressure should not exceed;
2 psi for pressure 70 psi
3 % for pressure > 70psi
[see ASME BPVC Section VIII, Division 1, Paragraph UG 134(d)(1)].
Within 0 % or +10 %.
[see ASME BPVC Section VIII, Division 1, Paragraph UG 125(c)(3)].
Any allowance for hot setting should be made in accordance with the
manufacturer's data. Any adjustment to the CDTP required to
compensate for (1) in-service backpressure, (2) service temperature, or
(3) test media should be made in accordance with the manufacturer's or
users valve specification data.
Check for leakage

during pressurization.
Overpressure
CDTP
Accumulation
6.2.16 Checking Valve for Tightness

at 90 % of the CDTP , observes the discharge side of the valve
for evidence of leakage (all pressure boundary).
1. soft rubber gasket attached to

face of detector to prevent
leakage
2. weld cup to detector
3. C clamp
4. air pressure
5. outlet tubecut end smooth and square

6. safety valve
7. water level control holemaintain in. from
bottom of tube to bottom of hole
8. waxed paper to relieve pressure if valve
opens during test
Bubbles per minute - Leakage rates corresponding

to 0.3 ft3 in 24 hours
Figure 40Safety Valve and Relief Valve Leak Detector
Internal area of tube (square inches)
6.2.17 Completion of Necessary Records

the records are critical to its effective future use.
records may be required by governmental regulations.
6.2.18 Inspection,
Testing, Maintenance,
and Setting of ASME
BPVC Section VIII
Pressure-relief Valves on
Equipment
when a valve operates in nonfouling service, experience may indicate that

inspection of the valve while on the equipment is safe and suitable.
Bonnet removed, visual inspection and minor repairs.
Testing for set pressure with inert gas testing medium through a
bleeder.
If insufficient volume to attain about half lift, It yields inaccurate
test results for metal-seated pressure-relief valves and the use of a
restricted lift device is recommended to avoid damaging the valve by
too rapid of a closure.
A pressure-relief valve may be tested on-stream with a specialized
hydraulically lift device that will determine the set pressure (not
blowdown).
6.2.19 Inspection,
Testing, Maintenance,
and Setting of
ASME BPVC Section
I Boiler Safety
Valves
ASME BPVC Section I requires;
Boiler safety valves may be welded to the boiler

Boiler safety valves can be tested periodically by raising the steam
pressure
requires the boiler safety valves have a substantial lifting device be
lifted from its seat when the working pressure on the boiler is at
least 75 % of the set pressure.
A pressure-relief valve may be tested on-stream with a specialized
hydraulically lift device that will determine the set pressure (not
blowdown) .
6.2.20 Inspection, Testing, Maintenance, and Setting of

Pilot-operated Pressure-relief Valves
Inspection, testing,
maintenance, and setting of
the pilot mechanism may
be handled separately from
the main valve.
the set pressure of some
types of pilots may be
accurately tested while the
valve is in service.
Due to the variety of
pilot-operated valves
available, the valve
manufacturer's
recommendations for
inspection, repair, and
testing should be consulted
and followed.
6.2.21 Inspection, Testing, Maintenance and Setting of

Weight-loaded Pressure - and / or Vacuum-vents on Tanks
They are prone to failure by sticking.
Set pressure is usually a standard 0.5 oz/in.2 (0.215 kPa), but may
go as high as 24 oz/in.2 (10.34 kPa).]
6.2.22 Inspection and Replacement of Rupture Disks

Do not reinstall the disk once it has been removed from its holder.
rupture disks should be replaced on a regular schedule based on their
application, the manufacturers recommendations.
Reverse-buckling rupture disks may be used to facilitate and allow onstream testing of pressure-relief valves.
6.3 Visual On-stream Inspection

Visual checks should include;
Leakages
Visual inspection on parts visible.
Rupture disk orientations.
Verify that there is no pressure buildup between the rupture disk and
pressure-relief valve (gauge reading).
Supports and vibrations.
Tagging and correct valve (type/location) installation.
Ensure block valve is in its proper position including locking devices
6.4 Inspection Frequency

6.4.1 General
In API 510, the subsection on pressure-relieving devices establishes a

maximum interval between device inspections or tests of 10 years,
unless qualified by a risk-based inspection (RBI) assessment.
API510
6.4.2 Frequency of Shop Inspection/Overhaul

Factors affecting the interval;
Normal Basis:
Manufacturers Basis
Jurisdictional Basis
RBI Basis
6.4.2 Frequency of Shop Inspection/Overhaul

Factors affecting the interval;
Normal Basis:
Corrosive, fouling vs clean, nonfouling services.

Vibration.
pulsating loads.
low differential between set and operating pressures to valve leakage
other circumstances leading to leakage.
As received CDTP test results.
Manufacturers Basis
Manufacturer recommendations on part replacements etc.
Jurisdictional Basis
Required frequency established by regulatory bodies.
RBI Assessment Basis.
RBI techniques to determine the initial and subsequent

inspection intervals;
overpressure events - probability and consequence of failure
of pressure-relief devices to open on demand during emergency.

normal operation -probability that a pressure-relief device will
leak in service and consequences associated with this leakage
during
API572, 6.4.3 Frequency of Visual On-stream Inspections

The maximum interval for visual on-stream inspections is five years.
API510 6.6.2.2 (incl. E&P services)
Pressure relief devices testing and
inspection interval
API576 6.4.3
Visual on-stream inspection interval
Five year
6.5 Time of Inspection
6.5.1 Inspection on New Installations;

spring adjustment pressure-relief valves should be field inspected and
tested before they are installed on process equipment.
If the factory setting is done in a nearby shop, this additional
testing may be unnecessary.
Pressure- and/or vacuum-vent valves on atmospheric storage tanks
should also be inspected after installation but before the tank is
hydrostatically tested or put into service. should also be inspected
whenever the tank is taken out of service.
Routine
inspection least interferes with the process and maintenance

manpower is readily available.
Unscheduled Inspection
If a valve fails to open within the set pressure tolerance, it requires

immediate attention.
Inspection After Extended Shutdowns
On extended shutdown should be inspected and tested before the

resumption of operations.
On change in operating conditions is to follow the shutdown.
7 Records and Reports
API576 Charlie Chong/ Fion Zhang/ He Jungang / Li Xueliang
7.1 Objective
The primary objective for keeping records is to make
available the information needed to ensure that the
performance of pressure-relieving devices meets the
requirements of their various installations.
7.2 The Need to Keep Records

Operational, maintenance and repairs needs.
Governmental agencies require that certain records and
reports be maintained.
7.3 Responsibilities
Some companies assign these duties and responsibilities

to equipment inspectors (engineering/inspection).
Others have
(1)process unit operators
(2)maintenance personnel
to follow up on an established program under the
guidance of the engineering / inspection
group.
7.4 Sample Record and Report System
The forms in Annex B are samples of records and reports.

Much of the report writing, recordkeeping, inspection, and
test scheduling handled by the reports and records should
be managed with an electronic database system.
Annex A (informative)
Pressure-relief Valve Testing
A.1 Need and Function of Test Block

The amount/volume of liquid or gas that it can discharge is limited;
it is not generally practical to measure relieving capacity or
blowdown.
may fail to cause a distinct pop, and an inaccurate
set pressure may result.
if properly functioning, the shop test block gives
good indications of the pressure at which the
valve will open and its tightness.
Testing mediums;
air for safety valves.
water for relief valves.
Bottled nitrogen for high-pressure valves.
http://www.wilhelmvalve.com/flash.swf
A.2 Testing with Air

Air is compressible and causes reaction-type valves to relieve
with a short pop and closely approximates operating conditions
for pressure-relief valves in vapor and gas services.
A quantitative leakage measurement may be made by trapping
the leakage and
conducting it through a tube submerged in water. Figure 40
shows the standard equipment used to determine leakage rates
in API 527.
Leaks can also be detected with ultrasonic sound detection
equipment.
A.3 Testing with Water

water test is usually limited to measuring the set pressure.
Leakage or tightness tests are usually made with air. However,
leakage tests may instead be made with water as described in API
527.
A.4 Description of Test Block

The schematic arrangement in Figure A.1 illustrates the essential
elements of and instructions for a test block that uses air as the testing
medium. Where air pressure is unavailable, water systems may instead
be used to test relief valves if acceptable to the local authority or
jurisdiction.
Key
1. test station
2. adaptor for mounting safetyrelief valves of various sizes
3. threaded flange
4. 6-in. full-area gate or ball valve
5. drain and gauge vent
6. from reservoir
7. 3-in. diamond-point plug valve
that is extended-wrench
mounted vertically to facilitate
testing
8. water in under pressure
9. test drum 12 in. in diameter and
6 ft long
10. 10 drain

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API-RP-576

Inspection of Pressure-relieving Devices

Fion Zhang/ Charlie Chong

Fion Zhang/ Charlie Chong

Speaker: Fion Zhang

Fion Zhang/ Charlie Chong

Fion Zhang/ Charlie Chong

5 Causes of Improper Performance

Fion Zhang/ Charlie Chong

7 Records and Reports

Fion Zhang/ Charlie Chong

Fion Zhang/ Charlie Chong

Fion Zhang/ Charlie Chong

The recommendations in this publication are not intended to supersede requirements

weak seams or sections in tanks,

Fion Zhang/ Charlie Chong

The recommendations in this publication are not intended to

Table 9.1.1 Approval authorities

Fion Zhang/ Charlie Chong

This publication does not cover training requirements for

Fion Zhang/ Charlie Chong

Fion Zhang/ Charlie Chong

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pilot-operated pressure-relief valves

Fion Zhang/ Charlie Chong

Fion Zhang/ Charlie Chong

Fion Zhang/ Charlie Chong

weight-loaded pressure vacuum vents

Fion Zhang/ Charlie Chong

Fion Zhang/ Charlie Chong

Fion Zhang/ Charlie Chong

ASME PTC 25, Pressure Relief Devices

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3 Terms and Definitions

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3.1.3 non-reclosing pressure-relief device

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3.2 Dimensional Characteristics of Pressure-relief Valves

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3.2.3 inlet size

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Force & pressure, area relations.

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The pressure below the valve must increase

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Fp = p*Ah = Force by pressure

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