Summary of API 576 PRD Highlights For The API Exam

Youssef Maaty
https://www.linkedin.com/in/youssef-maaty/
API 576
PRV / PSV / Combination of PRV and PSV
4 Pressure-relieving Devices
Pressure-relieving devices PRDs protect equipment and personnel by opening at predetermined pressures and
preventing the adverse consequences of excessive pressures.
Pressure-relieving Devices
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- Pressure-relief Valve
- Direct-acting Pressure-relief Valve
- Pilot-operated Pressure-relief Valves
- Rupture Disk Device
- Pin-actuated Devices
4.2 Pressure-relief Valve

classified as a safety valve, relief valve, or a safety relief valve.
- Safety valve rapid opening or pop action used on steam boiler drums and superheaters general used in air,
gas, and steam services.
- Relief valve opens normally in proportion to the pressure increase over the opening pressure. A relief valve
is normally used with incompressible fluids.
- Safety relief valve pressure-relief valve that may be used as either a safety or relief valve depending on
- the application, trim of the safety relief valve will provide stable lifting characteristics on either
compressible or incompressible media.
4.3 Direct-acting Pressure-relief Valve
4.4 Pilot-operated Pressure-relief Valves

Controlled by a self-actuated auxiliary pressure-relief valve (pilot)
Q are generally used
- low differential exists between the normal operating pressure and the set pressure of the valve;
4.5 Rupture Disk Device

If rupture disk device associated with the pressure-relief valve and the rupture disk is removed from its holder
manufacturer recommendations should rupture disk replacement
Rapture disk might suitable be used to protect the upstream side of a pressure relief valve against corrosion
Q Because a reverse-acting rupture disk is operated with pressure applied on the convex side, thicker disk materials
may be used, thereby lessening the effects of corrosion,
5 Causes of Improper Performance

5.1 Corrosion
Corrosion is a basic cause of many of the difficulties encountered with pressure-relief devices.
Spring in pressure relief valves typically failed by corrosion.
sticking may be caused by corrosion or galling of the metal or by foreign particles in the guiding surfaces.
Foreign particles in the guiding surfaces tend to roll metal up, causing severe galling.
Examples of Preventative Actions for Corrosion

rupture disk device installed on the inlet and/or outlet of a pressure-relief valve can provide added corrosion
protection of the valve internals.
use of an O-ring or resilient seat in a pressure-relief valve may stop leakage past the seating
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5.2 Damaged Seating Surfaces

a) Corrosion. b) Foreign particles.
C) seating surfaces damaged by chattering and frequent fluctuations of pressure (cycle of opening and closing)
5.3 Failed Springs

Although springs may weaken and fail due to the use of improper materials in high-temperature service,
failed springs are almost always caused by corrosion. Surface corrosion and stress corrosion cracking are the most
prevalent of this type of failure in refineries.
5.5 Plugging and Fouling
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Process solids and contaminants such as coke, sand, or solidified products can sometimes plug various parts.
5.6 Galling
When galling of the metal in the guiding surfaces is not due to corrosion or foreign particles, it is often due to
valve chatter or flutter caused by improper piping at the valve inlet or outlet or by severe oversizing of the valve.
Galling may also occur if the system operates too close to the set pressure resulting in frequent relieving.
5.8 Improper Location, History, or Identification

should be maintained and referred to when the devices are removed for inspection and repair. Most pressure-
relief devices have an identifying serial or shop number placed on the device
5.9 Improper Handling

Can occur during shipment, maintenance, or installation. This improper handling of the relief valve can cause a
change of the set pressure, damage lifting levers, damage tubing and tubing fittings, damage pilot assemblies, or
cause internal leakage when the valve is in service.
Once a rupture disk is removed from its holder, the rupture disk should not be reinstalled.
9.10 Improper Differential Between Operating and Set Pressures

5.11 Improper Inlet/Outlet Piping Test Procedures
When hydrostatic tests of inlet/outlet piping are performed, blinds shall be installed.
6 Inspection and Testing

Inlet and outlet piping should be inspected for the presence of internal deposits, and records should be kept of
their condition and cleaning.
6.2 Shop Inspection/Overhaul

6.2.7Inspection of Adjacent Inlet and Outlet Piping
When a PRDs is removed from service, the upstream and downstream piping is often open and available for
inspection. However, where block valves are closed to enable removal PRDs during operation, it is usually
impossible to directly inspect this piping.
In potential fouling services, profile radiography should be considered for piping upstream or downstream PRDs
looking for locations where potential fouling deposits may collect that could restrict flow or cause corrosion
under deposits
6.2.9 - re
as-received pop testing should be conducted prior to cleaning in order to yield accurate as-received pop testing
results that will help establish the appropriate inspection and servicing interval.
Q Pop testing in the as-received condition for valves in acid/caustic/toxic services can be accomplished by
- utilizing a pop test stand built on site in the area where the valve is installed
- or by contracting with a service supplier that has a portable test stand that can be brought on site.
utilizing a test stand but onsite in the area where the valve is installed
Q If the initial as-received pop testing valve open at a pressure higher than CDTP, the valve should be tested a
second time.
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If it then pops higher near the CDTP, the valve may not have originally popped at the CDTP because of deposits.
Q Pressure-relief valves that do not pop at inlet pressures of 150 % of CDTP should be considered as stuck shut.
If the initial pop is at a pressure lower than the CDTP, the spring may have become weakened
This as- is used in determining the inspection interval.
important to understand the root cause of - in order to determine if any corrective

actions are necessary
For example, in API 581 a relief valve that does not pop at 130 % of the set pressure is considered failure to open.
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Q As a default criterion for a valve being stuck shut, a number of companies use 150 % of the set pressure beyond
which the valve is classified as stuck shut if it does not pop and test is discontinued.
Setting of Valve Set Pressure (tolerances) Opening permissible
Q Normally, for ASME BPVC VIII valves [see ASME BPVC Section VIII, Division 1, Paragraph UG134(d)(1)]
The deviation of the as-found set pressure from the nameplate set pressure should:
- not exceed ±2 psi (±15 kPa) for pressures less than or equal to 70 psi (500 kPa)
- or ±3 % for pressures greater than 70 psi (500 kPa)
Checking Valve for Tightness
valve is set to pop at its CDTP, it should be checked for leakage. On the test block, it can be tested (oftentimes this
is 90 % of the CDTP)
9 Inspection Frequency
Unless documented experience and/or a RBI assessment indicates that a longer interval is acceptable
Test and Inspection Intervals
- a) 5 years for typical process services, and
- b) 10 years for clean (non-fouling)
9.2 Frequency of Shop Inspection/Overhaul

If a valve fails to activate on the test block at 150 % or more of CDTP, it can be assumed that it would have failed to
activate on the unit during an overpressure event.
9.2.5 Frequency of Visual On-stream Inspections

The maximum interval for visual on-stream inspections should be five years.
After maintenance of the valve(s) is completed, a full visual on-stream inspection shall be performed before
startup.
9.3 Time of Inspection

9.3.1Inspection on New Installations
All PRDs that depend on a spring adjustment for proper functioning should be inspected and tested before they
are installed on process equipment (i.e. verify CDTP pressure and visual inspection).
Exam Question
32. A hydrostatic test is to be performed on the piping on the discharge side of a pressure relief device. Which of the
following is correct regarding blinding/blanking? Blinds should be installed between the pressure relieving device
discharge flange and the pipe flange
59- Pressure-relief valves are considered stuck if they fail to pop at the inlet pressure of what pressure of the CDTP? 150

Summary of API 576 PRD Highlights For The API Exam

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Youssef Maaty

4.2 Pressure-relief Valve

4.3 Direct-acting Pressure-relief Valve

4.4 Pilot-operated Pressure-relief Valves

4.5 Rupture Disk Device

5 Causes of Improper Performance

Examples of Preventative Actions for Corrosion

5.2 Damaged Seating Surfaces

5.3 Failed Springs

5.5 Plugging and Fouling

5.8 Improper Location, History, or Identification

5.9 Improper Handling

9.10 Improper Differential Between Operating and Set Pressures

6 Inspection and Testing

6.2 Shop Inspection/Overhaul

important to understand the root cause of - in order to determine if any corrective

Setting of Valve Set Pressure (tolerances) Opening permissible

Checking Valve for Tightness

9.2 Frequency of Shop Inspection/Overhaul

9.2.5 Frequency of Visual On-stream Inspections

9.3 Time of Inspection

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