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FRS-DU-5056-C

SIZING, SELECTION, AND INSTALLATION OF


PRESSURE RELIEF DEVICES

APPLICATION: ONSHORE

This document is the confidential property of Chevron USA Inc. Neither


the whole nor any part of this document may be disclosed to any third
party without the prior written consent of Chevron USA Inc. Neither the
whole nor any part of this document may be reproduced, stored in any
retrieval system or transmitted in any form or by any means (electronic,
mechanical, reprographic, recording or otherwise) without the prior written consent of Chevron USA Inc.

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Sizing, Selection, and Installation of


Pressure Relief Devices

FRS-DU-5056-C

CONTENTS
1.0

Scope ..........................................................................................................................4

2.0

References ..................................................................................................................4
2.1 ......Purchaser Specifications ..................................................................................4
2.2 ......Purchaser Drawings .........................................................................................4
2.3 ......Industry Codes and Standards .........................................................................4

3.0

General ........................................................................................................................5

4.0

Determination of Cold Differential Test Pressure ...................................................5


4.1 ......General .............................................................................................................5
4.2 ......Formula ............................................................................................................6
4.3 ......Back Pressure Correction ................................................................................6
4.4 ......Temperature Correction ...................................................................................6

5.0

Pressure Relief Valve Capacity Formulas ...............................................................7


5.1 ......Pressure Relief Valve Nozzle Effective Areas (Typical) per API Std 526 ........7
5.2 ......Sizing of Pressure Relief Valves ......................................................................7
5.3 ......Pressure Relief Valve Liquid Formula ..............................................................7
5.4 ......Pressure Relief Valve Gas or Vapor Formula ..................................................9
5.5 ......Pressure Relief Valve Steam Formula ...........................................................11
5.6 ......Pressure Relief Valve Fire Expansion Gas Formula ......................................11
5.7 ......Rupture Disk Sizing ........................................................................................12
5.8 ......Temperature Relief Device Liquid Formula ....................................................13
5.9 ......Vacuum Safety Valve Gas Formula ...............................................................13
5.10 ....Liquid-Vapor Mixture ......................................................................................13

6.0

Selection of Pressure Relief Device .......................................................................14

7.0

Selection of Valve Construction .............................................................................14


7.1 ......Open Spring Type Valves ..............................................................................14
7.2 ......Closed Spring Type Valve (Preferred Type) ..................................................14
7.3 ......Pressure Relief Valves With Lifting Levers ....................................................14
7.4 ......Temperature Relief Devices ...........................................................................15
7.5 ......Pressure Relief Valve Caps ...........................................................................15
7.6 ......Pressure Relief Valve Drains .........................................................................15
7.7 ......Test Gags .......................................................................................................15
7.8 ......Flushing or Purging Pressure Relieving Devices ...........................................15
7.9 ......Heat Tracing Pressure Relieving Devices ......................................................15
7.10 ....Freeze Precaution ..........................................................................................15

8.0

Materials for Pressure Relief Valves ......................................................................15


8.1 ......General ...........................................................................................................15
8.2 ......Body Material .................................................................................................16
8.3 ......Trim Material ..................................................................................................16
8.4 ......Spring Material ...............................................................................................16
8.5 ......Valve Bonnet or Spring Housing Material and Coating ..................................16
8.6 ......Bellows Material for Balanced Bellows Valves ...............................................16

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Sizing, Selection, and Installation of


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9.0

FRS-DU-5056-C

Ratings for Pressure Relief Valves .........................................................................16


9.1 ......Inlet Flange and Inlet Body Rating .................................................................16
9.2 ......Outlet Flange and Outlet Body Ratings ..........................................................17

10.0

Connections for Pressure Relief Valves ................................................................17

11.0

Block Valves to Permit Removal of Pressure Relief Valves ................................17


11.1 ....Inlet Block Valves ...........................................................................................17
11.2 ....Discharge Block Valves ..................................................................................17
11.3 ....Locking System ..............................................................................................18

12.0

Rupture Disk Installation .........................................................................................18

13.0

Pressure Relief Valve Handling Before Installation and Test ..............................18

14.0

Inspection and Test .................................................................................................18

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Sizing, Selection, and Installation of


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1.0

FRS-DU-5056-C

SCOPE
1. This specification defines:
a. Technical requirements for sizing overpressure protection devices.
b. Design requirements for type, construction, materials, and installation of overpressure
protection devices.
2. Application of overpressure protection devices and disposal systems are defined in
FRS-DU-5057.
3. Overpressure protection for atmospheric storage is defined in TAM-DU-971 and
FRS-SU-5038.

2.0

REFERENCES

2.1

Purchaser Specifications
This specification contains references to the following Purchaser specifications:

2.2

FRS-DU-5057

Overpressure Protection

FRS-SU-5032

Relief Valves

FRS-SU-5033

Rupture Discs

FRS-SU-5038

Tank Pressure-Vacuum Vent Valves

NCM-DU-5096

Design for Onshore Noise Control

PIM-DU-5138

Piping Design

PIM-SU-5112

Material Specifications for Carbon Steel, Cr-Mo, and Stainless Steel Piping
Systems

PVM-SU-1322

Stainless Steel Clad Pressure Vessels

TAM-DU-971

Venting Equipment for Atmospheric Above Ground Storage Tanks with


Cone Roofs

Purchaser Drawings
This specification contains references to the following Purchaser drawings:
GB-J1442

2.3

Instrumentation for Vacuum Breaker on Fractionator Towers

Industry Codes and Standards


This specification contains references to the following industry codes and standards:
2.3.1

American Petroleum Institute (API)

RP 520

Parts I and II - Sizing, Selection and Installation of Pressure Relief Devices


in Refineries

Std 526

Flanged Steel Safety-Relief Valves

RP 576

Inspection of Pressure Relieving Devices

2.3.2

American Society of Mechanical Engineers (ASME)

Boiler and Pressure Vessel Code

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Sizing, Selection, and Installation of


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FRS-DU-5056-C

Section I
Section VIII
2.3.3

American National Standards Institute (ANSI)

B 1.20.1
3.0

Pipe Threads, General Purpose (inch)

GENERAL
1. Pressure relief valves shall be sized using calculation techniques (capacity formulas) that simulate the condition during each relief situation which is considered. Pressure relief valve data
sheets with sizing basis and calculated orifice area by Supplier shall be submitted to Purchaser
for future reference.
2. Relief load, fluid properties, relieving pressure, and back pressure shall be determined in
accordance with TAM-DU-971.
3. A copy of pressure relief valve summary sheets indicating operating set pressure, cold differential set pressure, valve size and type, fluid specifications, and complete material specifications shall be submitted to Purchaser for review.
4. Sizing of all valves for service conditions, including back pressure given, shall be checked by
Supplier. Sizing calculations for each valve shall be submitted.
5. All items defined in this specification shall comply with noise level requirements specified in
NCM-DU-5096.
6. Deviations from this specification shall be subject to Purchaser approval.
7. Relief valves shall comply with FRS-SU-5032.
8. Rupture discs shall comply with FRS-SU-5033.
9. Pressure relief valves for ASME code stamped boilers or ASME code stamped pressure vessels shall be marked with:
a. Code stamp.
b. Certified capacity.
c. Other data required by ASME code.
10. Pressure relief devices for pressure vessels provided without ASME stamp shall be subject to
Purchaser's written authorization.

4.0

DETERMINATION OF COLD DIFFERENTIAL TEST PRESSURE

4.1

General
1. Cold differential test pressure shall be such that pressure relief valve meets all constraints of
this specification and FRS-DU-5057.
2. Test pressure shall:
a. Not exceed maximum allowable accumulated pressure of pressure relief valve being
tested.
b. Provide a suitable margin to exist between pressure relief valve's set pressure and operating pressure (to minimize unnecessary operation and/or leakage of relief device).

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Sizing, Selection, and Installation of


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FRS-DU-5056-C

3. All constraints shall be met throughout minimum to maximum range of variable superimposed
back pressure.
4.2

Formula
Cold differential test pressure (psig) equals set pressure (psig) minus minimum superimposed back
pressure (psig) (zero shall be used for balanced pressure relief valves), plus correction (psi) for
higher service temperatures that reduce spring loading.

4.3

Back Pressure Correction


1. Back pressure corrections referenced in this section shall be used only to determine cold differential test pressure. They shall not be used to determine relief valve capacity.
2. Conventional pressure relief valves with closed disposal system discharges shall have back
pressure correction equal to minimum superimposed back pressure.
3. Conventional pressure relief valves with atmospheric discharges shall have back pressure correction of 0 psi.
4. Balanced pressure relief valves with closed disposal system discharges shall have back pressure correction of 0 psi.
5. For purpose of this specification, all closed disposal system minimum superimposed back
pressures between +1 and -1 psig shall be considered to be 0 psig in determining cold differential test pressure.

4.4

Temperature Correction
1. Pressure relief valves, no matter whether they will experience high or low temperatures in service, are usually adjusted and tested at atmospheric temperature. An increase in temperature
causes a reduction of valve set pressure. This reduction is due to thermal expansion of valve
body and bonnet and to higher spring temperature, both of which reduce spring loading.
2. An adjustment shall be made in cold differential test pressure to compensate for effect of
higher pressure relief valve service temperatures. Service temperature correction for each particular type of pressure relief valve design and spring material is listed in manufacturer's bulletin. This adjustment may be important in reducing chronic pressure relief valve leakage.
3. As an example, the table below shows some temperature correction factors. Generally, set
pressure minus minimum superimposed back pressure is multiplied by correction factor.
Resulting psi is used to obtain cold differential test pressure.
(Example only, see Manufacturer's bulletin for actual values).
Service Temperature (F)

June 2008

Correction Factor

-100 to 200

None

201 to 400

1.02

401 to 900

1.03

901 to 1100

1.04

1101 to 1400

1.05

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FRS-DU-5056-C

5.0

PRESSURE RELIEF VALVE CAPACITY FORMULAS

5.1

Pressure Relief Valve Nozzle Effective Areas (Typical) per API Std 526
Nozzle
Orifice
Letter

Effective Area
SQ. Inches

*Normal Size Designations

0.110

1D2, 1-1/2D2, or 1-1/2D2-1/2

0.196

1E2, 1-1/2E2, or 1-1/2E2-1/2

0.307

1-1/2F2 or 1-1/2F2-1/2

0.503

1-1/2G2-1/2 or 2G3

0.785

1-1/2H3 or 2H3

1.287

2J3, 2-1/2J4, or 3J4

1.838

3K4 or 3K6

2.853

3L4 or 4L6

3.600

4M6

4.340

4N6

6.380

4P6

11.050

6Q8

16.000

6R8 or 6R10

26.000

8T10

*Manufacturer's standard designations. First number is nominal inlet size. Last number is
nominal outlet size. For particular pressure rating, manufacturer's catalog shall be consulted for actual size available.
5.2

Sizing of Pressure Relief Valves


Pressure relief valves shall be sized in accordance with latest edition of API RP 520.

5.3

Pressure Relief Valve Liquid Formula


1. Liquid pressure relief valves shall be sized in accordance with API RP 520.
2. Temperature relief valves for liquid thermal expansion shall comply with Section 5.8.
3. Valves that are ASME code stamped and have trim open at 10% overpressure in liquid service
shall be sized with the following formula:

GPM
G
A = -------------------------------------------------------- -----------------------38 ( K D ) ( K W ) ( K C ) ( K V ) ( P R P B )
Where:
A

June 2008

Effective discharge area, in square inches.

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Sizing, Selection, and Installation of


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GPM =

FRS-DU-5056-C

Flow rate at flowing temperature and selected overpressure, in U.S. gallons per
minute.

KD

= Coefficient of discharge, which should be obtained from valve manufacturer. If KD


is unknown, a conservative valve of 0.65 is recommended.

KW

= Capacity correction factor due to back pressure. If back pressure is atmospheric,


factor can be disregarded, or KW = 1.00. Conventional valves with back pressure
require no special correction, KW = 1.00. Balanced bellows valves with back pressure shall require correction factor as determined from API RP 520, Section 4, Figure 31, or manufacturer.

KC

Combination correction factor for installations with rupture disk upstream of pressure relief valve. This value equals 1.0 if rupture disk is not installed and 0.9 if rupture disk is installed.

KV

Capacity correction factor due to applications, viscosity may not be significant, in


which case KV = 1.00. If a relief valve is sized for viscous liquid viscosity. For
most service KV is obtained from API RP 520, Section 4 and Figure 36.

Specific gravity of liquid at flowing temperature referred to water = 1.00 at 70F.

PR

Relieving pressure, in psig. This equals set pressure plus overpressure and shall not
exceed maximum allowable accumulated pressure.

PB

Back pressure, in psig.

4. Valves that do not require capacity certification (on non ASME application or older style liquid trim pressure relief valves built to open at 25% overpressure shall be sized in accordance
with the following formula:

GPM
G
A = -------------------------------------------------------------------- ------------------------------38 ( K D ) ( K W ) ( K C ) ( K V ) ( K P ) ( 1.25P P B )
Where:
A

June 2008

Effective discharge area, in square inches.

GPM =

Flow rate at flowing temperature and selected overpressure, in U.S. gallons per
minute.

KD

Coefficient of discharge, which should be obtained from valve manufacturer. If K


is unknown, a conservative valve of 0.62 is recommended.

KW

Capacity correction factor due to back pressure. If back pressure is atmospheric,


factor can be disregarded, or KW = 1.00. Conventional valves with back pressure
require no special correction, KW = 1.00. Balanced bellows valves with back pressure shall require correction factor as determined from API RP 520, Section 4, Figure 31, or manufacturer.

KC

Combination correction factor for installations with rupture disk upstream of pressure relief valve. This value equals 1.0 if rupture disk is not installed and 0.9 if rupture disk is installed.

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5.4

FRS-DU-5056-C

KV

Capacity correction factor due to viscosity. For most applications, viscosity may
not be significant, in which case KV = 1.00. If a relief valve is sized for viscous
liquid service KV is obtained from API RP 520, Section 4 and Figure 36.

KP

Capacity correction factor due to overpressure. Many, if not most, relief valves in
liquid service on non ASME stamped equipment are sized on basis of 25% overpressure. This factor for overpressure can be obtained from API RP 520, Section 4,
Figure 37. If other than nozzle valve, manufacturer's curve or capacity tables shall
be consulted for particular valve.

KP

For 25% accumulation = 1.00

KP

For 20% accumulation = 0.92

KP

For 10% accumulation = 0.60

KP

For 5% accumulation = 0.35

Specific gravity of liquid at flowing temperature referred to water = 1.00 at 70F.

Set pressure at which relief valve is to begin opening, in psig.

PB

Back pressure, in psig.

Pressure Relief Valve Gas or Vapor Formula


1. Valve shall be sized for relief in accordance with API RP 520, Section 3.6.
2. Gas or vapor relief valves in critical flow conditions shall be sized in accordance with the
following formula:

W
TZ
A = ----------------------------------------------------- ------C ( KD ) ( PR ) ( KB ) ( KC ) M
Where:

June 2008

Effective discharge area of valve, in square inches.

Flow through valve, in lb/hr.

Coefficient determined by ratio of specific heats of gas or vapor at standard conditions. This can be obtained from API RP 520, Section 4, Figure 32 or Table 8. This
can also be obtained from some manufacturer's bulletins. C can also be determined
solely by isentropic expansion coefficient of an actual gas. If specific heat ratio or
isentropic expansion coefficient cannot be determined, it is suggested to let
C = 315. (This corresponds to a specific heat ratio and an isentropic expansion
coefficient of 1.0).

KD

Coefficient of discharge, which value is obtainable from valve manufacturer. K for


a number of nozzle type valves is 0.975.

PR

Relieving pressure in psia. This equals set pressure plus overpressure plus atmospheric pressure. Largest value of PR would be maximum allowable accumulated
pressure given in psia.

KB

Capacity correction factor due to back pressure. This can be obtained from API RP
520, Section 4, Figure 35, which applies to conventional pressure relief valves, or

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Sizing, Selection, and Installation of


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FRS-DU-5056-C

from Figure 30, which applies to balanced bellows valves. Correction factor value
shall be read from curve specifically applying to type of valve under consideration.
For conventional valves KB = 1.0 if back pressure does not exceed critical pressure
(normally taken as 0.55 x absolute relieving pressure in psia). If back pressure
exceeds critical, manufacturer's bulletins shall be consulted for correction. For balanced bellows valves KB = 1.0 if back pressure does not exceed 0.30 x set pressure, in psig. If back pressure exceeds 30%, manufacturer's bulletins shall be
consulted for correction. For set pressures lower than 50 psig, valve manufacturer
shall always be consulted for proper value of correction factor KB.
KC

Combination correction factor for installations with rupture disk upstream of pressure relief valve. Value of 1.0 shall be used if no rupture disk is installed. Value of
0.9 shall be used if rupture disk is installed in combination with pressure relief
valve. If available, Supplier data shall be used.

Absolute temperature of inlet vapor, in F + 460.

Compressibility factor for deviation of actual gas from a perfect gas, a ratio evaluated at inlet conditions.

Molecular weight of gas or vapor.

3. Gas and vapor relief valves in subcritical flow conditions shall be sized in accordance with the
following formula:

W
TZ
A = --------------------------------------------- -----------------------------------735 ( F 2 ) ( K D ) ( K C ) MP R ( P R P B )
Where:
A

Effective discharge area of valve, in square inches.

Flow through valve, in lb/hr.

F2

Coefficient of subcritical flow


(k 1) k

F2 =

June 2008

k - 2 / k 1---------------------------r
---------(r)
k 1
1r

ratio of specific heats

ratio of backpressure to upstream relieving pressure PB/PR

KD

Coefficient of discharge, which value is obtainable from valve manufacturer. K for


a number of nozzle type valves is 0.975.

KC

Combination correction factor for installations with rupture disk upstream of pressure relief valve. KC = 1.0 if no rupture disk is installed and 0.9 if rupture disk is
installed.

Absolute temperature of inlet vapor, in F + 460.

Compressibility factor for deviation of actual gas from a perfect gas, a ratio evaluated at inlet conditions.

Molecular weight of gas or vapor.

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5.5

FRS-DU-5056-C

PR

Relieving pressure in psia. This equals set pressure plus overpressure plus atmospheric pressure. Largest value of PR would be maximum allowable accumulated
pressure given in psia.

PB

Back pressure, in psia.

Pressure Relief Valve Steam Formula


1. Valve shall be sized for steam relief in accordance with API RP 520.
2. The following formula shall apply:

W
A = --------------------------------------------------------------------------------------51.5 ( P R ) ( K D ) ( K B ) ( K C ) ( K N ) ( K SH )
Where:
A

Effective discharge area, in square inches.

Flow rate, in lb/hr.

PR

Relieving pressure, in psia. This equals set pressure plus overpressure plus atmospheric pressure. ASME Code Section I applications are permitted only 6% accumulation. Other applications may need to comply with ASME Unfired Pressure
Vessel Code, wherein 10% accumulation is permitted.

KD

Coefficient of discharge, which value is obtainable from valve manufacturer. The


K for a number of nozzle type valves is 0.975.

KB

Capacity correction factor due to back pressure. This can be obtained from manufacturer's literature or estimated from Figure 30. Back pressure correction factor
applies to balanced bellows valves only. For conventional valves, KB = 1.0 shall be
used.

KC

Combination correction factor for installations with rupture disk upstream of pressure relief valve. KC = 1.0 if no rupture disk is installed and 0.9 if rupture disk is
installed.

KN

Correction factor for Napier equation. KN = 1 if PR </= 1500 psia. If PR is greater


than 1500 psia, the following equation shall be used:

0.1906P R 1000
K N = ----------------------------------------0.2292P R 1061
KSH

5.6

Correction factor due to amount of superheat in steam. This can be obtained from
manufacturers' tables and/or API RP 520, Table 9. For saturated steam at any pressure factor KSH = 1.0.

Pressure Relief Valve Fire Expansion Gas Formula


1. Valves for gas expansion due to external fire shall be sized in accordance with API RP 520.

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2. The following calculation method shall be used only as a last resort. Purchaser shall be consulted for alternate calculation methods and/or equipment selection, prior to using the following formula:

FS A = ---------------0.5
( PR )
Where:
A

Safety valve effective orifice area, sq. in.

Safety valve factor. Recommended minimum value is F = 0.01. If actual value is


unknown, F = 0.045 shall be used.

Surface of vessel exposed to fire, square feet.

PR

Relieving pressure, psia.


1.25

0.1406 ( DT )
F = ------------------------------------0.65
CK ( T 1 )
Where:
F

Safety valve factor. Recommended minimum value is F = 0.01. If actual value is


unknown, F = 0.045 shall be used.

DT

TW - T1

Coefficient determined by specific heats of gas or vapor at standard conditions.


This can be obtained from API RP 520. If specific heat ratio cannot be determined,
it is suggested that C = 315 for hydrocarbons and C = 356 for diatomic gases (this
corresponds to specific heat ratios of 1.0 and 1.4, respectively.)

Coefficient of discharge, which value is obtainable from valve manufacturer. The


K for a number of nozzle type valves is 0.975.

T1

Temperature of gas at relieving pressure, R. This T1 corresponds to relieving pressure obtained on basis of constant volume pressure increase.

( PR ) ( TN )
T 1 = ----------------------PN
Where:

5.7

T1

Temperature of gas at relieving pressure, R. This T1 corresponds to relieving pressure obtained on basis of constant volume pressure increase.

PR

Relieving pressure, psia.

TN

Initial or normal operating temperature, R.

PN

Initial or normal operating pressure, psia.

Rupture Disk Sizing


1. Rupture disks shall be sized in accordance with API 520, Section 3.11.

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FRS-DU-5056-C

2. Rupture disks can be used in series with a pressure relief valve in accordance with API 520,
Section 3.11.2.
5.8

Temperature Relief Device Liquid Formula


1. Temperature relief device designs generally correspond to spring loaded relief valves.
2. Capacities shall be obtained from appropriate formulas or manufacturer's tables.
3. Relief valve size, to protect for thermal relief on water side of heat exchangers, shall as a minimum be NPS 3/4.
4. If expansion relief is required around check valves, block valves, or pumps, sizes NPS 3/4 and
larger are acceptable, provided the line material specification permits screwed connections for
small sizes.

5.9

Vacuum Safety Valve Gas Formula


5.9.1

General
ASME Code, Section VIII, Div. 1 and Div. 2, does not provide safety valve guidance (set
pressure, accumulation, and capacity calculation) for vessels in vacuum service.

5.9.2

Vacuum Breaker System


1. If necessary, vacuum breaker system shall be installed to protect vessels against excessive external pressure.
2. System shall consist of instrument control loop that actuates a single seated, quick
opening, control valve through which a high pressure source of inert gas or emergency
air enters vessel that requires vacuum relief.
3. Control valve shall normally be held closed by instrument air, with an automatic nitrogen or emergency air backup supply to keep valve closed in case of air failure.
4. System shall be installed in accordance with Drawing GB-J1442.

5.9.3

Vacuum Safety Valve


1. For rare situations that require a vacuum safety valve, valve capacity shall be obtained
from specific manufacturer's curves, formulas, or tables.
2. Refer to FRS-DU-5057.

5.10

Liquid-Vapor Mixture
1. Total orifice area required for pressure relief of liquid-vapor mixture shall be determined by
using methodologies detailed in API 520, Part I, Appendix D.
2. The calculation shall be required for relief of a two phase stream (saturated liquid and saturated vapor) entering PSV and liquid flashing, two phase system highly subcooled containing
noncondensables entering PSV with no flashing, subcooled liquid entering PSV and flashing,
or two phase system containing both condensable and noncondensable gas/vapor and either
subcooled liquid or saturated liquid entering PSV and flashing.

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6.0

FRS-DU-5056-C

SELECTION OF PRESSURE RELIEF DEVICE


Pressure relief device (conventional pressure relief valve, balanced bellows pressure relief valve,
pilot operated pressure relief valve, or rupture disk) shall be selected in accordance with
FRS-DU-5057.

7.0

SELECTION OF VALVE CONSTRUCTION

7.1

Open Spring Type Valves


1. Open spring type valves shall be permitted only in:
a. Steam service, such as boilers and waste heat boiler, if required by ASME Code, Section I.
b. Steam service, such as turbine cases, located inside shelters or buildings.
2. Open spring type pressure valves located outdoors on an operating unit shall have a metal
hood over safety valve spring to prevent water seepage into valve interior or accumulation of
foreign material, such as catalyst dust.
3. Drawings of hood shall be submitted by manufacturer for approval, since spring covers shown
in manufacturers' catalogs are not typically considered satisfactory.

7.2

Closed Spring Type Valve (Preferred Type)


1. Closed spring type valves shall be required in:
a. Steam service, such as turbine cases exposed to weather, if ASME Code, Section I, does
not apply.
b. Hydrocarbon service.
c. Chemical service.
d. Air service.
2. Vent connections shall as a minimum be NPS 1/2 inch.
3. Closed bonnet of pressure valves shall have vent connections.
4. Conventional pressure relief valve bonnet vent shall be closed by installing a threaded plug in
vent connection.
5. Balance bellows pressure relief valve bonnet vent shall be vented to closed flange system or to
atmosphere. If vented to atmosphere, vent shall have a bugproof screen.

7.3

Pressure Relief Valves With Lifting Levers


1. Lifting levers shall be provided only if required by ASME Code.
2. Applications for which lifting levers are required in accordance with ASME Code include:
a. Steam safety valves to which ASME Code, Section I, applies.
b. Pressure relief valves on air, steam, and water over 140F service, to which ASME Code,
Section VIII, applies.
c. Safety valves for air receivers.
3. Lifting levers, if required, shall be standard type.
4. Safety valves with closed bonnets, where no leakage of vapor at lifting lever can be tolerated,
shall have packed lifting levers.

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Sizing, Selection, and Installation of


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7.4

FRS-DU-5056-C

Temperature Relief Devices


7.4.1

Water Service
If high pressure hydrogen or other hazardous materials would discharge to atmosphere in
event of a tube leak in a condenser or cooler, temperature relief valves shall be top guided.

7.4.2

Hydrocarbon or Chemical Service


1. Valves that discharge to drain or sewer shall be top guided standard relief valves with
size and type connection as required by the line material specification.
2. Poppet type spring loaded check valves, equal to Teledyne Republic Mfg. Co. 450
Series, are acceptable alternates if expansion relief is required around check valves,
block valves, or pumps for services limited to maximum pressure of Class 300 ANSI
flange ratings and maximum temperature of 500F.

7.5

Pressure Relief Valve Caps


Closed bonnet pressure relief valves shall have threaded or bolted caps over spring adjusting
screw.

7.6

Pressure Relief Valve Drains


Relief valve drain piping shall comply with FRS-DU-5057.

7.7

Test Gags
Unless approved in writing by Purchaser, test gags shall not be included.

7.8

Flushing or Purging Pressure Relieving Devices


Inlets of pressure relief devices shall have clean flushing or purging medium if process fluid may
cause plugging of valve inlet, i.e., contains solids or can generate solids by coking precipitation,
condensation, or chemical reaction.

7.9

Heat Tracing Pressure Relieving Devices


Inlet and outlet lines of pressure relieving devices shall have heat tracing if process fluid might
solidify at ambient temperatures.

7.10

Freeze Precaution
Insulation cover or heating shall be provided if water would potentially condense on inlet nozzle or
disk.

8.0

MATERIALS FOR PRESSURE RELIEF VALVES

8.1

General
1. Pressure relief valve body and trim material depend upon service. Manufacturer's recommendations shall be followed.
2. Ratings, dimensions, orifice designations, and areas shall comply with API Std 526.
3. Materials of inlet portions of valve body and trim shall be suitable at design conditions for
fluid or vapor contained in line, vessel, or equipment upon which pressure relief valve is
installed.

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Sizing, Selection, and Installation of


Pressure Relief Devices

FRS-DU-5056-C

4. Materials of outlet portions of valve body and trim shall be selected as follows:
a. If valve and its discharge piping are self draining, manufacturer's standard body and trim
material shall be acceptable, except in corrosive services. In corrosive services, outlet trim
and spring shall be of suitable material or have suitable coating to resist corrosion from
any leakage of such fluid or vapor.
b. If pressure relief valve outlet is connected into piping system, such as pump and compressor suction lines, or common pressure relieving system into which other pressure relief
valves discharge, valve body, outlet trim, and spring material shall be suitable for fluid or
vapor contained in such piping systems.
8.2

Body Material
Valve body material shall be in accordance with PIM-SU-5112.

8.3

Trim Material
1. Trim material shall be manufacturer's standard for service involved.
2. Soft seats may be used only with Purchaser's written approval.

8.4

Spring Material
Spring material shall be manufacturer's standard for service and temperatures.

8.5

Valve Bonnet or Spring Housing Material and Coating


1. Valve bonnet or spring housing material shall be same material as valve body.
2. Valve spring and inside of valve bonnet or spring housing shall be coated as follows:
a. Manufacturer's standard coating (such as Plasite #7122) for temperatures less than 500F.
b. Aluminized for temperatures 500F and higher.

8.6

Bellows Material for Balanced Bellows Valves


1. Bellows material for services not listed in paragraphs 2. through 4. shall be subject to written
Purchaser approval.
2. Material for noncorrosive services shall be 316L SS or Inconel 625 uncoated.
3. Material for services above 500F shall be 316L SS or Inconel 625 uncoated.
4. Material for services up to 500F in which hydrogen sulfide and/or chlorides are present shall
be 316L SS coated with Teflon or Kel-F. Such services include:
a. Crude and vacuum towers (overhead systems to fuel gas).
b. Hydrotreater (effluent and recycle gas).
c. Platformer (effluent and recycle gas).
d. Fuel gas.

9.0

RATINGS FOR PRESSURE RELIEF VALVES

9.1

Inlet Flange and Inlet Body Rating


1. Rating of pressure relief valve inlet body (upstream of pressure relief valve seat) shall be same
as pressure relief valve inlet flange rating, if possible.

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Sizing, Selection, and Installation of


Pressure Relief Devices

FRS-DU-5056-C

2. If large relief devices are required and inlet body rating is not the same as inlet flange rating,
an inlet body rating suitable for relieving conditions shall be used.
3. Pressure relief valve inlet flange and inlet body ratings shall be suitable for design and relief
conditions of line, vessel, or equipment upon which it is to be installed.
4. Inlet flange and inlet body of steel pressure relief valves shall as a minimum be Class 150
ANSI.
5. Minimum pressure rating of valves with screwed connections shall match the rating corresponding to ANSI 600. Pipe threads shall comply with ANSI B 1.20.1.
9.2

Outlet Flange and Outlet Body Ratings


1. Rating class for the outlet body and outlet flange of the pressure relief valve shall be equivalent to the flange rating of the line into which the valve discharges.
2. If pressure relief valve can be blocked in during normal operation of its protected system,
valve and pipe components from pressure relief valve seat to closed outlet block valve shall be
protected against excessive pressure due to leakage through closed inlet block valve and pressure relief valve seat.
3. Protection shall consist of plant operating procedure that provides for opening of inlet vent
valve followed by closure of outlet block valve immediately prior to time of pressure relief
valve removal.
4. Outlet flange rating specified shall be checked against manufacturer's pressure-temperature
limitations on pressure relief valve outlet for orifice area required.
5. Minimum outlet flange and body ratings shall be Class 150 ANSI.

10.0

CONNECTIONS FOR PRESSURE RELIEF VALVES


1. Pressure relief valves with threaded inlet and outlet connections may be used, provided calculated relieving capacity can be met, as follows:
a. On vessels in services and sizes in which threaded nozzle connections are permitted by
PVM-SU-1322.
b. On piping services and sizes in which threaded valves and fittings are permitted by PIMDU-5138 and PIM-SU-5112.
2. Pressure relief valves with flanged inlet and outlet connections shall be used on vessels and
piping for all sizes and services other than those for which threaded connections are permissible. Flange facing shall comply with PIM-SU-5112.
3. Pressure relief valve inlet or outlet connections shall not be NPS 3/8, 1-1/4, 3-1/2, or 5.

11.0

BLOCK VALVES TO PERMIT REMOVAL OF PRESSURE RELIEF VALVES

11.1

Inlet Block Valves


Block valves on inlets to pressure relief valves shall comply with FRS-DU-5057.

11.2

Discharge Block Valves


Block valves on discharges from pressure relief valves shall comply with FRS-DU-5057.

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Sizing, Selection, and Installation of


Pressure Relief Devices
11.3

FRS-DU-5056-C

Locking System
1. Block valves at inlet or outlet of pressure relief valves shall have chain or bar devices provided
by Supplier that will allow a padlock (provided by Purchaser) to be used by authorized persons
to lock block valve in an open or closed position.
2. List of all pressure relief valves with block valves that must be locked shall be provided to
Purchaser's field project engineer for use in procuring padlocks which comply with plant master lock system.
3. Block valves shall be continually maintained in locked open position, except as follows:
a. Spare pressure relief valves, except if needed in service, shall normally be maintained
offline by locking inlet valve closed. Discharge block valve shall be locked closed, except
if pressure relief valve set pressure exceeds design pressure of pressure relief outlet in
accordance with API Standard 526, in which case discharge block valve shall be locked
open.
b. After spare pressure relief valve is placed in service with locked open blocked valves, one
of normal pressure relief valves may be taken out of service for inspection and test by
locking its inlet block valve closed, opening its inlet vent valve, and locking its discharge
block valve closed.
c. If all protected equipment is shut down, depressured, emptied, and opened to atmosphere,
pressure relief valve inlet and discharge block valves may be locked closed.

12.0

RUPTURE DISK INSTALLATION


Rupture disks shall be installed in accordance with FRS-DU-5057.

13.0

PRESSURE RELIEF VALVE HANDLING BEFORE INSTALLATION AND TEST


1. Inlet and outlet flanges of pressure relief valves shall be protected and openings covered to
prevent entrance of foreign matter or moisture.
2. Valves shall be transported and stored vertically to keep out all foreign materials in accordance
with API 520, Part 2, Installation, Section 9.
3. Valves shall:
a. Be handled carefully.
b. Not subjected to heavy shocks.
c. Stored in an orderly manner.
4. Caution shall be taken before testing or installing pressure relief valves to ensure that any
extraneous material inside body or nozzle is completely removed.
5. Valve set pressures shall be checked before valve is installed.
6. Pressure relief valve connections shall be cleaned before installing valve.
7. Pressure relief valve inlet or block valve ahead of relief device shall be blinded off while pressure testing piping systems, equipment, or vessels.

14.0

INSPECTION AND TEST


Inspection and test shall comply with API RP 576 and Purchaser's general instructions for inspection and test.

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