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APPLICATION: ONSHORE
June 2008
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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
5.0
6.0
7.0
8.0
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10.0
11.0
12.0
13.0
14.0
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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
NCM-DU-5096
PIM-DU-5138
Piping Design
PIM-SU-5112
Material Specifications for Carbon Steel, Cr-Mo, and Stainless Steel Piping
Systems
PVM-SU-1322
TAM-DU-971
Purchaser Drawings
This specification contains references to the following Purchaser drawings:
GB-J1442
2.3
RP 520
Std 526
RP 576
2.3.2
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FRS-DU-5056-C
Section I
Section VIII
2.3.3
B 1.20.1
3.0
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
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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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
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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5.0
5.1
Pressure Relief Valve Nozzle Effective Areas (Typical) per API Std 526
Nozzle
Orifice
Letter
Effective Area
SQ. Inches
0.110
0.196
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
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
5.3
GPM
G
A = -------------------------------------------------------- -----------------------38 ( K D ) ( K W ) ( K C ) ( K V ) ( P R P B )
Where:
A
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Flow rate at flowing temperature and selected overpressure, in U.S. gallons per
minute.
KD
KW
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
PR
Relieving pressure, in psig. This equals set pressure plus overpressure and shall not
exceed maximum allowable accumulated pressure.
PB
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
GPM =
Flow rate at flowing temperature and selected overpressure, in U.S. gallons per
minute.
KD
KW
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
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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
KP
KP
KP
PB
W
TZ
A = ----------------------------------------------------- ------C ( KD ) ( PR ) ( KB ) ( KC ) M
Where:
June 2008
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
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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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.
Compressibility factor for deviation of actual gas from a perfect gas, a ratio evaluated at inlet conditions.
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
F2
F2 =
June 2008
k - 2 / k 1---------------------------r
---------(r)
k 1
1r
KD
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.
Compressibility factor for deviation of actual gas from a perfect gas, a ratio evaluated at inlet conditions.
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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
W
A = --------------------------------------------------------------------------------------51.5 ( P R ) ( K D ) ( K B ) ( K C ) ( K N ) ( K SH )
Where:
A
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
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
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.
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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
PR
0.1406 ( DT )
F = ------------------------------------0.65
CK ( T 1 )
Where:
F
DT
TW - T1
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
TN
PN
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2. Rupture disks can be used in series with a pressure relief valve in accordance with API 520,
Section 3.11.2.
5.8
5.9
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
5.9.3
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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7.0
7.1
7.2
7.3
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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
7.5
7.6
7.7
Test Gags
Unless approved in writing by Purchaser, test gags shall not be included.
7.8
7.9
7.10
Freeze Precaution
Insulation cover or heating shall be provided if water would potentially condense on inlet nozzle or
disk.
8.0
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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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
8.6
9.0
9.1
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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
10.0
11.0
11.1
11.2
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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
13.0
14.0
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