You are on page 1of 15

Contract File Reference Page

Number:P1007 1007-DISQ-0-J-SS-33055-Rev.1 1 of 15

RWE Dea

Disouq Field Development


FEED

Safety Relief Valves Specification

Document number
1007-DISQ-0-J-SS-33055

1 15.11.11 Issued for Approval A Saleh / A Fawzi A Hamdan RWE


A Khamisy

0 31.10.11 Issued for Client comment A Saleh / A Fawzi A Hamdan RWE


A Khamisy

Rev Date Description Issued By Checked Approved Client


By By Approval
Onspec Engineering Solutions
Disouq Field Development Project
Safety Relief Valves Specification

Changes List
Date
Rev. prepared Prepared by Description
(dd.MM.yyyy)
A Saleh / Modified the document to comply with RWE
01 11.11.2011 A Khamisy comments.

Page: 2 of 15
Onspec Engineering Solutions
Disouq Field Development Project
Safety Relief Valves Specification

Table of Contents
1 INTRODUCTION .......................................................................................................... 5
1.1 Scope ........................................................................................................................... 5
1.2 Definitions .................................................................................................................... 5
1.3 Abbreviations ............................................................................................................... 5
1.4 Units of Measurements ................................................................................................ 6
1.5 Climate Condition ......................................................................................................... 6
2 APPLICABLE CODES AND STANDARDS................................................................... 7
3 SAFETY RELIEF VALVES ......................................................................................... 10
3.1 Application.................................................................................................................. 10
3.2 Basis and Valve Type Selection Criteria ..................................................................... 10
3.2.1 Valve Rating and Valve Class .................................................................................... 10
3.2.2 Relief valves ............................................................................................................... 10
3.2.3 Valve Types & Accessories ........................................................................................ 11
3.2.3.1 Pilot Operated Relief Valves ................................................................................ 11
3.2.3.2 Conventional Relief Valves.................................................................................. 11
3.2.3.3 Bellows Type Relief Valves ................................................................................. 11
3.2.3.4 Balanced Bellows Relief Valves .......................................................................... 12
3.2.3.5 Vacuum Relief Valves ......................................................................................... 12
3.2.3.6 Valve Accessories ............................................................................................... 12
3.2.3.6.1 Lifting Levers ....................................................................................................... 12
3.2.3.6.2 Test Gag ............................................................................................................. 12
3.3 Valve Sizing ............................................................................................................... 12
3.4 Materials .................................................................................................................... 13
3.5 Valve Nozzles ............................................................................................................ 13
3.6 Valve Bonnets ............................................................................................................ 13
3.7 Body Connections ...................................................................................................... 14
3.8 Face-to-face Dimensions............................................................................................ 14
3.9 Seat Tightness ........................................................................................................... 14
3.10 Vessel Pressure Safety Valve .................................................................................... 14
4 STAMPING AND CERTIFICATION: ........................................................................... 14
5 TAGGING AND NAMEPLATES ................................................................................. 14
6 DOCUMENTATION.................................................................................................... 15
8 QUALITY ASSURANCE PROVISIONS ...................................................................... 15

Page: 3 of 15
Onspec Engineering Solutions
Disouq Field Development Project
Safety Relief Valves Specification

ATTACHMENTS

1 Pressure Relief Valve Data Sheet


2 Rupture Disc Data Sheet

Page: 4 of 15
Onspec Engineering Solutions
Disouq Field Development Project
Safety Relief Valves Specification

1 INTRODUCTION

1.1 Scope
This specification describes the minimum technical requirements for the selection, manufacture
and testing of pressure safety relief valves suitable for installation on RWE Disouq Field
Development Project.
The following documentations shall be necessary in safety relief valves selection and sizing:
Document Reference no.
P&ID 1007-DISQ-0-P-DW-48031 to 480xx (HOLD)
Safety Relief Valve Data Sheets (HOLD)
Field Instrumentations General Specifications 1007-DISQ-0-J-SS-33010
and Testing Requirements

1.2 Definitions
RWE Dea Egypt, in a later project state a JV formed between the RWE Dea Egypt
Company
and EGAS

Vendor Supplier is the party, which manufactures or supplies equipment

1.3 Abbreviations
ANSI American National Standards Institute

API American Petroleum Institute

ASTM American Society of Testing and Material

ASME American Society of Mechanical Engineers

ISA Instrumentation Systems & Automation Society

MSS Manufacturers Standardization Society of the Valve and Fittings Industry

NACE National Association of Corrosion Engineers

NEMA National Electrical Manufacturers Association

NFPA National Fire Protection Association

CENELEC European standard Code

IEC International System

SI International Electro-technical Commission

PSV Pressure Safety Valve

Page: 5 of 15
Onspec Engineering Solutions
Disouq Field Development Project
Safety Relief Valves Specification

1.4 Units of Measurements


Units of Measurements shall be in accordance to the International System of Units (SI System),
the following units shall be used in all documents, including drawings, and for all purpose
under the scope of work.
Units of measurement to be applied:

Temperature C
Pressure (gauge) Psig
Pressure (absolute) Psia
LEVEL % of range; or mm for tanks
Mass Kg
Area m
Length M
Liquid absolute density kg/m (@ 15 C)
Vapour flowing density kg/m
Flow rate (gas) MMscfd
Flow rate (liquid) bbl/d
Time S
Velocity m/s
Enthalpy J/kg
Viscosity cP
Electrical Power kW, MW
Voltage V, mV
Current A, mA
Electric resistance Ohm
Frequency Hz
Speed RPM

1.5 Climate Condition


The shut down valves shall be suitable to operate in the north delta climate conditions:
Ambient Temperatures 0 C to 35 C normal, up to 50 C maximum
Metal Surface C 85 C
Humidity range (Min. & Max) 60 to 75%
Average Rainfall app. 200 mm/year with possible showers during Nov-March
Seismic Zone Moderate risk, 10% probability to exceed 0.8 m/s Ground
acceleration in 50 years
Wind Speed & Direction Predominant NW direction, max. 39-44 m/s

Page: 6 of 15
Onspec Engineering Solutions
Disouq Field Development Project
Safety Relief Valves Specification

2 APPLICABLE CODES AND STANDARDS


The design, construction, testing and general requirements shall comply with the latest
edition of applicable codes and standards.
The Vendor shall consider the most recent codes and standards issued by the following
associations and approved bodies as part of this specification.
Reference Title

American National Standards Institute (ANSI)

B 1.20.1 Standard for Pipe Threads, General Purpose


Pipe Threads (Except Dryseal) Specifications, Dimensions, and Gauging for
B2.1
Taper and Straight Pipe Threads Including Certain Special Applications
B9.1 Safety Code for Mechanical Refrigeration

B16.20 Ring-Joint Gaskets and Grooves for Steel Pipe Flanges

B 16.47 Large Diameter Steel Flanges NPS 26 Thru NPS 60

B16.5 Pipe Flanges and Flanged Fittings

B 16.9 Factory Made Wrought Steel Buttwelding Fittings

B 16.11 Forged Steel Fittings, Socket Welding and Threaded

B 31.1 Power Piping Code

B31.2 Fuel Gas Piping

B 31.3 Chemical Plant and Petroleum Refinery Piping


Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas,
B 31.4
Anhydrous Ammonia, and Alcohols
B31.5 Refrigeration Piping

B31.6 Chemical Process Piping

B31.7 Gas Transmission and Distribution Piping Systems

B 31.8 Gas Transmission and Distribution Piping Systems


Valves - Flanged and Buttwelding End Steel, Nickel Alloy and Other Special
B16.34
Alloys
B16.104 Valve Leakage Classifications

B 36.10M Welded and Seamless Wrought Steel Pipe

C 37.96 IEEE Guide for AC Motor Protection

Page: 7 of 15
Onspec Engineering Solutions
Disouq Field Development Project
Safety Relief Valves Specification

American Petroleum Institute (API)

1104 Standard for Welding of Pipelines and Related Facilities

2B Specification for Fabricated Structural Steel Pipes


Recommended practice for classification of locations for
500 electrical installations at petroleum facilities classified as
Class 1, Division 1 and Division 2.
5L Specification for Line Pipe

SPEC 6D Specifications for Pipeline Valves, End Closures, Connectors and Swivels
Specifications for Wellhead Surface Safety Valves and Underwater Safety
SPEC 14D
Valves for Offshore Service
STD 607 Fire Test for Soft Seated Ball Valves
Recommended Practice for the Design and Installation of Pressure Relieving
RP 520
Systems in Refineries, Part 1 - Design, and Part 2 Installation
RP 521 Guide for Pressure Relief and Depressuring Systems
Testing Procedure for Pressure Relieving Devices Discharging Against
RP 525
Variable Back Pressure
RP 526 Flanged Steel Safety Relief Valves

RP 527 Commercial Seat Tightness of Safety Relief Valves with Metal-To-Metal Seats
Manual on Installation of Refinery Instruments and Control Systems, Part 1 -
RP 550 Process Instrumentation and Control, Section 6 - Control Valves and
Accessories
Recommended Rules for Design & Construction of Large, Welded.
RP 620
Low-Pressure Storage Tanks
554 Process Control and Instrumentation

SPEC 6D Specifications for Pipeline Valves, End Closures, Connectors and Swivels
Venting Atmospheric and Low-Pressure Storage Tanks (Nonrefrigerated and
STD 2000
Refrigerated)
Design and Construction of LP-Gas Installations at Marine and Pipeline
STD 2510 Terminals, Natural Gas Processing Plants, Refineries, Petrochemical Plants
and Tank Farms
Use of Pressure-Vacuum Vent Valves for Atmospheric Pressure Tanks to
STD 2521
Reduce Evaporation Loss
American Society for Testing and Materials (ASTM)
A193 / Specification for Alloy Steel and Stainless Steel Bolting Materials for
A193M High Temperature Service
Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High-
A194 Pressure
/ High-Temperature Service

Page: 8 of 15
Onspec Engineering Solutions
Disouq Field Development Project
Safety Relief Valves Specification

Standard Specification for Piping fittings of Wrought Carbon Steel and Alloy
A234
Steel for Moderate and Elevated Temperatures
Standard Specification for Seamless and Welded Austenitic
A269
Stainless Steel Tubing for General Service
Specification for Seamless and Welded Austenitic Stainless Steel Tubing
A269
for General Service
Specification for Alloy Steel Bolting Materials for Low
A320
Temperature Service
High Strength Bolts for Structural Joints, including Suitable
A325
Nuts and Plain Hardened Washers
Methods and Definitions for Mechanical Testing of Steel
A370
Products.
Standard Specification for Wrought Austenitic Stainless Steel
A403
Piping Fittings
Standard Specification for General Requirements for Carbon
A450/450M
Steel, Ferritic Alloy, and Austenitic Alloy Steel Tubes.
American Society of Mechanical Engineers (ASME)

Section II Material Specifications

Section VIII Pressure Vessels

Section IX Welding and Brazing Qualifications

National Electrical Manufacturers Association (NEMA)

ICS-2 Industrial Control Devices, Controllers and Assemblies

MG-1 Motors and Generators

250 Enclosures for Electrical Equipment

National Fire Protection Association (NFPA)

70 National Electrical Code


Standard for the Installation of Air Conditioning and
90A
Ventilation Systems
493 Intrinsically Safe Apparatus
Standard for Purged and Pressurized Enclosures for
496
Electrical Equipment in Hazardous (Classified) Locations
International Electro-technical Commission (IEC)
Insulation co-ordination within low-voltage systems including
664
clearances and creep age distances for equipment
60059 IEC Standards Current Ratings

60085 Thermal Evaluation and Classification of Electrical Insulation

Page: 9 of 15
Onspec Engineering Solutions
Disouq Field Development Project
Safety Relief Valves Specification

60228 Specification for conductors in insulated cables.

60331 Test for electric cables under fire conditions Circuit integrity

60529 Degrees of protection provided by enclosures (IP Code)

60534 Industrial Process Control Valves Inspection & Routine Testing

Instrument Society of America (ISA)

S75.01 Control Valve Sizing Equations

S75.02 Control Valve Capacity Test Procedures


Uniform Face-to-face Dimensions for Flanged Globe Style Control Valve
S75.03
Bodies
S75.04 Face-to-face Dimensions of Flangeless Control Valves

Manufacturers Standardization Society of the Valve and Fittings Industry (MSS)

SP 61 Pressures Testing of Steel Valves

National Association of Corrosion Engineers (NACE)

MR-01-75 Sulfide Stress Cracking Resistant Metallic Material for Oil Field Equipment

3 SAFETY RELIEF VALVES

3.1 Application
Safety Valves for gas applications and Relief Valve for liquid applications are actuated
automatically by inlet static pressure to relieve the excessive pressure to protect packages,
pipeline and/or equipment

3.2 Basis and Valve Type Selection Criteria


The vendor shall be responsible for the selection of safety Relief Valve suitable for its intended
application.

3.2.1 Valve Rating and Valve Class


The minimum rating class for inlet flanged safety relief valves shall be ANSI 300. The
minimum rating for outlet flanges shall be ANSI 150. The minimum rating class for valves
with screwed connections shall be ANSI 600.
The valve body rating shall not be less than that permitted by the corresponding pipe
classification.

3.2.2 Relief valves


Relief Valves shall be selected and designed as per API 526, 627, 598 and API guide for
inspection of refinery equipment chapter XVI for the following:

Page: 10 of 15
Onspec Engineering Solutions
Disouq Field Development Project
Safety Relief Valves Specification

o Pressure vessels and piping systems if an upstream or downstream pressure


source could exceed the allowable working pressure of the vessel, line, or other
equipment.
o Pressure storage tanks or vessels where loss of refrigeration and resultant
pressure rise from the ambient pressure will exceed the vessel maximum
allowable working pressure.
o The process side of all heaters (including direct fired heaters and heaters that are
heated by circulating hot mediums such as oil, steam, air, and certain gases) if
control failure of the heating medium and/or stoppage of the coolant stream could
result in exceeding the allowable working pressure of the tubes.
o The discharge of all positive displacement pumps. Built-in pump relief valves are
not an acceptable alternative for a relief valve.
o Shell and tube exchangers and similar equipment if a tube failure could result in
exceeding the maximum allowable pressure of the shell.
o Lines, exchangers, and piping systems to relieve pressure caused by thermal
expansion of liquid in a dead line or captive system.
o Other cases where good judgement and experience indicate the need to protect
personnel and equipment with a relief valve.

3.2.3 Valve Types & Accessories

3.2.3.1 Pilot Operated Relief Valves


Pilot operated relief valves are preferred for most services, especially for pressure ranges
below 15 PSIG.
The location of the sensing line shall be remote from the valve.
Pilot operated relief valves shall be furnished with a field test connection complete with a
check valve and a block valve in the pilot supply line.
Backflow preventers shall be supplied on all pilot operated relief valves.

3.2.3.2 Conventional Relief Valves


Conventional relief valves are preferred for liquid, gas, or vapour service if the sum of the
maximum superimposed backpressure and built-up backpressure is less than 10% of the
set pressure.
The valves shall be of the direct spring-loaded, top guided, high lift nozzle type.
The valves shall have a closed bonnet. The bonnet shall be internally vented to the
discharge side of the valve.

3.2.3.3 Bellows Type Relief Valves


Bellows type relief valves shall be installed where the spring and trim should be protected
against severe fouling and corrosion, and if the sum of the maximum superimposed
backpressure and build-up backpressure is less than 10% of the set pressure.
The bellows area shall be equal to the area of the nozzle that overcomes the effect of the
backpressure on the set pressure.

Page: 11 of 15
Onspec Engineering Solutions
Disouq Field Development Project
Safety Relief Valves Specification

3.2.3.4 Balanced Bellows Relief Valves


Balanced bellows relief valves shall be provided if a variable backpressure exists in the
vent system, or if the sum of maximum superimposed backpressure and build-up
backpressure is greater than 10% of the set pressure.
The valves shall have a bonnet vented to the atmosphere. The bonnet shall not be
vented toward possible sources of ignition.
The valves shall be installed so that vapour does not release into personnel areas or
impinge on lines or equipment.

3.2.3.5 Vacuum Relief Valves


Vacuum support discs shall be provided in most applications if the pressure margin of the
vacuum disc is compatible with vessel design standards. The rupture margin (the
difference between normal operating pressure of a system and the pressure rating of
disc) shall be in accordance with the manufacturer's recommendation. The operating
pressure normally shall not exceed 70% of the rated rupture pressure for conventional
concave discs and 90% for vacuum support discs.
Vacuum relief devices shall be provided on all tanks designed for operation from
0.03125 pounds per square inch vacuum through 15 PSIG pressure.
Vacuum relief devices shall be provided in accordance with API RP 620, "Recommended
Rules for Design Construction of Large, Welded, Low-pressure Storage Tanks," and API
Standard 2000, "Venting Atmospheric and Low-pressure Storage Tanks."
Vacuum relief devices shall be of the weight loaded pallet or pilot operated type.

3.2.3.6 Valve Accessories

3.2.3.6.1 Lifting Levers


Lifting levers shall be provided only for air or steam service applications covered by
ASME Section VIII.

3.2.3.6.2 Test Gag


Test gags shall be provided only if required by applicable codes. Test gags shall be used
to hold the relief valve closed during hydrostatic testing when pressures are above the set
point. Test gags shall be removed after hydrostatic testing.

3.3 Valve Sizing


Safety Relief valves shall have sufficient capacity for relief requirements from thermal
expansion or fire exposure or blocked outlet.
All pressure relieving valves shall be sized in accordance with API RP 520.
The design capacity of relief valves shall be based on the maximum design capacity of
the vessel or system being protected, plus the capacity of any side streams that enter
during upset.
The equivalent area of pilot operated relief valves shall be the curtain area between the
disk and the nozzle. The area controlling flow shall be the equivalent area and not the
nozzle bore.
Before sizing pressure relief valves for vessels with low operating pressures, conditions
shall be investigated to determine if raising the design pressure of the vessel (allowing

Page: 12 of 15
Onspec Engineering Solutions
Disouq Field Development Project
Safety Relief Valves Specification

higher backpressures) and permitting the vessels to relieve into common relief headers
rather than into separate low pressure headers is economical.
The sizing of safety relief valves shall be determined from the following possible process
upsets, whichever establishes the largest requirement:
Cooling Water Failure
Power Failure
Instrument Air or Instrument Failure
Mechanical Failure of any Equipment
Excessive Pumping Rates
After the relief valve has been sized and selected, the vendor shall calculate the friction
loss in the inlet and outlet piping at the maximum possible flow. The inlet piping loss shall
not exceed 3 % of the set point. The calculations shall be submitted to the Company for
review before the final design of the piping system.
Calculations for failure of an upstream control valve shall be based on the largest trim
that can be put in the valve regardless of the initial trim size. The calculations shall
indicate which failure is controlling.
Valves shall not be set greater than the stamped maximum allowable working pressure of
the vessel or equipment.
The percent pressure accumulation used in calculating sizes of relieving devices shall be
as follows:
10 % gas or vapour service, and for liquids, except as follows for liquid service for
thermal relief:
o 25 % in liquid service for thermal relief of pipelines and pump discharges
o 20 % fire exposure on unfired pressure vessels
If a larger relief valve orifice area is required than can be supplied by a single relief valve,
multiple relief valve installations shall be provided

3.4 Materials
If corrosion is not a problem, materials for relief valves shall be in accordance with
technical Requirements and Piping Material Specification (1007-DISQ-0-L-SS-39010)
Viton soft goods shall be specified for services with continuous temperatures from -65F
(-55C) to 400F (205C). Other soft goods materials may be considered for special
applications.

3.5 Valve Nozzles


All relief valves of size 1 and above shall be full nozzles type.
Relief valves with sizes less than 1 shall be Modified nozzle type.

3.6 Valve Bonnets


Plain closed bonnets shall be provided with a tapped and plugged vent for easy
conversion to balanced relief valves.
Exposed spring bonnets shall be provided for steam service above 450 F (230 C) as
required by the ASME Boiler and Pressure Vessel Codes.
All valves shall have screwed caps.

Page: 13 of 15
Onspec Engineering Solutions
Disouq Field Development Project
Safety Relief Valves Specification

3.7 Body Connections


Flanged connections shall be furnished on all process service relief valves 1 inch and
larger.
Flanged connections shall be furnished on all utility service relief valves 2 inches and
larger.
Flanges shall conform to ANSI B16.5, "Pipe Flanges and Flanged Fittings."
Screwed connections shall be furnished on 3/4-inch valves and smaller in accordance
with the Technical Requirements. Screwed connections shall conform to ANSI B2.1
"Pipe Threads" (except Dry seal).

3.8 Face-to-face Dimensions


The face-to-face dimensions of flanged steel relief valves shall conform to API RP 526,
"Flanged Steel Safety Relief Valves."

3.9 Seat Tightness


Metal to metal seats shall be rated for commercial tightness in accordance with API RP
527, "Commercial Seat Tightness of Safety Relief Valves with Metal to Metal Seats."
Valve seats with bubble tightness, which permits no leakage, shall only be provided if
specified by Company.

3.10 Vessel Pressure Safety Valve


Vessels with input sources capable of developing pressures in excess of the vessel rating
shall be provided with one safety relief valve. Safety relief valves should not have any
isolation valves at inlet and outlet side of the PSV. The valve shall be sized for fire and
thermal relief and shall be set at the vessel maximum working pressure (design
pressure).
If two vessels are connected in series, both vessels may be protected by the same relief
valve(s) provided that the line connecting the vessels has either no valves or valves for
maintenance only. The maintenance valves shall be car seal open and sized so that the
maximum pressure drop does not exceed 3% of the relief valve(s) set pressure. The
pressure drop shall be calculated with the maximum rated flow through the pressure relief
valve selected. The total wetted area of both vessels shall be included in sizing for fire
exposure.
If a vessel is provided with two relief valves, the combined capacity of the valves may be
used to meet the relief requirements for fire exposure.

4 STAMPING AND CERTIFICATION:


All Valves shall be marked and certified in accordance with the ASME Boiler and
Pressure Vessel Code.

5 TAGGING AND NAMEPLATES


Nomenclature shall be in accordance with API RP 520, "Recommended Practice for the
Design and Installation of Pressure Relieving Systems in Refineries."
Safety relief valves shall be equipped with a manufacturers nameplate of 316 stainless
steel permanently attached with stainless steel screws or rivets indicating the specified

Page: 14 of 15
Onspec Engineering Solutions
Disouq Field Development Project
Safety Relief Valves Specification

data. In addition to specified data the following data shall be provided which is a
minimum:
o Valve serial number
o Tag number
o Valve model number or catalogue number
o Set pressure
o Valve manufacturer
o Orifice designation
o Valve inlet and outlet connection sizes and rating
o Back pressure
o ASME Code stamp shall be marked

6 DOCUMENTATION
Documentation shall be provided in accordance with the Technical Requirements, with the
following additional requirements.
Safety Relief valve design calculations shall be provided. The calculations shall be
competed and detailed.
Each possible cause of overpressure shall be considered in the calculations, including
fire.
Safety Relief valve calculations shall be made, copies forwarded to the Company for
review 3 weeks prior to purchase of any valve.
At the conclusion of the job, a complete set of calculations shall be provided for the
Company's permanent files.

7 REVIEW & APPROVAL


Company will respond to vendor documentation approval requests within two weeks of receipt of
information. Company approval in no way relieves the vendor of any responsibility for
compliance with the Technical Requirements.

8 QUALITY ASSURANCE PROVISIONS


Quality assurance provisions shall be in accordance with the Technical Requirements, with the
following additional requirements:
The vendor shall test and document all safety relief valves for set pressure.
Testing for valve leakage shall be in accordance with API RP 527.
Relief valve metallurgy and associated piping metallurgy shall be checked by means of
the pressure-reduction/temperature-reduction effect (Joule-Thomson).
All valves shall be shipped and stored upright.

Page: 15 of 15