RELIEF VALVES

Presented By,
Shino Antony
Senior Leader-Aftermarket
Dresser Al-Rushaid Valve & Instrument Company
Ltd.
Topics Covered
INTRODUCTION TO RELIEF
Relief System- Hazards & Case Studies
EVT Method of Testing the valves ONLINE
INTRODUCTION TO RELIEF
Objectives

• Define concept of relief

• Describe and Discuss the relief
locations, types, scenarios.
• Discuss the relief system in specific
unit operations.
Defense against accidents

1. Inherent safety – plant design consideration

2. Better process control – control systems, alarms, safety

shutdown systems

3. Install relief systems – to relieve liquids or gases before

excessive pressure are developed.
Relief systems
• compose of the relief device and the associated
downstream process equipment & safety handle the
material ejected.
Relief Method
The method used for safe installation of pressure relief
devices:
Relief Concept
Pressure relief systems are required for the following
reasons:

• to protect personnel from the dangers of

overpressurizing equipment,
• to minimize chemical losses during pressure
upsets,
• to prevent damage to equipment,
• to prevent damage to adjoining property,
• to reduce insurance premiums,
• to comply with governmental regulations.
Let’s Think…

• Assume that an exothermic reaction is

occurring within a reactor.
• If cooling is lost because of a loss of cooling
water supply, failure of a valve, or other
scenario, then the reactor temperature will rise.
Let’s Think…

• As the temperature rises, the reaction rate increases

• leading to an increase in heat production.
• This self-accelerating mechanism results in a runaway
reaction.
Let’s Think…

• The pressure within the reactor increases because of

increased vapor pressure of the liquid components
and/or gaseous decomposition products resulting from
the high temperature.
Let’s Think…
• Reaction runaways for large commercial reactors can
occur in minutes, with temperature and pressure
increases of several hundred degrees per minute and
several hundred psi per minute, respectively.

• What happen if the reactor has no relief system?

Figure 8-2 Pressure versus time for runaway reactions:
(A) relieving vapor, (B) relieving froth (two-phase
flow), and (C) closed reaction vessel.
• Curve C – reactor has no relief system
- P and T increases until the reactant are
completely consumed.
- after the reactants are consumed, the
heat generation stop and the pressure
subsequently drop.
• Curve B - has a relief system (two phase froth)
- The pressure increase until the relief
device activates
• Curve A – has a relief system (vapor relief only)
- The pressure drop immediately when
the relief device opens
Relief System

The network of components around a relief device,

including the pipe to the relief, the relief device, discharge
pipelines, knockout drum, scrubber, flare, or other types of
equipment that assist in the safe relief process.
Location of Reliefs

• Pressure relief devices are installed at

every point identified as potentially
hazardous (potential problems that may
result in increased pressures)
Location of Reliefs
• Guidelines for specifying relief positions:
1. All vessels – reactors, storage tanks, towers
and drums.
2. Positive displacement pumps, compressors
and turbines need reliefs on the discharged
side.
3. Blocked-in section of cool liquid-filled lines
that exposed to heat such as heat exchanger &
cooling coil
4. Vessel steam jackets
Example 8.1
Specify the location of reliefs in the simple
polymerization reactor system illustrated in Figure 8-
5. The major steps in this polymerization process
include:

(1) pumping 100 lb of initiator into reactor R-1,

(2) heating to the reaction temperature of 240°F,
(3) adding monomer for a period of 3 hr, and
(4) stripping the residual monomer by means of a
vacuum using valve V-15.

Because the reaction is exothermic, cooling during

monomer addition with cooling water is necessary.
Figure 8-5 Polymerization reactor without
Safety reliefs.
Figure 8-6 Polymerization reactor with safety reliefs.
• Refer to Figures 8-5 and 8-6 and Table 8-1 for relief
locations.

a. Reactor (R-1): A relief is installed on this reactor

because, in general, every process vessel
needs a relief. This relief is labeled PSV-1 for
pressure safety valve 1.

b. Positive displacement pump (P-1): Positive

displacement pumps are overloaded,
overheated, and damaged if they are dead-
headed without a pressure-relieving device
(PSV-2). This type of relief discharge is usually
recycled back to the feed vessel.
c. Heat exchanger (E-1): Heat exchanger tubes
can rupture from excessive pressures when
water is blocked in (V-10 and V-11 are closed)
and the exchanger is heated (by steam, for
example). This hazard is eliminated by adding
PSV-3.

d. Drum (D-1): Again, all process vessels need

relief valves, PSV-4.

e. Reactor coil: This reactor coil can be pressure-

ruptured when water is blocked in (V-4, V-5,V-6,
and V-7 are closed) and the coil is heated with
steam or even the sun. Add PSV-5 to this coil.
 Relief Types

• Specific types of relief devices are chosen for specific

applications:
- for liquid,
- gases,
- liquid & gases,
- solid
- corrosive materials
 Relief Types
• 2 categories of relief devices:
a) spring-operated valves
1. conventional
2. balanced-bellows
- relief set pressure – 10% above the normal operating
pressure.

b) rupture discs
- Rupture discs are specially designed to rupture at a
specified relief set pressure.
- can be made from exotic corrosion-resistant
material
- problem: once it open, it remain open – lead to
complete discharge of process material.
• Rupture discs are frequently installed in series to a
spring-loaded relief
(1) to protect an expensive spring-loaded device
from a corrosive environment,
(2) to give absolute isolation when handling
extremely toxic chemicals (spring-loaded reliefs
may weep),
(3) to give absolute isolation when handling
flammable gases,
(4) to protect the relatively complex parts of a spring-
loaded device from reactive monomers that
could cause plugging,
(5) to relieve slurries that may plug spring-loaded
devices.
• 3 sub-category types of spring-loaded pressure
reliefs:

1. The relief valve is primarily for liquid service.

- The relief valve (liquid only) begins to open
at the set pressure.
- This valve reaches full capacity when the
pressure reaches 25% overpressure.
- The valve closes as the pressure returns to
the set pressure.
2. The safety valve is for gas service.
- Safety valves pop open when the pressure
exceeds the set pressure.

3. The safety relief valve is used for liquid and gas

service.
- Safety relief valves function as relief valves
for liquids and as safety valves for gases.

****************END OF SESSSION*******************
RELIEF SYSTEM- HAZARDS &
CASE STUDIES
What is the Hazard?
Despite safety precautions …

o Equipment failures
o Human error, and
o External events, can sometimes lead to …

• Increase in process pressures beyond safe levels,

potentially resulting in …

o OVERPRESSURE due to a RELIEF EVENT

What is a Relief System?
• A relief device, and

• Associated lines and process equipment to safely handle

the material ejected
Why Use a Relief System?
• Inherently Safe Design simply can’t eliminate every
pressure hazard

• Passive designs can be exceedingly expensive and

cumbersome

• Relief systems work!

Pressure Terminology
• MAWP
• Design pressure
• Operating pressure
• Set pressure
• Overpressure
• Accumulation
• Blowdown
Pros & Cons:
Conventional Valve
Advantages
• Most reliable type if properly sized and operated
• Versatile -- can be used in many services

Disadvantages
• Relieving pressure affected by back pressure
• Susceptible to chatter if built-up back pressure is too high
Pros & Cons:
Balanced Bellows Valve
Advantages
• Relieving pressure not affected by back pressure
• Can handle higher built-up back pressure
• Protects spring from corrosion

Disadvantages
• Bellows susceptible to fatigue/rupture
• May release flammables/toxics to atmosphere
• Requires separate venting system
Pros & Cons:
POSRV’s
Advantages
• Smaller package on the larger pipe sizes.
• Seals more tightly as the system pressure approaches but
does not reach set pressure.
• Control pilot can be mounted remotely.

Disadvantages
• More expensive at smaller sizes (starts to even out as
pipe size increases).
• Small parts in pilot valve are sensitive to contaminant
particles.
Rupture Devices
• Rupture Pin • Rupture Disc
When to Use a Spring-Operated Valve
• Losing entire contents is unacceptable
• Fluids above normal boiling point
• Toxic fluids
• Need to avoid failing low
• Return to normal operations quickly
• Withstand process pressure changes, including vacuum
When to Use Both Types
• Need a positive seal (toxic material, material balance
requirements)

• Protect safety valve from corrosion

• System contains solids

Installation, Inspection, and Maintenance
To undermine all the good efforts of a design crew, simply
…
• Improperly install relief devices
• Fail to regularly inspect relief devices, or
• Fail to perform needed/required maintenance on relief
devices
Anything Wrong here?

Bellows plugged
in spite of sign

Failed
Inspection
Program
 Discharges
Pointing Down
Anything Wrong here?
 Reduced
Inlet Piping

Anything Wrong here?

 Will these
bolts hold
in a
relief event?

Anything Wrong here?

Summary
• Pressure Relief
• Very Important ACTIVE safety element
• Connected intimately with Process Hazard Analysis
• Requires diligence in design, equipment selection, installation,
inspection and maintenance
EVT®-PRO
ELECTRONIC BEST
UNDER PRESSURE
VALVE TESTER
Exclusively Available
Through Your Local GTC®
• In-Situ Testing - No Problem
• Manage OSHA PSM 1910 Standards
• Test All Manufacturers Pressure Relief Valves
• Improve Plant Uptime
• Increased Revenue
• Time saving & Cost effective
Technologically
Advanced Testing
• The EVT-Pro device enables you to meet OSHA
requirements for periodic testing and documentation
without shutting down processes or removing valves from
service.
• In-situ testing without removing the valve from the
process line
• True “ HOT SET PRESSURE”
Four Major Parts
See Exact Set Pressures
• Colorful and clear graphics assist the end user in seeing
exact set pressures for the valve in test.
• Unique acoustic sensor feature provides confirmation of
set pressure on force curves delivering confidence in
each test.
Features & Benefits
Feature
• In Line Testing
• Pre-Planning Outages
• Ability to Test any Brand
• Portable and Lightweight
• Auto Shutdown Safety Feature
• Graphic Reporting
• Test Gas, Liquid and Steam
• ASME Qualified
Benefit
• Maximize Plant Uptime
• ID Problem Valves for Rapid Turn-
arounds
• Relief Valve One Stop Testing by
GTC®
• Can be Placed in any Location in
any Plant Quickly and Easily
• Unique Safety Feature Allows for
Closure of Valve Under Full-Lift
Circumstances
• Easy to Read and Understand
• Capable of Testing all Medias
• Meets ASME Code Requirements
How EVT®-Pro Works
• Testing is Based on a Force Balance Analysis of the Valve
Where F3 + F2 = F1
• Force of spring = F1
• System inlet pressure=F2
• EVT pull= F3
 Mathematics of In Situ PRV Testing

• The ability to accurately determine PRV set pressure

during in situ testing relies on three known factors:
• Hydraulic force generated by test equipment;
• Inlet pressure resulting from process pressure;
• Effective seat area of PRV.
• Equation: Set pressure = Inlet Pressure + (Hydraulic
Force ÷ Effective Seat Area).
Graphical representation of results
EQUIPMENTS/TOOLS
• EVT Pro test equipment
• - Tool box
Safety Precautions
• Do not stand in front of the discharge side of a pressure relief
valve when testing.
• Exercise extreme care when examining a pressure relief valve
for visible leakage.
• Know the points of possible media exhaust or leakage for the
valve being tested. Some valves exhaust media at locations
other than the valve outlet.
• Ensure installed pressure relief valves provide adequate
access around the valve to include overhead clearance for
equipment mounting.
• Use caution when testing pressure relief valves installed in
flammable or toxic environments. Ensure appropriate protective
measures are being implemented.
• DO NOT OPERATE THE EVT-PRO IF SAFETY IS
QUESTIONABLE.
Required PRV data

• The following parameters, as a minimum, must be

entered before the PRV data can be stored:
• Expected set pressure;
• Functional seat area; this data is derived from the Seat
area calculation methods available on the EVT-Pro data
screen.
• Tolerance norm, i.e. ASME Sec I, ASME Sec VIII, etc;
• Process pressure.
THANK YOU
Consolidated Products
Certification