ENGINEERING DESIGN GUIDELINES Relief Valves Sizing and Selection Rev Web

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Guidelines for Processing
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Rev 02 May 2012
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Process Equipment Design Guidelines

Chapter Ten
PRESSURE RELIEF VALVE
SELECTION AND SIZING
(ENGINEERING DESIGN GUIDELINES)
Co Authors
Rev 01 Ai L Ling
Rev 02 K Kolmetz
Rev 03 Reni Mutiara Sari
Editor / Author
Karl Kolmetz
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TABLE OF CONTENT
INTRODUCTION
Scope
General Consideration
10
Important of Pressure Relief System

Relief Devices Design Consideration
(A) Cause of overpressure
10
10
10
(I) Blocked Discharge
11
(II) Fire Exposure
11
(III) Check Valve Failure
12
(IV)Thermal Expansion
12
(V) Utility Failure
12
(B) Application of Codes and Standard
13
(C) Determination of individual relieving rates
14
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( ENGINEERING DESIGN GUIDELINE)
Design Procedure
16
DEFINITIONS
17
NOMENCLATURE
20
THEORY
22
Selection of Pressure Relief Valve
22
Pressure Relief Devices
22
I. Reclosing Pressure Relief Devices
22
(A) Conventional Pressure Relief Valve

Thermal Relief Valve
22
24
(B) Balanced Relief Valves
27
(C) Pilot Operated Relief Valves
28
II. Non Reclosing Pressure Relief Devices
32
(A) Rupture Disk
32
Procedure for Design
36
(A) Set Pressure
36
(B) Maximum Allowable Accumulation
37
(C) Back Pressure
37
(D) General Operation and Characteristics Relief Valves
41
Standard Relief Valve Designation
44
Procedure for Sizing
47
These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases.
They were designed for engineers to do preliminary designs and process specification sheets. The final design must
always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the
amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for
young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
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(A) Sizing for Gas or Vapor Relief for Critical Flow
47
(B) Sizing for Gas or Vapor Relief for Subcritical Flow
49
(C) Sizing for Steam Relief
50
(D) Sizing for Liquid Relief: Requiring Capacity Certification
52
(E) Sizing for Liquid Relief: Not Requiring Capacity Certification
53
(F) Sizing for Two-phase Liquid/Vapor Relief
54
(G) Sizing for Rupture Disk Devices
58
(H) Sizing Thermal Relief Valves Expansion Thermal
59
(I) Sizing for External Fire Condition
61
Pressure Relief Valve Sizing Installation
67
(A) Pressure Relief Valve Location
67
(B) Selection of Discharge for Pressure Relief Valves
67
(C) Installation
68
APPLICATION
Example 1: Sizing of Relief Valve of Vapor/Gas Critical Flow
72
Example 2: Sizing of Relief Valve of Vapor/Gas- Subcritical Flow
74
Example 3: Sizing of Relief Valve - Steam Service
77
Example 4: Sizing of Relief Valve - Liquid Requiring Capacity Certification
79
Example 5: Sizing of Relief Valve - Liquid Not Requiring Capacity Certification
82
Example 6: Sizing of Thermal Relief Valve-Thermal Expansion - Water
84
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Example 7: Sizing of Thermal Relief Valve-Thermal Expansion - Hydrocarbon
89
Example 8: Sizing of Relief Valve - External Fire Condition
94
REFEREENCES
98
LIST OF TABLE
Table 1: Determination of individual relieving rates
15
Table 2: Advantages and disadvantages of rupture disks
33
Table 3: Rupture Disk Selection and Applications
34
Table 4: Comparison Set Pressure in ASME Section I and VIII
36
Table 5: Minimum recommended pressure differentials
37
Table 6: Maximum allowable accumulation
37
Table 7: API Standard Nozzle Orifice Designation
45
Table 8: Typical Saturated Steam Capacity of Orifice Designation for

Specific Set Pressure
46
Table 9: Capacity Correction Factor (Kw)-Back Pressure Effect on

Balanced Bellows Pressure Relief Valves in Liquid Services
53
Table 10: Value cubic expansion coefficient for hydrocarbon liquid
59
Table 11: Value cubic expansion coefficient for water
60
LIST OF FIGURE
Figure 1: Conventional Safety-Relief Valve
23
Figure 2: Conventional pressure relief valve with threaded connections
25
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Figure 3: Balanced Pressure Relief Valve
27
Figure 4: Pilot Operated Relief Valve
31
Figure 5: Forward-Acting Solid Metal Rupture Disk Assembly
35
Figure 6: Constant superimposed backpressure
39
Figure 7: Variable superimposed backpressure
40
Figure 8: The operation and characteristics of a pressure relief valve
41
Figure 9: The operation and characteristics of a pressure relief valve
43
Figure 10: Constant Total Back Pressure Factor, Kb for Balanced Bellows
Pressure Relief Valve (Vapors and Gases) Critical Flow
48
Figure 11: Superheat Correction Factors, KSH
51
Figure 12: Capacity Correction Factor Due to Overpressure for

Noncertified Pressure Relief Valves in Liquid Service
54
Figure 13: Critical flow ratio base on omega parameter
57
Figure 14: Fire sizing vessel (tank) selection diagram
62
Figure 15: Logic diagram effective liquid level
63
Figure 16: Typical Pressure Relief Valve Installation: Atmospheric Discharge
69
Figure 17: Typical Pressure-Relief Valve Installation: Closed System Discharge
70
Figure 18: Typical Rupture Disk Device Installation: Atmospheric Discharge
71
Figure 19: Typical Pressure Relief Valve Mounted on Process Line
71
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INTRODUCTION
Scope
Safety is the most important factor in designing a process system. Some undesired
conditions might happen leading to damage in a system. Control systems might be
installed to prevent such conditions, but a second safety device is also needed. One kind of
safety device which is commonly used in the processing industry is the relief valve. A relief
valve is a type of valve to control or limit the pressure in a system by allowing the
pressurised fluid to flow out from the system.
The pressure in a system can build up by a process upset, instrument or equipment failure,
or fire. When considering safety factors to minimizing the damage in industrial plant, it is
important to properly select the pressure relief valve to be utilized. This design guideline
covers the sizing and selection methods of pressure relief valves used in the typical
process industries. It assist engineers and operations personnel to understand the basic
design of the different types of pressure relief valves and rupture disks, and increase their
knowledge in selection and sizing.
Pressure relief valves controls the pressurised fluid by direct contact; hence it should be
designed with materials compatible with the process fluids. There are some codes and
standards to govern the design and use of pressure relief valves, but there are also some
additional parameters used to select the design in a typical process.
In material selection, some important parameters are based on fluid properties and
process requirements; such as temperature, pressure, chemical attack by process fluid, or
corrosiveness.
There are many available guidelines developed to aid engineers in selecting and sizing the
relief valves, but mostly these guidelines are developed by certain companies and might
only be suitable for the application of the valves provided by their own companies. Hence, it
is important to obtain a general understanding of pressure relief valve sizing and selection
first. Later, whenever changes are needed in a process system, this basic knowledge is still
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applicable. This guideline is made to provide that fundamental knowledge and a step by
step guideline; which is applicable to properly select and size pressure relief valves in a
correct manner.
INTRODUCTION
General Consideration
Important of Pressure Relief System
In the daily operation of chemical processing plant, overpressure may happen due to
incidents like inadvertent blocked discharge, fire exposure, tube rupture, check valve
failure, thermal expansion at a heat exchanger, and utility failures. This may lead to major
incident in a plant if the pressure relief system is not in place or not functional.
Is very important to properly select the size and the location and to maintain the pressure
relief system to prevent or minimize the losses from major incident like a fire. The pressure
relief system is used to protect piping and equipment against excessive over-pressure and
insure personnel safety. Pressure relief systems consist of the pressure relief device, the
flare piping system, flare separation drum and flare system. A pressure relief device is
designed to open and relieve the excess pressure and then it recloses after normal
conditions have been restored to prevent the further flow of fluid.
Pressure Relief Devices Design Consideration
Several things have to be considered to design a pressure relief valve such as cause of
overpressure (to determine the maximum or minimum required valve in such conditions),
valid codes and standards, and general cases of individual relieving rates.
(A) Cause of overpressure
Overpressure incidents in chemical plants and refinery plants have to be reviewed and
studied. This is important in preliminary step of pressure relief system design. It helps the
designer to understand the causes of overpressure and to minimize the effect.
Overpressure is the result of an unbalance or disruption of the normal flows of material and
energy that causes the material or energy, or both, to build up in some part of the system.
(1)
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(I) Blocked Discharge

Blocked discharge can be defined as any vessel, pump, compressor, fired heater, or other
equipment item in which the closure of block valve at outlet either by mechanical failure or
human error. This will expose the vessel to a pressure that may exceed the maximum
allowable working pressure (MAWP), and a pressure relief device is required unless
administrative procedures to control valve closure such as car seals or locks are in place.
(II) Fire Exposure
Fire may occur in an oil and gas processing facility, and create relieving requirements. All
vessels must be protected from overpressure with protected by pressure relief valves,
except as bellow
(i)
A vessel which normally contains no liquid, since failure of the shell from
overheating would probably occur even if a pressure relief valve were
provided.
(ii)
Vessel (drums or towers) with 2 ft or less in diameter, constructed of pipe,

pipe fittings or equivalent, may not require pressure relief valves for
protection against fire, unless these are stamped as coded vessels.
(iii)
Heat exchangers may not need a separate pressure relief valve for
protection against fire exposure since they are usually protected by
pressure relief valves in interconnected equipment or have an open
escape path to atmosphere via a cooling tower or tank.
(iv)
Vessels filled with both a liquid and a solid (such as molecular sieves or
catalysts) may not require pressure relief valve for protection against fire
exposure. In this case, the behavior of the vessel contents normally
precludes the cooling effect of liquid boiling. Hence rupture discs,
fireproofing and de-pressuring should be considered as alternatives to
protection by pressure relief valves.
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(III) Check Valve Failure

Check valve is normally located at a pump outlet. Malfunction of the check valve can lead
to overpressure in vessel. When a fluid is pumped into a process system that contains gas
or vapor at significantly higher pressures than the design rating of equipment upstream of
the pump, failure of the check valve from this system will cause reversal of the liquid flow
back to pump. When the liquid has been displaced into a suction system and highpressure fluid enters, serious overpressure may result.
(IV)Thermal Expansion
If isolation of a process line on the cold side of an exchanger can result in excess pressure
due to heat input from the warm side, then the line or cold side of the exchanger should be
protected by a relief valve.
If any equipment item or line can be isolated while full of liquid, a relief valve should be
provided for thermal expansion of the contained liquid. Low process temperatures, solar
radiation, or changes in atmospheric temperature can necessitate thermal protection.
Flashing across the relief valve needs to be considered.
(V)Utility Failure
Failure of the utility supplies to processing plant will result in emergency conditions with
potential for overpressure the process equipments. Utilities failure event are included,
electric power failure, cooling water failure, steam supplier failure, instrument air or
instrument power system failure.
Electric power failure normally causes failure of operation of the electrical drive equipment.
The failure of electrical drive equipment like electric pump, air cooler fan drive will cause
the reflux to fractionator immediate loss and lead to the overpressure at the overhead
drum.
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Cooling Water failure may occur when there is no cool water supply to cooler or condenser.
Same as electric power failure it will cause immediate loss of the reflux to fractionator and
vapor vaporized from the bottom fractionator accumulated at overhead drum will lead to
overpressure.
Loss of supply of instrument air to control valve will cause control loop interruptions and
may lead to overpressure in process vessel. To prevent instrument air supply failure
multiple air compressors with different drivers and automatic cut-in of the spare machine is
require and consideration of the instrument air the pressure relief valve should be proper
located.
(B) Application of Codes, Standard, and Guidelines
Designed pressure relieving devices should be certified and approved under Code,
1. ASME- Boiler and Pressure Vessel Code Section I, Power Boilers, and Section
VIII, Pressure Vessels.
2. ASME- Performance Test Code PTC-25, Safety and Relief Valves.
3. ANSI B31.3, Code for Petroleum Refinery Piping.
API are recommended practices for the use of Safety Relief Valves in the petroleum
and chemical industries are:
1. API Recommended Practice 520 Part I - Sizing and selection of components for
pressure relief systems in Refineries.
2. API Recommended Practice 520 Part II Installation of pressure relief systems
in Refineries.
3. API Recommended Practice 521 Guide for Pressure-Relieving and
Depressuring Systems.
4. API Standard 526 - Flanged Steel Pressure Relief Valves
5. API Recommended Practice 527 - Seat Tightness of Pressure Relief Valves
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6. API Standard 2000 - Venting Atmospheric and Low-Pressure Storage Tanks:

Nonrefrigerated and Refrigerated
7. API Standard 2001- Fire Protection in Refineries.
(C) Determination of individual relieving rates (1)
Table 1: Determination of individual relieving rates
Item
Condition
Closed outlet on vessels
Cooling water failure to condenser
Pressure Relief Device

(Liquid Relief)
Maximum
rate
liquid
pump-in
Pressure Relief Device

(Vapor Relief)
Total incoming steam and vapor plus that generated
therein at relieving conditions
Total vapor to condenser at relieving condition
Top-tower reflux failure
Sidestream reflux failure
Difference between vapor entering and leaving

section at relieving conditions
5
6
Lean oil failure to absorber

Accumulation of non-condensable
None, normally
Same effect in towers as found for Item 2; in other
vessels, same effect as found for Item 1
Entrance of highly volatile material

Water into hot oil
For towers usually not predictable
Light hydrocarbons into hot oil
For heat exchangers, assume an area twice the

internal cross-sectional area of one tube to provide
fro the vapor generated by the entrance of the
volatile fluid due to tube rupture
Maximum
rate
liquid
Total incoming steam and vapor plus that generated

therein at relieving condition less vapor condensed
by sidestream reflux
Overfilling storage or surge vessel
pump-in
9
10
Failure of automatic control

Abnormal heat or vapor input
Must be analyzed on a case-by case basis

Estimated maximum vapor generation including noncondensable from overheating
11
Split exchanger tube
Steam or vapor entering from twice the crosssectional area of one tube; also same effects found
in Item 7 for exchangers
12
Internal explosions
Not controlled by conventional relief devices but by

avoidance of circumstance
13
Chemical reaction
14
Power failure (steam, electric, or other)
Estimated vapor generation from both normal and

uncontrolled conditions
Study the installation to determine the effect of
power failure; size the relief valve for the worst
condition that can occur
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15
Fractionators
16
Reactors
17
Air-cooled exchangers
18
Surge vessels
Maximum liquid inlet rate
All pumps could be down, with the result that reflux

and cooling water would fail
Consider failure of agitation or stirring, quench or
retarding steam; size the valves for vapor generation
from a run-away reaction
Fans would fail; size valves for the difference
between normal and emergency duty
-
Design Procedure
General procedure in the design of protection against overpressure as below,
(i)
Consideration of contingencies: all conditions which will result in process equipment

overpressure is considered; the resulting overpressure is evaluated and the
appropriately increased design pressure; and each possibility should be analyzed
and the relief flow determined for the worse case.
(ii)
Selection of pressure relief device: the appropriate type for pressure relief device for
each item of equipment should be proper selection based on the service require.
(iii)
Pressure relief device specification: standard calculation procedures for each type
of pressure relief device should be applied to determine the size of the specific
pressure relief device.
(iv)
Pressure relief device installation: installation of the pressure relief valve should be
at the correct location, used the correct size of inlet and outlet piping, and with
valves and drainage.
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DEFINITION
Accumulation- A pressure increase over the set pressure of a pressure relief valve,
expressed as a percentage of the set pressure.
Back Pressure - Is the pressure on the discharge side of a pressure relief valve. Total
back pressure is the sum of superimposed and built-up back pressures.
Balanced Pressure Relief Valve- Is a spring loaded pressure relief valve that incorporates
a bellows or other means for minimizing the effect of back pressure on the operational
characteristics of the valve.
Built-Up Back Pressure- Is the increase pressure at the outlet of a pressure relief device
that develops as a result of flow after the pressure relief device opens.
Burst Pressure Inlet static pressure at which a rupture disc device functions.
Chatter, simmer or flutter - Abnormal, rapid reciprocating motion of the movable parts of
a pressure relief valve in which the disc makes rapid contacts with the seat. This results in
audible and/or visible escape of compressible fluid between the seat and the disc at an inlet
static pressure around the set pressure and at no measurable capacity, damaging the valve
rapidly.
Conventional Pressure Relief Valve- Is a spring loaded pressure relief valve which
directly affected by changes in back pressure.
Maximum Allowable Working Pressure (MAWP) - Is the maximum (gauge) pressure
permissible at the top of a vessel in its normal operating position at the designated
coincident temperature and liquid level specified for that pressure.
Disc Movable element in the pressure relief valve which effects closure.
Effective Discharge Area A nominal area or computed area of flow through a pressure
relief valve, differing from the actual discharge area, for use in recognized flow formulas
with coefficient factors to determine the capacity of a pressure relief valve.
Nozzle A pressure containing element which constitutes the inlet flow passage and
includes the fixed portion of the seat closure.
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Operating Pressure- The operating pressure is the gauge pressure to which the
equipment is normally subjected in service.
Overpressure- Overpressure is the pressure increase over the set pressure of the
relieving device during discharge, expressed as a percentage of set pressure.
Pilot Operated Pressure Relief Valve- Is a pressure relief valve in which the major
relieving device or main valve is combined with and controlled b a self actuated auxiliary
pressure relief valve (called pilot). This type of valve does not utilize an external source of
energy and is balanced if the auxiliary pressure relief valve is vented to the atmosphere.
Pop action - An opening and closing characteristic of an safety relief valve in which the
valve immediately snaps open into high lift and closes with equal abruptness.
Pressure Relief Valve This is a generic term applying to relief valves, safety valves or
safety relief valves. Is designed to relief the excess pressure and to recluse and prevent the
further flow of fluid after normal conditions have been restored.
Relief Valve - Is a spring loaded pressure relief valve actuated by the static pressure
upstream of the valve. Opening of the valve is proportion to the pressure increase over the
opening pressure. Relief valve is used for incompressible fluids / liquid services.
Rupture Disk Device Is a non-reclosing pressure relief device actuated by static
differential pressure between the inlet and outlet of the device and designed to function by
the bursting of a rupture disk.
Rupture Disk Holder- The structure used to enclose and clamps the rupture disc in
position.
Relieving Pressure- The
overpressure/accumulation.
pressure
obtains
by
adding
the
set
pressure
plus
Safety Valve- Pressure relief valve with spring loaded and actuated by the static pressure
upstream of the valve and characterized by rapid opening or pop action. A safety valve is
normally used for compressible fluids /gas services.
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Safety Relief Valve- Is a spring loaded pressure relief valve. Can be used either as a
safety or relief valve depending of application.
Set Pressure- Is the inlet pressure at which the pressure relief valve is adjusted to open
under service conditions.
Superimposed Back Pressure- The static pressure from discharge system of other
sources which exist at the outlet of a pressure relief device at the time the device is
required to operate.
Variable Back Pressure A superimposed back pressure which vary with time.
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NOMENCLATURE
A
AD
AN
Awet
B
c
C1
E
F
F2
Fs
G
k
K
Kb
Kc
Kd
KN
Kp
KSH
Kw
Kv
MW
Q
q
P
P1
P2
Pb
Pcf
PV
r
R
T1
Effective discharge area relief valve, in2

Disk area
Nozzle seat area
Total wetted surface of the equipment, ft2
Effective liquid level angle, degrees
Specific heat, kJ/kgK
Critical flow coefficient, dimensionless
Effective liquid level, ft
Environmental factor
Coefficient of subcritical flow, dimensionless
Spring force
Specific gravity of the liquid at the flowing temperature referred to
water at standard conditions, dimensionless
Ratio of the specific heats
Effective height liquid level
Capacity correction factor due to back pressure, dimensionless
Combination correction factor for installations with a rupture disk upstream of the
pressure relief valve, dimensionless
Effective coefficient of discharge, dimensionless
Correction factor for Napier equation, dimensionless
Correction factor due to overpressure, dimensionless
Superheat steam correction factor, dimensionless
Correction factor due to back pressure, dimensionless
Correction factor due to viscosity, dimensionless
Molecular weight for gas or vapor at inlet relieving conditions.
Flow rate, US.gpm
Heat input to vessel due to external fire, BTU/hr
Set pressure, psig
Upstream relieving pressure, psia
Total back pressure, psia
Total back pressure, psig
Critical flow Pressure, psia
Vessel gauge pressure, psig
Ratio of back pressure to upstream relieving pressure, P2/P1
Reynolds number, dimensionless
Relieving temperature of the inlet gas or vapor, R (oF+460)
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Vo
W
xo
Z
Specific volume of the two-phase system inlet (ft3/lb)

Flow through the device, Ib/hr
Vapor mass fraction (quality) inlet.
Compressibility factor for gas, dimensionless
Greek letters
L
V
Absolute viscosity at the flowing temperature, centipoise

Heat absorbed per unit mass of vapor generated at relieving conditions, BTU/lb (as
latent heat)
Liquid density at relief conditions, lb/ft3
Vapor density at relief conditions, lb/ft3
Total heat input to system, Btu/h
Cubic expansion coefficient of liquid, dimensionless
Isothermal compressibility coefficient of liquid, dimensionless
Critical flow ratio
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THEORY
Selection of Pressure Relief Valve
To select a suitable pressure relief valve for a particular application it was not an easy task
especially with the wide variety of pressure relief valve in the market, it requires
considerable evaluation such the contingency, advantages and disadvantages each
pressure relief device, operation and characteristic pressure requirements.
Pressure Relief Devices
This section gives detail of the pressure relief devices commonly used to relieving liquids
and gases with various causes.
I.
Reclosing Pressure Relief Devices
(A) Conventional Pressure Relief Valve

Types of pressure relief valves majority used in refinery and chemical processing plant are
the spring loaded, top-guided, high lift, nozzle type pressure relief valve, which classified as
conventional relief valve. (Refer Figure 1.)
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Bonnet Vented to Atmosphere

Vented Bonnet
Spring Fs
Cap, Screwed
Compression Screw
Disk
P2
P2
Bonnet
AD>AN
Spring
PV
Stem
PV AN = Fs P2 (AD-AN)
Back Pressure Decreases Set Pressure
Guide
Non-Vented Bonnet
Body
Spring Bonnet
Spring Fs
Disc Holder
Disc
P2
Disk
P2
Nozzle
PV
PV AN = Fs + P2 AN
Back Pressure Increases Set Pressure
Valve Cross Section
Effect of Back Pressure on Set Pressure
Figure 1: Conventional Safety-Relief Valve

Basic elements of spring-loaded pressure relief valve included an inlet nozzle connected to
the vessel to be protected, movable disc which controls flow through the nozzle, and a
spring which control the position of disc.
Working principal of the conventional relief valve is the inlet pressure to the valve is directly
opposed by a spring force. Spring tension is set to keep the valve shut at normal operating
pressure. At the set pressure the forces on the disc are balanced and the disc starts to lift
and it full lifted when the vessel pressure continues rise above set pressure.
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In spring operated pressure relief valves, leakage between the valve seat and disc or called
simmer typically occurs at about 95% of set pressure. However, depending upon valve
maintenance, seating type, and condition, simmer free operation may be possible at up to
98% of set pressure. Simmer is normally occurs for gas or vapor service pressure relief
valve before it will pop.
The conventional relief valve used in refinery industrial normally is designed with the disc
area is greater that nozzle area. Back pressure has the difference effect on such valve,
based on the difference design for the bonnet at valve. The effect of back pressure on
spring-loaded pressure relief valve is illustrated in Figure 1.
Conventional type relief valves can be used when the back pressure is relatively constant
or the maximum relieving back pressure is not greater than 10% of the set pressure, since
changes in back pressure seriously affect the valve performance of this type.
Advantage of this valve compare to rupture disc is the disc of the valve will resets when the
vessel pressure reduce to pressure lower than set pressure, not replacement of disc is
required.
Thermal Relief Valve
When a liquid filled system is blocked in and heated, the resulting expansion can cause
very high pressures. The heat source of thermal expansion can be a heater, heat
exchanger, or heat tracing, or it can be solar or other radiant heat or external fire. Examples
of such occurrences are:
Piping or vessels are blocked-in while there are filled with a cold liquid and are
subsequently heated by heat tracing and coils.
A heat exchanger is blocked-in on the cold side with flow in the hot side.
Piping or vessels are blocked-in while there are filled with a cold liquid at lower than
ambient temperature and are heated by direct solar radiation.
If the blocked in liquid has a potential to vaporize because of its high vapor pressure, the
pressure relief valve should be capable of handling generated vapor.
This will result in tremendous internal hydraulic forces inside the pipe or pressure vessel,
as the liquid is non-compressible and needs to be evacuated. This section of pipe then
needs thermal relief.
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Thermal relief valves are small, usually liquid relief valves designed for very small flows on
incompressible fluids. There are included self-actuated spring-loaded pressure relief valve,
which classified as conventional relief valve. They open in some proportion of the
overpressure. Thermal expansion during the process only produces very small flows, and
the array of orifices in thermal relief valves is usually under the API-lettered orifices, with a
maximum orifice D or E. It is, however, recommended to use a standard thermal relief
orifice (e.g. 0.049 in2 )[9]. The valve shown in Figure 2 is available in small sizes commonly
used for thermal relief valve applications.
Cap
Stem (spindle)
Adjusting screw
Bonnet
Spring
Disk
Seating surface
Base (body)
Figure 2 : Conventional pressure relief valve with threaded connections
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Thermal relief valves should be installed if a section of the process can be blocked in
during maintenance or shutdown. The installation of thermal relief valves is recommended
when the blocked-in section contains toxic or environmentally hazardous materials.
On the other hand, no metal seated block valve can provide 100% bubble-tight closure.
Therefore, if the blocked-in pipe section is of small diameter and less than 100 ft in length,
the required thermal expansion relieving capacity is less than the leakage of the block
valve, so a thermal relief valve may not be required. Thermal relief valves are not required
for process plant piping, storage or transport piping sections which are not normally shut in
for operational or emergency purposes lines in which there is normally a two-phase flow.
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(B) Balanced Relief Valves
Cap, Screwed
Compression Screw
Vented Bellows
Spring
Spring Fs
Bellows Type
Vented Bonnet
Vent
Bonnet
P2
Disc
Spring
AP = AN
Stem
PV
Guide
Balanced Disk and

Vented Piston Type
Bellows
Disc Holder
Disc
P2
Piston
Spring Fs
Body
P2
Disk
Vented
Bonnet
Nozzle
P2
P2
P2
AB = AN
P1
Set Pressure, P = PV =
Fs
Spring Force
=
A N Nozzle Seat Area
Bellows Valve Cross Section
PV AN = Fs
Effect of Back Pressure on Set Pressure
Figure 3: Balanced Pressure Relief Valve
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Balanced pressure relief valve is a spring-loaded pressure relief valve which is consisted of
bellows or piston to balance the valve disc to minimize the back pressure effect on the
performance of relief valve.
Balanced pressure relief valve is used when the built-up pressure (back pressure caused
by flow through the downstream piping after the relief valve lifts) is too high for conventional
pressure relief or when the back pressure varies from time to time. It can typically be
applied when the total back pressure (superimposed + build-up) does not exceed <50% of
the set pressure.
Typical balanced pressure relief valve is showed in Figure 3. Based on API RP 520(2000)
the unit of the balanced pressure relief valve to overcome the back pressure effect is
explained as when a superimposed back pressure is applied to the outlet of valve, a
pressure force is applied to the valve disc which is additive to the spring force. This added
force increases the pressure at which an unbalanced pressure relief valve will open. If the
superimposed back pressure is variable then the pressure at which the valve will open will
vary (Figure 1).
In a balanced-bellows pressure relief valve, a bellows is attached to the disc holder with a
pressure area, AB, approximately equal to the seating area of the disc, AN. This isolates an
area on the disc, approximately equal to the disc seat area, from the back pressure. With
the addition of a bellows, therefore, the set pressure of the pressure relief valve will remain
constant in spite of variations in back pressure. Note that the internal area of the bellows in
a balanced-bellows spring loaded pressure relief valve is referenced to atmospheric
pressure in the valve bonnet. (1) The interior of the bellows must be vented through the
bonnet chamber to the atmosphere. A 3/8 to 3/4 in. diameter vent hole is provided in the
bonnet for this purpose. Thus, any bellows failure or leakage will permit process fluid from
the discharge side of the valve to be released through the vent.
(C) Pilot Operated Relief Valves
A pilot operated relief valve consists of two principal parts, a main valve (normally encloses
a floating unbalanced piston assembly) and a pilot (Figure 4). Piston is designed with a
larger area on the top compare to the bottom. During the operation, when the pressure is
higher than the set pressure, the top and bottom areas are exposed to the same inlet
operating pressure. The net force from the top holds the piston tightly against the main
valve nozzle. When the inlet pressure increases, the net seating force increased and tends
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to make the valve tighter. At the set pressure, the pilot vents the pressure from the top of
the piston; the resulting net force is now upward causing the piston to lift, and process flow
is established through the main valve. After the over pressure, re-establishing pressure
condition can be achieve when the pilot has closed the vent from the top of the piston, and
net force will cause the piston to reseat.
The advantages of pilot-operated pressure relief valves are
(a)
capable of operation at close to the set point and remains closed without simmer
until the inlet pressure reaches above 98% of the set pressure;
(b)
once the set pressure is reached, the valve opens fully if a pop action pilot is
used;
(c)
a pilot-operated pressure relief valve is fully balanced, when it exhausts to the

atmosphere;
(d)
pilot-operated pressure relief valves may be satisfactorily used in vapor or liquid

services up to a maximum back pressure (superimposed plus built-up) of 90% of
set pressure, provided that the back pressure is incorporated into the sizing
calculation;
(e)
A pilot operated valve is sufficiently positive in action to be used as a

depressuring device. By using a hand valve, a control valve or a solenoid valve
to exhaust the piston chamber, the pilot-operated PR valve can be made to open
and close at pressures below its set point from any remote location, without
affecting its operation as a pressure relief valve.
(f)
Pilot-operated pressure relief valves can be specified for blowdown as low as

2%.
(g)
It applications involving unusually high superimposed back pressure.
The disadvantages of pilot-operated pressure relief valves are
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(a) Not recommended for dirty or fouling services, because of plugging of the pilot valve
and small-bore pressure-sensing lines. If the pilot valve or pilot connections become
fouled, the valve will not open.
(b) A piston seal with the O ring type is limited to a maximum inlet temperature of
450oF and the newer designs are available for a maximum inlet temperature of
about 1000oF in a limited number of valve sizes and for a limited range of set
pressures.
(c) Vapor condensation and liquid accumulation above the piston may cause the valve
to malfunction.
(d) Back pressure, if it exceeds the process pressure under any circumstance (such as
during start-up or shutdown), would result in the main valve opening (due to exerting
pressure on the underside of the piston that protrudes beyond the seat) and flow of
material from the discharge backwards through the valve and into the process
vessel. To prevent this backflow preventer must be installed in the pilot operated
pressure relief valve.
(e) For smaller sizes pilot operated pressure relief valve, it is more costly than springloaded pressure relief valve.
Pilot-operated relief valves are commonly used in clean, low-pressure services and in
services where a large relieving area at high set pressures is required. The set pressure of
this type of valve can be close to the operating pressure. Pilot operated valves are
frequently chosen when operating pressures are within 5 percent of set pressures and a
close tolerance valve is required.
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Set pressure
adjustment screw
Spindle
Seat
Pilot Valve
External blow down

adjustment
Pilot supply line
Pilot exhaust
Outlet
Piston
Optional pilot
filter
Seat
Internal pressure
pickup
Main valve
Inlet
Figure 4: Pilot Operated Relief Valve
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II.
Non Reclosing Pressure Relief Devices
(A) Rupture Disk

Rupture disk structure consists of a thin diaphragm held between flanges. It is a device
designed to function by the bursting of a pressure-retaining disk (Figure 5). This assembly
consists of a thin, circular membrane usually made of metal, plastic, or graphite that is
firmly clamped in a disk holder. When the process reaches the bursting pressure of the
disk, the disk ruptures and releases the pressure.
Rupture disks can be installed alone or in combination with other types of devices. Once
blown, rupture disks do not reseat; thus, the entire contents of the upstream process
equipment will be vented. Rupture disks are commonly used in series (upstream) with a
relief valve to prevent corrosive fluids from contacting the metal parts of the valve. In
addition, this combination is a re-closing system. The burst pressure tolerance at the
specified disk temperature shall not exceed 2 psi for stamped burst pressure up to and
including 40 psi and 5% for stamped burst pressure above 40 psi[6].
Rupture disks can be used in any application, it can use single, multiple and combination
used with other pressure relief valve (either installed at the inlet / outlet of a pressure relief
valve). Rupture disk is installed at inlet of pressure relief valve when to provide corrosion
protection for the pressure relief valve and to reduce the valve maintenance. When it
installed at outlet of a pressure relief valve, it is functioning to protect the valve from
atmospheric or downstream fluids. When used in highly corrosive fluid, two rupture disks
are requiring installing together. It can use for process with high viscosity fluid, including
nonabrasive slurries. The advantages and disadvantages of rupture disks show in following
table.
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Table 2 : Advantages and disadvantages of rupture disks[9]

Advantages
Disadvantages
Instaneous full opening
Non-reclosing (vent until inlet and outlet
pressures equalize)
Zero leakage
Requires high margin between operating
and opening pressures
Very large sizes easily and relatively Can fail by fatigue due to pulsations of
economically available
pressure
Wide range of materials easily available
Burst
pressure
highly
sensitive
to
temperature
Economical when exotic materials are No possibility to check the burst pressure in
imposed for the process
the field
Virtually no maintenance
Requires depressurizing equipment for
replacement after bursting
Full pipe bore (almost)
Tolerance usually 5%
Low pressure drop
Low cost
There have 3 types rupture disk in market which are forward-acting (tension loaded),
reverse-acting (compression loaded), and graphite (shear loaded). Refer to Table 3 for the
selection of the rupture disks and applications.
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Table 3: Rupture Disk Selection and Applications

Type of Rupture Disk
Forward-Acting
(a) Forward-Acting Solid
Metal
(a)
Operating pressure up to 70% of the marked burst

pressure of the disk; not suitable for installation
upstream of a pressure relief valve
(b)
Operating pressure up to 85%-90% of the marked

burst pressure of the disk; withstand vacuum
conditions without a vacuum support; acceptable
for installation upstream of a pressure relief valve
(c)
Designed to burst at a rated pressure applied to

the concave side; some designs are nonfragmenting and acceptable for use upstream of a
pressure relief valve
(a)
Designed to open by some methods such as

shear, knife blades, knife rings, or scored lines.
(b)
Suitable for installation upstream of pressure relief

valves.
(c)
Provided satisfactory service life with operating

pressure 90% or less of marked burst pressure.
(a)
Provided satisfactory service life for operating

pressure up to 80% of the marked burst pressure
and can used for both liquid and vapor service, but
not suitable fro installation upstream of a pressure
relief valve.
(b)
Used for vacuum or back pressure conditions with

furnished with a support to prevent reverse flexing.
(b) Forward-Acting Scored
(c) Forward-Acting Composite
Reverse-Acting
(Formed solid metal disk
designed to reverse and burst
at a rated pressure applied on
the convex side.)
Graphite Rupture Disks
Applications
(Machined from a bar of fine

graphite
that
has
been
impregnated with a binding
compound.)
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Page 31 of 94
Chapter Ten
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Before:
After:
Outlet
Standard studs
and nuts
Standard Flange
Rupture
Disk
Insert-Type Rupture
Disk Holder
Pre-assembly side
clips or pre-assembly
screws
2 special flanges
Standard Flange
Inlet
Figure 5: Forward-Acting Solid Metal Rupture Disk Assembly

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Page : 1 of 94

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KLM Technology Group

Process Equipment Design Guidelines

Important of Pressure Relief System

(I) Blocked Discharge

(II) Fire Exposure

(III) Check Valve Failure

(V) Utility Failure

(B) Application of Codes and Standard

(C) Determination of individual relieving rates

( ENGINEERING DESIGN GUIDELINE)

Selection of Pressure Relief Valve

Pressure Relief Devices

I. Reclosing Pressure Relief Devices

(A) Conventional Pressure Relief Valve

(B) Balanced Relief Valves

(C) Pilot Operated Relief Valves

II. Non Reclosing Pressure Relief Devices

(A) Rupture Disk

Procedure for Design

(A) Set Pressure

(B) Maximum Allowable Accumulation

(C) Back Pressure

(D) General Operation and Characteristics Relief Valves

Standard Relief Valve Designation

Procedure for Sizing

( ENGINEERING DESIGN GUIDELINE)

(B) Sizing for Gas or Vapor Relief for Subcritical Flow

(C) Sizing for Steam Relief

(D) Sizing for Liquid Relief: Requiring Capacity Certification

(E) Sizing for Liquid Relief: Not Requiring Capacity Certification

(F) Sizing for Two-phase Liquid/Vapor Relief

(G) Sizing for Rupture Disk Devices

(H) Sizing Thermal Relief Valves Expansion Thermal

(I) Sizing for External Fire Condition

Pressure Relief Valve Sizing Installation

(A) Pressure Relief Valve Location

(B) Selection of Discharge for Pressure Relief Valves

Example 2: Sizing of Relief Valve of Vapor/Gas- Subcritical Flow

Example 3: Sizing of Relief Valve - Steam Service

Example 4: Sizing of Relief Valve - Liquid Requiring Capacity Certification

Example 5: Sizing of Relief Valve - Liquid Not Requiring Capacity Certification

Example 6: Sizing of Thermal Relief Valve-Thermal Expansion - Water

( ENGINEERING DESIGN GUIDELINE)

Example 8: Sizing of Relief Valve - External Fire Condition

Table 2: Advantages and disadvantages of rupture disks

Table 3: Rupture Disk Selection and Applications

Table 4: Comparison Set Pressure in ASME Section I and VIII

Table 5: Minimum recommended pressure differentials

Table 6: Maximum allowable accumulation

Table 7: API Standard Nozzle Orifice Designation

Table 8: Typical Saturated Steam Capacity of Orifice Designation for

Table 9: Capacity Correction Factor (Kw)-Back Pressure Effect on

Table 10: Value cubic expansion coefficient for hydrocarbon liquid

Table 11: Value cubic expansion coefficient for water