Series 3500

Pilot Operated Relief Valves

Superior Pressure Relief Products

Hydroseal Series 3500 Pilot Operated Relief Valve

The Hydroseal Series 3500 is a high performance pilot operated
safety relief valve that is offered in both Modulating and Snap
action. Useful for air, gas, mixed phase and liquid services, these
valves are designed for reliable operation, long seat life and
easy low cost field service. The Series 3500 product line is
offered in a wide range of orifices, materials, pressures and
temperature ranges.

General Design Features

Proven Soft Seat Design:
Hydroseal's unique captured
o-ring design used across
many of our other product
lines allows many different
Elastomers to be offered at
the lowest cost possible. Using
standard size o-rings also allows
for easy replacement.
Seat Tightness: The difference in area
of the dome side and the seat side of
the piston keeps the main valve bubble
tight right up to the set pressure. Pilot
valves are an excellent choice for
applications with operating pressures
very close to set pressure.
Snap Action: The snap action control pilot fully opens the
main valve at set pressure achieving full capacity until
the reseat point is reached and the main valve closes.
The snap pilot has an adjustable blowdown and is built
for minimal maintenance and easy repair. Standard for
air and gas only.
Modulating Action: Ideal for applications where a minimal
amount of product loss is critical. The modulating control
pilot gradually opens and closes the main valve to relieve
only the excess pressure in a system. It will fully open
the main valve before 10% overpressure is reached.
Standard for liquid and optional for air and gas.
Easy Repair: All seals are o-rings that are easily replaced
and are offered in a wide array of materials such as
Fluorocarbon, Nitrile and PTFE. The main valve's bolted
construction allows for easy disassembly.
Orifice Areas: All orifice sizes meet or exceed competitors
dimensions for easy interchangeable replacement.
API Dimensions: Main valve centerline to face dimensions
meet API 526.

Accessories
Field Test Connection: Allows for in service testing of the
valve by charging the pilot through a test port reducing
maintenance and system down time.
Back-Flow Preventer: Prevents backpressure on the
main valve outlet from opening the main valve by allowing
the outlet pressure to charge the dome when the back
pressure exceeds the inlet pressure.
Pressure Snubber: Filters out pressure spikes in the inlet
pressure that can cause the main valve to pop early.
Filter: Recommended for extra dirty
service that could cause blockages or
wear to the control pilot valve.
Lift Lever: Another option for in service
testing. By lifting a handle, the control
pilot is opened thereby opening the
main valve until the handle is released.
Remote Sensing:Allows the set pressure
signal to come from somewhere other
than the inlet of the main valve. By
leaving the sense line off the pilot valve
and plugging the pitot, the end user
can plumb the supply pressure from a
different location.

Size & Range

Inlet x
Outlet
1x2
11/2
x2
11/2
x3
2x3

3x4

4x6

6x8
8 x 10

Hydroseal Series 3500 Pilot Operated Relief Valve

D
E
F
D
E
F
G
H
G
H
J
J
K
L
L
M
N
P
Q
R

Nozzle Diameter
in.
cm
0.437 1.11
0.560 1.42
0.688 1.75
0.437 1.11
0.560 1.42
0.688 1.75
0.871 2.21
1.125 2.86
0.871 2.21
1.125 2.86
1.382 3.51
1.382 3.51
1.653 4.20
2.063 5.24
2.063 5.24
2.314 5.88
2.537 6.44
3.125 7.94
4.060 10.31
4.882 12.40

6.257

Orifice

15.89

Nozzle Area
in. 2
cm 2
0.150 0.97
0.246 1.59
0.372 2.40
0.150 0.97
0.246 1.59
0.372 2.40
0.596 3.84
0.994 6.41
0.596 3.84
0.994 6.41
1.500 9.68
1.500 9.68
2.146 13.85
3.343 21.57
3.343 21.57
4.206 27.14
5.054 32.61
7.670 49.48
12.946 83.52
18.719 120.77

Lift

0.350 in.
8.89 cm

0.572 in.
14.53 cm

Max.
Pressure

6170
psi(g)
425.5
bar(g)

0.703 in.
17.86cm
1.049 in.
26.64 cm
1.590 in.
40.39cm

2.484 in.
63.09 cm
3.183 in.
30.748 198.38 80.85 cm

3705
psi(g)
255.5
bar(g)
1480 psi(g)
102.1bar(g)
900 psi(g)
62.1 bar(g)

Hydroseal Series 3500 Operation, Snap & Modulating Action

Closed Position

Modulating Closed Position

Dome Pressure Equal

To Inlet Pressure

Dome Pressure Equal

To Inlet Pressure

Pilot

Pilot

Vent

Main Valve

Main Valve

Inlet Pressure Less Than Set Pressure

Inlet Pressure Less Than Set Pressure

Relieving Position

Modulating Relieving Position

Dome Pressure Less
Than Inlet Pressure

Dome Pressure
Venting To ATM

Vent
To
ATM

Flow
To
ATM

Flow
To
ATM

Pilot

Pilot

Vent

Main Valve

Main Valve
Inlet Pressure Greater Than Set Pressure

Inlet Pressure Greater Than Set Pressure

Snap Action Pilot

Modulating Action Pilot

Below Set Pressure: The pilot allows the inlet pressure to

pass through and charge the dome of the main valve keeping
the main valve seat tightly closed.
Above Set Pressure: The pilot upper seat lifts fully venting
the dome pressure to atmosphere allowing the main valve
piston to rise opening the main valve. Simultaneously, the
pilot lower seat closes keeping the inlet pressure from the main
valve from re-charging the dome. When the inlet pressure
drops to the reseat point, the pilot lower seat opens and the
pilot upper seat closes, recharging the dome and closing the
main valve.

Below Set Pressure: The pilot allows the inlet pressure to

pass through and charge the dome of the main valve keeping
the main valve seat tightly closed.
Above Set Pressure: The modulating pilot allows the dome
pressure to be vented gradually in proportion with the
increase in inlet pressure. As the inlet pressure increases from
100% to 110% of set pressure, the main valve goes from
closed to full open. As the system pressure drops below the
set pressure, the modulating pilot gradually recharges the
dome of the main valve in proportion with the drop in system
pressure, closing the main valve.

Hydroseal Series 3500 Pilot Operated Relief Valve

Hydroseal Series 3500, Weights & Dimension Data

Orifice

D
API Area .110 in. 2 / .71 cm 2
Actual Area .150 in. 2 / .97 cm 2

E
API Area .196 in. 2 / 1.27 cm 2
Actual Area .249 in. 2 / 1.59 cm 2

F
API Area .370 in. 2 / 1.98 cm 2
Actual Area .372 in. 2 / 2.40 cm 2

G
API Area .503 in. 2 / 3.25 cm 2
Actual Area .596 in. 2 / 3.84 cm 2

H
API Area .785 in. 2 / 5.06 cm 2
Actual Area .994 in. 2 / 6.41 cm 2

Inlet x Outlet

Class

Max. Set

1x2
1x2
1x2
1x2
1x2
1 1/2 x 2
1 1/2 x 2
1 1/2 x 2
1 1/2 x 2
1 1/2 x 2
1x2
1x2
1x2
1x2
1x2
1 1/2 x 2
1 1/2 x 2
1 1/2 x 2
1 1/2 x 2
1 1/2 x 2
1x2
1x2
1x2
1x2
1x2
1 1/2 x 2
1 1/2 x 2
1 1/2 x 2
1 1/2 x 2
1 1/2 x 2
1 1/2 x 3
1 1/2 x 3
1 1/2 x 3
1 1/2 x 3
1 1/2 x 3
2x3
2x3
2x3
2x3
2x3
1 1/2 x 3
1 1/2 x 3
1 1/2 x 3
1 1/2 x 3
1 1/2 x 3
2x3
2x3
2x3
2x3
2x3

150 x 150
300 x 150
600 x 150
900/1500 x 300
2500 x 300
150 x 150
300 x 150
600 x 150
900/1500 x 300
2500 x 300
150 x 150
300 x 150
600 x 150
900/1500 x 300
2500 x 300
150 x 150
300 x 150
600 x 150
900/1500 x 300
2500 x 300
150 x 150
300 x 150
600 x 150
900/1500 x 300
2500 x 300
150 x 150
300 x 150
600 x 150
900/1500 x 300
2500 x 300
150 x 150
300 x 150
600 x 150
900/1500 x 300
2500 x 300
150 x 150
300 x 150
600 x 150
900/1500 x 300
2500 x 300
150 x 150
300 x 150
600 x 150
900/1500 x 300
2500 x 300
150 x 150
300 x 150
600 x 150
900/1500 x 300
2500 x 300

285
740
1480
3705
6170
285
740
1480
3705
6170
285
740
1480
3705
6170
285
740
1480
3705
6170
285
740
1480
3705
6170
285
740
1480
3705
6170
285
740
1480
3705
6170
285
740
1480
3705
6170
285
740
1480
3705
6170
285
740
1480
3705
6170

Hydroseal Series 3500 Pilot Operated Relief Valve

A
4.12
4.37
4.37
4.93
4.93
4.87
4.87
4.87
5.87
5.87
4.12
4.37
4.37
4.93
4.93
4.87
4.87
4.87
5.87
5.87
4.12
4.37
4.37
4.93
4.93
4.87
4.87
4.87
5.87
5.87
5.12
5.12
5.12
6.37
6.37
5.37
5.37
5.37
6.56
7.00
5.12
5.12
5.12
6.37
6.37
5.37
5.37
5.37
6.56
7.00

Dimensions (in.)
B
4.50
4.50
4.50
4.75
4.75
4.75
4.75
4.75
5.50
5.50
4.50
4.50
4.50
4.75
4.75
4.75
4.75
4.75
5.50
5.50
4.50
4.50
4.50
4.75
4.75
4.75
4.75
4.75
5.50
5.50
4.87
4.87
4.87
6.75
6.75
4.87
4.87
4.87
6.75
6.75
4.87
4.87
4.87
6.75
6.75
4.87
4.87
4.87
6.75
6.75

C
14.50
14.62
14.62
15.25
15.25
15.00
15.00
15.00
16.25
16.25
14.50
14.62
14.62
15.25
15.25
15.00
15.00
15.00
16.25
16.25
14.50
14.62
14.62
15.25
15.25
15.00
15.00
15.00
16.25
16.25
16.12
16.12
16.12
18.62
18.62
16.87
16.87
16.87
18.87
19.25
16.12
16.12
16.12
18.62
18.62
16.87
16.87
16.87
18.87
19.25

Weight (approx.)
lbs.
kg
24
10.9
26
11.8
26
11.8
32
14.5
35
15.9
26
11.8
30
13.6
30
13.6
40
18.2
50
22.7
24
10.9
26
11.8
26
11.8
32
14.5
35
15.9
26
11.8
30
13.6
30
13.6
40
18.2
50
22.7
24
10.9
26
11.8
26
11.8
32
14.5
35
15.9
26
11.8
30
13.6
30
13.6
40
18.2
50
22.7
58
26.4
61
27.7
61
27.7
95
43.2
104
47.3
59
26.8
62
28.2
62
28.2
103
46.8
115
52.3
58
26.4
61
27.7
61
27.7
95
43.2
104
47.3
59
26.8
62
28.2
62
28.2
103
46.8
115
52.3

Hydroseal Series 3500, Weights & Dimension Data

Orifice

J
API Area 1.287 in. 2 / 8.30 cm 2
Actual Area 1.500 in. 2 / 9.68 cm 2

K
API Area 1.838 in. 2 / 11.86 cm 2
Actual Area 2.146 in. 2 / 13.85 cm 2

L
API Area 2.853 in. 2 / 18.41 cm 2
Actual Area 3.343 in. 2 / 21.57 cm 2

M
API Area 3.600 in. 2 / 23.23 cm 2
Actual Area 4.206 in. 2 / 27.41 cm 2

N
API Area 4.340 in. 2 / 28.00 cm 2
Actual Area 5.054 in. 2 / 32.61 cm 2

P
API Area 6.380 in. 2 / 41.16 cm 2
Actual Area 7.670 in. 2 / 49.48 cm 2

Q
API Area 11.050 in. 2 / 71.29 cm 2
Actual Area 12.946 in. 2 / 83.52 cm 2

R
API Area 16.000 in. 2 / 103.23 cm 2
Actual Area 18.719 in. 2 / 120.77 cm 2

T
API Area 26.000 in. 2 / 167.74 cm 2
Actual Area 30.748 in. 2 / 198.38 cm 2

Inlet x Outlet

Class

Max. Set

2x3
2x3
2x3
2x3
2x3
3x4
3x4
3x4
3x4
3x4
3x4
3x4
3x4
3x4
3x4
3x4
3x4
3x4
3x4
3x4
4x6
4x6
4x6
4x6
4x6
4x6
4x6
4x6
4x6
4x6
4x6
4x6
4x6
4x6
4x6
4x6
4x6
4x6
4x6
4x6
4x6
6x8
6x8
6x8
6x8
6x8
6x8
8 x 10
8 x 10
8 x 10

150 x 150
300 x 150
600 x 150
900/1500 x 300
2500 x 300
150 x 150
300 x 150
600 x 150
900 x 300
1500 x 300
150 x 150
300 x 150
600 x 150
900 x 300
1500 x 300
150 x 150
300 x 150
600 x 150
900 x 300
1500 x 300
150 x 150
300 x 150
600 x 150
900 x 300
1500 x 300
150 x 150
300 x 150
600 x 150
900 x 300
1500 x 300
150 x 150
300 x 150
600 x 150
900 x 300
1500 x 300
150 x 150
300 x 150
600 x 150
600 x 300
900 x 300
1500 x 300
150 x 150
300 x 150
600 x 150
150 x 150
300 x 150
600 x 150
150 x 150
300 x 150
600 x 150

285
740
1480
3705
6170
285
740
1480
2220
3705
285
740
1480
2220
3705
285
740
1480
2220
3705
285
740
1480
2220
3705
285
740
1480
2220
3705
285
740
1480
2220
3705
285
740
1480
1480
2220
3705
285
740
1480
285
740
1480
285
740
900

A
5.37
5.37
5.37
6.56
7.00
6.12
6.12
6.37
7.50
7.50
6.12
6.12
6.37
7.50
7.50
6.12
6.12
6.37
7.50
7.50
7.75
7.75
7.75
9.81
9.81
7.75
7.75
7.75
9.81
9.81
7.75
7.75
7.75
9.81
9.81
7.75
7.75
7.75
9.81
9.81
9.81
9.43
9.43
9.68
9.43
9.43
9.68
10.87
10.87
11.68

Dimensions (in.)
B
4.87
4.87
4.87
6.75
6.75
6.37
6.37
6.37
7.12
7.12
6.37
6.37
6.37
7.12
7.12
6.37
6.37
6.37
7.12
7.12
8.25
8.25
8.25
9.18
9.18
8.25
8.25
8.25
9.18
9.18
8.25
8.25
8.25
9.18
9.18
8.25
8.25
8.25
9.18
9.18
9.18
9.50
9.50
9.50
9.50
9.50
9.50
11.00
11.00
11.00

C
16.87
16.87
16.87
18.87
19.25
18.12
18.12
18.12
20.00
20.00
18.12
18.12
18.12
20.00
20.00
18.12
18.12
18.12
20.00
20.00
21.37
21.37
21.37
24.00
24.00
21.37
21.37
21.37
24.00
24.00
21.37
21.37
21.37
24.00
24.00
21.37
21.37
21.37
24.00
24.00
24.00
25.62
25.62
25.87
25.62
25.62
25.87
27.37
27.37
28.12

Weight (approx.)
lbs.
kg
59
26.8
62
28.2
62
28.2
103
46.8
115
52.3
100
45.5
106
48.2
106
48.2
141
64.1
153
69.5
100
45.5
106
48.2
106
48.2
141
64.1
153
69.5
100
45.5
106
48.2
106
48.2
141
64.1
153
69.5
184
83.6
192
87.3
202
91.8
285
129.5
300
136.4
184
83.6
192
87.3
202
91.8
285
129.5
300
136.4
184
83.6
192
87.3
202
91.8
285
129.5
300
136.4
184
83.6
192
87.3
202
91.8
276
125.5
285
129.5
300
136.36
352
160.0
369
167.7
394
179.1
352
160.0
369
167.7
394
179.1
511
232.3
534
242.7
575
261.4

Hydroseal Series 3500 Pilot Operated Relief Valve

Hydroseal Series 3500, Parts List & Materials

1

5
6
7
8

Parts List & Materials, Series 3500 Relief Valve

Index

Description

1
2
3
4
5
6
7
8
9
10
11
12

Tube
Tube Fitting Straight
Tube Fitting 90
Bracket
Bonnet
Return Spring
Guide
Piston
Body
O-Ring Retainer
Nozzle
Pitot

0
SS
CS
CS
CS
SA36
316SS
17-4 PH
316SS
WCB
316SS
316SS
316SS

Material
2
3
SS
SS
CS
SS
CS
SS
CS
SS
SA36
316SS
X750
316SS
17-4 PH
316SS
316SS
316SS
WCB
CF8M
316SS
316SS
316SS
316SS
316SS
316SS

4
SS
SS
SS
SS
316SS
X750
316SS
316SS
CF8M
316SS
316SS
316SS

9
10
11
12

Parts List & Materials

Snap Action Pilot
Index
1
2
3
4
5
6
7
8
9
10
11

Description
Cap
Adjusting Screw
Pilot Bonnet
Top Adaptor
Spring
Lower Spring Plate
Disc
Pilot Disc Guide
Pilot Body
Pilot Seat Cap
Pilot Nozzle

12

Pilot Nozzle Seal

13
14

Blowdown Seat
Blowdown Shuttle
Blowdown
Adjustment Housing
Blowdown
Adjustment Nut

15
16

Material
316SS
316SS
316SS
316SS
316SS*
316SS
316SS
316SS
316SS
316SS
316SS
Gasket
Material
316SS
316SS

3
4
5

6
7
8
9
10
11
12
13

316SS
14

316SS

*Inconel X750 spring used for material codes 2 &4.

Hydroseal Series 3500 Pilot Operated Relief Valve

15
16

Parts List & Materials

Modulating Action Pilot
Index
Description
1
Cap
2
Adjusting Screw
3
Pilot Bonnet
4
Top Adaptor
5
Spring
6
Body
7
Large Clamp Ring
8
Upper Diaphragm
9
Input Module Body
10
Stop Pin
11
Input Spindle
12
Lower Diaphragm
13
Small Clamp Ring
14
Ball Holder
15
Ball
16 Control Module Body
17
Control Spindle
18

Control Spring

19

Spring Nut

Material
316SS
316SS
316SS
316SS
316SS *
316SS
316SS
Viton
316SS
316SS
316SS
Viton
316SS
316SS
316SS
316SS
316SS
Inconel
X750
316SS

*Inconel X750 spring used for material codes 2 &4.

3
4
5

6
7
8
9
10
11
12
13
14
15
16
17
18
19

Hydroseal Series 3500, Parts Number Codes & Engineering Data

S Snap (Air/Gas Only)

e
Typ
al
teri

C Neoprene
E EPDM

M
eat

t
Inle

Size
ice

Orif
let
Out

Size

ss
Cla
e
g
Flan acing
F
al
teri
a
M
s*
ion
Opt
ge
Ran
g
in
Spr

M Modulating (Air/Gas & Liquid)

K Kalrez
N Nitrile

T Teflon
V Viton

1 1"
A 1.5"

2 2"
3 3"

4 4"
6 6"

8 8"

DD
EE
FF
GG

HH
JJ
KK
LL

MM
NN
PP

QQ
RR
TT

2 2"
3 3"

4 4"
6 6"

8 8"
10 10"

A 150 x 150
B 300 x 150

C 600 x 150
D 900 x 300

E 1500 x 300
F 2500 x 300

1 RF x RF

2 RTJ x RF

3 RTJ x RTJ

0 CS Std.
2 CS NACE

3 SS Std.
4 SS NACE

B Backflow
Preventer

F Filter
L Lift Lever

S Snubber
U Unloader

Consult Factory for Spring Chart.

*Multiple options can be selected.

Temperature Limits
Temperature

35 X X X X X X X X X / XX

Lower F
Upper F

Nitrile
-65
225

EPDM
-70
300

Seat Material
Viton Neoprene
-15
-45
400
300

Kalrez
30
550

Teflon
-300
400

Sizing Equations
US Units
Air/Gas
W= CK d AP1

M
TZ

Liquid
Q= 38K d K v A

P1 - Pd
G

Where
P1=1.1 Pset +14.7 Over 30 psi
Or
P1 = Pset +17.7 Under 30 psi
C= 520

2
k+1

k+1
k -1

SI Units
W = Capacity in lbm/hr
Pset = Set Pressure in psig
Pd = Discharge Pressure
A = Orifice Area
K d = .878 for Air/Gas
K d = .784 for Liquid
K v = Viscosity Correction
Factor
Q = Capacity in GPM
Z = Compressibility Factor
T = Temperature in R
k = Ratio of Specific Heats
M = Molecular Weight
G = Specific Gravity

Air/Gas

W = Capacity in kg/hr
Pset = Set Pressure in kPag
M
W=13160 CK d AP1
Pd = Discharge Pressure
TZ
A = Orifice Area
Liquid
K d = .878 for Air/Gas
K d K v A P1 - Pd
K d = .784 for Liquid
Q=
11.78
G
K v = Viscosity Correction
Where
Factor
P1=1.1 Pset +101.3 Over 207 kPa Q = Capacity in liter/min
Z = Compressibility Factor
Or
T = Temperature in K
P1 = Pset +122 Under 207 kPa
k = Ratio of Specific Heats
k+1
2
M = Molecular Weight
k -1
C= 520 k
k+1
G = Specific Gravity

Hydroseal Series 3500 Pilot Operated Relief Valve

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Hydro-Pilot3500-June-09-HP 2009 CIRCOR Energy Products, Inc. Hydroseal is a KF Industries Brand Litho USA Hydroseal reserves the right to change designs, materials or
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