Api 520521 Day1 TBS

API 520/521
Relief and Flare Systems Workshop

Prepared by: Ezaideen Ahmad
Expectation
Experience
Designation
Name
Introduce Yourself
About Me
• Mr Ezaideen has an over of 10 years’ experience in the field
of Process Safety Management Aspects, Process Safety Risk
Assessment, Barrier Management, Hazards and Effects
Management Process, HSE Case Development, Bowtie Risk
Analysis, Process Technology and Plant Operations, Multi-
Disciplinary Engineering Application on Safety, Process
Design & Specification, Consequence Modelling, Pressure
Relief Design & Verification, Process Hazard Analysis,
Incidents Review, HAZOP/HAZID Methodology, Development
of Process Safeguarding Memorandum and Process
Safeguarding Flow Scheme, Process Design Safety Review,
Qualitative and Quantitative Risk Based Inspection, LOPC
Management Framework and Process Simulation.
PRD Related Experiences

• OFFSHORE:
• Provision for Detailed Design Engineering Services of Flare, Relief & Blowdown Verification for, TAPIS EOR and Rejuvenation Project – Greenfield (ExxonMobil Exploration and Production
Malaysia Inc)
• Pressure Relief Device Risk Based Inspection, PRD RBI for Small Field, Bunga Kertas FPSO and Onshore Gas Terminal (PETRONAS Carigali Sdn Bhd)
• HAZID Study For Offshore Hook Up And Commissioning Of South Acis Main Production Platform (SA-PA) & Utility Platform (SA-AA) (Murphy Oil Corp & Brooke Dockyard and Engineering
Works Corporation)
• HAZOP Study for Design and Engineering Services for Modification of Gas Outlet of Production Separator for MCR-A Platform (PETRONAS Carigali Sdn Bhd- Turkmenistan)
• Provision for Detailed Design Engineering Services of Flare, Relief & Blowdown Verification for, DAMAR Satellite Platform Project – Greenfield (ExxonMobil Exploration and Production
Malaysia Inc)
• Field Development Plan for D35 (Sarawak Shell Bhd)
• HAZOP for Design and Engineering Services for SKO Pipelines and Facilities Rejuvenation Project, Baram Field (PETRONAS Carigali Sdn Bhd- SKO)
• HAZOP for Design and Engineering Services for SKO Pipelines and Facilities Rejuvenation Project, Miri Crude Oil Terminal MCOT (PETRONAS Carigali Sdn Bhd- SKO)
• Provision of Temana Field Benefit Study at Sarawak for (PETRONAS Carigali Sdn Bhd- SKO)
•
• ONSHORE:
• Equipment Based Pressure Relief Capacity Verification, Relief Header Hydraulic Analysis, Knock-Out Drum Analysis and Flare Radiation Study for Slugcatcher, Stabilization, Gas Metering, Acid
Gas Treating, Dehydration, Liquefaction, Fractionation and Utilities (MALAYSIA LNG SDN. BHD.)
• Provision for Detailed Design Engineering Services of Flare, Relief & Blowdown Verification for, Bintulu Onshore Receiving Facilities (BORF) (MURPHY Oil Corp & Technip Malaysia)
• Pressure Relief Device Risk Based Inspection and Consequence Modelling, PRD RBI for Ammonia, Urea and Utility Plant (PETRONAS Chemicals Fertilizer Kedah Sdn Bhd)
• Pressure Relief Device Risk Based Inspection and Consequence Modelling, PRD RBI for KR1, KR2A & KR2B (PETRONAS Penapisan Terengganu Sdn Bhd)
• Pressure Relief Device Risk Based Inspection and Consequence Modelling, PRD RBI for Terengganu Crude Oil Terminal (TCOT; PETRONAS Carigali Sdn Bhd- PMO)
• Pressure Relief Device Risk Based Inspection and Consequence Modelling, PRD RBI at Peninsular Gas Utilization (PGU I and II; PETRONAS Gas Bhd – Transmission Operation Division)
• Pressure Relief Device Risk Based Inspection and Consequence Modelling, PRD RBI for Central Utility Facilities, CUF Kerteh and Gebeng (PETRONAS Gas Berhad)
• Equipment Based Pressure Relief Analysis for Propane Dehydrogenation Plant (MTBE Malaysia SDN. BHD.)
• Equipment Based Pressure Relief Analysis, (SHELL REFINERY (MALAYSIA) SDN. BHD)
• Relief Valve Survey, Data Management and Criticality Risk Assessment Project (Malaysia LNG Sdn Bhd)
• Provision of Engineering, Procurement, Construction and Commissioning (EPCC) for Leak Detection System, KLIA Aviation Fuel Hydrant System (K.A.F.S.) (PETRONAS Dagangan Berhad)
Overall Objectives of Workshop

• Enhance Pressure Relief Device Adequacy Assurance competency
• Develop skills in ensuring the safety in design through avoidance of overpressure and under pressure
• Able to specify equipment design pressure, fundamental understanding of the causes of
overpressure and under pressure, development of overall relief philosophy and detailed specification
of hardware and systems to protect the process
• Develop ability to calculate provision for pressure/vacuum relief as ultimate protection to prevent
loss of primary containment
• Ability to calculate the loading on flare header during design relief case in ensuring adequate
capacity and minimize backpressure
Open
Do you know the status of your relief system?

• If throughput of your crude unit needed to be increased by 10%, 20%, 30%?
• Or…
• I have a different crude composition…
• Or…
• I need to increase my control valve and line size..
• Question:
• How easily could we determine which safety valves would be impacted?
• How easily could we determine the new relief rates for these safety valves?
• What impact would this increase have on the flare system from a hydraulic perspective and adequacy of network equipment?
• Who in your organization would be responsible for ensuring that the above mentioned details are managed properly?
Open
Incidents Throughout History

• When doing a LOPA or HAZOP, do you completely go through all upset scenarios?
• Only pressure relief devices remain as your last line of defense if your IPF fails.
• Do you review the documentation for all upset scenarios and adequacy of relieving system?
• Do you always fully understand the process, materials and potential hazards of material?
Open
Typical Drivers for a Pressure Relief Analysis…

• Safety – plant has undergone significant changes over the years and there may be concerns on
adequacy of overpressure protection (common driver)
• Compliance – pressure relief design documentation needs to be updated or in many cases recreated
for regulatory needs
• Capital Projects – capacity enhancements, plant expansions and debottlenecking studies
• Standardization – Implementing standard pressure relief design and documentation methodologies
and systems corporate-wide
Open
Compulsory baseline
Step 1: Define Nodes
Step 5: Step 2:
Perform Flare Identify Overpressure
Analysis Scenarios
Step 3:
Step 4:
Calculate Required
Size Relief Devices
Relief Rates
Open
Equipment Based Pressure Relief Analysis
Equipment
Pressure Overpressure
Relief Devices Scenarios
Open
COURSE OUTLINE: DAY 1

• MODULE 1: Overview of typical relief systems and key components
• MODULE 2: Pressure Relief Systems Overpressure Protection Philosophy (API 520 & 521)
• Safety implications and causes of overpressure
• Safe Operating Envelope
• Overpressure protection philosophy including source isolation and relief
• Hands on Training:
• Defining system nodes
• Process Safeguarding Identification
MODULE 1
Overview of typical relief systems and key
components
Module Overview
• Most of our refining and chemical processes require the confinement
of hydrocarbons and chemicals under pressure, and at times, at
elevated temperatures
• Designing all equipment for emergency pressure conditions and

some method of overpressure relief is necessary
• This training module describes some of the pressure relieving

systems used for protection
Purpose of Module 1
• Upon completion of this training module you understand the
following:
• The function and operation of pressure relief valves:
• Conventional relief valves
• Bellows seal relief valves
• Pilot operated relief valves
• Pressure-vacuum relief valves
• Typical uses of pressure relief valves
• Typical relief valve types (pressure, thermal)
• The function and operation of typical rupture disks
MODULE 1
PRESSURE RELIEF VALVES INTRODUCTION
Purpose of Pressure Relief Valves

• Fluids under pressure perform many important functions in our
plants and transportation systems
• Kept under control, pressure can perform valuable services. Pressure

that becomes too great or too little can damage the system
Types of Pressure Relief Valves
• Each system must have a means for relieving excess pressure or vacuum to
prevent damage
• The main types of mechanical devices that relieves pressure are:

• Relief Valve, Safety Valve, Safety Relief Valve (Conventional, Balanced Bellows, Pilot
Operated)
• Rupture discs
• Pressure-vacuum relief valves
• Rupture pins
PRD Differences in Vapor or Liquid Services

• VAPOR PRDs
• Specifically designed for "pop" action, i.e., Vapor PRDs move to the full open position
at only a slight overpressure. When the rated capacity is fully discharged, the valve
remains fully open as the pressure builds to the permissible maximum
• LIQUID PRDs
• Designed to lift progressively with rising pressure until the full open position is
reached
• Vapor and liquid PRDs will be described in more detail later in the
presentation
Basic Terminology
Open
Pressure Relationships
Open
Pressure Relationships
Open
PRD Terminology
• Accumulation
• The difference in pressure between a pressure relief valve beginning to
open and when it is full-open; usually ex-pressed as a percentage of valve
set pressure
• Blowdown
• The difference in pressure between the set pressure of a pressure relief
valve and the pressure at which the valve reseats, expressed in either
percentage of valve set pressure or differential pressure.
PRD Terminology (continued)

• Chatter
• Abnormal rapid reciprocating motion of a pressure relief valve in which the disk
contacts the seat
• Chattering is controlled by adjusting the amount of blowdown a valve has
• Closing pressure
• Value of decreasing inlet pressure at which the valve disk reestablishes contact with the
seat or at which lift becomes zero
• Lift
• Actual travel of the disk away from the closed position when a valve is relieving

• Popping pressure
• Value of increasing inlet pressure at which the disk moves in the opening direction at a
faster rate as compared with corresponding movement at higher or lower pressures
• Set pressure
• Value of increasing inlet pressure at which a relief valve displays the operational
characteristics as defined under popping pressure.
• This is one value of pressure stamped on the relief valve nameplate. Popping pressure
and set pressure are often used interchangeably.

• Seat tightness
• The specified inlet pressure at which a quantitative pressure seat leakage test is performed in accordance
with a standard procedure; or that pressure at which the process will be prevented from seeping through
the nozzle and disk seat interface. If seats are properly conditioned, a finely machined valve can be
shown to be tight to 94 percent of the valve’s set pressure.
• Superimposed Back Pressure

• Pressure in discharge header before valve opens
• Can be constant or variable
• Built-up Back Pressure

• Pressure in discharge header due to frictional losses after valve opens
• Total back pressure = Superimposed + Built-up

Superimposed Back Pressure

• Pressure in discharge header before valve opens
• Can be constant or variable
Open
Built-up Back Pressure

• Pressure in discharge header due to frictional losses after valve opens
• Total = Superimposed + Built-up
Open
MODULE 1
CONVENTIONAL
PRESSURE RELIEF DEVICES (PRD )
Conventional PRD − Common Parts

• Adjusting screw
• Spring
Adjusting
• Stem Screw
• Disk
• Seat Spring
• Inlet port
• Outlet port Stem Body
• Body Outlet
Disk Port
Seat
Inlet Port
Conventional PRD − Outlet Port

• Depending on the system
being protected, the outlet of
a relief valve can be directed:
• To the atmosphere
• To a flare or gas recovery system
• To a lower-pressure area within
the system
Outlet
Port
Conventional PRD − Flange Connected

• Conventional PRDs and
the related PRDs
(balanced bellows type
and pilot operated type)
are always connected to Flange
the process equipment
with flanges
Conventional PRD − Valve Body

• The outer shell of the relief valve is called the valve body
• The body provides a path through which over-pressurized liquids flow
• The body also serves to hold the internal parts of the valve in the valve’s
proper position
Conventional PRD − Valve Disk

Adjusting • Disk blocks the path between the
Screw inlet and the outlet when system
pressure is normal
• Firm and even contact between the
Spring disk and the seat prevents fluid
from leaking around the disk
Disk Stem
Blowdown
Ring
Seat
Outlet
Port
Nozzle Inlet Port
Conventional PRD − Valve Seat

Adjusting • In some PRDs, the seat
Screw
consists of a threaded seat
bushing so the seat can be
Spring replaced, if necessary
Disk Stem
• In other valves, the seat is a
Blowdown permanent part of the valve
Ring
Seat
Outlet
Port
Nozzle Inlet Port
Conventional PRD − Valve Stem

Adjusting • Stem (also called a spindle) guides
Screw the up and down motion of the disk
• The stem is loosely connected to
the disk holder via a "lost thread"
Spring (not shown in the figure)
Disk Stem
Blowdown
Ring
Seat
Outlet
Port
Nozzle Inlet Port
Conventional PRD − Spring & Adjusting Screw

Adjusting • Spring:
Screw • The spring holds the disk in place against
the seat to resist normal system pressure.
• Adjusting Screw:
• The adjusting screw adjusts the
Spring compression (closing pressure) of the
spring.
Disk Stem • A lock nut holds the adjusting screw in
Blowdown position after the adjusting screw has
Ring been set.
Seat
Outlet
Port
Nozzle Inlet Port
Conventional PRD − Spring Compression

• Spring compression is an important factor in relief valve operation. Spring
compression is the force that acts in opposition to system pressure
• After extended service, a spring shows the effects of wear and loses some
of the spring’s stiffness. When this happens, the valve may not open and
close at the proper point
• Improper opening and closing is one of the main reasons PRDs are
inspected and tested for proper release pressure on a regular basis
Conventional PRD − Spring Compression (Cont’d)

• Minor adjustments are made by means of the spring adjusting screw
• Tightening the adjusting screw increases the compression on the disk and
thus raises the opening pressure of the valve
• Loosening the adjusting screw reduces the amount of compression on the
disk and allows the valve to open at a lower pressure
• Note that the actual amount of adjustment is limited, as each PRD is
designed to handle only a certain range of pressures
• Some PRDs are designed to handle large pressure range changes by
interchanging spring types
MODULE 1
THERMAL PRD
EQUIPMENT DESCRIPTION
Thermal PRD − Common Parts

• Adjusting screw
Adjusting
• Spring Screw
• Disk
• Seat
• Inlet port Spring
Body
• Outlet port
• Body Outlet
Disk Port
Seat
Inlet Port
Thermal PRD − Internal Parts and Connections

• Most internal parts of a thermal Adjusting
PRD are the same as for a Screw
conventional PRD
• Thermal PRDs can use threaded Spring
connections to the process Body
equipment Outlet
Disk Port
Seat
Inlet Port
Thermal PRD − Applications

• PRDs normally used in liquid
service
• PRDs release excess pressure that
results from an increase in
temperature
Outlet
• Causes of temperature increase: Port
• Equipment being completely blocked in
• Increases in ambient temperatures
• Fire
Inlet Port
Thermal PRD − Discharge − Within Process

• Thermal relief PR valves on piping and other equipment handling flammable
and combustible fluids must discharge per the following:
• Fluids with an operating temperature above or within 8C (15F) of the fluid’s flash
points must discharge to a closed system such as a flare pipe header or other process
equipment
• Fluids with an operating temperature below the fluid’s flash point minus 8C (15F)
may discharge to a sewer or catch basin if permitted by governmental regulations and
local practices
• Thermal relief PR valves that release toxic fluids must discharge to an appropriate
closed system
Thermal PRD − Discharge − Outside Process

• Design Guidelines:
• Thermal relief valves are to be positioned to discharge safely and to ensure protection of
the environment
• Thermal relief valves for dock lines should be grouped and discharged to a gathering system
• When discharge to a collection system is not practical, thermal relief valves may discharge
to the ground if permitted by government regulations and local practices
• Thermal relief PR valves that release toxic fluids must discharge to an appropriate closed
system
MODULE 1
OPERATION OF A PRD
IN LIQUID SERVICE
Operation of PRD in Liquid Service

• Conventional PRD in liquid service is set to open when the pressure in a system
reaches a specific predetermined value.
• For example, if a valve is set for 20 psig, the valve will begin to open when
system pressure reaches 20 psig
• At 20 psig:
• The system pressure pushing on the disk begins to overcome the compression in the spring
• The disk begins to lift off the seat
• When the disk begins to left off the disk seat, pressurized liquid is released
through the valve outlet
Operation of PRD in Liquid Service (Continued)

• If the pressure in the system continues to increase, the valve disk will continue
to lift until the disk has risen as far as the valve disk can go.
• That point is called the full rated lift position of the valve.
• PRDs have lifts anywhere from millimeters (fractions of an inch) to centimeters

(several inches).
• The lift is usually limited by a backseat or limit stop device.

• A liquid service PRD remains in the fully open position until the excess
pressure in the system has been relieved
• The valve begins to close as system pressure begins to return to normal
• As system pressure decreases, the upward force the system pressure exerts
on the valve disk also decreases

• The compression in the spring gradually takes over, and the disk is moved back
toward the seat
• If the disk began to lift at 140 kPa (20 psig), the disk will be reseated when the
system pressure falls below 140 kPa (20 psig), commonly called blowdown
• As the pressure continues to decrease, spring compression completely
overcomes system pressure so that the valve is held firmly closed
MODULE 1
OPERATION OF PRD
IN GAS/VAPOR SERVICE
Operation of PRD in Gas/Vapor Service

• The operation of a conventional PRD in gas, vapor or two phase flow service
is caused by pressure of the fluid (gas).
• The valve has a large disk area exposed to the pressure which causes the
valve to pop fully open after the set pressure is reached.
• The area exposed to the pressure is increased after the valve starts to open.
Operation of PRD in Gas/Vapor Service (Cont’d)

• With a greater surface area, a greater force is exerted against the spring pressure and the
valve pops fully open
• As the valve opens, the spring is compressed and offers more resistance to further
opening
• Proper operation of any valve in this service requires increasing the force to increase the
lift to maximum
Operation of PRD in Gas/Vapor Service (Cont’d)

• The increasing force is obtained by an effective increase in the exposed disk
area as the disk rises
• The valve closes suddenly because of this fact in reverse.
• As the pressure drops, the spring tension overcomes the decreasing lift force
(pressure is being relieved) and starts to close the valve
• The closing action decreases the area of lift force, which allows the spring to
suddenly overcome the lifting force
MODULE 1
BALANCED BELLOWS
PRESSURE RELIEF VALVES
Balanced Bellows PRD Overview

• Balanced bellows PRDs are similar
to conventional PRDs, but are
designed to minimize the effect of
outlet back pressure on valve
performance
• Back pressure affects conventional
and balanced bellows valves
differently
Conventional vs. Balanced Bellows

• In a conventional valve, if the back Conventional safety valve is designed
pressure increases, the set pressure to provide full opening when there is
increases minimum or no back pressure
• When back pressure fluctuates on a

conventional valve, the valve may
open at too low a pressure or
exceed the equipment’s rating.
Under or over pressure depends on
the back pressure adjustment and Outlet:
spring pressure adjustment. Low Pressure
Side
Inlet: High Pressure Side

Conventional vs. Balanced Bellows (Continued)

• With the balanced bellows valve,
outlet back pressure has little
effect on set pressure
• The balanced bellows balances Vent
the valve disk by venting the
interior of the bellows through
the bonnet chamber to the Bellows
atmosphere Outlet: Low
Pressure
Side
Inlet: High
Pressure Side
Conventional vs. Balanced Bellows (Continued)

• Venting arrangements must be
carefully designed. Any bellows Vent (no plug)
failure permits process material
from the discharge side to be
released to the atmosphere.
Bellows
• Small bore piping is connected
between the vent and a sealed Outlet: Low
system to stop an atmospheric Pressure
release if the bellows leaks. Any Side
valves that are used must be car
sealed open. Vent piping is Process or High
Pressure Side
described in more detail later.
Balanced Bellows PRD Design

• Balanced bellows is specially
designed to reduce the effect of Vent (no plug)
outlet back pressure.
• Differential pressure required to
open the valve is the pressure Bellows
inside the equipment minus the
atmospheric pressure.
Outlet: Low
Pressure
Side
Process or High
Pressure Side
Balanced Bellows PRD − Applications

• High / Fluctuating Back Pressure:
• Back pressure has little effect on balanced bellows set pressure. When back pressure
fluctuates on a conventional valve, the valve may open at too low a pressure or permit the
vessel to exceed equipment rating
• Fouling or Corrosive Service:

• Balanced bellows PRDs are used in these services because the bellows shields the spring
from the process fluid
• High Back Pressure:

• The balanced bellows PRDs can be used at considerably higher outlet back pressure than
conventional PRDs
Advantages/Disadvantages
• Advantages:
• Back pressure has no affect on relieving pressure
• Handles higher built-up back pressure
• Protects spring from outlet corrosion
• Disadvantages:
• Bellows susceptible to fatigue/rupture
• Requires separate venting system to avoid release of flammables/toxics to
atmosphere
MODULE 1
PILOT OPERATED PRDS
Pilot Operated PRDs − Overview

• Pilot operated PRDs have a main
Pilot
valve combined with and controlled
Valve
by a self-actuated auxiliary valve or
pilot valve
• The pilot valve is a type of small
PRD
• Pilot operated valves use process
pressure instead of a spring to keep
the valve closed
Pilot Operated PRDs − Piston Design

Pressure Adjusting Screw
Pilot Valve Piston • The piston and seating
arrangement in the main
Pilot
Exhaust
valve is designed so that the
bottom area of the piston,
O-Ring
exposed to the inlet fluid, is
Outlet
less than the area of the top
Main Valve
Piston of the piston (or disk
Inlet
depending on type of Main
PRD)
Pilot Operated PRDs − Piston Design (Cont’d.)

• Both ends of piston are exposed to
Pilot Valve Piston the fluid at the same pressure
• Under normal system operating
Pilot conditions, the closing force,
Exhaust resulting from the larger top area, is
greater than the inlet force
O-Ring
• Resultant downward force,
Outlet therefore, holds the piston firmly on
Main Valve the piston’s seat
Piston
Inlet
Pilot Operated PRDs − Operating Principles

• A rise in inlet pressure increases net
Pilot Valve Piston closing force on the piston, continually
maintaining tight shut-off
Pilot
Exhaust • However, when inlet pressure reaches
O-Ring pilot set pressure, pilot valve opens to
release fluid pressure above PRD
Outlet
piston to the discharge header
Main Valve
Piston
• Sometimes the pilot vents the top of
Inlet the piston to the atmosphere
Pilot Operated PRDs − Operating Principles

Pilot • With no fluid pressure acting on
Valve upper surface of piston, inlet
Dome pressure now exceeds pressure
Piston above piston/disk
Seal
• Inlet pressure exceeding pressure
above the piston/disk causes main
valve to pop open, allowing the
Main process fluid to discharge
PRD
Disk Pressure
Pick Up
Inlet
Pilot Operated PRDs −Operating Principles (Cont’d)

Pilot • When inlet pressure has been
Valve sufficiently reduced, pilot valve closes.
Dome • The pressure to the top of the main
Piston
piston/disk increases
Seal
• Increase in pressure causes the main
PRD to close
Main
PRD
Disk Pressure
Pick Up
Inlet
Pilot Operated PRDs − Applications

Pilot • Offer good overpressure and
Valve blowdown performance
Dome (blowdown of 2% is attainable)
Piston
Seal
• Used where a narrow margin is
required between the set pressure
and the system operating pressure
Seat
Pressure
Pick Up
Inlet
Pilot Operated PRDs − Advantages

Pilot • Retrofits:
Valve May be used in retrofit situations
Dome where there is less margin between
Piston
operating and design pressure.
Seal
Simmer does not start until about
98% of set pressure
• Less Chattering:
Less subject to chattering because
Seat Pilot Operated PRDs are slower to
act than a conventional spring
Pressure
acting PR valve
Pick Up
Inlet
Pilot Operated PRDs − Advantages (Continued)

Pilot
• High Back Pressure
Valve
Dome • Can be used with backpressures as
Piston high as 50% to 75% of set pressure
Seal if backpressure is accounted for in
sizing valve
• In smaller sizes, pilot operated

Seat relief valves are more costly than
spring operated PRDs
Pressure
Pick Up
Inlet
Pilot Operated PRDs − Disadvantages

Pilot • Not recommended for fouling or
Valve dirty services because of plugging of
Dome pilot valve and tubing
Piston
Seal • Vapor condensation and liquid
accumulation above the piston (or
diaphragm) may interfere with
adequate lift
Seat • Valve may malfunction unless special
designs are used
Pressure
Pick Up
Inlet
MODULE 1
RUPTURE DISKS
Rupture Disks − Overview

• Rupture disk (RD) is a thin diaphragm (generally a solid metal disk) designed to rupture
(or burst) at a designated pressure
• RD is used as a weak element to protect vessels and piping against excessive pressure
(positive or negative)
Before
After
Rupture Disks − Overview (Continued)

• Unlike PRDs, an RD is non-reclosing
• Burst RD provides a permanent open path into the discharge system
• The discharge system may either be the atmosphere or a closed system, such as a flare
header
Before
After
Rupture Disks − Applications

• RDs may be used in conjunction with PRDs
• Special approval is required for RDs to be used alone
• Acceptable types of RDs are:
• Pre-scored tension loaded conventional (forward acting) for both liquid and gas/two-
phase service
• Pre-scored (cross-scored) reverse buckling for gas/two-phase only service
• Pre-scored (semi-circular) reverse buckling for gas/two-phase or liquid service. Pre-
scored (semi-circular) may not be used under PRDs due to possible fragmentation
• Fragmentation RDs are not used
• Metal fragments can lodge in PRDs or other equipment, causing severe damage
Rupture Disks − Tension Type

• Tension Type RDs are oriented in a
system with the process pressure
against the concave side of the Example of Tension RD Operation
rupture disk
• As process pressure increases
beyond allowable operating Process Side
pressure, rupture disk starts to grow
Rupture Disks − Tension Type (Continued)

• When the rupture disk starts to grow, growth continues as the pressure increases, until
the tensile strength of the material is reached and rupture occurs
Standard Flange
RD Holder
RD Top
RD Holder
Standard Flange Bottom
Standard
Pre-Assembly Studs &
Screws Process Side Nuts
Example of Tension RD Installation
Rupture Disks − Reverse Acting

• Reverse Acting RDs oriented with process media pressure against the
convex side of the disk, placing the rupture disk in compression
Process Side
Example of Reverse Acting RD Operation
Rupture Disks − Reverse Acting (Continued)

• As burst pressure rating of the disk is reached, compression loading
on rupture disk causes the disk to reverse. Disk snaps through the
neutral position and opens by a predetermined scoring pattern
Pre-Assembly Standard
Screws Studs &Nuts
Standard Flange
RD Holder
Top
RD RD Holder
Standard Flange Bottom
Process Side
Example of Reverse Acting RD Installation
Rupture Disks − Advantages

• No simmering or leakage
• Unless the RD is corroded or damaged, there is no simmering or leakage prior to bursting
• Open fully, rapidly

• RDs open fully very rapidly, so RDs are good for overpressure caused by an internal
deflagration or sudden pressurization
• Example, as a result of a tube failure in a high pressure exchanger
• Less expensive corrosion resistance

• Corrosion resistance for an RD is less expensive than for a conventional or balanced bellows
relief valve
• RDs can be made or coated with variety of corrosion resistant materials
Rupture Disks − Advantages (Continued)

• Less fouling or plugging
• Rupture disks are less likely to foul or plug
• RD opening is essentially equal to the piping bore
• Overpressure / Depressure Use
• RDs can provide both overpressure and depressuring protection.
• Lower cost
• Rupture disk generally has lower initial cost than equivalent service PRD
Rupture Disks − Disadvantages

• Sensitivity to temperature
• Since burst pressure depends on disk material properties, temperature at time of burst
will cause the burst pressure to vary
• Choice of material has a great influence on the sensitivity of the bust pressure to
temperature
• Non-reclosing
• If burst RD is the only protective device, burst RD must be replaced before operations
continue
• If RD is used in series with a PR valve, operations can continue without replacing the
burst disk
• However, the extra protection afforded by the RD is lost until the burst disk is replaced
Rupture Disks − Disadvantages (Continued)

• Destructively tested
• Non-destructive testing of the RD burst pressure cannot be accomplished
• Unlike PR valves, which can be adjusted, accuracy of burst pressure is based solely on
manufacturer’s tests from the same lot
• Require periodic replacement

• Most vendors suggest RD replacement annually. However, replacement of RD's
annually seems excessive. RD's tend to rupture at reduced pressure with age, so the
interval of replacement is not driven by overpressure protection but by the need to
prevent nuisance bursts.
• More severe conditions require more frequent replacement
• More Easily damaged

• Rupture disks are more sensitive to mechanical damage than other pressure relief
devices
MODULE 1
RUPTURE PINS
Rupture Pins
• A rupture pin is designed to be a non-reclosing pressure relief device, similar to a rupture disc
• A piston is held in the closed position with a buckling pin which will fail at a set pressure according
to Euler's Law
• An o-ring on the piston is used to make a bubble tight seal
Open
Conventional Rupture Pin Device
Open
Comparison of Rupture Pins To Rupture Discs

Advantages
+ Not subject to premature failure due to fatigue
+ Can be operated closer to its set point
+ Setpoint is insensitive to operating temperature
+ Available as balanced or unbalanced device
+ Capable of operating as low as 0.1 psig (0.007 barg)
+ Suitable for liquid service
+ Resetting after release usually requires no breaking of flanges
+ Replacement pins are 1/3 to 1/4 the cost of replacement discs
Open
Comparison of Rupture Pins To Rupture Discs

Disadvantages
• The elastomer o-ring seal limits the maximum operating temperature to about 450oF (230oC)
• Initial cost of installation is greater than for a rupture disc
 twice as costly for 2” carbon steel

 up to seven times as costly for 8” stainless steel
Open
Potential Uses For Rupture Pins

• Replacement of rupture discs which have experienced frequent failures
• Replacing rupture discs with rupture pins will allow running slightly closer to design pressure
possibly resulting in a capacity increase
• Higher accuracy of rupture pins at < 40 psig (2.7 barg) gives significant advantage over rupture discs
• When installed under a PSV the rupture pin can be reset without removing the PSV
Open
MODULE 1
PRESSURE-VACUUM VENTS
Menu
Pressure-Vacuum (PV) Vent Overview

• Pressure-vacuum vent is a
specialized type of pressure relief
valve used on fixed roof tanks
• Located on tank roof, PV vent
protects tank from overpressure
and under-pressure (or vacuum)
conditions
• Internally, PV vent contains:
• Pressure valve and
• Vacuum valve
• Which are essentially two lift check
valves
PV Vent − Operation
• When tank pressure increases, Stem
tank vapors lift pressure valve Guide
(called a pallet), allowing the
Pressure Valve
vapors to flow out Stem
• When tank pressure Guide
decreases, atmospheric Vacuum
pressure lifts vacuum valve, Valve
allowing air to flow into the tank
Tank Roof
PV Vent − Pressure Activation

• PV vents typically mounted to a
Stem
flange or pipe that connects to Guide
vapor space of a storage tank
(space within the tank that is above Pressure Valve
the liquid surface) Stem
Guide
• As liquid is pumped into the tank
and level rises Vacuum
• Vapor space is compressed Valve
• Pressure increases
• Pressure valve then opens, Tank Roof
releasing the pressure to
atmosphere
PV Vent − Vacuum Activation

• As liquid is removed from
tank
• Pressure in vapor space
decreases
• Vacuum begins to form
• Vacuum valve opens to let
atmospheric air into tank to
eliminate vacuum
• Differential pressure
between partial vacuum and
atmospheric pressure can
cause a tank to collapse in on The tank’s PV vent was covered with a plastic bag
itself while the tank was painted. Liquid was pumped out
of the tank while the vent was covered, causing this
collapse because of the differential pressure.
PV Vent − Activation
• Atmospheric temperature changes cause an expansion or contraction
(hot sunny days, cool nights) of vapors in the vapor space, resulting in
pressure increases or decreases. The tank essentially “breathes”
• After the excess pressure or vacuum condition has been relieved, the
valve reseals automatically
• Tank's vapor space is always maintained within the safe range of the
tank’s pressure and vacuum operating design limits
Flame Arresters
• Flame arrester protects tanks against fire and
explosion caused by exterior sources of ignition
such as lightning
• Valve disks in the vent housing minimize air and

vapor loss as the tank "breathes"
• Disks open and close just enough to maintain safe

working pressures and avoid damage to tank
• Flame arrester is mounted externally and is

exposed to vapors only when venting
PV Vent − Applications & Requirements

• Pressure-vacuum vents are used when one or more of the following conditions
apply, subject to review:
• Stock stored has a flash point below 38C (100F)
• Temperature of the stored product is above or within 8C (15F) of the product’s flash point
at the highest operating temperature.
• Stocks stored are
• Valuable and
• Have a low vapor pressure
• Example, alcohol
• Tanks are gas or nitrogen blanketed
PV Vent − Applications & Requirements (Cont’d)

• Non-freezing features of pressure-vacuum vents
• In areas where daily mean temperature falls below −1C (30F) or below the freezing
point of the stored material for periods exceeding 24 hours, pressure-vacuum vents
should be equipped with non-freezing features, including:
• Valve disks (Pallets) with drip rings
• Pallets with flexible diaphragms to prevent metal-to-metal contact on seating surfaces
PV Vent − Applications & Requirements (Cont’d)

• Open vents and PV should be covered with 4-mesh screen
(4.75 mm avg. opening).
• Asphalt service and other high viscosity and high pour point stocks that tend to plug are the
exception, and the following limitations apply:
• Use open vents without screens – the gooseneck or mushroom type.
• PV vents can be used when tank is blanketed with gas injected at the vent nozzle, which prevents
plugging of the vent in asphalt service
• Gas blanketing keeps nozzle clear and does not allow air to enter the tank
• If local conditions cause ice build up, the screens can be removed during the
winter
MODULE 1
Pressure Relief Valve Review Questions
Review Question 1
PRD inspection identified a problem Click on the correct answer.
with one of these bellows valves.
What is the problem?
PRDs are the
wrong color
Bonnet vent is plugged
Lack of room between

PRD and railing
Review Question 2
A PRD inspection identified a
problem with this bellows valves,
which is ___________
the valve is dirty

wrong color
bonnet vent plugged
Click on the correct answer

Answers to Quiz on Pressure Relief

1Q. The highest allowable set pressure of any safety valve is the maximum allowable working pressure
of the vessel being protected. (T/F)
2Q. The Design Pressure and the Maximum Allowable Working Pressure of a vessel are one and the
same. (T/F)
Open

3Q. An oversized safety valve can be vulnerable to the phenomenon known as chatter. (T/F)
4Q. Safety valve chatter in liquid service is potentially more serious than in vapor service. (T/F)
Open

5Q. For operating contingencies, the ASME Code allows the relief capacity of a single safety valve to be
calculated at 110% of the MAWP. (T/F)
6Q. Under a fire contingency, the vessel is allowed to reach a higher pressure than under an operating
contingency. (T/F)
7Q. It is permissible to have a second safety valve on a vessel set at 105% of the MAWP. (T/F)
8Q. Accumulation means the same as blowdown. (T/F)
Open

9Q. If a single safety valve is present only for fire, it is permissible to set it at 110% of the MAWP. (T/F)
10Q. If there are two safety valves on a vessel, pressure during discharge is allowed to reach 116% of
the MAWP. (T/F)
Open

11Q. If a safety valve is to be routinely operated within 10% of its set pressure, it is advisable to provide
a rupture disc beneath the safety valve to eliminate losses due to “simmering”. (T/F)
12Q. Proper safety valve servicing requires testing each valve in the “as-received” condition. (T/F)
13Q. We should design for the possibility that safety valve discharges will become ignited. (T/F)
Open
MODULE 1 SUMMARY
SUMMARY Prepared by: Ezaideen Ahmad
Module Summary
• PRDs are used to protect for overpressure conditions in closed
liquid and gas systems.
• PRDs are used for hydrocarbon gases and oils, compressed air,
and chemicals.
• PRDs may be self-actuated or pilot-actuated depending on

their design and function.
SUMMARY Prepared by: Ezaideen Ahmad
Module Summary
• During certain transient operations in an enclosed system,
pressure will increase at a rate that exceeds the control
capacity of the system
• PRDs are designed and used to prevent catastrophic releases.
• Pressure-Vacuum Vents used to prevent drawing a vacuum in a tank
• RDs pressure relieving devices

• Used to protect under side of PRDs from corrosion and relieve pressure
MODULE 2
Pressure Relief Systems Overpressure Protection Philosophy
(API 520 & 521)
Module Overview
• This training module describes the overview for causes of
overpressure
• It includes the Safe Operating Envelope and Limits Philosophy in

preventing overpressure
• It also describes the Layer of Protections Philosophy to safeguard

against overpressure
• This module includes Bowtie representation to inculcate Barrier

Mindset
MODULE 2
Safety Implications and Causes of Overpressure
What is overpressure?
Operating Pressure > Set pressure of PRD

Open
What could cause overpressure?
Open
Overpressure Philosophy
NO CREDIT - Double jeopardy

NO CREDIT - Favorable instrument actions (ASC valves)
Open
Closed Outlet
• Pressure vessel (vapor outlet)
• Overfilling (liquid outlet)
• Compressor discharge
• Pump discharge
• Likelihood (Once in 10 years)
Open
Cooling or Reflux Failure

• Reflux Pump failure
• Air fin coolers failure
• Cooling Water failures
Open
Failure of Automatic Controls

• Inlet/outlet control valve fully open regardless of Fail-Safe positions.
• Likelihood (Once in 10 years – same direction; Once in 50 years – opposite direction)
Open
External Fire
• Pool fire (eq. within fire zone)
• Jet fire
• BLEVE (C3-C4 vessels with >4m3
inventory
Open
Abnormal Heat Input

• Regenerator column
• Condensate Stabilization Columns
• Fractionation Columns
Open
Inadvertent Valve
Opening
Open
Check Valve Leakage or Failure

• Multi Stage Compressors
• Parallel train compressors
• Parallel train pumps
• Utility supply
Open
Transient Pressure Surges
• Water hammer
• Steam hammer
• Condensate steam hammer
Open
Chemical Reaction
• Runaway reaction
• Hydrogen explosion
• Hot oil into water and vice versa
Open
Hydraulic Expansion
• Could be isolated
• Liquid full (>95%)
• Inventory (>500 L)
• Operates at ambient or lower
• Exposed to solar radiation
Open
Heat Transfer Equipment Failure
• HP Side Operating Pressure > Hydrotest
pressure of LP Side
• Likelihood (Once in 1000 years) with proper
maintenance
Open
Global Contingency – Utility Failures

• Electric Power Failure
• Cooling water
• Instrument air
• Steam
• HTF
• Fuel gas
• Inert gas
Open
Overpressure Prevention During Maintenance

a) introducing a high-pressure fluid into the equipment under maintenance;
b) introducing a fluid or energy source that can react with fluid that may be left in the
equipment;
c) introducing a high-temperature fluid that can vaporize a fluid that may be in the vessel;
d) isolation valves that are closed rather than open;
e) unexpected plugging in the equipment;
f) steaming the vessel;
g) purging the vessel;
Open
MODULE 2
Safe Operating Envelope
Illustration of the Safe Operating Limit Concept for a Specific Parameter

MODULE 2
Overpressure Protection Philosophy:
Layers of Protection
MODULE 2: PRESSURE RELIEF SYSTEMS

OVERPRESSURE PROTECTION
PHILOSOPHY
Defining System Nodes
What Makes a Good Node Demarcation?

• Selecting the correct boundaries
• Similar Pressure System (Operating and Design Conditions)
• Protected by the same protecting mechanisms
• Equipment in Open Communication
• Clear demarcation through pressure letdown mechanisms (Pressure.
Flow or Level Control Valves)
REVIEW QUESTIONS Prepared by: Ezaideen Ahmad
Review Question 3
• Depending on the system being protected, the outlet of a relief valve can be directed to
the atmosphere, a flare header or gas recovery system, or to a _______________ within
the system
• lower-pressure area
• higher-pressure area Click on the correct answer.
Review Question 4
The outer shell of the relief valve is called the valve _______.
• stem
• disk
• body
Click on the correct answer.
Review Question 5
• The Pressure Relief Valve (PRD) adjusting _______ is used to adjust the compression
(closing pressure) of the spring.
• screw
• disk Click on the correct answer.
Review Question 6
Thermal pressure relief valves are normally used in _____ service
• gas
• liquid Click on the correct answer.
INTERNATIONAL STANDARDS
REFERENCES
International Standards References

• API Standard 520, Sizing, Selection, and Installation of Pressure-relieving Devices in Refineries, Part II—
• Installation
• API Standard 521, Pressure-relieving and Depressuring Systems
• API Standard 526, Flanged Steel Pressure-relief Valves
• API Standard 527, Seat Tightness of Pressure-relief Valves
• API Standard 2000, Venting Atmospheric and Low-pressure Storage Tanks
• ASME Boiler and Pressure Vessel Code (BPVC) 1, Section I: Power Boilers
• ASME Boiler and Pressure Vessel Code (BPVC), Section VIII: Pressure Vessels; Division 1
• ASME Boiler and Pressure Vessel Code (BPVC) Code Case 2203 2, Omission of Lifting Device
• Requirements for Pressure Relief Valves on Air, Water Over 140°F, or Steam Service
• ASME B31.1, Power Piping
• ASME B31.3, Process Piping

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API 520/521

Relief and Flare Systems Workshop

PRD Related Experiences

Overall Objectives of Workshop

• Able to specify equipment design pressure, fundamental understanding of the causes of

loss of primary containment

capacity and minimize backpressure

Do you know the status of your relief system?

• How easily could we determine which safety valves would be impacted?

Incidents Throughout History

Typical Drivers for a Pressure Relief Analysis…

adequacy of overpressure protection (common driver)

for regulatory needs

• Capital Projects – capacity enhancements, plant expansions and debottlenecking studies

• Standardization – Implementing standard pressure relief design and documentation methodologies

and systems corporate-wide

Equipment Based Pressure Relief Analysis

COURSE OUTLINE: DAY 1

• Designing all equipment for emergency pressure conditions and

• This training module describes some of the pressure relieving

Purpose of Pressure Relief Valves

• Kept under control, pressure can perform valuable services. Pressure

Types of Pressure Relief Valves

• The main types of mechanical devices that relieves pressure are:

PRD Differences in Vapor or Liquid Services

PRD Terminology (continued)

PRD Terminology (continued)

PRD Terminology (continued)

• Superimposed Back Pressure

• Built-up Back Pressure

• Total back pressure = Superimposed + Built-up

Superimposed Back Pressure

• Can be constant or variable

Built-up Back Pressure

• Total = Superimposed + Built-up

Conventional PRD − Common Parts

Conventional PRD − Outlet Port

Conventional PRD − Flange Connected

Conventional PRD − Valve Body

Conventional PRD − Valve Disk

Conventional PRD − Valve Seat

Conventional PRD − Valve Stem

Conventional PRD − Spring & Adjusting Screw

Conventional PRD − Spring Compression

Conventional PRD − Spring Compression (Cont’d)

Thermal PRD − Common Parts

Thermal PRD − Internal Parts and Connections

Thermal PRD − Applications

Thermal PRD − Discharge − Within Process

Thermal PRD − Discharge − Outside Process

Operation of PRD in Liquid Service

Operation of PRD in Liquid Service (Continued)

• PRDs have lifts anywhere from millimeters (fractions of an inch) to centimeters

Operation of PRD in Liquid Service (Continued)

Operation of PRD in Liquid Service (Continued)

Operation of PRD in Gas/Vapor Service

Operation of PRD in Gas/Vapor Service (Cont’d)

Operation of PRD in Gas/Vapor Service (Cont’d)

Balanced Bellows PRD Overview