Test, Calibration and Maintenance for Pressure Safety

Devices to Prevent Explosions and Fires

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2009

DEVELOPMENT RESEARCH AND
TECHNOLOGICAL PLANNING CENTER
CAIRO UNIVERSITY

Pressure Relief Devices
Contents
Hazard and factors contribute to an accident.
Fundamentals of pressure safety relief devices.
Terminology and types of pressure relief devices.
Code and standards requirements.
Location and choosing of safety relief devices.
Installation, Inspection, and maintenance.
Chatter (principle causes and solutions).
Testing and calibration.
Accident due to missing and fail of safety devices.
Video for safety relief devices (Operation, location,
maintenance).
Hazard and factors contribute to an accident

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Factors contribute to an accident
Human error
Equipment malfunction
Upset plant conditions
Fire or explosion near the apparatus
Improper procedures
Severe weather conditions
The following causes were noted for 88 incidents that
occurred in refining and chemical unit operations from
1959 to 1978:
28 % equipment failures
28 % human error
13 % faulty design
11 % inadequate procedures
5 % insufficient inspection
2 % process upsets
13 % education

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Fundamentals of pressure safety relief devices
An overpressure event refers to any condition which would
cause pressure in a vessel or system to increase beyond the
specified design pressure or maximum allowable working
pressure (MAWP). Since pressure relief valves are safety
devices, there are many Codes and Standards written to
control their design and application.
A pressure relief valve must be capable of operating at all
times, especially during a period of power failure when
system controls are nonfunctional.
Once a condition occurs that causes the pressure in a
system or vessel to increase to a dangerous level, the
pressure relief valve may be the only device remaining to
prevent a catastrophic failure.
Pressure relief valve (PRV) must open at a predetermined set
pressure, flow a rated capacity at a specified overpressure, and
close when the system pressure has returned to a safe level. PRV
must be designed with materials compatible with many process
fluids from simple air and water to the most corrosive media.

Type of safety devices Spring loaded valve
The basic spring loaded pressure relief valve has been
developed to meet the need for a simple, reliable, system
actuated device to provide overpressure protection. Figure
below shows the construction of a spring loaded pressure relief
valve. The valve consists of a valve inlet or nozzle mounted on
the pressurized system, a disc held against the nozzle to prevent
flow under normal system operating conditions, a spring to hold
the disc closed, and a body/bonnet to contain the operating
elements. The spring load is adjustable to vary the pressure at
which the valve will open.
Spring loaded valve
Materials must also resist chemical attack by the process fluid and the
local environment to ensure valve function is not impaired over long
periods of exposure.

Pressure relief valves on clean non-toxic, non-corrosive systems may be
vented directly to atmosphere. Pressure relief valves on corrosive, toxic or
valuable recoverable fluids are vented into closed systems.

Valves that vent to the atmosphere, either directly or through short vent
stacks, are not subjected to elevated back pressure conditions. For valves
installed in a closed system, or when a long vent pipe is used, there is a
possibility of developing high back pressure.

Back pressure which may occur in the downstream system while the valve
is closed is called superimposed back pressure. This back pressure may
be a result of the valve outlet being connected to a normally pressurized
system or may be caused by other pressure relief valves venting into a
common header. Compensation for superimposed back pressure which is
constant may be provided by reducing the spring force.

Seat leakage will result in continuous loss of system fluid and may cause
progressive damage to the valve seating surfaces.

Application of pressure relief valves should be assigned only to fully
trained personnel and be in strict compliance with rules provided by the
governing Codes and Standards.




Rupture Disk Devices
A rupture disc is a thin diaphragm (generally a solid metal
disc) designed to rupture (or burst) at a designated
pressure. It is used as a weak element to protect vessels
and piping against excessive pressure.
There are five major types available
Conventional tension-loaded rupture disc
Pre-scored tension-loaded rupture disc
Composite rupture disc
Reverse buckling rupture disc with knife blades
Pre-scored reverse buckling rupture disc
They are often used as the primary pressure relief device.
Very rapid pressure rise situations like runaway reactions.
When pressure relief valve cannot respond quick enough.
They can also be used in conjunction with a pressure relief
valve to:
Provide corrosion protection for the PRV.
Prevent loss of toxic or expensive process materials.
Reduce fugitive emissions to meet environmental requirements
Rupture Disk Devices
When compared with PR valves, rupture discs have:
Advantages
Reduced fugitive emissions - no simmering or leakage prior to
bursting.
Protect against rapid pressure rise cased by heat exchanger
tube ruptures or internal deflagrations.
Less expensive to provide corrosion resistance.
Less tendency to foul or plug.
Provide both over pressure protection and depressuring.
Provide secondary protective device for lower probability
contingencies requiring large relief areas.
Disadvantages
Dont reclose after relief.
Burst pressure cannot be tested.
Require periodic replacement.
Greater sensitivity to mechanical damage.
Greater sensitivity to temperature
Rupture Disk Devices
Every rupture disk shall have
a stamped burst pressure
below within a manufacturing
design at a specified disk
temperature and shall be
marked with a lot number.

A rupture disk device may be
installed on the outlet side of a
spring loaded safety relief
valve which is opened by
direct action of the pressure in
the vessel.

Terminology - Pressure Relief Valve - PRV
Relief Valve. A relief valve is a pressure relief device actuated by inlet
static pressure having a gradual lift generally proportional to the
increase in pressure over opening pressure.

Safety Valve. A safety valve is a pressure relief valve actuated by
inlet static pressure and characterized by rapid opening or pop action.

Safety Relief Valve. A safety relief valve is a pressure relief valve
characterized by rapid opening or pop action, or by opening in
proportion to the increase in pressure over the opening pressure.

Advantages of PRV
+ Most reliable type if properly sized and operated
+ Can be used in many services

Disadvantages of PRV
Relieving pressure affected by back pressure
Susceptible to chatter if built-up back pressure is too high

Non-Reclosing Pressure Relief Devices.
Rupture Disc Device. A
rupture disc device is a non-
reclosing pressure relief device
actuated by inlet static
pressure and designed to
function by the bursting of a
pressure containing disc.
Rupture Pin Device. 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
Rupture Discs Are Well Suited For Some
Applications
When compared with PR valves, rupture discs have:
Advantages
+ Reduced fugitive emissions - no simmering or
leakage prior to bursting.
+ Protect against rapid pressure rise cased by heat
exchanger tube ruptures or internal deflagrations.
+ Less expensive to provide corrosion resistance.
+ Less tendency to foul or plug.
+ Provide both over pressure protection and
depressuring.
+ Provide secondary protective device for lower
probability contingencies requiring large relief areas.
Rupture Discs Are Less Well Suited For Other
Applications
When compared with PR valves, rupture discs have:

Disadvantages

Dont reclose after relief.
Burst pressure cannot be tested.
Require periodic replacement.
Greater sensitivity to mechanical damage.
Greater sensitivity to temperature

Code and standards requirements
General Code requirements include:
ASME Boiler & Pressure Vessel Codes
ASME B31.3 / Petroleum Refinery Piping
ASME B16.5 / Flanges & Flanged Fittings
All pressure vessels subject to overpressure shall be protected by a
pressure relieving device
Liquid filled vessels or piping subject to thermal expansion must be
protected by a thermal relief device
Multiple vessels may be protected by a single relief device provided
there is a clear, unobstructed path to the device
At least one pressure relief device must be set at or below the MAWP.
Relieving pressure Relieving pressure shall not exceed MAWP
(accumulation) by more than:
- 3% for fired and unfired steam boilers
10% for vessels equipped with a single pressure relief device
16% for vessels equipped with multiple pressure relief devices

Location and choosing of safety relief
devices.
Overpressure protection is a primary consideration in the design of
any piping system. The objective of overpressure protection is to
maintain the pressure downstream of a regulator at a safe
maximum value.
In the system shown below, a high-pressure transmission system
delivers natural gas through a pressure reducing regulator to a
lower pressure system that distributes gas to individual customers.
The regulators, the piping, and the devices that consume gas are
protected from overpressure by relief valves.


choosing of safety relief devices.
Selection and Sizing Criteria
There are a number of common steps in the relief valve selection
and sizing process. For every application, the maximum pressure
conditions, the wide-open regulator flow capacity, and constant
downstream demand should be determined. Finally, this
information is used to select an appropriate relief valve for the
application.
The following is a suggested list of service conditions which
must be provided in order to properly size and select a
pressure relief valve;
1.Fluid Properties: a. Fluid and State, b. Molecular Weight, c. Viscosity, d.
Specific Gravity, Liquid (referred to water), Gas (referred to air), e. Ratio of
Specific Heats (k), f. Compressibility Factor (Z)
2. Operating Conditions: a. Operating Pressure (psig maximum), b.
Operating Temperature (F maximum), c. Max. Allowable Working Pressure
(psig)
3. Relieving Conditions: a. Required Relieving Capacity Gas or Vapor (lb/hr)
Gas or Vapor (scfm), Liquid (gpm), b. Set Pressure (psig), c. Allowable
Overpressure %, d. Superimposed Back Pressure (psig), e. Built-Up Back
Pressure (psig), f. Relieving Temperature (F)
Installation, Inspection, and maintenance.
It is essential that routine inspection and maintenance occurs on
these important valves. In time of emergency, can you be sure your
pressure relief valve will operate properly?
A number of guidelines for pressure relief valve service and
maintenance exist to ensure that pressure relief valves work
correctly. Some tips in brief include the following;
Atmospheric discharge lines should have adequate rain and
moisture protection, and be capable of draining condensate and
rainwater.
Check to make sure the relief valve exit stays unobstructed.
Routine maintenance of pressure relief valves should include visual
inspection of the relief valve and discharge piping every six months.
Relief valves should be replaced at intervals of no longer than five
years of service.
Maintain pressure relief valve data in an inventory record, including
location, size, set pressure, manufacturer, capacity, date installed,
dates of inspections, and latest date for replacement.
Installation, Inspection, and maintenance.
Pressure relief valves should not be discharged during installation or start-up.
Replace pressure relief valves once they have discharged.
Never expose your face or body to a connected relief valve exit.
Avoid trapped ice build up between valves and other equipment.
Reduce inlet pressure to zero before attempting to install or replace any
pressure relief valve. Preferably, and as required by most codes,
Use a three-way dual shut-off valve to isolate relief valves for individual
inspection or replacement.
Check the nameplate or installation date tag to be sure the time-in-service does
not exceed five years.
Look for corrosion and leaks. If there is any doubt about the internal condition of
a relief valve, remove and inspect it internally. If there is any question about a
valves condition, replace it.
Shut down gas supply, drain gas from relief valve and system before any
maintenance.
When using a vise or wrench on the valve, use only enough torque to hold or
move the part.

Periodic Maintenance
If the valve is sits for long periods it may not perform as expected.
Disks may stick in seats, setpoints can shift over time, and small
passages can become clogged with pipeline debris. Therefore,
periodic maintenance and inspection is recommended.
Installation, Inspection, and maintenance.
Undersized
inlet piping
Consider the pressure drop
from all these connections
Installation, Inspection, and maintenance.
Discharge directed
downward
Discharge too
near deck
Installation, Inspection, and maintenance.
Long moment arm
Shipping plug
still
in bellows vent
Installation, Inspection, and maintenance.
Will these bolts hold
when the PRV relieves?


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Pressure Relief Valves) Safety )

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Chatter ( ) (principle causes and
solutions)
Chattering is the rapid, alternating opening and
closing of a PR Valve.
Resulting vibration may cause misalignment,
valve seat damage and, if prolonged, can cause
mechanical failure of valve internals and
associated piping.
Chatter may occur in either liquid or vapor
services
Chatter - Principal Causes
Excessive inlet pressure drop
Excessive built-up back pressure
Oversized valve
Valve handling widely differing rates
Chatter ( ) (principle causes and
solutions)
Chatter Mechanism
Excessive Inlet Pressure Drop
Chatter Solutions
Excessive Inlet Pressure Drop
Venting
- The venting end shall be at least 6 m above the floor level and
at least
2.5 m above the compressor enclosure.
Furthermore, as regards own and neighboring constructions, it
shall comply with the following formula:
h > H D + 2.5
where h = venting height (m)
H = neighboring or own construction height (m) (the highest
one)
D = neighboring construction horizontal distance (m)
- Venting pipe shall have a noise dampener system that shall be
activated when noise exceeds the admissible levels.
- Discharge of all relief systems inside the compressor
enclosure shall be delivered into a shock absorber tank which
design and construction shall be approved by Gas del Estado
or of any other system enabling a safe and clean operation.
- Service venting normally closed with manual valves and plugs
shall be admitted to be located in suitable pipe runs.
- Permanent or periodical venting of gas either due to
operation, lack of maintenance of installations or others shall
not be accepted except
(Testing and Calibration)


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Conventional
Relief Valve


Accident due to missing and fail of safety devices
On November 19,
1984, a series of
explosions at the
PEMEX petroleum
storage facility (LPG)
at San Juan
Ixhuatepec in Mexico
City ignited a major
fire and killed about
500 people. The cause
of explosion was
safety relief valve
missing.