Relief valves

Presented by
ARAVIND R
 Pressure Relief Valves
• Pressure relief valve is designed to open for relief of excess pressure and
reclose thereby preventing further flow of fluid after normal conditions are
restored
• Pressure relief valve opens when upstream pressure reaches the opening
pressure
• It allows fluid to flow until upstream pressure reaches closing pressure
 Important terms and definitions

• Set pressure- inlet gauge pressure at which the pressure relief valve is set to open
• MAWP- maximum permissible gauge pressure at the top of the vessel at designated coincident
temperature specified for that pressure
• Design pressure- pressure used in design of vessel together with coincident design metal
temperature for the purpose of determining minimum possible thickness. It is equal to or less
than MAWP
• CDSP- pressure at which the device is set to open on the test stand
 Important terms and definitions
• Over pressure- pressure increase over set pressure of the pressure relief valve. It is normally
expressed as a percentage of set pressure
• Blow down- the difference between set pressure and closing pressure
• Simmer- audible or visible escape of compressible fluid between seat and disc of the
pressure relief valve at a pressure less than set pressure
• Chatter- opening and closing of pressure relief valve at a very high frequency
• Back pressure- pressure existing at the outlet of the pressure relief valve as a result of
pressure in the discharge system
 Pressure relief valve- types
• Safety valve
• Relief valve
• Safety relief valve
 Safety valve

• Direct spring loaded pressure relief valve that is actuated by static pressure
upstream and characterised by rapid opening or pop
• Normally used with compressible fluids
• Not to be used in liquid service or as pressure control valves
 Relief valve

• Direct spring loaded pressure relief valve actuated by static pressure

upstream and opens in proportion to the pressure increase over set pressure
• Relief valve achieve full lift at 10%-25% overpressure
• Normally used for incompressible fluid service
 Safety-relief valve

• Direct spring loaded pressure relief device which can be used as safety valve
or relief valve as per application
• When used in gas service, 10% overpressure causes full opening
• When used in liquid service, full lift achieved at 10%-25% overpressure
 Pressure relief valve-construction
• Nozzle
• Disc and disc holder
• Disc seat
• Spring
• Compression screw and lock nut
• Bonnet
• Guide
• Blowdown adjusting ring
• Blowdown adjustment nut
 Safety valves- operation in gas service

• The operation is based on force balance. The spring load is set to

equal the pressure exerted on the disc by the fluid when operating
pressure reaches set pressure
• when inlet pressure exceed the set pressure, the pressure force on
disc exceeds the spring force and the disc lifts
• When inlet pressure has fallen below the set pressure, the valve
recloses
`
• when vessel pressure closely approaches the set pressure, fluid will move
into the huddling chamber

• Due to restriction between disc holder and adjusting ring, pressure builds
up in the huddling chamber

• Since pressure acts on a larger area, the additional force overcomes the
spring force and valve pop open
• Once valve has opened, additional pressure build up occurs due to
sudden flow increase and restriction to flow through the annular orifice
formed between inner edge of disc holder and outer edge of adjusting
ring causing further lift

• Valve closes when inlet pressure has dropped sufficiently for the spring
force to overcome the combined forces in the disc holder and huddling
chamber area

• By controlling the area of huddling chamber, we can control the

pressure build up governing the popping of the valve
 Huddling chamber
• Annular pressure chamber located downstream of seat for
assisting to achieve lift
• As disc begins to lift, it enters the huddling chamber exposing a
larger area to the system pressure causing expansive force which
exceeds the spring force causing pop
• It also reverses the direction of fluid flow causing momentum
effect further increasing force
• Thus with allowable over pressure, valve can achieve full lift
 Huddling chamber- adjustment
• By changing the area of huddling chamber, we can control the pressure build up which
determines the popping ability of the valve
• More fluid contained in huddling chamber leads to higher force on the disc causing rapid
pop
• Lesser fluid quantity signifies just the opposite
• Area of huddling chamber is adjusted with blowdown ring
 Huddling chamber- adjustment

Blowdown ring in top position Blowdown ring in bottom position

• Maximum restriction for fluid to move out • Minimum restriction for fluid movement
• More fluid contained in huddling chamber • Less fluid contained in huddling chamber
• Immediate popping of valve • Delayed popping of the valve
• Longer blowdown • Shorter blowdown
Safety valves- operation in liquid service

• They do not pop in the same manner as vapour service valves due to absence
of expansive forces. They rely on reactive force to achieve lift
• When valve is closed, the spring force exceeds the pressure exerted by the
liquid
• When pressure reaches the set pressure, escaping liquid forms a thin sheet of
fluid between the seating surfaces. The liquid is then deflected down creating
a reactive (turbine) force tending to move the disc upwards.
• These forces build slowly during the first 2%-4% of overpressure
Safety valves- operation in liquid service

• As flow gradually increases, the velocity head of liquid moving through

nozzle also increases.
• This momentum force combined with the reactive force cause substantial
lift of the disc
• The valve will surge to 50%-100% at 2%-6% overpressure
• Liquid service valves are required to reach rated capacity at 10%
overpressure or less
 Backpressure

• pressure existing at the outlet of the pressure relief

valve as a result of pressure in the discharge system

• Backpressure can manifest in two ways

• Super imposed backpressure

• Built-up back pressure

 Super imposed backpressure

• Static pressure that exists at the outlet of the relief valve at the
time the device is required to operate
• Superimposed backpressure is a result of pressure in discharge
system coming from other sources
• It can be constant or varying in nature
 Built-up backpressure

• The increase in pressure at the outlet of the pressure relief valve

that develops as a result of glow after the relief valve opens
• The sum of superimposed and built-up backpressure gives the
total backpressure
Effect of backpressure on valve operation

• When backpressure is applied to the outlet of a PRV, a pressure

force acts on the valve disc which is additive to the spring force.
• This increases the pressure at which the PRV will open
• If back pressure is variable, then the opening pressure will also
be variable
Pb = back pressure
Spring force + Pb * disc area = force on the top side
Process pressure * nozzle area + Pb * bottom disc area =
force on bottom side
Spring force + Pb * nozzle area = closing force on the disc
seat
Suppose we have a back pressure of 2 kg/cm2.If we have
set the spring to open at 10 kg/cm2 and process pressure is
10 Kg/cm2, then now the extra 2 kg/cm2 will act on the
disc which will cause the disc to lift only at 12 kg/cm2
 Conventional pressure relief valve

• Direct spring loaded pressure relief valve

• The operational characteristics are directly affected by the changes in
back pressure
• The conventional pressure relief valves can be used when back pressure
is less than 10% of the set pressure.
• Above 10% we will have to rely on balanced pressure relief valves or
pilot operated valves
 Balanced bellow pressure relief valve

• Spring loaded PRV that incorporates a bellow or other means

to balance the valve disc to minimise the effects of
backpressure
• In a balanced bellows PRV, a bellow is attached to the disc
holder with effective bellow area equal to or greater than that
of the nozzle area
• This isolates the top section of the disc thus eliminating the
effect of backpressure
• The bellow is normally screwed to the disc holder and sealed
with a gasket
• The internal area of bellow should be referenced out to
atmosphere pressure in the valve bonnet through the spring
bonnet vent.

• Leakage through vent also indicates damage to the bellow

• Bellow has a limit to the amount of backpressure it can withstand

Balanced piston pressure relief valve

• Disc holder has seal which isolate spring bonnet from back pressure
• Back pressure will act on equal areas on the top and bottom of the disc
holder and thus have no effect on the opening pressure
• Withstand higher back pressure than bellows
• Disadvantage is that seal are made of elastomers which are bound to get
damaged due to service fluid nature
 Pilot operated pressure relief valve

• Pilot operated PRV uses process pressure, instead of spring or

weight to keep the primary seat disc closed at pressure below set
pressure
• The main valve is attached to the vessel or system to be protected
• The pilot valve controls the opening and closing of the main
valve
• The process pressure enters the main valve and exerts an upward
force on the seat
• The same process pressure is also transmitted to the pilot valve
via the pressure pickup line
• The pilot is a direct acting spring loaded relief valve which is set to open at set pressure of the
main valve

• When process pressure is less than set pressure, the process fluid is allowed to exit the pilot and
act on the top of the main valve disc. So more pressure leads to more closing force

• When pressure reaches set pressure, the pilot vents the process fluid from the dome area causing
the disc to move up and relieve the fluid from main valve

• Pilot operated valves can relieve process fluid in two ways-snap acting or modulating
 Snap acting Pilot operated PRV

• The red color represents process pressure and when pilot relief seat is closed, the pressure
is ported to the dome area.
• Same pressure acts on top and bottom of the main valve piston and due to larger area at the
top, downward seating force is higher
• When process pressure beneath relief seat overcomes spring compression, pilot will open
allowing dome pressure to vent causing immediate and full lift
• No overpressure required to achieve full lift as in direct spring loaded valve
• Pressure at the inlet of the pilot remains at set pressure when
main valve is relieving
• The pilot is non flowing as no flow occurs through it when
main valve relieves
• The blowdown seat seals off flow to pilot when relief seat is
open
• The relief seat and blowdown seat will not be open at the same
time thus preventing flow through the pilot
• The main valve recloses when pilot valve sense reduced process
pressure. The relief seat closes and blowdown seat opens
reloading dome pressure thus closing the main valve
 Modulating Pilot operated PRV

• For service in incompressible media

• Pilot should not allow full evacuation of dome pressure as in
snap acting PRV
• A regulated amount of dome pressure should be reduced by the
pilot so that the piston remains in some partial lift position to
modulate the relief operation
• The green color illustrates the process pressure entering the main valve and exerting upward force
on the main valve seat
• The same pressure is allowed to enter the modulating action pilot and ported to the sense
diaphragm
• The sense diaphragm is mechanically attached to the feedback piston and both will move as a
single unit
• The inlet seat communicates the process pressure from pilot inlet to the main valve dome keeping
it closed due to area difference between top and bottom
• The piston seal area will have more area than the main valve seat area-approximately 30%
• The main valve will not open until the pilot has regulated the exhaust of minimum 30% of the
dome pressure
• When process pressure nears the set pressure, the sense diaphragm will move up along with
feedback piston
• The feedback piston will close the inlet seat cutting process flow to the dome
• If pressure rises further, the feedback piston will literally pick up the spool and move up opening
the outlet seat
• The process fluid vents out through the outlet seat. When dome pressure is reduced by 30% main
valve opens and relief through it happens
• As process pressure rises over set pressure, dome pressure reduction will continue and main
valve rises further to obtain needed left to deliver only required capacity of overpressure
• When pressure decays, inlet seat will open and outlet seat will close restoring pressure to the
dome
• At no time will inlet and outlet seat be both open so as to achieve no flow condition in pilot
• Unlike snap acting, modulating PRV requires overpressure to achieve full lift
 Remote sensing in pilot operated PRV

• Since pilot is controlling the opening and closing of main valve, the remote sense line
will allow pilot to see the true system pressure
Backflow preventer in Pilot operated PRV

• As operating pressure increases, the seating force increases. This

is normally advantageous except in case back pressure exceed
operating pressure
• The operating pressure wont be high enough to overcome
upward force causing valve to open and causing backflow to
happen
• Similar condition exist when valve is open to atmosphere and
there is normal vacuum condition at the inlet
• To prevent the reverse flow, we use a backflow
preventer
• It is a check valve that allow back pressure to enter
dome of the main valve and keep it closed tight,
incase back pressure exceed inlet pressure
 Inlet piping consideration

• Mostly PRV is mounted away from equipment to be protected for ease of

accessibility or maintenance purpose etc.
• Inlet piping of considerable length and bends can cause pressure loss which
affect the valve operation
• API 520 part II and non mandatory appendix M of ASME sex VIII guide to
design for maximum pressure loss of 3% of set pressure
• Improper design can cause chattering as shown in the example
• Set pressure = 100 kg/cm2
• Reseat pressure = 93 kg/cm2
• Inlet pressure loss = 3 kg/cm2
• At set pressure valve will open and blowdown will happen
causing closing at 93 kg/cm2. the valve will close and
system pressure will be 96 kg/cm2
• Set pressure = 100 kg/cm2
• Reseat pressure = 93 kg/cm2
• Inlet pressure loss = 10 kg/cm2
• Valve reseats at 93 kg/cm2 but system pressure is 103 kg/cm2. so immediately
after reseating, valve will open because system pressure is still higher than set
pressure. This can cause rapid cycling or chatter.
 PRV testing procedure

• Several tests are performed at relief valve testing shed to inspect its functionality after repair
• The tests include pop test, leak test and back pressure test
• If the PRV has a lifting lever, hand popping test is also performed
• Before repairs, an “as received” pop test is done to obtain the pop pressure
• The testing is as per API 527 and API 576
 “As received” pop pressure

• Check seals and ascertain their intactness

• The PRV is mounted on the test stand and pressure is gradually
increased
• The pressure at which the PRV relieves is the as received pop
pressure
• The inlet pressure is not raised more than 1.5 times the CDSP
• If popping doesn’t happen even then, the valve is considered stuck
shut
 Testing procedure inside KR

• Setting of valve set pressure or initial pop test

• Checking valve for tightness or leak test
• Back pressure test
• Hand popping test
Setting of valve set pressure or initial pop test

• After the valve has been reconditioned and reassembled, pop test is done to check whether it will pop at
CDSP
• It is recommended to perform pop test at-least 3 times as the first pop properly align the valve components
while successive pop verify the CDSP
• Deviation of pop pressure from CDSP should not be more than +/-0.14 kg/cm2 for CDSP up to 4.92
kg/cm2 and should not be more than +/-3% for CDSP more than 4.92 kg/cm2 as per Section VIII,Division
1, paragraph UG 134(d)(1), of the ASME Code
• For pressure relief valves that comply with Section VIII, Division 1, paragraph UG 125(c)(3), of the ASME
Code, the deviation shall not be less than 0% or greater than +10%
Checking valve for tightness or leak test

• Test is performed as per API 527- seat tightness of pressure relief valves
• Test medium will be same as that for pop test. It can be air, water or steam
• In KR mostly testing is done with air (nitrogen) as the medium
• The tube should have outer diameter as 7.9mm
with wall thickness as 0.89mm
• The end of the tube should be kept at 12.7mm
below the water surface
• The tube shall be perpendicular to the surface of
the water
• Leakage will appear as bubbles
• For valves with set pressure greater than 3.5 kg/cm2, the leak test will be performed at 90% of set
pressure
• For valves with set pressure less than or equal to 3.5 kg/cm2, the leak test will be performed at
“set pressure-0.35 kg/cm2”
• Before bubble count, pressure shall be held for 1 minute in case of valves with NPS 2 or lesser, 2
minutes for valves with NPS between 2 and 6 and 5 minutes for valves with NPS equal to or
greater than 6
• The leakage is then observed for at least 1 minute
• For soft seated valve, there should not be even a single bubble
• For metal seated valves, the acceptance criteria is given in API 527
 Back pressure test

• The discharge is connected to the air cylinder and pressure is set at back
pressure value
• Soap solution is poured on all joints
• Leakage will manifest as bubbles
• The spring bonnet vent should be in open position as leakage through the
vent implies bellow damage