API 520 (Sizing, Selection and Installation of Pressure-relieving Devices in Refineries)

Part 1 Sizing and Selection

1. Scope (About this document)
PRDs used in refineries and related industries for equipment with working max allowable working
pressure > 15psig ( 103kPag)
PRDs to protect unfired pressure vessels and etc. against overpressure from operating fire
contingencies
Basic information and definitions of operational and application of PRDs
PRDs; protect against overpressure ONLY. Does not protect against structural failure. (refer to API
521)
Atmospheric and low-pressure storage tanks covered in API 2000

2. Normative References
API RP 520
API Std 521/ISO 23251
API Std 526
API Std 527
API Std 2000
ASME Boiler and Pressure Vessel Code,
Section I
ASME Boiler and Pressure Vessel Code,
Section VIII
ASME BPVC Code Case 2091-3
ASME BPVC Code Case 2203
ASME BPVC Code Case 2487
ASME B31.1
ASME PTC 25

3. Terms & Definitions (Few of it)
Actual discharge area (actual orifice area) area of PRV is the minimum net area that determines
the flow through a valve
Blowdown difference between set pressure and the closing pressure of a PRV, in % or pressure
unit
Bore area nozzle area, nozzle throat area, throat area, minimum cross-sectional flow area of
nozzle in a pressure relief valve
Burst pressure upstream static pressure minus the downstream static pressure just prior to when
the disk bursts.
Coefficient of discharge ratio of mass flow rate in a valve to that of an ideal nozzle. Used for
calculating flow through a PRD.
Curtain area area of the cylindrical or conical discharge opening between the seating surfaces
above the nozzle seat created by the lift of the disc
Lift the actual travel of the disc from the closed position when a valve is relieving
Overpressure pressure increase over the set pressure of the relieving device, usually expressed in
pressure units or as a percentage of set pressure.
PRD a device actuated by inlet static pressure and designed to open during emergency or
abnormal conditions to prevent the rise of internal fluid pressure in excess of a specified design
value. Can also be designed to prevent excessive internal vacuum. Cab be a pressure relief valve, a
non-reclosing pressure relief device or a vacuum relief device.
PRV a pressures relief device designed to open and relieve excess pressure and to reclose and
prevent the further flow of the fluid after normal conditions have been restored.
4. Pressure Relief Devices (PRDs)
4.1. General
Description of basic principles, operational characteristics, applications and selection of pressure relief
devices either used independently or combinations. Devices includes; spring-loaded and pilot operated
PRVs, rupture disk devices and etc. Refer to figure 1 to 29 (API 520 Part 1)

4.2. Pressure relief valve (PRVs)
4.2.1. Spring-loaded PRVs
4.2.1.1. Conventional PRVs ( see figure 1 and figure 4)
Self-actuated spring-loaded PRV
Designed to open at a predetermined pressure and protect a vessel system from excess
pressure.
It removes or relieving the fluid from that vessel or system
Figure 4 commonly used for thermal relief valve applications
Basic element: inlet nozzle connected to the vessel or system to be protected, a movable disc
which controls flow through the nozzle and a spring which controls the position of the disc.
Normal condition: inlet pressure < set pressure, hence the disc is seated on the nozzle
preventing outflow.

Spring-loaded PRVs terms; safety valves, relief valve or safety relief valve.
Applied to gas/vapor service, liquid service or multi-services applications

Spring-loaded PRVs operates based on force balance (figure 5).
Spring load is preset to equal the force exerted on the closed disc by the inlet fluid when the
system pressure is at the set closed position.
If inlet pressure < set pressure, disc remains seated on the nozzle (closed).
If inlet pressure > set pressure, the pressure force on the disc overcomes the spring force which
will cause the valve to open.
As it inlet pressure reduces, the valve will closed back.

(Figure 5, Item A) When valve is closed at normal operation system or vessel pressure acting
against the disc surface is resisted by the spring force. As the pressure approaches the set
pressure, the seating force between the disc and nozzle approach zero (PIC)
(Figure 5, Item B) in a vapor/gas situation, the valve will simmer first before itll pop. When the
vessel pressure approaches set pressure, the fluid will move past the seating surface into the
huddling chamber B. Pressure will build up there and provide an expansion force which will
overcome the spring force. Disc will move away from the nozzle seat, hence valve will open.
(PIC)
(Figure 5, Item C) When valve opened, there is an additional pressure build up (at C). This cause
by sudden flow increase and restriction to flow. This force cause the disc to lift substantially at
pop (PIC).
Flow is restricted by the opening between the nozzle and the disc until the disc is lifted of the
nozzle diameter from the nozzle. After this, flow then is controlled by the bore area rather than
the area between the seating surfaces.
Valves closes back after the inlet pressure decreases until below the set pressure. The pressure
at which the valve re-seats is the closing pressure. Difference between the set pressure and the
closing pressure is blowdown.



4.2.1.2. Spring-loaded PRVs Designed for Liquid Service Applications
Liquid service valves dont pop like the vapor valve (See Figure 7), this is due to the expansive
forces produced by vapor is not present in liquid flow. For this valve it relies on the reactive
forces to achieve lift.
When the valve is closed the force acting is the same as vapor situation however force
relationship is totally different.
Figure 7, Item A escaping liquid forms a very thing sheet of fluid at initial opening. This will
expand radially between the seating surfaces. The liquid strikes the reaction surface and
deflected downward, creating a reactive turbine force tending to move the disc and holder
upward. These forces build slowly during 2%-4% of OVP.
Figure 7, Item B As flow increases, the velocity head increases. The momentum forces plus
the reactive forces are substantially enough to cause the valve to go into lift. The valve will
suddenly surge to 50-100% lift at 2-6% OVP. As OVP increases, the forces increases hence the
valve will be fully lift.
While the valve closing, the OVP decreases, momentum and reactive forces decreases, allowing
spring force to move the disk back into contact with the seat.
PRVs used in liquid application were safety relief designed for compressible service. These
valves required high OVP (25%) to achieve full lift and stable operation, since liquid doesnt
provide expansion forces.
PRVs designed for liquid develop to achieve full lift, stable operation and rated capacity 10%
OVP. Blowdown is adjustable in some designs.
Capacity certification data for sizing is obtained from the manufacturer, this will be used for
final sizing and application of the valve.
Spring-loaded PRVs are balance to minimize the effects of backpressure. The valves are
sometimes are multi-phase mixture.
PRVs designed for liquid and gas should be specified for the fluid to which the valve is normally
exposed.
Some applications required to relieve a liquid or a gas depend on the condition causing the
overpressure. For this case a valve designed for liquid service or liquid and gas services is
recommended.

4.2.1.3. Balanced PRVs
Spring-loaded PRV which incorporates bellows or other means of balancing the valve dis to
minimize the effects of backpressure on the performance characteristics.
Superimposed backpressure is applied to the outlet of a spring-loaded PRV, a pressure force is
applied to the disc. This will cause the unbalanced PRV to open. If the superimposed
backpressure is variable then the pressure at which the valve will open will vary (Figure 8).


Balanced-Bellows PRVs bellows is attached to the disc holder with effective bellows area (A
B
)
> the seating area of the disc (A
N
).This will isolates an area on the disc from
backpressure.(CHECK BACK 4.2.1.3.3)


The internal area of the bellows is referenced to atm pressure in the valve bonnet. It is
important to be vented to atm for the bellows to work properly. If the valve located where atm
venting is hazardous or against regulation, it should be piped to a safe location that is free of
backpressure which will affect the PRV opening pressure.
They are other means of balancing a spring-loaded PRV, such as sealed piston are use in valve
designs.
When superimposed backpressure is constant, the spring load can be reduced to compensate
for the effect of backpressure on the set pressure and a balanced valve is not required. Some
cases backpressure is not always constant and should be evaluate carefully.
Balanced PRVs should be considered where the built-up backpressure is too high for a
conventional pressure relief. It may also be used as a means to isolate the guide, spring, bonnet
and other parts within the valve from the relieving fluid. This may be important as corrosive
fluid may cause damage to these parts.
Important to remember that the bonnet of a balanced PRV shall be vented to atm at all times.
Should be cautioned of the potential for freezing of atm moisture inside the bonnet in cold
service due to ambient or auto-refrigeration.

4.2.2. Pilot-operated PRVs
Pilot-operated PRV consists of; main valve which normally encloses a floating unbalanced
piston assembly and an external pilot.
Piston is designed to have a larger area on the top than on the bottom. Also the top and
bottom areas are exposed to the same inlet operating pressure.
Since the area of the top piston is larger, the net force holds the piston tightly against the main
valve nozzle.
As the operating pressure increases, the net seating force increases and tends to make the
valve tighter. These featured allows most of pilot-operated valves to be used in condition
where maximum expected operating pressure is higher than the percentage in Figure 15.
At set pressure, the pilot vents the pressure from the top of the piston; the resulting net force
is upward and cause the piston to lift, and process flow is established through the main valve.
After OVP, the pilot will close the vent from the top of the piston and the net force will cause
the piston to reseat.

(4.2.2.1.2)
The lift of the main valve piston or diaphragm is not affected by built-up backpressure. This will
allow for even higher pressure in the relief discharge manifolds.
The pilot vent can either directly exhausted to atmosphere or the the main valve outlet depend
of the pilots design and user requirements.
Balanced-type of pilot where set pressure is unaffected by backpressure, should be installed
with its exhaust connected to a location with varying pressure.
4.2.2.1. Backflow Prevention
A backflow preventer is needed when there is possibility of pressure developing on the
discharge side of the valve that exceeds the inlet pressure of the valve.
Higher discharge pressure can cause sufficient upward force on the diaphragm or piston to
open the valve and cause flow reversal.
The preventer allow the discharge pressure to provide a net downward force on the
diaphragm/piston to keep the valve closed (Figure 11)
Proper operation of the backflow preventer is critical to further ensuring no flow reversal
occurs in the valve.
Selection of material and seals of backflow preventer should be consistent with the PRV

4.2.2.2. Pilot Types
Pilot operates the main valve: pop-action or modulating pilot.
Figure 16, pop-action pilot; causes the main valve to lift fully at set pressure w/o OVP. This
immediate release of pressure provides extremely high opening and closing forces on the main
valve seat. Not recommended for liquid services to avoid valve instability

Figure 17, modulating pilot; opens the main valve only to satisfy the required relieving capacity
and can be used in gas, liquid of two-phase flow applications. It limits the amount of relieving
fluid to only the amount required to prevent the pressure from exceed allowable accumulation.
Calculation for the built-up backpressure of modulating pilot may be based on the required
relieving rate instead of the rated relieving capacity of the valve. It can also reduce interaction
with the other pressure control equipment in the system during and upset condition, reduce
unwanted atm emissions and reduce the noise level associated with discharge to the atm.

The pilot can be a flowing or non-flowing type:
o Flowing type; allow process fluid to continuously flow through the pilot when the main
valve is open, non-flowing does not.
o Non-flowing type reduce the possibility of hydrate formation (icing) or solids in the
lading fluid affecting the pilots performance

4.2.2.3. Application and Limitations of Pilot-operated PRVs
Pilot-operated PRVs; available for use in liquid and vapor services. Some operating
characteristics are unaffected by the state of fluid and are recommended for two phase flow
applications
Most main valve and pilots contain non-metallic components. Therefore process temperature
and fluid compatibility can limit their use
Consideration of fluid properties is needed such as polymerization of fouling, viscosity, the
presence of solids and corrosiveness. It should be consult to ensure proposed application is
compatible with available valves.

4.2.2.4. Pilot- operated PRV accessories
Varieties of accessories and options to provide additional functions.
Field Test Connection
Pilot-operated PRVs can be tested for verification of set pressure during normal system
operation
Done via pressure from and independent source ie; nitrogen bottle, where gas is slowly
admitted through a metering valve.
The pilot and main valve dome are pressurized simulating an increased system pressure.
The field test pressure will actuate the pilot and may/may not actuate the main valve.
Backflow Preventer
Also called as vacuum block; prevent the valve from reverse flow when the pressure at the
outlet flange (a.k.a superimposed backpressure) is greater than the current system pressure.
Reverese flow can occure with any standard type of design of pilot-operated PRV when
sufficient reverse differential pressure exists.
A backflow preventer permits the introduction of outlet pressure into the dome of the main
valve, thereby holding the piston firmly on the nozzle, overcoming the effect of a reverse
differential pressure.
A backflow preventer should be specified whenever deal with the following:
o The protected equipment can be depressured and isolated while line up to an active
line header
o A vacuum may be present at the inlet connection due to unusual operating
conditions/during startup
o The valve is connected to a downstream pressure vessel where pressure may vary from
time to time in excess of the pressure in the upstream system.
o The discharge of multiple PRVs is combined into single manifold or vent system,
creating superimposed backpressure in excess of the current upstream system
pressure.
Pilot Supply Filter
Protects the pilot from particulate matter in the flow stream.
Installed in the pilot supply line; expand the service application for pilot-operated PRVs.
Cautioned is needed when plugging, frequent maintenance of the filter is required to achieve
the benefits
For excessive particulate matter, other methods ie: addition of purge system may required.
Pressure Spike Snubber

Remote Pressure Sense Connection
Manual or Remote Unloader
Pilot Lift Lever
CDTP (Cold Differential Test Pressure)

4.3. Rupture Disk Devices
4.3.1. General
4.3.2. Application of Rupture Disks
4.3.3. Type of Rupture Disks
4.3.4. Rupture Disk Holders
4.3.5. Rupture Disk Accessories
4.3.6. Rupture Disk Selection and Specification
4.4. Pin-actuated Devices
4.4.1. General
4.4.2. Buckling Pin Devices
4.4.3. Breaking Pin Devices
4.4.4. Other Type of Devices