PETRONAS TECHNICAL STANDARDS

DESIGN AND ENGINEERING PRACTICE

TECHNICAL SPECIFICATION

SETTINGS OF RELIEF VALVES &

PRESSURE TRIP SENSORS

PTS 20.195
MAY 1992
 PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,
of PETRONAS OPUs/Divisions.

They are based on the experience acquired during the involvement with the design, construction,
operation and maintenance of processing units and facilities. Where appropriate they are based
on, or reference is made to, national and international standards and codes of practice.

The objective is to set the recommended standard for good technical practice to be applied by
PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical
plants, marketing facilities or any other such facility, and thereby to achieve maximum technical
and economic benefit from standardisation.

The information set forth in these publications is provided to users for their consideration and
decision to implement. This is of particular importance where PTS may not cover every
requirement or diversity of condition at each locality. The system of PTS is expected to be
sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to
their own environment and requirements.

When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the
quality of work and the attainment of the required design and engineering standards. In
particular, for those requirements not specifically covered, the Principal will expect them to follow
those design and engineering practices which will achieve the same level of integrity as reflected
in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his
own responsibility, consult the Principal or its technical advisor.

The right to use PTS rests with three categories of users :

1) PETRONAS and its affiliates.

2) Other parties who are authorised to use PTS subject to appropriate contractual
arrangements.
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with
users referred to under 1) and 2) which requires that tenders for projects,
materials supplied or - generally - work performed on behalf of the said users
comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with
users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury
or death) suffered by any company or person whomsoever as a result of or in connection with the
use, application or implementation of any PTS, combination of PTS or any part thereof. The
benefit of this disclaimer shall inure in all respects to PETRONAS and/or any company affiliated
to PETRONAS that may issue PTS or require the use of PTS.

Without prejudice to any specific terms in respect of confidentiality under relevant contractual
arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by
users to any company or person whomsoever and the PTS shall be used exclusively for the
purpose they have been provided to the user. They shall be returned after use, including any
copies which shall only be made by users with the express prior written consent of PETRONAS.
The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe
custody and PETRONAS may at any time require information satisfactory to PETRONAS in order
to ascertain how users implement this requirement.
 REVISION REGISTER

Revision No. Date Details of Revision

1 5/92 First formal issue as SEP based on notes

EDV / 4-88 / 459 dated 4.11.88 and EDV / 4-
88 / 541 dated 29.12.88

TABLE OF CONTENTS

1. SCOPE

2. DEFINITIONS

3. ABBREVIATIONS

4. REFERENCES

5. PHILOSOPHY

5.1 Relief Valves Settings

5.2 PZA-H Settings

5.3 PZA-L Settings

6. APPENDICES

APPENDIX I PRESSURE DIAGRAM, TOPSIDE FACILITIES

APPENDIX II PRESSURE DIAGRAM. PIPELINES

1. SCOPE

This philosophy provides guidelines on the settings of relief valves and pressure trip sensors
for process pipework, pipelines, pressure vessels and other pressurized equipment onshore
and offshore. The philosophy shall apply to all new designs and form a basis for review of
existing facilities.

The scope includes:

a) All relief valves settings.

b) PZA-H and PZA-L settings for shutdown on vessels, wellhead flowlines, and
pipelines.

The control of field settings is not addressed in this document since it is procedural in nature.

2. DEFINITIONS

For the purpose of this document, the following definitions shall apply:
SHALL - The word 'shall' is to be understood as mandatory.
SHOULD - The word 'should' is to be understood as strongly
recommended to comply with the requirements of this
document.
MAY - The word 'may' indicates a possible course of action.
FLOWLINE - Flowlines transport the well fluids from the wellhead to the
collection manifold. (EP- 55000-3530)
PIPELINE FLOWLINE - A pipeline flowline transports subsea the flow from a
satellite platform to a production platform.
PIPELINE - Piping which directs fluids between platforms or between a
platform and a shore facility. (API-RP 140C)
INCOMING PIPELINE - An incoming pipeline directs fluid onto a platform or a
departing pipeline.
DEPARTING PIPELINE - A departing pipeline transports fluid from a platform or
incoming pipeline or both platform and incoming pipeline.
TRUNKLINE - Pipelines handling the flow of one or more production
platforms to shore, or to other platforms en route to shore.
GASLIFT LINES - Pipelines which carry gas for lifting / injection from a
production or gas lift compression platform to a satellite
(Also injection) platform.
SBM LINES - Pipelines connecting a terminal with a single buoy mooring
facility
MAXIMUM ALLOWABLE - The highest operating pressure allowable at any point in any
WORKING PRESSURE component other than a pipeline during normal operation or
(MAWP) (PROCESS) static conditions. (API RP 14C)
- The maximum gauge pressure permissible at the top of a
completed vessel in its operating position for a designated
temperature. This pressure is based on calculations for
each element in a vessel using nominal thicknesses,
exclusive of allowances for corrosion and thickness required
for loadings other than pressure. (API RP 521)
 MAXIMUM ALLOWABLE - The highest operating pressure allowable at any point in a
OPERATING PRESSURE pipeline system during normal flow or static conditions . (API
(MAOP) (PIPELINES) RP 14C). Usually the MAOP is equal to the pipeline design
pressure. Exceptions may be pipelines with derated MAOP
because of corrosion.
DESIGN PRESSURE(DP) - The pressure used in the design of a vessel to determine
the minimum permissible thickness or other physical
characteristics of the different parts of the vessel. (API RP
521)
- The design pressure of each component in a piping system
shall be not less than the pressure at the most severe
condition of coincident internal or external pressure and
temperature (minimum or maximum) expected during
service. The most severe condition is that which results in
the greatest required component thickness and the highest
component rating. (ASME/ANSI B31.3)
SET PRESSURE - The inlet pressure at which the pressure relief valve is
adjusted to open under service conditions (APT RP 521)
OPERATING PRESSURE - The pressure to which the vessel is usually subjected in
/ WORKING PRESSURE service. A processing vessel is normally designed for a
maximum allowable working pressure that will provide a
suitable margin above the operating pressure in order to
prevent any undesirable operation of the relieving device.
(API RP 521)
- Operating pressure is termed as working pressure in PTS
01.00.01.30., whereby working pressure is the pressure
which exists inside equipment and piping during the
intended operation.
OVERPRESSURE - Pressure in a process component in excess of the
maximum allowable working pressure.(API -RP 14C)
(Process)
OVERPRESSURE - Pressure rises due to surge and other variations from
(PIPELINES) normal operations shall not exceed the internal design
pressure at any point in the piping system and equipment by
more than 10%. (ASME/ANSI B31.4)
LEAK - The accidental escape from a process component of liquid
and/or gaseous hydrocarbons to atmosphere. (API RP 14C)
PROCESS COMPONENT - A single functional piece of production equipment and
associated piping, used in a process station such as a
separator, heater, pump or tanks. (API RP 14C)

3. ABBREVIATIONS

PTS - PETRONAS TECHNICAL STANDARD

- Exploration and Production

EP

CITHP - Closed In Tubing Head Pressure

DP - Design Pressure

MAOP - Maximum Allowable Operating Pressure

 MAWP - Maximum Allowable Working Pressure

OP - Operating Pressure

PSD - Process Shutdown

PZA-H - High Pressure Trip Sensor

PZA-HH - High-High Pressure Trip Sensor

PZA-L - Low Pressure Trip Sensor

RV - Relief Valve

SP - Set Point

USD - Unit Shutdown

WP - Working Pressure

4. REFERENCES

4.1 Group Documents

PTS 01.00.01.30 Definition and Determination of Temperature and Pressure Levels

PTS 31.22.10.32 Pressure Vessels (Amendments/Supplements to BS 5500)

Pressure Vessels (Amendments/Supplements to ASME VIII Div. 1

PTS 31.22.20.31
and Div. 2 Including December '88 Addenda..

PTS 80.45.10.10 Pressure Relief and Flare System

PTS 20.067 Flowline Overpressure Protection

EP-55000 - 2127 Overpressure Protection Systems

EP 55000 - 3530 Safety Practices For Operating Wellstream Gathering Systems.

Production Handbook 1991 Volume 6

Paragraph 2.14 Equipment/Process Protective Devices

Paragraph 2.14.1 Safety Relief Valves

Paragraph 2.14.2 Low Pressure (LP)and High Pressure (HP) Pilots

4.2 National/International/Industry Standards

Recommended Practice for Analysis, Design, Installation

API RP 14C and Testing of Basic Surface Safety Systems for Offshore
Production Platforms

API 521 Guide for Pressure Relieving and Depressuring System

 ANSI/ASME B31.3 Chemical Plant and Petroleum Refinery Piping.

Liquid Transportation Systems for Hydrocarbons, Liquid

ANSI/ASME B31.4
Petroleum Gas, Anhydrous Ammonia, and Alcohols.

ANSI/ASME B31.8 Gas Transmission and Distribution Piping System.

ASME section VIII Rules for Construction of Pressure Vessels, Division 1 & 2.

BS 5500 Unfired Fusion Welded Pressure Vessels.

5. PHILOSOPHY

5.1 Relief Valves Settings

The purpose of the relief valves is to provide secondary protection from overpressure in a
pressure containing component whilst PZA-H is to provide primary protection.

a) Pressure Vessels (ASME VIII - Div. 1 & 2 & BS 5500) and Process Pipework (ANSI
ASME B31.3)

All relief valves on new topside facilities shall be set to operate at a pressure not
exceeding the design pressure, which conforms to the requirements of ASME Section
VIII - Division 1 and 2, API -521, ANSI/ASME B31.3, BS 5500, PTS 31.22.10.32, PTS
31.22.20.31 and PTS 80.45.10.10

lt is recommended to set relief valves on new topside facilities relative to the design
pressure instead of the MAWP because by definition, for new topside facilities design
pressure is less than the MAWP. Furthermore, for new projects the MAWP of
equipment is not determinable at the design stage, since the actual material
properties and the wall thicknesses provided are not known. Design pressure is the
pressure used in the design to determine the minimum permissible component
thickness and component rating while MAWP is the calculated value based on stress
calculations for all equipment parts subjected to pressure, using the actual
thicknesses and material properties, exclusive of allowances for corrosion and
thickness required for loadings other than pressure.

Existing topside facilities which have their MAWP downrated below their original
design pressure, e.g. due to corrosion, should have their relief valves settings
changed to a pressure below the new MAWP with due consideration given to the
corrosion rate of the facilities.

A conventional relief valve that discharges into a relief system which has a back
pressure (superimposed and built-up) that exceeds 10% of the relief valve setting
should have its setting reduced by an amount equal to the backpressure. In the rare
event that this backpressure is significant, then the use of balanced bellows relief-
valves should be considered provided that the backpressure does not exceed 30% of
the relief valve set pressure. When a balanced bellows relief valve is used then the
relief valve setting need not be reduced against the backpressure.

b) Pipelines (ANSI/ASME R31.4 and B31.8)

For oil and gas pipelines, which are equipped with relief valves, the relief valves shall
have sufficient capacity and shall be set to operate to prevent the pressure from
exceeding the pipeline MAOP plus 10% . Pilot operated relief valves should be
considered for gas export pipelines. Where sizing of the full flow relief of the piping
 system becomes impractical, the use of a high integrity PZA-H trip system, e.g. two
out of three voting PZA-H's with a shutdown valve, may be a more feasible option
than relief valves. However, it should be noted that the use of relief valves is
preferred where practical.

5.2 PZA-H Settings

The purpose of the PZA-H is to provide primary protection from over pressure in a pressure
containing component by isolating the source of pressure, e.g. wells, oil pumps and
compressors. Over pressure is pressure in a process component in excess of the MAWP.

The FZA-H settings shall he as follows:

a) Flowlines (ANSI/ASME R31.3)

FZA-H is, in theory, not required on flowline where the well CITHP is less than the
flowline design pressure. In practice, it is noted that the predicted well CITHP may at
times not resemble the actual well CITHP. In view of the above, it is a common
practice to design PZA-H-on flowlines.

Flowline primary PZA-H shall be set at a pressure not exceeding 90% of the flowline
design pressure.

Where a second surface safety valve with an independent PZA-HH is used for
secondary over pressure protection of the flowlines, due to the well CITHP exceeding
the flowline design pressure the setting of this secondary PZA-HH shall be at the
flowline's design pressure.

b) Pipeline Flowlines (ANSI/ASME B31.4 and B31.8)

PZA-H on pipeline flowlines shall be set at 30% above the maximum expected
operating pressure during normal operation but not more than the CITHP of the wells
being lined up to the pipeline flowline and the pipeline flowline MAOP. The
requirement to set the PZA-H as a function of the operating pressure is to minimize
trapped-in pressure on shutdown.

c) Pipelines/Trunklines (ANSI/ASME B31.4 and B31.8)

PZA-H on crude oil trunklines being fed by centrifugal pumps shall be set at 5%
below the pump maximum discharge pressure but not exceeding the trunkline MAOP.
This is to ensure that the PZA-H would operate on closure of a downstream valve at
the downstream installation. For crude oil trunklines fed by positive displacement
pumps, it is in theory possible for the pumps to continue increasing the pressure until
it is in excess of the line MAOP, therefore the PZA-H shall be set at a pressure not
exceeding tie trunkline MAOP.

PZA-H on gas and two phase pipelines which are subjected to linepack requirements
may be set as high as possible up to the line MAOP, whilst still ensuring that it will
cause a trip on closure of a downstream valve. In cases that a relief valve is provided
for secondary overpressure protection of the pipeline, consideration should be given
to the PZA-H instrument selection to ensure that its set point tolerance will not cause
the relief valve to be operated earlier than the PZA-H.
 There is normally no requirement for PZA-H's on incoming pipelines. An exception is
for oil or gas incoming lines which have their MAOP reduced by a spec break on the
pipeline section downstream. In this instance a PZA-H shall be provided and this shall
be set at the MAOP of the lower rated section of the oil or gas pipeline. This PZA-H
shall operate a shutdown valve located in the higher rated portion of the pipeline.

For SBM lines, where PZA-H is provided to protect against inadvertent closure of a
valve at the tanker end, the PZA-H shall be set at a pressure net higher-than the
MAOP of the SBM lines or pump discharge pipework, whichever is lower.

d) Vessels (BS 5500 & ASME VIII Div. 1 & 2)

PZA-H on vessels shall be set at a pressure not exceeding 90% of the vessels relief
valve's setting. However, if it is operationally required to operate the vessels close to
the design pressure and insufficient margin is available to set the PZA-H at 10%
below the relief valves setting then it is acceptable to set the PZA-H at 5% below the
relief valve setting provided that the set point tolerances of the relief valve and PZA-H
can accommodate the small pressure setting differential. This usually would
necessitate the use of pilot-operated relief valves and electronic instrumentation for
the high pressure trip sensors.

5.3 PZA-L Settings

The purpose of the PZA-L is to provide primary protection from leaks of sufficient rate to
create an abnormal operating condition.

The PZA-L settings shall be as follows:

a) Flowlines

Flowline PZA-L shall be set at a pressure not less than 70% of the flowline normal
operating pressure. This setting is based on the premise that the flowline pressure
will not drop by more than 25% during normal operation with the 25% margin
provided for the PZA-L set point tolerance. Unless a lower pressure dip is expected
during normal operations setting the PZA-L lower would make it less effective for no
operational benefit.

b) Pipeline Flowlines

PZA-L on a pipeline flowline shall be set at a pressure not less than 70% of the
average operating pressure after a review of the historical record of operating
pressure of the pipeline flowline. The PZA-L setting shall be updated in case of
changes in mode of operation. In general, the PZA-L shall be set as high as
operationally possible.

c) Pipelines/Trunklines

For crude oil trunklines, which receive hydrocarbons from more that one station or
jacket, i.e. subject to wide variations in operating pressure, the PZA-L setting shall be
based on the trunkline operating pressure historical data. The PZA-L shall be set as
high as operationally possible.

PZA-L on gas trunklines shall be set at a pressure not less than 70% of the trunkline
normal operating pressure.
 Where a PZA-L is installed on an incoming pipeline, e.g. to protect the downstream
facility from the pipeline content then the PZA-L shall be set at a pressure not less
than 70% of the average pipeline operating pressure at the incoming end.

d) Vessels

PZA-L on pressure vessel shall be set at a pressure not less than 70% of the vessel
normal operating pressure.

PZA-L is not required for atmospheric tanks or pressure vessels which normally
operate at atmospheric pressure.
 APPENDIX I PRESSURE DIAGRAM, TOPSIDE FACILITIES

NOTES:
1 MAWP DEPENDS ON ACTUAL CONDITIONS OF EQUIPMENT, E.G. MATERIAL QUALITY, WALL THICKNESS, TEMP, CONDITIONS ETC. AND APPLICABLE
DESIGN CODES. FOR NEW TOPSIDE FACILITIES MAWP IS GREATER THAN DESIGN PRESSURE
2 MINIMUM GAP IS 5% OF OPERATING PRESSURE, OPERATING PRESSURE FOLLOWS FROM PROCESS REQUIREMENT.
3 MIN. PZA-L TO BE NOMINALLY SET AT 30% BELOW OPERATING PRESSURE
4 MAX. PZA-H MAY BE SET AT 95% OF DESIGN PRESSURE IF OPERATIONALLY REQUIRED.
5 RELIEF VALVE SET POINT MAY BE SET AT 100% OF DESIGN PRESSURE IF MAWP IS NOT KNOWN.
6 SECONDARY PZA-HH ON UNDERRATED FLOWLINE TO BE SET AT FLOWLINE DESIGN PRESSURE.
7 MAX. PZA-H TO BE SET AT 90% OR 95% OR RELIEF VALVE SET POINT. SEE ALSO NOTES 4 & 5
 APPENDIX II PRESSURE DIAGRAM, PIPELINES

NOTES:
1 PZA-H TO BE SET AS PER SECTION 5.2(b)
2 OPERATING PRESSURE FOLLOWS FROM PROCESS REQUIREMENT.
3 PZA-L TO BE NOMINALLY SET AT 30% BELOW THE OPERATING PRESSURE
4 MOAP IS USUALLY EQUAL TO THE PIPELINE DEIGN PRESSURE. EXCEPTION MAY BE PIPELINES WITH DERATED MAOP BECAUSE OF
CORROSION.