Process Safety and Pressure-Relieving Devices 417
Relief Mechanisms r·�����A������
������-e�������
Reclosing Devices, Spring Loaded
Safety and relief valves must be the direct spring loaded '----C. �� ..... iiiiiiii�..,....---�----��J
type, and for pressure ranges noted below the code [I] l
requires:
�����J
Max. Spring Reset Referenced
Set Pressure to Set Pressure"
�250 psig ±10%
;::250 psig ± 5%
*Marked on valve
As$embly #FA-7a
Assembly #FA-2
Anembly #FA-4 AIMmMy fFA-5
l �
- .
Auembly #FA-9
Figure 7-BQ. Typical bolted type safety head assemblies with angular seat design. By permission, B.S.&B. Safety Systems, Inc.
418 Applied Process Design for Chemical and Petrochemical Plants
a) Epoxy vent
b) Composite vent
c) Epoxy vent with support d) Typical explosion vent and mounting frame
Figure 7-SR. Low pressure bursting vents for explosion relief on storage silos, buildings, etc. Usually burst 1.0 to 8.0 psig depending on
design. Round vents also available. By permission, Fike Metal Products Div., Fike Corporation, Inc.
Figure 7-9A. Non-metal frangible disk. Ruptured disk showing com-
plete breakout of membrane. Courtesy of Falls Industries, Inc.
Figure 7-98. Standard non-metal frangible disk (graphite), Teflon®
coatings or linings are available on entire disk. By permission, Zook
Enterprises.
The set pressure tolerances of pressure relief valves are
not to exceed ±2 psi for pressures up to and including 70
psig and ±3% for pressures above 70 psig. Indirect opera- The pilot valve is a self-actuated pressure relief valve
tion of safety valves, for example, by pilot valve, is not that controls the main valve opening.
acceptable unless the primary unloading valve will auto-
matically open at not over the set pressure and will oper- Nonreclosing Pressure Relieving Devices
ate fully in accordance with design relieving capacity con-
ditions if some essential part of the pilot or auxiliary Rupture disks must have a specified bursting pressure
device should fail [ 1]. at a specified temperature. There must be complete iden-
Process Safety and Pressure-Relieving Devices 419
Figure 7-9C. Armored graphite disk. Note steel ring bonded to cir-
cumference of disk to increase safety in toxic or flammable services
and improve reliability by preventing unequal piping stresses from
reaching the pressure membrane. Teflon® coatings or linings are
available on the entire disk. By permission, Zook Enterprises. Rupture disc installation
Vent side (lower pressure side)
Product side (higher pressure side)
Figure 7-9D. Protection against two different pressures from opposite directions using graphite disks, such as in closed storage tanks. Par-
ticularly APl-type to guard against failure of primary breathers, conservation vents, etc. These require a differential of at least 10 psig between
the two burst ratings, depending on diameters of disks. By permission, Continental Disc Corporation.
420 Applied Process Design for Chemical and Petrochemical Plants
tification of the metallurgy (if metal) or other properties
if graphite or plastic, and the disk must be guaranteed by
the manufacturer to burst within 5% (±) of the specified
bursting pressure at the rated temperature. - ANSI flange
Std
The connection nozzle holding the disk must have a
net cross-sectional area no less than that required for the
design rated conditions of the disk.
The certification of disk performance is to be based on
actual bursting tests of two or more disks from a lot of the
same material of the exact same size as the disk to be sold
by the manufacturer. The holder for the test disks must be
identical to the design, dimensions, etc., for the disk ,---,,------ Optional TFE liner blocks
being certified. (See details ASME code, Par. UG-127 [l]). water and dirt from disks
in open vents.
Pressure Settings and Design Basis
Unfired steam boilers, i.e., nominally termed waste heat
boilers or, heat exchangers, which generate steam by heat
interchange with other fluids (See ASME code [I] Par. U-
Duplex
DUPLEX Disks extend corrosion resistance
to highly oxidizing agents. halogens except
Std
free fluorine, and virtually all other cor- - ANSI flange
rosives. A sheet of PTFE is used as a bar-
rier on the service side of the disk. See page
12. Additionally. these disks are processed
to accommodate temperatures to 392F L.....H-=---Gaskets
without insulation. L--1'----- TFE liner
- ANSI flange
Std
"����-··· !J: • J
Flow arrows (2)
*Insulated
INSULATED Disks are available in MONO, g:::;:;��s
INVERTED. and DUPLEX styles to accom-
modate temperatures exceeding 338F to
700F. They are furnished as an attached -!. � ..
unit as shown because the nameplate rat- F-----1-n- s u- l a-t � i on J
ing of the disk must be established at the nameplate
cold face temperature of the insulation. 4!.....::��-- Gaskets (all included)
Std AAR vent
-
Figure 7-9E. Duplex and insulated disks. By permission, Zook Enterprises.
Process Safety and Pressure-Relieving Devices 421
Figure 7-9E. Continued.
To meet code requirements, the relieving device must
be directly open to the system to be relieved, see Figures 7-
10, 7-11, and 7-12. For Figures 7,10, 7-11, and 7-12, the rup-
ture disk and the relief valve must be designed to handle
the relieving capacity at the relieving temperature without
allowing more than a 10% pressure build-up above the
maximum allowable working pressure of the unfired pres-
sure vessel ( or corresponding overpressure for other code
requirements). Figure 7-11 requires that the rupture disk
be designed the same as for Figure 7-10, 7-13A and 7-13B;
and Figure 7-12 requires that the relief valve be the prima-
Figure 7-9F. For pressure ratings of 15 psig or lower, subject to inter- ry device and meet the process relief requirements; it may
nal vacuum conditions, a vacuum support is required that is an inte- have additional capacity to accommodate such conditions
gral part of the rupture disk and cannot be added in the field. By per- as external fire, or this additional requirement may be
mission, Falls Industries.
installed in a separate relief valve or rupture disk as shown.
Also the separate rupture disk may be in a secondary func-
1 ('g), should be equipped with pressure relieving devices tion not covered by the code for such conditions as run-
required by the ASME Code, Section I, as far as applica- away reactions and internal explosion. For these condi-
ble; otherwise, use Par. UG-125. Vessels, which per Par. U- tions the setting of the rupture disk is left up to the
1 (g)), follow Par. UG-125ffare: designer, and may be higher than that for the usual relief.
Of course, it should be set sufficiently below the rupture
1. Evaporators or heat exchangers condition for the vessel or component in order to avoid a
hazardous condition and meet Code requirements.
2. ''Vessels in which steam is generated by the use of
heat resulting from operation of a processing system Unfired Pressure Vessels Only, But Not Fired or Unfired
containing a number of pressure vessels such as used Steam Boilers
in the manufacturer of chemical and petrochemical
products" [l]
• Non-fire exposure
3. Par. U-1 (h) "Pressure vessels or parts subject to direct
firing from the combustion of any fuel, which are not Single pressure relief valve installation. Must be set to
within the scope of Sections I, III or IV, may be con- operate at a pressure not exceeding the maximum allow-
structed in accordance with the rules of Section VIII, able working pressure of the vessel (MAWP), Ref [ l] Par.
Div. I, Par. UW-2 (d) [l]. UG-134, but may be set to operate at pressures below the
422 Applied Process Design for Chemical and Petrochemical Plants
Stb- V
Excess flow *Rupture disk set
*Metal rupture disk higher than SRV for
only. Disk set lower \ - emergency relief
than SRV* --+--•11 \.. Tell-tale
Vessel Vessel
(a) (b)
Note: *All reliefs must conform to code.
Low pressure rupture 1
vent manifold
disk to prevent mani- · � o
fold contents from
back-flowing into SRV -+
A ___
I 1
/__ "-sRV
Note: Rupture /�
disk may also be
installed here,
see (a).
Vessel
Vessel
(c) (d)
Figure 7-10. Rupture disk installations.
MAWP. The device must prevent the internal pressure of 110% of the MAV17P of the vessel (ASME Par. UG-
from rising more than 10% above the l'v!AWP. 134b).
Multiple pressure relief valves installation. If the When valves are used to meet the requirements of
required capacity is provided using more than one pressure both Par. UG-125(c) and UG-125c-(2); that is, both
relieving device, a. only one device must be set at or below internal process pressure and external fire/heat
the MA,VP of the vessel, and, b. the additional device(s) requirements, the valve(s) must be set lo operate not
may be set to open at higher pressures, but in no case at a over the J\tfA HP of the vessel. For these conditions of the
pressure any higher than 105% of the MAV17P. The combi- additional hazard of extreme fire or heat, supplemental
nation of relieving valves must prevent the pressure from pressure relieving devices must be installed to protect
rising more than 16% above the MAWP. See ASME Ref the vessel. The supplemental devices must be capable
[l] Par. UG-125C and C-1 and Par. UG-134a. of preventing the pressures from rising more than
• External fire or heat exposure only and process relief 21 % above the MAWP (note: this is not the setting).
The same pressure relieving devices may be used to
Valves to protect against excessive internal pres- satisfy the capacity requirements of Par. UG-125c or
sures must be set to operate at a pressure not in excess C(l) and Par. UG-125c-(2) provided the pressure set-
Process Safety and Pressure-Relieving Devices 423
• Vessels operating completely filled with liquid must
be equipped with liquid relief valves, unless otherwise
protected (Par. UG-125-3(g).
• Safety and safety relief valves for steam service should
meet the requirements of ASME Par. UG-131 (b), Ref
(1]. Note that the requirements for these valves are
slightly different than for process type valves.
Relieving Capacity of Combinations of Safety Relief Valves and
Rupture Disks or Non-Reclosure Devices (Reference ASME
Code, Par. UG-127, UG-132).
• Primary Relief
A single rupture disk can be used as the only over-
pressure protection on a vessel or system (Figure 7-10).
Figure 7-11. Safety valve and rupture disk installation using pres-
sure rupturing disk on inlet to safety relief valve, and low pressure The disk must be stamped by the manufacturer with
disk on valve discharge to protect against back flow/corrosion of the guaranteed bursting pressure at a specific tempera-
fluid on valve discharge side, possibly discharge manifold. By per- ture. The disk must rupture within ±5% of its stamped
mission, Fike Metal Products Div., Fike Corporation, Inc. bursting pressure at its specified burst temperature of
operation. The expected burst temperature may need
ting requirements of Par. UG-134(a) are met. See Par. to be determined by calculation or extrapolation to be
(A) 1 and 2 above and see Figure 7-7A. consistent with the selected pressure.
The set burst pressure should be selected to per-
mit a sufficiently wide margin between it and the ves-
When pressure relief devices are intended primar- sel's used or design operating pressure and tempera-
ily for protection against overpressure due to exter- ture to avoid premature failure due to fatigue or
nal fire or heat, have no permanent supply connec- creep of metal or plastic coatings.
tion, and are used for storage at ambient
temperature of non-refrigerated liquefied com- Selected Portions of ASME Pressure Vessel Code, quoted l1y
pressed gases, they are excluded from requirements permission [I]
of Par. UG-125c (1) and C (2), with specific provi-
sions. See ASME code (1) for detailed references and Section VIII, Division I Superscript = Footnote reference
conditions. July I, /989 Edition in Code Figure No., for this text.
Safety Relief Valve
I ·J-Bolt
Test Pressure
Connection
Figure 7-12. Rupture disk mounted beneath a pressure relieving spring-loaded valve. A reverse buckling® disk arrangement is often recom-
mended here. By permission, B.S.&B. Safety Systems, Inc.
424 Applied Process Design for Chemical and Petrochemical Plants
t Vent 3. Application of Rupture Disks
a. A rupture disk device may be used as the sole
Flanges
Gaskets (Soft pressure relieving device on a vessel.
Material such os
Neaprene Rubber�--,,1,,1!!!!1' Rupture Disk Note: When rupture disk devices are used, it is
Preferred for
Top Gaskel.J recommended that the design pressure of the
Vessel Nozzle
vessel be sufficiently above the intended operat-
Install Disk with Pressure Mtmbrone up. When inverted, ing pressure to provide sufficient margin
the Disk Bursts ot about 65% Increase in Pressure. Disk between operating pressure and rupture disk
Must be Positioned True Center al Vent Line and Norrie. II
Eccentric, Burst Characteristics Might Not Hold True. bursting pressure to prevent premature failure of
the rupture disk due to fatigue or creep.
Figure 7-13A. Installation of graphite rupture disk. Adapted by per-
mission, Falls Industries, Inc. Application of rupture disk devices to liquid ser-
vice should be carefully evaluated to assure that the
design of the rupture disk device and the dynamic
energy of the system on which it is installed will
result in sufficient opening of the disk.
Vent b. A rupture disk device may be installed between a
i pressure relief valve 48 and the vessel provided.
(See Figure 7-10.)
1. The combination of the spring loaded safety or
safety relief valve and the rupture disk device is
I t F Gaskets ample in capacity to meet the requirements of
UG-133 (a) and (b).
2. The stamped capacity of a spring loaded safety
or safety relief valve (nozzle type) when
(b) Inverted graphite disk bursts at higher pressure than with flat sur- installed with a rupture disk device between the
face on top.
inlet of the valve and the vessel shall be multi-
Figure 7-138. Inverted graphite disk bursts at higher pressure than plied by a factor of 0.80 of the rated relieving
with flat surface on top. Adapted by permission, Falls Industries, Inc. capacity of the valve alone, or alternatively, the
capacity of such a combination shall be estab-
lished in accordance with Par. 3 below;
Rupture Disk Devices, 44 Par UG-127 3. The capacity of the combination of the rup-
ture disk device and the spring loaded safety or
1. General safety relief valve may be established in accor-
a. Every rupture disk shall have a stamped bursting dance with the appropriate paragraphs of UG-
pressure within a manufacturing design range 35 at I 32, Certification of Capacity of Safety Relief
a specified disk temperature 36 and shall be Valves in Combination with Non-reclosing
marked with a lot number, and shall be guaran- Pressure Relief Devices.
teed by its manufacturer to burst within 5% (plus 4. The space between a rupture disk device and a
or minus) of its stamped bursting pressure at the safety or safety relief valve shall be provided with
coincident disk temperature. a pressure gauge, a try cock, free vent, or suit-
able telltale indicator. This arrangement per-
mits detection of disk rupture or leakage. 19
2. Capacity Rating 5. The opening"? provided through the disk, after
a. The calculated capacity rating of a rupture disk burst, is sufficient to permit a flow equal to the
device shall not exceed a value based on the capacity of the valve (Par. 2 and 3 above) and
applicable theoretical formulas (see Par. UG-131) there is no chance of interference with proper
for the various media multiplied by K = coeffi- functioning of the valve; but in no case shall
cient = 0.62. The area A (square inches) in the this area be less than 80% of the area of the
theoretical formula shall be the minimum net inlet of the valve unless the capacity and func-
area existing after burst. 47 tioning of the specific combination of rupture
Process Safety and Pressure-Relieving Devices 425
disk and valve have been established by test in Footnotes to ASME Code
accordance with UG-132.
Note that in lieu of testing, Par (b) 2 and (b) 47. The minimum net flow area is the calculated net
3 above allows the use of a capacity factor of 0.80 area after a complete burst of the disk with appro-
as a multiplier on the stamped capacity of the priate allowance for any structural members which
spring loaded safety relief valve (nozzle type). may reduce the net flow through the rupture disk
Some manufacturers test specific valve/rupture device. The net flow area for sizing purposes shall
disk combinations and determine the actual not exceed the nominal pipe size area of the rup-
capacity factor for the combination, and then ture disk device.
use this for the net capacity' determination. See 48. Use of a rupture disk device in combination with a
Figures 7-10, 7-11, 7-12, 7-13A and 7-13B. safety or safety relief valve shall be carefully evalu-
c. A rupture disk device may be installed on the out- ated to ensure that the media being handled and
let side 50 of a spring loaded safety relief valve the valve operational characteristics will result in
which is opened by direct action of the pressure in pop action of the valve coincident with the burst-
ing of the rupture disk.
the vessel provided. (Figure 7-12)
49. Users are warned that a rupture disk will not burst
at its design pressure if back pressure builds up in
l. The valve is so designed that it will not fail to the space between the disk and the safety or safety
open at its proper pressure setting regardless of relief valve which will occur should leakage develop
any back pressure that can accumulate between in the rupture disk due to corrosion or other cause.
the valve disk and the rupture disk. The space 50. This use of a rupture disk device in series with the
between the valve disk and rupture disk shall be safety or safety relief valve is permitted to minimize
vented or drained to prevent accumulation of the loss by leakage through the valve of valuable or
pressure due to a small amount of leakage from of noxious or otherwise hazardous materials and
the valve. 51
where a rupture disk alone or disk located on the
2. The valve is ample in capacity to meet the inlet side of the valve is impracticable, or to prevent
requirements of UG-133 (a) and (b). corrosive gases from a common discharge line
3. The stamped bursting pressure of the rupture from reaching the valve internals.
disk at the coincident disk temperature plus any 51. Users are warned that an ordinary spring loaded
pressure in the outlet piping shall not exceed safety relief valve will not open at its set pressure if
the design pressure of the outlet portion of the back pressure builds up in the space between the
safety or safety relief valve and any pipe or fit- valve and rupture disk. A specially designed valve is
ting between the valve and the rupture disk required, such as a diaphragm valve or a valve
device. However, in no case shall the stamped equipped with a bellows above the disk.
bursting pressure of the rupture disk al the
coincident operating temperature plus any *Reprinted with ASME permission. ASME Pressure Vessel Code, Section
pressure in the outlet piping exceed the maxi- Vlll, Division I, UG-127, 1989 Edition, pp. 8�8.
mum allowable working pressure of the safety or
safety relief valve. Establishing Relieving or Set Pressures
4. The opening provided through the rupture The pressure at which the valve is expected to open
disk device after breakage is sufficient lo permit (set pressure) is usually selected as high as possible con-
a flow equal to the rated capacity of the sistent with the effect of possible high pressure on tl1e
attached safety or safety relief valve without
exceeding the allowable overpressure. process as well as the containing vessel. Some reactions
have a rapid increase in temperature when pressure
5. Any piping beyond the rupture disk cannot be increases, and this may fix the maximum allowable
obstructed by the rupture disk or fragment. process pressure. In other situations the pressure rise
6. The contents of the vessel are clean fluids, free above operating must be kept to some differential, and
from gumming or clogging matter, so that accu- the safety valve must relieve at the peak value. A set pres-
mulation in the space between the valve inlet sure at the maximum value (whether maximum allowable
and the rupture disk ( or in any other outlet working pressure of vessel, or other, but insuring protec-
that may be provided) will not clog the outlet. tion to the weakest part of the system) requires the small-
7. The bonnet of the safety relief valve shall be est valve. Consult manufacturers for set pressure compen-
vented to prevent accumulation of pressure. sation (valve related) for temperatures >200°F.
426 Applied Process Design for Chemical and Petrochemical Plants
Table 7-IA For situations where explosions may be involved-
Compensation Factors for Safety Relief Valves chemical liquid, vapor or dust-it is generally advisable to
Between Atmospheric Test Temperature and obtain rate of pressure rise data and peak explosion pres-
Actual Operating Temperature [24] sure data in order to intelligently establish the design
parameters. Such data are available [7, 8, 14, 15, 16, 19,
Operating Temperature Percent Increase in Set Pressure 41, 54]; however, it is important to evaluate whether the
OF at Atmospheric Temperature conditions are comparable between the systems when
-450 to 200 None selecting the values for design. In general the lower the
201 to 450 2 setting for pressure relief, the lower will be the final inter-
451 to 900 3 nal peak pressure in the vessel. It is extremely important
901 to 1200 4
to realize that the higher the system pressure before
By permission, Teledyne Farris Engineering Corp., Cat. FE-316, relief, the higher will be the peak pressure attained in the
p. 12.
vessel. In some difficult cases it may be advisable to set
relief devices at two pressures, one lower than the other.
Of course, each must be designed for the conditions
expected when it relieves, and one or all must satisfy code
requirements or be more conservative than code.
For pulsating service, the set pressure is usually set
Table 7-lB greater than the nominal 10% or 25 psig above the aver-
Set Pressure Compensation for Saturated Steam age operating pressure of the system in order to avoid
Service Safety-Relief Valves Between Atmospheric unnecessary releases caused by surging pressure peaks, but
Test Temperature and Actual Operating Temperature still not exceeding the MAv\lP of the vessel/ system. Careful
analysis must be made of the proper set condition.
Saturated Steam Service Safety-relief valves are available for relieving or set pres-
Set Pressure % Increase in sures as low as 2, 10, and 20 psig, as well as higher pressures.
(PSIG) Spring Settling
Lower pressures are available on special order. Usually a
10-100 2% more accurate relief is obtained from the higher pressures.
101-300 3% Safety relief valves are normally tested in the shop, or
301-1000 4%
1001-3000 5% even on the equipment at atmospheric temperature. The
set tolerances on the valves as manufactured are estab-
By permission, Teledyne-Farris Engineering, Cat. 187C lished by the Code as discussed earlier. In order to recog-
nize the difference between the test temperature and the
When the pressure rise in a system is gradual and not actual operating temperature at actual relief, the correc-
"explosive" in nature, a safety or safety relief valve is the tions shown in Table 7-lA and 7-lB are applied. An
proper device, but when it is critical to completely increase in temperature above design causes a reduction
depressure a system or the rate of pressure increase in valve set pressure due to the effects of temperature on
might be expected to be rapid, then a rupture disk is the the spring and body.
proper device. Properly designed a pilot operated valve Testing of pressure relieving spring loaded valves al
may be selected after checking its performance with the atmospheric temperature requires an adjustment in set
manufacturer. pressure at ambient conditions to compensate for higher
operating temperatures. For process services see Table 7-
lA and for saturated steam, use Table 7-1 B.
Often a system (a group of vessels not capable of being
isolated from each other by block valves, or containing Safety and Safety Relief Valves for Steam Service
restriction to flow and release of pressure) may need a
relief valve set reasonably close, sat + 15% to 20% when Pressure relieving devices in process plants for process
system is below 1000 psig; above, typically use 7% to 15% and utility steam systems must conform to the require-
above as set criteria related to normal operating pressure ments of ASME [l] Par. UG-131b. This is not necessarily
to catch any pressure upswing. Then this may have a back- satisfactory to meet the ASME Power Boiler Code for
up valve set higher (but within code) to handle further applications on power generating equipment.
pressure increase. Or, the second device may be a rupture Vessels or other pressure containing equipment that
disk. It is not unusual to have two relief devices on the operates filled with liquid must be provided with liquid
same equipment set at different pressures. relief valves, unless protected otherwise [l]. Any liquid
Process Safety and Pressure-Relieving Devices 427
relief valve must be at least ,If in. in pipe size, [1] Par UG- quately known. They should be researched or investigated
128 (see [79]). by laboratory testing for possible runaway conditions and
then the kinetic and heat/pressure rise calculations
Selection and Application should be performed, even if some assumptions must be
made to establish a basis. Refer to later paragraphs and
Causes of System Overpressure the American Institute of Chemical Engineers Design
Institute for Emergency Relief [67]. At the time of aves-
Figure 7-14, Operational Check Sheet [25], lists 16 pos- sel or pressure/vacuum system failure, the calculations
sible causes of overpressure in a process system. There are for the effected pressure-relief devices are always reviewed
many others, and each system should be reviewed for its by plant management and the Occupational Safety and
peculiarities. System evaluation is the heart of a realistic, Health Administration (OSHA) inspectors. A few notes
safe and yet economical overpressure protection installa- on causes of process system failures are noted below, with
tion on any single equipment or any group of equipment. additional comm en ts in API-521 [13, 33a, b, c]
Solving formulas with the wrong basis and/ or data can be
disastrous. The following should be reviewed:
Failure of Cooling Water: assume all cooling mediums
fail, determine relief capacity for the total vapors entering
1. The sources of possible overpressure
2. Maximum overpressure possible from all sources the vessel, including recycle streams. See [3] and [10].
3. Maximum rate of volume increase at the burst pres-
sure, and temperature at this condition. Reflux Failure: (a) At top of distillation column, capaci-
4. Length of duration of overpressure. ty is total overhead vapor [iO], (b) when source of heat is
in feed stream, capacity is vapor quantity calculated in
Capacity Requirements Evaluation for Process immediate feed zone [3], (c) when reboilers supply heat
Operation (Non-Fire) to system, capacity is feed plus reboil vapors [3]. Each sit-
uation must be examined carefully.
Each system and item of equipment should be exam-
ined for operational safety as set forth by specific plant
area (and process fluids) requirements and the codes Blocked Outlets on Vessels: (a) For liquid, capacity is max-
previously cited. The codes particularly [10, 13, 27, 33a, b, imum pump-in rate. (b) For liquid-vapor system, capacity
c] establish guides based on wide experience, and are is total entering vapor plus any generated in vessel [ 10].
sound requirements for design. Relief capacity is based on
the most severe requirement of a system, including possi-
ble two-phase flow [67]. A system is generally equipment Blocked Outlets and Inlets: for systems, lines or vessels,
or groups of equipment which is isolated by shut-off capable of being filled with liquid and heated by the sun
valves. Within these isolated systems a careful examina- or process heat, require thermal relief to accommodate
tion of the probable causes of overpressure is made [6]. the liquid expansion (assuming vaporization is negligible).
Figures 7-15, 7-16, and 7-17 are suggested guides [25].
Capacities are calculated for conditions of temperature Instrument Failure: assume instrument control valves
and pressure at actual state of discharge. Final discharge freeze or fail in open position (or closed, which ever is
pressure is the set pressure plus overpressure. worse), determine capacity for relief based on flows, tem-
It must be emphasized, that the determination of the peratures, or pressures possible under these circum-
anticipated maximum overpressure volume at a specified stances. The judicious selection of instrument failure
pressure and temperature is vital to a proper protection sequence may eliminate or greatly reduce relief valve
of the process system. The safety relief calculations should requirements.
be performed at the actual worst conditions of the system,
for example, at the allowable accumulated pressw·e and
its corresponding process temperature. These can be Equipment Failure: pumps, tubes in heat exchangers and
tedious and perhaps time-consuming calculations, but furnaces, turbine drivers and governor, compressor cylin-
they must not be "glossed" over but developed in a man- der valves are examples of equipment which might fail
ner that accounts for the seriousness of the effort. They and cause overpressure in the process. If an exchanger
must be documented carefully and preserved permanently. tube splits or develops a leak, high pressure fluid will
The situation is just as critical, if not more so, for run- enter the low side, overpressuring either the shell or the
away reactions or reaction conditions that are not ade- channels and associated system as the case may be.
428 Applied Process Design for Chemical and Petrochemical Plants
SAFETY VALVE DESIGN OPERATIONAL CHECK SHEET
Date: Job No.: ------
Checked: By:
Vessel or System: --------=------------------�
Process Evaporator
Design Pressure: 75 PSIG
Allowable Pressure for Capacity Relief: 75 + (75+ 10%) =
= 82.5 PSIG
Operating Conditions: Fluid: PDC Mol Wt. 113.5
Oper.
Sp.Gr. 1.16 Temp. -=---------
Latent Heat 125 BTU/Lb. Corrsive No
----
Physical Conditions: Vessel Dia. 5 feet x Length : 6 feet
Insulation: Yes, 2 11
__
Fi re Con tr o 1 Me a-s�u-r_e_s_ : N_o_S_p_r_i_n_k_l_e_r S_y_s- .
======================================================================
Cause of Overpresure Capacity Requiremant, Lb./Hr.
1. Failure Cool water/Elect/Mechanical
2. Reflux and/or Condensing Failure
3. Entrance of a Highly Volatile Fuel
4. Vapor generation, external fire ----2,920---------------
5. Excessive Operating Heat Inputs ---22,500---------------
6. Accumulation of Non-Condensibles
7. Closed Outlets ---22,500 or less-------
8. Failure of Automatic Controls/Instr. ---22,500 or less-------
9. Internal Explosions(Use Rupture Disk)
10.Chemical Reaction/Run-a-Way(" " )
11.Two Phase Flow Conditions
12.Inadvertent opening valve into system
13.Check Valve failure
14.Cooling Fans failure
15.Heat Exchanger Tube rupture/failure
16,Circulating Pump failure
Causes that may occur simutaneously: ------------------------
------ Any of the four considered may occur simultaneously------
Probability of occurence: --Closed outlet with a failure of
automatic control resulting in excessive heat input.----------
Allowance to made:----None------------------------------------
Relief capacity used for sizing valve(s)------22,500 Lb./Hr.--
======================================================================
Auxiliaries Cause of Overpressure Capacity Requirement
1. Exchangers Split tube(s) 1482 Lb.Hr.
Thermal Vaporization
2. Pumps Discharge Restriction
3. Length of Line Thermal Vaporization
Figure 7-14. Safety valve design operational check sheet. Adapted and added to by permission, N. E. Sylvander and D. L. Klatz, Design and
Construction of Pressure Relieving Systems, Univ. of Michigan Press, Ann Arbor (1948). Six items of overpressure list above by this author
and from API Rec. Practice 521 (1982).
Process Safety and Pressure-Relieving Devices 429
Solely Valve Vacuum: (a) Removal of liquid or vapor at greater rate
SV-1 +
High fl .$-• I Block than entering a vessel, capacity determined by volume dis-
Pressure� Vo Ive placed. (b) Injecting cold liquid into hot (steamed out)
t
Steam Reducing I I Driven Equipment
Station • -- (Ctntrifugal Camprmor I vessel, the condensing steam will create vacuum, and must
Pump, etc.)
Sleom Turbine be relieved. Capacity is equivalent to vapor condensed.
Driver
Safely Valve Required lo Protect Reducing Slotion Solely Valve SV-2 is Set to Protect In-breathing and Out-breathing Pum,1J In and Out: See
Discharge Pressure in Cose of Valve Failure. SV-1 Discharge Side of Turbine, as ii is
is Set at Slightly Above Downstream Pressure of Not Designed lo Withstand Inlet section on Pressure-Vacuum Relief for Low Pressure
Reducing Station, ond Protects All Equipment Steam Pressure on Exhaust Side.
Operating ot this Pressure on Sleom Header. Storage Tanks.
Figure 7-15. Safety valve protecting specific equipment operation.
Installation
Never place a block valve on the discharge side of a
pressure relief device of any kind, except see [I] Par. U-
135(e).
Never place a block valve on the inlet side of a pressure
relief device of any kind, unless it conforms to the code
Positive D isplacemenl practice for rupture disks or locking devices. See [1] Par.
Pump or Compressor
UG-135(e) and Appendix M, ASME code.
Sotery Valve Required to Protect Against Closed
B!ock Vo Ive Anywhere in Discharge Sys fem. Note that the intent of the ASME Code is to ensure
that under those circumstances where a pressure relieving
Figure 7-16. Safety valve in positive displacement system.
device can be isolated by a block valve from its pressure,
or its discharge, that a responsible individual lock and
unlock the block valve to the safe open position and that
this individual remain at the block valve the entire time
that the block valve is closed.
Safety (relief, or safety-relief) valves are used for set
pressures from 10 psig to 10,000 psig and even higher. At
the low pressures the sensitivity to relieving pressure is not
Oistillotion
Column always as good as is required for some processes, and for
This is Accepfoble os there is r.o Block Valve Isolating this reason most valve installations start at 15 to 20 psig.
ony Item. II Block Vo Ive Installed ot A, Sofery Valve would Figures 7-10 and 7-18 illustrate a few typical safety valve
be RE quired to Protect Condenser and Receiver. II Additional
Bloc• Valve Installed ot B, Safety Valve would be Required installations. Care must be shown in designing any mani-
for Condenser ond also for Receiver.
fold discharge headers collecting rhe vents from several
Figure 7-17. System protected by safety valve on column. valves. Sharp bends are to be avoided. Often two or more
b w ! Vent or
To Manifold 1;0 � 1 interconnected Locking Device
r<:,
Dischcrqe Hecder
Free-Opening
Covered Special
3-Way
Discharge
Plugs or
Full-open
--...
Gate Valve
Liquid
Drain
Hole
vessel
Vessel Vessel
or Pipe or Pipe
Dischorqe , A:tcrr.ote Arrongemer.ls Inlet, Alternate Arrangements Figure 7-18. Safety relief valve installations.
430 Applied Process Design for Chemical and Petrochemical Plants
collection systems are used in order to avoid discharging requirements. Multiple valves may also be individually
a high pressure valve into the same header with a low pres- installed separately on a vessel.
sure valve. The simultaneous discharge of both valves
might create too great a back pressure on the Jaw pres- Figure 7-19 illustrates a newer approach at simplifying
sure valve, unless adequate arrangement has been made the dual safety relief valve installation, ASME Sect. Vlll,
in the valve design and selection. The balanced safety- Div. 1, UG-135(b) [l] and API RP-520, Part II Confor-
relief valve can overcome most of the problems of this mance [33). Note that the SRV valves are mounted on top
type system. of each of one dual vertical connections and are bubble
tight. Also see cross section view. The flow C,, valves for
Whenever possible the individual installation of valves each size device are available from the manufacturer.
is preferred, and these should be connected directly to
the vessel or pipe line [ 1, 28). If a block-type valve is con- The operational instructions of Anderson Greenwood
sidered necessary for a single valve installation, it must be & Co. for Figure 7-19 are quoted by permission:
of the full open type, and locked open with the key in The AGCO Safety Selector Valve body houses a
responsible hands, as stated earlier.
uniquely designed switching mechanism. The inter-
Dual installations are frequently made in continuous nal rotor smoothly diverts flow to either safety relief
processes, to allow switching from one valve to another valve. Conventional direct spring operated valves or
without shut down of the pressure system. A special three- pilot operated valves may be used. The inactive valve
way plug of full open type is installed directly on the ves- is totally isolated by external adjustment. To begin
sel, and the safety valves are attached to it with short pip- switchover, the retraction bushing is rotated to its
ing (Figure 7-18). The three-way valve insures that one stop. This separates the isolation disk from the stand-
side of the safety valve pair is always connected to the ves- by valve channel and temporarily "floats" it in the
sel, as this pattern valve does not have a blind point dur- main valve cavity. The index shaft is then rotated
ing switching (Also, see Figure 7-19). One of the impor- 180° to the alternate channel. The retraction bush-
tant justifications for this dual arrangement is that ing is then returned to its original position, securely
safety-relief valves may leak on reseating after discharging. seating the isolation disk beneath the valve taken out
This leak may be caused by a solid particle lodged on the of service. A red pointer indicates which valve is in
seat. This valve can be removed for repair and cleaning service and double padlocking provisions allow the
after the process has been switched to the second valve. safety selector valve to be locked in either safety relief
Each valve must be capable of relieving the full process valve position. The padlocks or car seals can only be
Figure 7-19. Safety selector valve for dual safety relief valve installation with switching. By permission, Anderson, Greenwood and Co.© AGGO.
Process Safety and Pressure-Relieving Devices 431
Retraction Bushing Index Shaft
Lessthan3%
Connection and pressure loss
Bleed Port for at rated flow
standbySRV
Spare
Isolation Disc
(Soft Seated)
(By others)
Figure 7-19 cont.
installed with the internals in the proper position. Discharge piping must be sized for low pressure drop
No special tools are necessary for switching. at maximum flow not only from any one valve, but for the
combined flow possibilities in the discharge collection
The alternate concept which has been in use for many manifold all the way to the vent release point, whether it
years is to fabricate or purchase a Tee connection upon be a Oare, incinerator, absorber or other arrangement
which the two safety relief valves can be mounted on top of [ 13). See Figures 7-20 illustrations.
their full-port plug or gate valve with required locking lugs. Conventional safety relief valves, as usually installed,
Rupture disks are often used in conjunction with safe- produce unsatisfactory performance when variable back
ty valves as shown in Figures 7-10, 7-l l, 7-12, and 7-18. pressure exists [10, 33). See Figure 7-6. The same variable
back pressure forces affect the set pressure release also. At
Inlet piping is held to a minimum, with the safety low back pressures, the valve flow falls rapidly as com-
device preferably mounted directly on the equipment and pared with the flow for a theoretical nozzle. See Figures
with the total system pressure drop loss to pressure relief 19 and 20 in Ref. [33a].
valve inlet not exceeding 3% of the set pressure in psig, of For conventional valves, pressure drop or variations in
maximum relief flowing conditions [JO]. To conform to back pressure should not exceed 10% of set pressure.
code (see ASME code, Sect, VIII, Div. l-UG-127 [l]) avoid Because most process safety valves are sized for critical
high inlet pressure drop and possible valve chatter:
pressure conditions, the piping must accommodate the
capacity required for valve relief and not have the pres-
1. Never make pipe connection smaller than valve or sure at the end of vent or manifold exceed the critical
disk inlet pressure. Designing for pressure 30% to 40% of critical
with balanced valves, yields smaller pipes yet allows prop-
2. Keep friction pressure drop very low, not over I to 2 er functioning of the valve. The discharge line size must
percent of allowable pressure for capacity relief [l, not be smaller than the valve discharge. Check the manu-
10, 25, 28, 33].
facturer for valve performance under particular condi-
3. Velocity head loss should be low, not over 2% of tions, especially with balanced valves which can handle up
allowable pressure for capacity relief [25]. to 70% to 80% of set pressure as back pressure.
432 Applied Process Design for Chemical and Petrochemical Plants
r
Weather cap
(may be required)
Pressure
relief
Support to resist weight If pressure relief valve valve
and reaction forces ---·, is connected to a closed
system, care should be
taken to keep piping strains
away from the valve
under all conditions Pressure
of process operation drop not
\ more than
3 percent of
---------- , I set pressure
---------------------V Vessel
Pressure � nal
drop not low-point drain
more than
3 percent of Nominal pipe
set pressure diameter no less
Vessel than valve
Inlet size Note: The stop valve must have a full port area greater than or
equal to the inlet size of the pressure relief valve. The stop valve
should be used only as permitted by the applicable codes.
Typical pressure relief valve without a stop valve Typical pressure relief valve with a stop valve
: , ,--------------, ' l See 2.2.2 for Pressure
,� pressure-loss relief Discharge piping
valve
limitation
Inlet piping sized so that
pressure drop from vessel to
pressure relief valve inlet
Vessel flange does not exceed
3 percent of valve set pressure
.
I
I
I
I
'
' ....... 1
Typical pressure relief valve mounted on process line Typical pressure relief valve mounted on long inlet pipe
Figure 7-20. Recommended APl-520 piping for safety relief valve installations. Reprinted by permission, American Petroleum Institute, Sizing,
Selection and Installation of Pressure Relieving Devices in Refineries, Part II-Installation, API RP-520, 3rd Ed., Nov. 1988.
For non-critical flow the maximum back pressure must erances, and whose rated pressure is the result of bursting
be set and pressure drop calculated by the usual friction tests of representative sample disks which burst within the
equations. range specified. The engineer should specify only ASME
code certified disks. It is not possible to obtain a disk for
When process conditions permit, the low pressure
range is handled by bursting disks which will relieve down the usual process application set to burst at a given pres-
to 2 psig. These disks are also used up to 100,000 psig and sure, as is the relieving pressure of a safety valve. Increase
above. The rupture pressures and manufacturing ranges in temperature above the disk rating temperature (72°:F)
of metal disks are given in Tables 7-2 and 7-3. For non- decreases the bursting pressure to 70% to 90% depending
metallic materials such as graphite, bursting pressures are upon the metal and temperature. See Tables 7-4A and B.
available from the manufacturers. From these manufac- The minimum rupture pressure of disks of various met-
turing tolerances it can be seen that the relation of disk als and combinations vary so widely that individual manu-
bursting pressure to required relieving pressure must be facturer must be consulted.
carefully considered. Manufacturing practice is to furnish For the usual installation, the rupture disk is installed
a disk which will burst within a range of pressures and tol- as a single item between special flanges which hold the
Process Safety and Pressure-Relieving Devices 433
Figure 7-20 cont.
F
Ventplpe �
Long-radius elbow
Pressure
relief--�
valve
Typical pilot-operated pressure relief valve installation Typical pressure relief valve installation with vent pipe
� Pressure relief
valve
Process laterals should
generally not be connected
to pressure relief valve
piping_\
inlet -------------
\--------------------
Vessel
Typical installation avoiding process laterals connected to pressure
relief valve inlet piping
edges securely and prevent pulling and leakage. If the sys-
tem is subject to vacuum or pressure surges, a vacuum
support must be added to prevent collapse of the sealing
disk. The flanges which hold the disk may be slip-on, weld
neck, etc. Disks to fit screwed and union-type connections
are also available. See Figures 7-8 and 7-9.
- The service life of a rupture disk is difficult to predict,
Excess flow valve since corrosion, cycling pressures, temperature and other
(optional) process conditions can all affect the useful life and cause
premature failure. A graphite-type disk is shown in Figure
7-9. In some processes it is safer to replace disks on a
Bleed valve
(may be car-sealed open) schedule after the life factor has been established, as a
Typical rupture disk assembly installed in combination with a pres- planned shut-down is certainly less costly than an emer-
sure relief valve gency one.
434 Applied Process Design for Chemical and Petrochemical Plants
Table 7-2
Typical Prebulged Solid Metal Disk
Manufacturing Ranges and Tolerances
Manufacturing Range/Burst Tolerance @ 72°F
Specified Manufacturing Range
Burst Pressure % % Rated (Stamped)
Rating, psig Under Over Burst Tolerance %
2-5 -40 +40 ±25%
6-8 -40 +40 ±20%
9-12 -30 +30 ±15%
13-14 -10 +20 ±10%
15-19 -10 +20 ± 5%
20-50 -4 +14 ± 5%
51-100 -4 + 10 ± 5%
101-500 -4 + 7 ± 5%
Inlet flanges ----......
1-----,1-----, 501-up -3 + 6 ± 5%
Note:
Inlet pipe---....
1. Special reduced manufacturing ranges can be obtained for
the STD prebulged metal disk. ){, Y,, and X ranges are available
Branch connection �
upon request. Please consult your representative or the facto-
ry for additional information.
2. Burst tolerances are the maximum expected variation from
the disk's rated (stamped) burst pressure.
Run pipe 3. Standard-type rupture disks comply with ASME code require-
ments.
1. -I The manufacturing range is defined as the allowable pressure
Manufacturing Range
� Not less than 1 O pipe diameters range within which a rupture disk is rated. IL is based upon the
from any device that causes turbulence customer specified burst pressure. The manufacturing ranges for
Typical installation avoiding excessive turbulence at pressure relief Continental's standard rupture disk are outlined in Table 7-2.
valve inlet.
Bursi Tolerance
Figure 7-20 cont. After the disk has been manufactured and tested, it is stamped
with the rated burst pressure. The rated (stamped) burst pres-
sure is established by bursting a minimum of two disks and aver-
aging the pressures at which the disks burst. This average is the
rated (stamped) burst pressure of the disk. Standard rupture
Rupture disks are often placed below a safety valve to disks above 15 psig@ 72°F are provided with a burst tolerance of
prevent corrosive, tarring or other material from entering ±5% of the rated (stamped) burst pressure. This is in accordance
the valve nozzle. Only disks which do not disintegrate with the ASME code. Burst tolerances for disks below 15 psig @
72°F are outlined in Table 7-2. Burst tolerance applies only Lo the
when they burst (Figures 7-10, 7-11, 7-12, 7-18) can be used rated (stamped) burst pressure of the disk. Burst certificates are
below a safety valve, as foreign pieces which enter the valve provided with each disk lot.
might render it useless. This is acceptable to certain code By permission, Continental Disc Corporation, Catalog STD-1184.
applications [ 1]. These disks are also used to provide sec-
ondary relief when in parallel with safety valves set at lower
pressures. They can also be installed on the discharge of a
safety valve to prevent loss of hazardous vapors, but cau- that in order lo accomplish the required pressure relief
tion should be used in any serious situation. the proper selection and application of type of device is
essential.
Selection Features: Safety, Safety-Relief Valves, and
Rupture Disks Safety Valve: normally used for steam service, but suit-
able for gases or vapors. When used in steam generation
Referring to the description and definitions in the and process steam service the valves conform to the
introduction for this chapter, it is important to recognize ASlv1E Power Boiler Code as well as the ASJ\1E Pressure Vessel
Process Safety and Pressure-Relieving Devices 435
Table 7-3 Table 7-4A
Typical Metal Disk (Single) Bursting Pressures at 72°F Typical Recommended Maximum Temperatures
Using Different Metals for Metals Used in Disks
Disk Minimum Burst Pressure Max. Temperature, F
Size PSIG@ 72°F (Without Liners)
Aluminum 250-260
Alum Silver Nickel Mon el In cone I 316SS Silver 250-260
X" 160 450 600 700 1120 1550 Nickel 750-800
� II 65 220 300 350 560 760 Mone I 800
I" 29 120 150 180 250 420 Inconel 900-1000
1-w· 22 80 iOO 116 160 275 316 Stainless steel 900
2" 13 48 60 70 110 150
3" 10 35 45 50 80 117 Source: Various manufacturers' technical catalogs.
4" 7 26 35 40 70 90
6" 5 20 25 30 47 62 Table 7-48
8" 4 15 20 23 34 51 Typical Recommended Maximum Temperatures
10" 4 16 17 30 43 for Linings and Coatings with Metals Used with Disks
12" 3 13 15 25 36
14" 3 ]] 13 21 31 Teflon® FEP Plastic 400
16" 3 10 12 19 28 Polyvinylchloride 150-180
18" 3 9 11 17 24 Lead 250
20" 3 8 9 16 22
24" 3 Source: Various manufacturers' technical catalogs.
30"
36"
Safety-Relief Valve: normally selected for vapors and
(-) = Consult factory gases as may be found in all types of industrial processes.
�special designs of some manufacturers may exceed] 50,000 psi for small Characteristically this valve will open only enough to allow
sizes. The pressures listed are generally typical but certainly not the only
ones available for the size shown. the pressure to drop below the set pressure, and then it
will reseat until additional overpressure develops. If the
Note: pressure persists or increases, then the valve will remain
1. Maximum burst pressure depends upon disk size and applica- open or increase its opening up to the maximum design,
tion temperature. Pressures to 80,000* psig are available. but as the pressure falls the valve follows by closing down
2. Other materials and sizes are available upon request. until it is folly reseated. Of course, as in any installation of
3. Other liner materials are available upon request. Minimum any "safety" type valve, the valve may not reseat complete-
burst pressures will change with change in liner material. ly gas tight. In such cases it may be necessary to switch to
4. For larger sizes or sizes not shown, consult your representative,
or the factory. Courtesy, Continental Disc Corp., Bui. 1184, p. a stand-by valve and remove the leaking valve for repair.
4-5. [See Figures 7-7A and 7-7B.J
Special Valves: because of the difficult and special seal-
ing requirements of some fluids such as chlorine and
Dowtherrn, special valves have been developed to handle
the requirements.
Code, Section VIII, and are tested at capacity by the Vacuum Relief and Combined Pressure-Vacuum Relief for
National Board of Boiler and Pressure Vessel Inspectors. Low Pressure Conditions: normally used for low pressures
This type of valve characteristically "pops" full open and such as 1 ounce water to 1.5 psig above atmospheric by
remains open as long as the overpressure exists. special spring or dead weight loading; and for vacuum
protection such as 0.5 psi below atmospheric. Usually
these conditions are encountered in large process, crude
Relief Valve: normally selected for liquid relief service oil, ammonia, etc., storage tanks. See later section cover-
such as hydraulic systems, fire and liquid pumps, marine ing this topic.
services, liquefied gases, and other total liquid applica-
tions. The valve characteristically opens on overpressure Rupture Disks: used for low as well as high pressure pro-
to relieve its rated capacity, and then reseats. tection of vessels and pipelines where sudden and total
436 Applied Process Design for Chemical and Petrochemical Plants
release of overpressure is required. Once the disk has rup- when bursting pressure is reached, the disk
tured, the process system is exposed to the environment being in compression reverses with a snap action
of the backpressure of the discharge system, whether at which time the four knife edges, Figure 7-SG
atmospheric or other. The process system is depressurized cut the metal and it clearly folds back without
and the disk must be replaced before the process can be fragmentation. There is another version of the
restarted. Typically, the types of disks available are same concept of reverse buckling, but it uses a
pre-scored disk and thereby omits the knife
1. Solid Metal Rupture Disk (Figure 7-8). This is the blades. These types of disks do not need vacuum
original type of rupture device, available in various supports, unless there is unusually high differen-
metals and non-metals. It should normally not be tial pressure across the disk.
used for operating pressures greater than 70% of 2. Graphite Rupture Disk (Figure 7-9). There are spe-
rupture pressure in a non-corrosive environment. cial designs of disks and disk assemblies for specific
The metal disks use a domed or hemispherical shape, applications, and the manufacturer should be con-
with pressure on the concave side. As the pressure sulted for his recommendation. Disks are available
internally increases, the metal wall thins as the metal for pressure service, pressure-vacuum applications,
stretches to achieve a smaller radius of curvature. high temperature conditions, and close tolerance
After the wall has thinned sufficiently, it will burst to bursting conditions. The bursting accuracy of most
relieve the pressure and tension loading on the designs is ±5% for rated pressures above 15 psig and
metal. The accuracy of metal disks is ±5%, except for ±0.75 psig for rated pressures 14 psig and below. It
the Reverse Buckling Disk Assembly, which is ±2%. should be noted that these ratings are not affected
The usual recommended maximum operating tem- by temperature up to 300°F.
peratures for metal rupture disks is given in Tables 7-
4A and B. Also see Figures 7-SG and SN. A new concept in graphite disks includes addition of
a fluorocarbon film barrier between the process and the
(a) Solid metal disk with vacuum support: When vacu- disk, and is termed a duplex disk. These disks are suit-
um can occur internally in the system, or when able for temperatures to 392°F, with accuracies as just
external pressure on the convex side of the disk mentioned.
can be greater than the pressure on the concave Graphite disks are normally used in corrosive services
side of the disk, a vacuum support is necessary to and/or high temperature situations where metal wall
prevent reversal of the disk, Figure 7-SD. thickness and corrosion rates make the metal units
(b) Solid metal disk with rating near minimum Jar size: impractical because of unpredictable life cycles. The disks
With a rating pressure near the minimum avail- are available down to 1 psig ±0. 75 psi, and are not affect-
able for the size and material of construction a ed by fatigue cracking. An interesting feature is the use of
special thin disk is attached to the under and pos- standard ASA (ANSI) flanges rather than special flanges.
sibly the upper sides of the rupture disk to ensure See Figure 7-9C.
freedom from deformity caused by the condition It is important to recognize here also that once the disk
of the disk holding surfaces, Figure 7-SE. There bursts the system is depressured, and there will be frag-
are several versions of what to include under such ments of graphite blown out with the venting system. Spe-
conditions, therefore it is advisable to clearly cial discharge designs are often used to prevent plugging
explain the installation conditions and applica- of discharge pipe and fragments from being sprayed into
tion to the manufacturer. the surrounding environment.
(c) Composite rupture disk: This type consists of a
metal disk (not necessarily solid, it may have Calculations of Relieving Areas: Safety and Relief Valves
slots) protected by an inner and/or an outer
membrane seal, Figure 7-SE. There are several References to the ASME Code [l] and the A.Pl Code
possible arrangements, including vacuum sup- [10] [33] are recommended in order that the design
port, as for the styles of paragraph (b) above. engineer may be thoroughly aware of the many details
This general class has the same use-rating limita- and special situations that must be recognized in the final
tion as for the solid disk. sizing and selection of a pressure relieving device. All
( d) Reverse acting or buckling disk assembly: This design details of these codes cannot be repeated here; however,
allows the disk to be operated in a system at up the usually important requirements are included for the
to 90% of its rated burst pressure. The pressure typical chemical and petrochemical application for the
is operating on the convex side of the disk and guidance of the engineer.
Process Safety and Pressure-Relieving Devices 437
Before performing any calculations, a thorough exami- Sizing Safety Relief Type Devices for Required Flow
nation of the possible causes and flow conditions of tem- Area at Time of Relief
perature and pressure should be evaluated. From this list,
select the most probable and perhaps the worst case possi- Before initiating any calculations, it is necessary to
bility and establish it as a design basis, Figure 7-14. See [80]. establish the general category of the pressure relief
valve being considered. This section covers conven-
When the possibilities of internal explosion or run- tional and balanced spring-loaded types.
away chemical reaction exists, or are even suspected, they Given the rate of fluid flow to be relieved, the usual
must also be rigorously examined and calculations per- procedure is to first calculate the minimum area
formed to establish the magnitude of the flow, pressure, required in the valve orifice for the conditions con-
and temperature problems. Select the worst condition tained in one of the following equations. In the case
and plan to provide for its proper release to prevent rup- of steam, air or water, the selection of an orifice may
ture of equipment. This latter situation can only be han- be made directly from the capacity tables if so desired.
dled by application of rupture disks and/ or remote sens- In either case, the second step is to select the specif-
ing and predetermined rupture of the disks (see Figures ic type of valve that meets the pressure and temper-
7-5A, 7-8K and 7-8L) or remote sensing and application of ature requirements.
quenching of the reaction/ developing explosive condi- General equations are given first to identify the
tion by automatic process action and/ or commercial
application of quenching medium. See later discussion basic terms which correlate with ASME Pressure Ves-
sel Code, Section VIII.
under Explosions.
It is recommended that computations of relieving
loads avoid cascading of safety factors or multiple
Standard Pressure Relief Valves Relief Area Discharge contingencies beyond the reasonable flow required
Openings Lo protect the pressure vessel."
*Extracted by permission from Teledyne-Farris Engineering Catalog.
The "orifice" area of these devices (see illustrations) is
at the outlet end of the SRV nozzle through which the dis- Effects of Two-Phase Vapor-Liquid Mixture on Relief
charging vapor/ gases/liquids must pass. These values are Valve Capacity
identified in industry as: (valve body inlet size in.) X (ori-
fice letter) X (valve body outlet size, in.). For example, a Many process systems when at conditions for safety
valve would be designated 3E4. relief valve discharge also are not single phase of all liquid
(through the valve) or all vapor, but a mixture either
inside the "containing" vessel or quite often as the fluid
The standard orifice area designations are (also refer
to mechanical illustrations of valves, previously shown this passes through the valve orifice and the liquid flashes to
chapter): partial vapor, or the flashing starts just ahead of the ori-
fice. Here a mixture attempts to pass through the orifice,
and the size must be sufficient or a restriction will exist
Orifice letter D E F G H J and pressure will build up in the vessel clue to inadequate
Area, sq. in. 0.11 0.196 0.307 0.503 0.785 1.287 relief. This problem was of considerable concern to the
Design Institute for Emergency Relief of the American
Orifice letter K L M N p Q Institute of Chemical Engineers during their studies [67].
Area, sq. in. l.838 2.853 3.600 4.340 6.380 11.05 As a result, considerable research was performed leading
Orifice ietter R T V* w W2* X* to design techniques to handle this problem. The details
Area, sq. in. 16.0 26.0 42.19 57.26 93.6 101.8 are more than can be presented here; therefore, the
60.75 designer is referred to the references in the bibliography
of this chapter. Also see Leung [77] for detailed proce-
Orifice letter Y* Z* Z2* AA BB BB2 dure and additional references.
Area, sq. in. 128.8 159.0 ------ The API-RP-520 [10] recommends caiculating the
82.68 90.95 108.86 136.69 168.74 185.00 amount of vapor flashed and the amount of residual liq-
uid (unflashed) and then sizing valve orifices for each
*Note: These lcuers and orifice areas are not consistent for these large condition. Select a valve (s) area that has a total area at
orifices between various manufacturers. Some sizes go to 185 sq in.,
which is a very large valve. When two values are shown, they represent least equal to the sum of these two areas. Before settling
two different published values by manufacturers. for this approach, this author recommends examining
438 Applied Process Design for Chemical and Petrochemical Plants
the details of the DIERS work noted in the above para- that exist when the gas velocity reaches the speed of
graph and at least comparing the results. Keep in mind sound. At that condition, the actual pressure in the throat
that the problem of two-phase flow under the relieving will not fall below P 1/rc even if a much lower pressure
conditions cannot be ignored. exists downstream (36]. The maximum velocity at outlet
end ( or restriction) in a pipe or nozzle is sonic or critical
Sizing for Gases or Vapors or Liquids for Conventional velocity. This is expressed (9]:
Valves with Constant Backpressure Only
This type of valve may be used when the variations in v, = � kg RT = � kg (144) P 'V (7- 5)
backpressure on the valve discharge connection do not
exceed 10% of the valve set pressure, and provided this where k = ratio of specific heats at constant pressure/ con-
backpressure variation does not adversely affect the set stant volume, cp/c,. see Table 7-5.
pressure. v, = sonic velocity of gas, ft/sec
g = acceleration of gravity, 32 ft/sec/sec
Procedure R = individual gas constant = (MR/M) = 154.4/M
MR = universal gas constant = 1544
1. For a new installation, establish pressure vessel nor- M = mol weight
0
mal maximum operating pressure, and temperature, ::!:_ = upstream absolute temperature, R
and then the safe increment above this for vessel V = specific volume of fluid, cu ft/lb
design conditions and determine the maximum P 1 = P' = upsu·eam pressure, psi abs
allowable working pressure (MAWP) of the new ves- d = pipe inside diameter, in.
sel. (Have qualified fabricator or designer establish W = gas rate, lb/hr
this. See previous discussion of topic.) Z = gas compressibility factor
2. Establish the maximum set pressure for the pressure Pc = Peril = critical pressure, psia
relieving valves as the MAWP, or lower, but never
higher. The critical pressure at a pipe outlet is [33c]:
3. Establish actual relieving pressure (and correspond-
ing temperature) from Figure 7-7A (at 110% of set Peri,= [W/(408d 2)] -(ZT/M) 112 ,psiabs (7-6)
pressure for non-fire and non-explosive conditions).
Explosive conditions may require total separate eval- The velocity v5 will occur at the outlet end or in a
uation of the set pressure ( never above the NIA MP), restricted area [9] when the pressure drop is sufficiently
which should be lower or staged; or, most likely, will high. The condition of temperature, pressure and specif-
not be satisfied by a standard SRV due to the ic volume are those occurring at the point in question.
extreme rapid response needed. Critical pressure will normally be found between 53%
and 60% of the upstream pressure, P', at time of relief
The capacity for flow through the valve is estab- from overpressure, including accumulation pressure in
lished by the conditions of this paragraph. psia. That is, P' represents the actual pressure at which the
relief device is "blowing" or relieving, which is normally
4. For existing vessel and re-evaluation of pressure above the set pressure by the amount of the accumulation
relieving requirements, start with the known MAW'P pressure, (see Figure 7-7A).
for the vessel, recorded on the vessel drawings and Thus, if the downstream or backpressure on the valve
on its ASME certification papers. Then follow step 2 is less than 53%-60% (should be calculated) of the values
and 3 above. of P', note above, critical (sonic) flow will usually exist. If
the downstream pressure is over approximately 50% of
Establish critical flow for gases and vapors the relief pressure, P', the actual critical pressure should
be calculated to determine the proper condition. Calcu-
Critical or sonic flow will usually exist for most ( com- lation of critical pressure (29]:
pressible) gases or vapors discharging through the nozzle
orifice of a pressure relieving valve. The rate of discharge Pc= P1 [2/(k + l)Jk/(k - l) (7-7)
of a gas from a nozzle will increase for a decrease in the
absolute pressure ratio P 2 /P 1 (exit/inlet) until the linear l'c/P1 = re = [2/ (k + 1) Jk/(k - I) (7-8)
velocity in the throat of the nozzle reaches the speed of
sound in the gas at that location. Thus, the critical or For critical flow conditions @13 � 0.2.
sonic velocity or critical pressures are those conditions This equation is conventionally solved by Figure 7-21.
Process Safety and Pressure-Relieving Devices 439
Table 7-5
Properties of Gases and Vapors
Critical
Conditions
Gases and Vapors
1. Acetylene C2 C2H2 26.04 59.5 905 557 -118.7 14.37 356.0 .397 .320 1.24
2. Air Nz+02 28.97 53.3 547 239 -317.7 13.09 91.8 .240 .171 1.40
3. Ammonia NH3 17.03 90.8 1657 731 - 28.l 22.10 590.0 .523 .399 1.31
4. Argon A 39.94 38.7 705 272 - 30.3 9.50 71.7 .125 .075 1.66
5. Benzene C6H6 78.11 19.8 714 1013 176.2 • 169.3 .240 .215 1.12
_6�.-'- l s�o_-�Bu�t_a_ne.:...._ -+-= i C4 C4H10_-+-_5_8_._1_ 2 -+-_2_6_._6--+-_5_29_,__7_3_5--+ __ l_0_ . 9--+- __ 6_._2_6--+-_ 1 5_7_._8_--+-_ . _ 3 8_7_-+-'-3_5_2___,_l_._l_O�
7.n-Butane nC � -·-c\H10 58.12 26.6 551 766 31.1 6.25 165.9 .397 .363 1.09
8. Iso-Butylene iC4 C4H8 56.10 27.5 580 753 19.6 6.54 169.5 .368 .333 1.10
9. Butylene nC4 C4H8 56.10 27. s '!i83 756 20. 7 6. 54 167. 9 . 327 . 292 1.11
10. Carbon Dioxide C02 44.01 35.l 1073 548 -109.3 8.53 248.8(1) I .199 .153 1.30
11. Carbon Monoxide CO 28.01 55.1 514 242 -313.6 13.55 91.0 , .246 .177 1.40
12. CarburetedWaterGas(3) - 19.48 79.5 454 235 - 19.60 - .281 .208 1.35
13. Chlorine Cl2 70.91 21.8 lll9 751 - 29.6 5. 25 123.8 . il5 .08,1 1.36
14. Coke0venGas(3) - 11.16 138.5 407 197 - 34.10 - .679 .514 1.32
15, n - Decane nC10 C10H22 142.28 10.9 312 1115 345.2 • 120.0 .401 .387 1.03
16. Ethane c2 C2H6 30.07 51.5 708 550 -127.5 12.52 210.7 .410 .343 1.19
17. Ethyl Alcohol C2H50H 46.07 33.5 927 930 172.9 • 368.0 .370 .328 1.13
_ 1 8_._E_ t h � y-l_c_ · h_w_r_i_d_ e --+---+-C_zH4C_ l -+-_64_._5_2-+_2_3_ . 9___,_7_6_4--+_8_2_ 9 -+-_5_4 � ._4-+-- � 5 � . 5 � 9___,_1_6_8 � . 5'---+--'" � 2-7 � 4--jf-'- ' � 2 3 � 0'--+..:cl � . � 1 9'---
19. Ethylene C 2 C2H4 28.05 55,1 749 510 -154.7 13.40 207.6 .361 .291 1.24
20. Flue Gas (2) - 30.00 51.5 563 264 - 12.63 - .240 .174 1.38
21. Helium He 4.00 386.0 33 9 -450.0 94.91 9.9 1.24 . 748 1.66
22. n - Heptane nC7 C7H16 100.20 15.4 397 973 209.2 • 136.2 .399 .379 I.OS
23. n - Hexane nC6 C6H14 86.17 17.9 434 915 155.7 • 144,8 .398 .375 , I.06
7
7
7
_2 � 4 � ·-Hy=-:-d � r_o � g_e_n-=-.,.....,....,....,. � ------+----+-:-cH2=----+---=- 2 ._0 � 2-+_7_6 5_ . 0::-t--:-c1 � 8 � 8-+--,=60-:--t- - 4-2 � 3-. 0-+--1-8_7_ . 8 � 0::-t-1 � 9 � 4- . 0,---+-3-._4 � 1--+-2- . 4-2,---+ ) -1_ . 4_1 __
25. Hydrogen Sulphide H2S 34.08 45.3 1306 673 - 76.5 11.00 236.0 I .254 .192 1.32
26. Methane C CH4 16.04 96.4 673 344 -258.8 23.50 219.7 I .526 .402 1.31
27.Methy!Alcohol I CH30H 32.04 48.3 1157 924 148.l • 473.0 .330 .275 1.20
28. Methyl Chloride CH3Cl 50. 49 30. 6 968 750 - 10. 8 6. 26 184. 2 . 200 . 167 1. 20
29.Natura!Gas(3) I - 18.82 82.1 675 379 - 20.00 - .485 .382 1.27
_3 � 0-._N_ i t-ro � g � e_n +---=-+--Nz -+-_28_._0 � 2-+_5_5_ . 1::-t_4_9_2-+_2 � 28-:--1-- - 3-2_0_ . _0-+--l-3 � . 5-3--+-8 � 5 � . 8--+---''-2_4_8___,-'- . - 1 7_7_+- l � . 4-0 �
31. n - Nonane nC9 C9H20 128.25 12.0 3}5 1073 303.4 • 125. 7 .400 .385 1.04
32. Iso-Pentane IC5 C5H12 72.15 21.4 483 830 82.1 • 145.7 .388 .361 1.08
33. 11 - Pentane n<::s C5H12 72.15 21.4 485 847 96.9 • 153.8 .397 .370 1.07
34. Pentylene C5 C5H10 70.13 22.0 586 854 86.0 • 149.0 .382 .353 1.08
35.n-Octane nC8 C8H18 114.22 13.5 362 1025 258.2 • 131.7 .400 .382 1.05
-3 � 6_._o � xy � g � e_n -+--=---+-,02---+--32_._o � o-+_4=8_ . 3::-t_7_3 � 0-+-2 � 7 8-1-- - 2-9_7_ . _4+--l- l � . 8 � 5--+-9 � 2 � . o--+ , _._2 � i � 9--+'-'- " l-5_6_1-- l � . 4_0 �
37. Propane C3 C3H8 44.09 .35.1 617 666 43.7 8.45 183.5 .388 J .342 1.13
38. Propylene Cj C3H6 42.08 36.7 668 658 - 53.9 8.86 188.2 I .354 ! .307 1.15
39. RefineryGas(HighParaffin)(4) - 28.83 53.6 674 515 - 1 13.20 - .395 33 1.20
40. Refinery Gas (High Olefin)(4) - 26.26 58.8 639 456 - 14.40 - ! ' .397 33 l.20
41. Sulphur Dioxide S02 64.06 24.l 1142 775 14.0 5.80 168 .147 .118 1.24
42. Water Vapor H20 18.02 85.8 3208 1166 212.0 • 970.3 .445 .332 1.33
• These substances are not in a vapor state at 14. 7 psia and 60 F and therefore sp. vol. values are not listed,
NOTES: Most values taken from Natural Gasoline Supply Men's Association Engineering Data Book, 1951 - Sixth Edition.
l - Heat of Sublimation.
2 - Flue gas·· Approximate values based on 80.5% N2, 16% co2, 3.5% 02. Actual properties depend on exact composition.
Reference: Mark's Engineering Handbook
3 - Carbureted Water Gas, Coke Oven Gas and Natural Gas. Based on average compositions. Actual properties will differ
depending on exact composition. Reference: Perry's Handbook (3rd Edition)
4 - Refinery gas (High Paraffin) - Has a greater mol. percent of saturated hydrocarbons (example C2H6)
Refinery gas (High Olefins) - Has a greater mol. percent of unsaturated hydrocarbons (example C2H4)
Reference: Perry's Handbook (3rd Edition).
By permission Elliott Turbornachinery Co., Inc.
440 Applied Process Design for Chemical and Petrochemical Plants
0.60 1 k � I Vl ma.� = maximum mass flow at critical or choked
\ I I 2 conditions, lb/sec
1
059 Pc /P • (k+I) 1 I
\ Pc= Pcrit = critical flow throat pressure, psia = sonic =
0.58 Pc = Critical Pressure, psi a. choked pressure = maximum downstream
\ P • Total Absolute Pressure Upstream pressure producing maximum flow
0.57 of Safety Valve at Full Relief, _
\ Equals Set Pressure pkJs
Q56 Overpressure , psla. When/if the downstream pressure exceeds the critical
\ flow pressure, then sub-critical pressure will occur and the
0.55
\ equations for sub-critical flow should be used.
a. 0.54 I\ When the downstream pressure is less than ( or below)
.....
a." \ the critical or choked pressure, the velocity and fluid flow
• 0.53 rate at a restriction or throat will not/ cannot be increased
.s ' \
.. \ fluid velocity at the restriction or throat is the velocity of
� Q52 by lowering the downstream pressure further, and the
.. I sound at the conditions [29].
� 0.5
.t 0.50 I\ The critical or sonic ratio is conveniently shown on Fig-
\
.; � ure 7-21, but this does not eliminate the need for calcu-
:= 0.49 lating the PJP1 ratio for a more accurate result.
·.::: \
u
0118 -, Example 7-2: Flow through Sharp Edged Vent Orifice
0117 (adapted after Ref. [29])
I\
0116
'\ A small hole bas been deliberately placed in a vessel near
0!45 I\ the top to provide a controlled vent for a nitrogen
\ purge/blanket. The hole is 0.2-inch diameter with the vessel
0·4 \o I.I 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 operating at 150 psig at 100°F. Determine the flow through
Ratio of Specific Heats, k = Cp/Cv this vent hole. Assume it acts as a sharp edged orifice.
Figure 7-21. Critical backpressure ratio for vapors and gases.
k (for nitrogen) = 1.4
Pc/P1 = See Equation 7-7 [2/(k + l)Jk/k - 1
1
Pc= (150 + 14.7) (2/1.4 + ])l.4/1.4 - = 86.9 psia, critical
At critical conditions, the maximum flow through the pressure
2
2
nozzle or orifice is: [29] Hole area= A= 1t d /4 = 1t (0.2) /4 = 0.0314 sq in.
= 0.0002181 sq ft
Discharge coef, (\ = assumed = 1.0 (Note, could calculate
Re to verify.)
\V max (crirical now) = Co AP o (7- 9) Inside pressure= 150 psig + 14.7 = 164.7 psia
T 0 = 100 + 460 = 560°R
where M = mo! wt of vapor or gas
0
TO = temp of service, R v\lma, = [1.0 (0.0002181)(164.7)(144sq in./sq ft)]
Rg = ideal universal gas constant = 1544, ft lb/lb- [ [ (1.4)(32.12)(28)](-2-)(l. 4+l)/(l.-1-l) l
mol-0R, also= MR
C = discharge coefficient for sharp-edged orifice -� ( 1545 ) ( 560 ) 1.4 + 1
0
= 0.61 for Reynolds Number> 30,000 and
not sonic
C = 1.0 for sonic flow, C increases from 0.61 to 1.0. critical flow rate, Wma.x = 0.002518 lb/sec
0
0
Use 1.0 Lo be conservative [29] [36]. 5th Ed.]
A = area of opening, orifice, or hole, or nozzle, Orifice Area Calculations [68]
sq. ft.
P 1 = P = upstream pressure, lb/sq foot, abs, (psfa) Calculations of Orifice Flow Area for Conventional
0
g = 32.12 ft/sec/sec Pressure Relieving Valves, and Flow is Critical (sonic)
M = mo!. wt. of vapor or gas Through Part of Relieving System, i.e., backpressure is
� = ratio of orifice diameter/pipe diameter (or less than 55% of the absolute relieving pressure (includ-
nozzle inlet diameter) ing set pressure plus accumulation). See Figure 7-7A, use
Process Safety and Pressure-Relieving Devices 441
Kb = 1.0 (Figure 7-26), constant backpressure with varia- capacity certified). A simplified equation based on the
tion not to exceed 10% of set pressure. ASME Pressure Vessel Code equations, Section VIII, Div.
a. for vapors and gases, in lb/hr; Kb = 1.0; "C" from 1, Mandatory Appendix XI uses K coefficient of discharge
Figure 7-25, P is relieving pressure absolute, psia in the equations, where K is defined as 90% of the average
K,i of certified tests with compressible or incompressible
fluids, see reference [68], pg 40.
vV) TZ .
A= , sq1n. For first trial, assume Ku for viscosity = 1.0
CKd PKb ,JM
( Effective net discharge area) (7 - 10) For final calculation use Ku from Figures 7-23 or 7-24
and substitute in the above equation. Determine the
b, For vapors and gases, in SCFM, Kb = 1.0
needed Reynolds number, Re, using the next size larger
orifice. Area is determined from that made in the first
v ,Jeri, . trial calculation [33].
J\ = , sq in. (7 - 11)
1.175 CKd PKb
(2800 G)
c. For steam, in lb/hr; Ki, = 1.0 and Ksh = 1.0 for satu- Re = V L t=: , or (7-16)
rated steam when backpressure is below 55% of µ-v A
absolute relieving pressure
Re= 12, 700VL/( u-...!A).
(Do not use when U < 100 SUS) (7- 17)
w
;\=----'----, sqin. (7- 12)
51.5 x , PKb K,h Kn
Re = Reynolds number
d. For air, in SCFM; I(i, = 1.0, when backpressure is µ = absolute viscosity@ flowing temperature, centipoise
below 55% of absolute relieving pressure P1 = set pressure, psig
U =viscosity@ flowing temperature, Saybolt Universal Sec-
Va ,iT onds (See Appendix A-12 and A-13)
A= (7 -13)
418 Kd PK 0 P 2 = total backpressure, psig
e. For liquids, GPM;
K,, = 1.0 @ 10% overpressure Calculations of Orifice Flow Area using Pressure Relieving
K,, = J _O at normal viscosities Balanced Bellows Valves, with Variable or Constant Back Pres-
LiP = P1 - P2 = upstream pressure, psig (set + overpres- sure. Must be used when backpressure variation exceeds
st.re) -- total backpressure, psig 10% of the set pressure of the valve. Flow may be critical
or non-critical for balanced valves. All orifice areas, A, in
ASME Code valves: Board Certified for liquids only. sq in. [68]. The sizing procedure is the same as for con-
ventional valves listed above (Equations 7-10 ff), but uses
VL fa equations given below incorporating the correction fac-
A=-------;:=== (7 - 14) tors K, and Kw. With variable backpressure, use maximum
value for P2 [33a, 68].
f. Non-ASME Code Liquid Valves [33a] non-board cer-
tified for liquids, but code acceptable for other ser- a. For vapors or gases, lb/hr
vices. KP from Figure 7-22, K,- 1 = 0.62, and 25% over-
pressure.
\V _! TZ .
A= , sq 111. (7-18)
CKct PK_. ,/ M
VL {c
A=----------- (7 - 15)
38 Kc1 K., Kr Ku � l.25P 1 -P 2 b. For vapors or gases, SCFM
To apply the viscosity correction K," a preliminary or
trial calculation should be made for the areas required
using the equation of paragraph (e) above or the modi- A= V ,/ GTZ , sq in. (7-19)
fied equation (still ASME conformance [33] but not 1-175 CKd PK,
442 Applied Process Design for Chemical and Petrochemical Plants
OVERPRESSURE SIZING FACTOR
Kp
OTHER THAN 25% OVERPRESSURE
Conventional and BalanSeal Valves- Non-Code Liquids Only
1.2
D..
x
a:: I.I -
f2
o 1.0
�
w .9
a::
::> .8
(/) EXAMPLE,
(/) FIND Kp FACTOR FOR 15 "lo OVERPRESSURE:
w .7 FOLLOW DOTTED LINE FROM 15 % OVERPRESSURE TO CURVE.
a: Kp =0.79
0.. CAPACITY AT 15 'ro O. P. = 0. 79 X RATED CAPACITY AT 25 % O.P.
0:: .6
w
>
0 .5
10 15 20 25 50
% ALLOWABLE OVERPRESSURE
Note: Pressure Relief Valve liquid capacities cannot be predicted by a general curve for overpressures below 100: 0
Figure 7-22. Liquids overpressure sizing factor, Kp, for other than 25% overpressure. Applies to Non-code liquids only using conventional and
balanced valves. By permission, Teledyne Farris Engineering Co.
c. For steam, lb/hr When the backpressure, P2, is variable, use the maxi-
mum value.
(7 - 20)
where (Courtesy of Teledyne Farris Engineering Co. [68]):
d. For air, SCFM A = required orifice area in square inches. This is as defined
in the ASME Code and A.t'-l'SI/ AP! Std 526.
W = required vapor capacity in lb/hr
(7 - 21) W = required steam capacity in lb/hr
5
V = required gas capacity in SCFM
v. = required air capacity in SCFM
e. For liquids, GPM; ASME Code valve
VL = required liquid capacity, gal/min (gpm)
G = specific gravity of gas (air = 1.0) or specific gravity of liq-
VL {G uid (water = 1.0) at actual discharge temperature. A spe-
A = sq in. (7- 22A)
--------,.-;:p-, cific gravity at any lower temperature will obtain a safe
38.0 x, K" Ku -V CH'
valve size.
M = average molecular weight of vapor
f. For liquids, GPM, non-ASME Code valve
P = relieving pressure in lbs per square inch abs. = [set pres-
sure, psig + overpressure, psig + 14.7,J psia. Minimum
overpressure = 3 psi.
P 1 = set pressure at inlet, psig
P2 = back pressure at outlet, psig
Process Safety and Pressure-Relieving Devices 443
"'""��t,c���-+.eo
l���===t:·711
••
.IO l
�...------t: n
���toc=====t: .. , W
� I
,.,,�111#,,"'4,�,rL-�������� ....
m�=============t ..
:.1
61'r,;!V':ll"'Jlf'7"-'.:.,....����������---t-.n �
J.!i"-'�:..._����������-t'"'
The voscos,ty ol the liquid may reduce the 119ioc1ty and capacity enough to re- For viscous hqurd service rt rs advisable to allow 25% overpressure where per-
quire a larger oriloce s,ze than the usuat l,quid capac,ty equation would ,ndocate m,ssable. to size conservanvetv. and lo consider lhe use of the bellows and/or
Tms s,mpl1hed voscos,ty chart and the ·K; viscostv correctoon factors obtainable steam 1ac1<.eted bodies (see page 63) for the purpose ol 1solat1n9 the moving parts
!rom 11 are tor use 1n properly swng relief val'o'e's intended for viscous liquid ser and to prevent lree,,ng of the lacllng llu1C!
111ce_ Equations and graphs used 1n prepanng lhts char! reflect conscrvanve
eng,neenng data on tho subject
Sizing Method
S,nce the viscosity correction factor is dependent upon the ac- Use the following equation
tual orifice area, direct solution rs not possible and a trial orifice v.
size must be found before the "Ku" can be determined A=��;::::====:=--����
accurately. 24.3¥ 1 25 P, -P, Kµ K� K., K,.
•example:
Viscosity- Secs. Say bolt Universal 1250 SSU @ 100° F Select the next larger orifice size. or an "M" orifice with 3.60 sq
Capacity Required 800 GPM in. orifice area. (This should be about 20% greater than the
Set Pressure .. 100 PSIG calculated area to allow for reduction of capacity due to the
Constant Back Pressure . . 10 PSIG viscosity correction factor "Ku")
Ditterent1al Pressure (1.25 P,-P2) .115 PSIG
Allowable Overpressure 25% Step 2-Use Chart To Find "Ku": Enter the v.scosny Correc-
Specific Gravify . 0.98@100°F tion Chart from the left. reading 1250 SSU. Follow the example
Relieving Temperature 100°F line horizontally to the required 800 GPM Drop vertically to the
selected trial orifice "'M" and proceed horizontally to the right to
Step 1- Calculate "'Dial Orifice: Calculate the trial required the Ku scale, reading K 0 = 0.955.
orifice area from the liquid equation on page 40 (Alternate used
in this example). Step 3-Vertty Orifice Selection: This chart is designed 10
minimize the trial and error required for solution. Note that the
A� V1 BOO - = 304sq 1n exit from the chart is from the orifice line to the K,. scale By
243¥125 P,-P? Kp Kq Ku 243¥ 125-10 (1)(1.010)(1) inspection vertically, the next larger or smaller orifice show alter
nate values of the "A" term and the corresponding ''K,." term.
If BalanSeal valve construction rs used and variable back without repeating all the steps.
pressure conditions exist. use the maximum back pressure to
determine P 0 in equation and correct Kw factor (see graph page 'Exampte given 1::; tor a non-ASME Code l:qu1d aupucauon H ASME Code �.
44) recurred sunstuure apnropnate equation
Figure 7-23. Liquids viscosity correction using chart method for K.,. By pennission, Teledyne Farris Engineering Co.
444 Applied Process Design for Chemical and Petrochemical Plants
Viscosity Correction Using Reynold's Where:
Number Method of API RP520 VL = flow rate at the flowing temperature in U.S. gallons
per minute.
As an alternate to Figure 7-23, you may wish to use the G = specific gravity of the liquid at the following
method given in API RP 520 for sizing viscous liquids. temperature referred to water= 1.00 at 70 degrees
Fahrenheit.
When a relief valve is sized for viscous liquid service, it
is suggested that it be sized first as for nonviscous type µ = absolute viscosity at the flowing temperature. in
application in order to obtain a preliminary required centipoises.
discharge area. A From manufacturer's standard ori-
fice sizes. the next larger orifice size should be used in A= effective discharge area. in square inches (from
determining the Reynolds number R, from either of the manufacturers' standard orifice areas).
following relationships:
U = viscosity at the flowing temperature, in Saybolt
Universal seconds.
R = VL(2,800 G)
µVA After the value of R is determined. the factor Kv tis ob·
tained from the graph. Factor Kv is applied to correct the
or "preliminary required discharge area" If the corrected
area exceeds the "chosen standard orifice area", the
.R = 12,700 VL above calculations should be repeated using the next
u\,/'j\ larger standard orifice size.
'Use ot ttus equation rs not recommended for viscosnies less than 100 SSU I K, of AP! = K, of Teledyne Fams
Figure 7-24. Viscous liquid valve sizing using the method of API RP-520. Reprinted by permission, Teledyne Farris Engineering Co. and Siz-
ing, Selection and Installation of Pressure-Relieving Devices in Refineries, Part I "Sizing and Selection," API RP-520, 5th Ed., July 1990, Amer-
ican Petroleum Institute.
Process Safety and Pressure-Relieving Devices 445
.1.P = Set pressure + overpressure, psig - back pressure, psig. 0.62 for rupture disks and non-reclosing spring loaded
AL 10% overpressure delta P equals 1.1 P 1 - P 2• Below devices; ASME [I], Par. UG-127.
30 psig set pressure, delta P = P1 + 3 - P2. **0.975 per AP! RP-520, balanced valves
T = inlet temperature °F absolute = (°F plus 460)
Where the pressure relief valve is used in series with a
Z = compressibility factor corresponding to T and P. If this rupture disk, a combination capacity of 0.8 must be applied
factor is not available, compressibility correction can be to the denominator of the referenced equations. Refer to a
safely ignored by using a value of Z = 1.0.
later section this text or to specific manufacturers.
C = gas or vapor flow constant, see Figure 7-25.
k = ratio of specific heats, Cp/C, .. If a value is not known the **Some manufacturers' National Board Certified Tests
use of k = 1.001, C = 315 will result in a safe valve size. will have different values for some of their valves. Be sure
!sen tropic coefficient, n , may be used instead of k. Lo obtain the manufacturer's certified coefficient for the
valve you select.
� = liquid capacity correction factor for overpressures lower
than 25% for non-code liquids equations only, (see Fig-
ure 7-22). Sizing Valve for Liquid Expansion (Hydraulic Expansion of
Kb = vapor or gas flow correction factor for constant back Liquid Filled Systems/Equipment/Piping)
pressures above critical pressure (see Figure 7-26).
K, = vapor or gas flow factor for variable back pressures for The API Code RP-520 [33a] suggests the following to
balanced seal valves only (see Figure 7-27A and Figure 7- determine the liquid expansion rate to protect liquid-
27B). filled (full) systems or locations where liquid could be
K,,. = liquid flow factor for variable back pressures for balanced trapped in parts of a system or an area could be subject to
seal valves only (see Figure 7-28). For atmos., K; = 1.0. blockage by process or operational accident. When ther-
Ku = liquid viscosity correction factor (see Figures 7-23 or Fig- mal input from any source can/ could cause thermal
ure 7-24). expansion of the enclosed liquid:
K,,h = steam superheat correction factor (see Table 7-7).
Kn = Napier steam correction factor for set pressures between
1500 and 2900 psig (see Table 7-6). GPM = BH/ (500 G Ch) (7-23)
Kc!= coefficient of discharge [68] :**
0.953 for air, steam, vapors and gases** This relation can be converted to solve for the required
0.724 for ASME Code liquids orifice area at 25% overpressure for non-viscous liquids
0.64 for non-ASME Code liquids discharging to atmosphere [24]
Table 7-6
Napier Steam Correction Factors, Kn, for Set
Pressures between 1500 and 2900 psig
SIZING FACTORS FOR STEAM
Kn NAPIER CORRECTION FACTOR Equation: Where
FOR SET PRESSURES BETWEEN 0.1906P·1000 P = relieving
1500 AND 2900 PSIG AT 100/o OVERPRESSURE K = 0 2292P·1061 pressure. psia
-
Set Set Set Set Set Set Set Set Set Set
Press. Kn Press. Kn Press. Kn Press. Kn Press. Kn Press. Kn Press. Kn Press. Kn Press. Kn Press. Kn
pslg psig psig psig psig pslg psig psig psig psig
1500 1.005 1640 1.014 1780 1.025 1920 1.037 2060 1050 2200 1.066 2340 1.083 2480 1.104 2620 1.128 2760 1.157
1510 1.005 1650 1.015 1790 1.026 1930 1.038 2070 1.051 2210 1.067 2350 1.085 2490 1.105 2630 1.130 2770 1.159
1520 1.006 1660 1.016 1800 1.026 1940 1.039 2080 1.052 2220 1.068 2360 1.086 2500 1.107 2640 1.132 2780 1.161
1530 1.007 16i'O 1.016 1810 1.027 1950 1.040 2090 1.053 2230 1.069 2370 1.087 2510 1.109 2650 1.134 2790 1.164
1540 1.007 1680 1.017 1820 1.028 1960 1.040 2100 1.054 2240 1.070 2380 1.089 2520 1110 2660 1.136 2800 1.166
1550 1.008 1690 1.018 1830 1.029 1970 1.041 2110 1.055 2250 1.072 2390 1.090 2530 li12 2670 1.138 2810 1.169
1560 1.009 1700 1.019 1840 1.030 1980 1.042 2120 1.057 2260 1.073 2400 1.092 2540 1.114 2680 1140 2820 1.171
1570 1009 1710 1.019 1850 1.031 1990 1.043 2130 1.058 2270 1.074 2410 1.093 2550 1.115 2690 1.142 2830 1.174
1580 1.010 1720 1020 1860 1.031 2000 1.044 2140 1.059 2280 1.075 2420 1.095 2560 1.117 2700 1144 2840 1.176
1590 1.011 1730 1.021 1870 1.032 2010 1.045 2150 1.060 2290 1.077 2430 1.096 2570 1.119 2710 1146 2850 1.179
1600 1.011 1740 1.022 1880 1.033 2020 1.046 2160 1.061 2300 1.078 2440 1.098 2580 1.121 2720 1148 2860 1.181
1610 1.012 1750 1.023 1890 1034 2030 1.047 2170 1.062 2310 1.079 2450 1.099 2590 1.122 2730 1150 2870 1.184
i
1620 1.013 1760 1.023 1900 1.035 2040 1.048 2180 1063 2320 1.081 2460 1.101 2600 1:124 2740 1152 2880 1.187
1630 11.014 1770 1.024 1910 1.036 2050 1.049 2190 1.064 2330 1.082 2470 1.102 2610 1.126 2750 1.155 2890 1.189
2900 1.192
Courtesy Teledyne-Farris Engineering Co., Cat. 187C.
446 Applied Process Design for Chemical and Petrochemical Plants
Table 7-7
Steam Superheat Correction Factors, K,,h
11•:..1:::::1:1:1::::r.!.l••••!!l!!l::::1••[1].:'l.:t'•l
Set Salumed TOTAL TEMPERATURE IN DEGREES FAHRENHEIT
Press. Steam
p.s.l.g. Temp. 'f. 280 300 320 340 360 380 400 420 440 460 480 500 520 540 560 580 600 620 640 660 680 700 770 740 760 780 800 820 840 860 880 900 920 94(1 960 !180 1000
,s 2:0 1 CJ I�:, 100 39 9l % 93 ,, % 95 9t. 91 92 91 90 S9 ea 87 86 86 85 8t. 83 23 82 81 a1 20 79 cl 75 iO 77 '6 76 7: -'5
97
2(· 259 1CJ lCJ 100 99 99 95 9o ,, 96 95 9t. 91 92 91 90 59 88 17 26 56 es 84 S3 a3 82 81 81 80 79 ,g ?8 76 -:7 71 '6 -5
« 281 I :c 'CQ I OQ 99 99 9� 96 95 9t. 93 92 9, 90 59 88 87 87 BG es e, 84 23 82 82 81 80 79 cl 78 78 77 77 76 -,
60 1(,8 - 1 co 1 CO 99 99 9, 9' 96 95 94 93 91 9· 90 59 88 87 87 ss 85 e, 8t. 83 B, 82 81 80 80 ;g 78 78 77 n '6 :' � "
80 32" - - - ICJ -co 99 99 98 9i 96 94 9J 91 g· 9J 59 89 86 87 es 85 e, 8t. 83 .82 82 a, BJ 80 79 78 78 77 " 76 76 75
IOc 338 - - - - •CQ . �� 99 98 97 96 9� 94 93 92 91 90 89 BB 87 88 85 85 83 .82 82 81 80 so el iY 10 77 'I .e '6 :·5
"' 83
'?O 350 - - - - . co . J: 99 98 91 96 95 g,: 93 92 91 90 Bl Bo 87 26 85 85 84 82 82 81 80 ea 79 78 7E '7 77 '6 7£: ,
1.::0 3&1 - - - - - ,, I CO 99 98 96 95 9, 93 92 91 9G 89 ee 87 16 85 85 z, 83 81 82 81 80 eo 79 78 7o 7? r 76 76 -n:
10 271 - - - - 10,'.J 1 CJ 99 ss 97 ss 9, 93 92 91 90 89 88 87 ss 86 85 E,.: 83 82 82 61 BJ 80 i9 79 IE 17 '7 76 76 '5
iso 39" - - - 1 CJ 99 96 97 96 95 93 92 91 9J 89 es 87 86 86 85 e, 83 81 82 SI BJ so -9 '9 72 r: 77 76 76 '5
zo 3,9 - - - - I 00 ss 99 97 96 95 93 92 91 90 89 88 87 36 85 85 .e, 83 83 82 91 8'. 80 '9 79 72 ?7 71 rs �E '5
,,
22(, 395 - - - - - ICO 10) 9, 98 96 95 94 93 92 91 .90 89 88 B? 85 85 St. St. �j 62 a, 21 SC '9 '9 72 78 7? 7E 76 75
2<C .:03 - - - - ICJ 9:f 98 97 ss 94 93 92 91 90 89 88 87 85 85 SJ 83 62 81 31 80 '9 79 78 78 77 re 76 -5
26: .109 - - - - 1CJ g� ss 9:' 96 9' 93 92 91 9J 89 8� Bi 86 95 es 84 eJ 52 a, a· 9�· '9 79 78 '8 77 76 '6 75
28C Jl6 - - - - - - 1CJ . co gg 97 96 95 93 92 91 9J 89 89 87 86 95 85 St. 83 92 82 a·· SC ED 79 78 '8 ,· 77 76 �5
JJ: ,22 - - - - - - - ·-::c, 99 96 96 95 93 92 91 9) 89 SS B! .85 BE B5 84 83 82 82 a· SC ee 19 78 78 l' 77 '6 'j
35� 436 - - - - - - - - . co 1 G: ss 97 95 31, 93 92 91 90 69 88 87 96 85 8'- eJ 93 82 8' 81 eo :9 78 78 17 77 76 �6
JCJ .:_4g - - - - - - - - I OJ 99 98 96 95 93 92 91 go 69 88 87 66 85 SJ e, 83 82 a· 81 80 79 79 78 7' 7/ 76 i6
45J ,50 - - - - - - - - - lCO 99 97 96 94 93 92 91 69 88 87 86 86 85 St. 83 82 82 81 se 79 79 78 78 77 76 76
5�:· J7C - - - - - - - - ICO 99 ss 96 94 93 92 91 90 89 6S 87 86 85 e1. 93 82 82 81 80 79 cl 78 18 77 76 !()
55(· ,a-a - - - - - - - ICO .99 97 95 9, 92 91 00 89 85 87 86 85 St. 83 82 82 81 80 60 79 78 i1i 77 76 16
6YJ 489 - - - - - - - - - lCO 99 98 96 9, 93 92 9() 89 as 87 86 85 Bt. et 83 82 81 se 8() 79 78 76 17 76 '6
650 .:97 - - - - - - - - - - 'cc- 33 97 95 94 92 91 9� 89 87 86 85 BS e, 83 82 91 81 so 79 78 78 77 :7 ;5
1CO 5C6 - - - - - I Jc 33 97 96 94 93 91 9:l 89 88 07 85 95 &J 83 82 61 81 eo 79 79 78 ., 77 76
7'::/J 513 ,. - - - - - - - - - I QJ ·co 98 96 95 93 92 9J 89 88 '67 E6 85 8'1 8j 63 62 .81 so 79 79 78 77 '7 It
800 52,J - - - - - - - 1(0 99 97 95 94 92 91 9() 8S 87 86 85 e, 84 83 82 81 so BO 79 18 78 n 7€
BY.I 527 - - - - - - - - - ,. I CO ss ss 96 94 93 92 9(, 69 es 87 56 25 84 93 .62 e1 81 80 79 76 78 ?I '.'E
9'.11 :Jj - - - - - - - . co I 00 9l 97 95 93 91 90 89 es 87 86 85 84 83 62 e1 81 80 ?9 19 78 F .n
950 :>,4C, - - - - - - - - - - - I 00 99 97 95 9, 92 91 &.9 ea ff/ 6t as 81 83 82 82 a, eo 79 1'! 78 -r- 77
,�:o �i4G - - - - - - - I OJ 99 98 96 9t. 93 91 90 89 87 S5 €5 8-1 93 83 62 e· 20 79 73 78 77
1050 552 - - - - - - - - - - I 00 WJ 99 97 95 93 92 90 89 es 87 86 85 8-1 .83 82 81 80 BQ i9 •8 r: -,
:10'.; 558 - - - - - - - - - 100 99 98 95 gt, 92 91 83 ea 87 26 85 94 83 82 81 81 SQ 79 7ll 78 -:7
'15� :�3 - - - - - - - - - - - - - 11)'.) 99 98 96 94 92 91 90 ea 87 06 85 84 83 82 81 81 B·J 79 19 '8 77
1,CJ :.69 - - - - - - - - - - - - 100 99 98 9? 95 93 91 90 89 87 es 85 84 83 .82 8! SI BQ 79 78 '6 "
12:J 574 - - - - - - - - - - - ·�J 99 37 95 93 92 90 89 56 37 as SS a, 83 92 81 BQ 79 7g 76 ;7
1?C) 579 - - - - - - - - - - - IIX) 99 98 96 94 92 91 89 EB a, 86 85 e, .83 92 61 8·J rs i:I 15 7.'
135] :e� - - - - - - - - - - - - l�J 99 98 96 94 93 91 9c EB e, 86 cs a, a, 62 51 80 SC 19 lo ,a
,,oo ssa - - - - - - - - - - - I 00 I CO gg 97 95 93 92 so 89 85 86 es a, eJ 52 €1 a· 8C 79 75 78
0' 92
· �50 �93 - - - - - - - - - - - - - IOJ 99 97 95 ,• �J 89 85 86 .85 e, 83 52 81 a• so ?3 ?8 '8
--1500 597 - - - - - - - - - - - - - 10{) 99 97 96 94 92 91 89 ,88 87 86 84 84 83 81 8• 1,0 79 75 78
,,w €C6 - - - - - - - - - - - - I CJ 98 97 96 94 9.3 91 29 86 8" 65 84 83 o2 81 ec 79 79 75 77
1700 615 - - - - - - - - 1 CJ 99 97 96 95 93 9i 89 es 66 85 .84 93 82 a1 79 79 78 77 ...
18CO 62� - - - - - - - - - - - - - - - 99 98 97 95 93 91 89 es 56 85 84 82 81 8·) 79 i9 ;5 77 '6
19'0 C3S - - - - - - - - - - - 'CJ 98 9' 95 93 91 89 88 56 85 .84 82 81 80 79 78 75 n 76
,,.,
1C-OJ f:j5 - - - - - - - - - - - - - - . co 98 96 93 91 89 87 .16 84 es 02 81 eo 79 78 77 76 ?6
2,co - - - - - - - - - - - - - I CO 98 95 93 91 89 87 ii6 St. 8j 62 81 79 78 77 77 '6 75
22CQ 65() - - - - - - - - - - - - - I CJ 98 95 ?3 91 89 87 85 84 82 81 SQ 79 78 77 iE 75 7,l
23CC· 658 - - - - - - - - - - - " - - I CJ 98 95 93 91 89 87 85 84 92 81 73 78 7; 76 75 75 !4
2400 663 - - - - - - - - - - - - - 98 95 93 91 89 87 85 BJ 82 10 79 78 77 76 75 74 �3
250J €69 - - - - - - - - - - - - - - - 98 95 93 90 88 ss Bt. 8j 81 .80 78 77 71: 15 7J 13 .,2
15 1,
2E�J 675 - - - - - - - - - - - - - - - I �J 96 93 9J BE 65 s, 82 80 ;g 77 7li 75 74 i3 72 •I
zco 680 - .. - - - - - - - - - - - - - - - I 00 95 9) 86 85 83 81 cl 78 76 73 72 71 7J
�- 6�6 - - - - - - - - - - - - - 1 00 95 9) 38 15 82 80 76 76 75 )J 73 72 71 7G 69
29:'i0 691 - - - - - - - - - - - - - - ICO 9) 87 e, 82 80 78 76 75 73 7'2 71 ;o E9 68
Courtesy Teledyne-Farris Engineering Co., Cat. l87C.
(7-24) H = total heat transfer rate, BTU/hr. For heat.
exchangers, Ref [33a] recommends that this
value be taken as the maximum exchanger duty
where GPM = flow rate at the flowing temperature, gal/min during operation.
13 = cubical expansion coefficient per degree F for G = specific gravity referred LO water. Ignore fluid
the liquid at the expected temperature. For val- compressibility.
ues see specific liquid data or see table below
for typical values. Ch = specific heat of the trapped fluid, BTU/lb/°F
Process Safety and Pressure-Relieving Devices 447
400 Values of Coefficient C
I / k c k c k c k c
/'
348
1.02
1.32
374
318
L92
349
1.62
395
380 .,v 1.01 317• 1.31 350 1.61 373 1.91 395
1.33
1.03
1.63
319
396
1.93
375
-: ·- 1.04 320 1.34 351 1.64 376 1.94 397
1.95
1.05
1.35
1.65
321
376
352
397
o 360 / L06 322 1.36 353 1.66 377 1.96 398
1.37
398
1.97
1.67
323
353
378
1.07
/ C=52iiVk(7ffr) : �� 1.08 325 1.38 354 1.68 379 1.98 399
/ 1.09 326 1.39 355 L70 379 1.99 400
1.69
I.IO
400
IAO
356
2.00
380
3Y7
.,' Lil 328 1.41 357 1.71 381
1.72
382
1.42
329
358
1.12
/ 1.13 330 1.43 359 1.73 382
1.14
331
360
1.44
1.74
383
,- � / 1.15 332 1.45 360 1.75 384
320 1.16 333 1.46 361 1.76 384
1.17 334 J.47 362 1.77 385
10 12 14 16 18 20 1.18 335 1.48 363 1.78 386
1.19 336 1.49 364 1.79 386
Specific heat ratio, k = Cp/Cy 1.20 337 1.50 365 1.80 387
1.21 338 1.51 365 1.81 388
1.22 339 1.52 366 l.82 389
1.23 340 1.53 367 1.83 389
1.24 341 1.54 368 1.84 390
1.25 342 1.55 369 1.85 39\
1.26 343 1.56 369 1.86 391
1.27 344 1.57 370 1.87 392
Figure 7-25. Constant "C" for gas or vapor related to spe- 1.28 345 1.58 371 1.88 393
cific heats. By permission, Sizing, Selection and Installa- 1.29 346 1.59 372 l.89 m
tion of Pressure-Relieving Devices in Refineries, Part I 1.30 347 1.60 373 1.90 394
"Sizing and Selection," API RP-520, 5th Ed., July 1990. 'Interpolated value, since C becomes indeterminate as k approaches l .00.
CONSTANT BACK PRESSURE SIZING FACTOR
Kb
- l'!!m��fflfflmmmm�rmfflmmmm1"4'+i++1fflmmmm1"4'+�fflfflfflfflffl�
1 1
w +r-Fc.+-+-+++-+-H·++-++++-1-+-+-++++-+-+-<- � •++-++-1-t-t-++++-t-+-t-++++-1-+-+ � ++-1-++-1-++-++++-1-t-t-++++-1-t-t-++-rl-1-H,+++++-t-1-H++-i-+-t+-1-n1
a:: .j..--J_,
::, 1.0 ,·.
Cl) i$�- -
Cl) 'r+..-+-,- � , .-+-,--++++-t-+-1-1-+-+-l-t-+-1++++++,1-t-t-++++-t-+-1-+++-+-t-+-1-++-t-�++lr++
9
l.t.l UJ · l1r� - ·. f�Hfi�-ffff00Mffi1!ffi:fffiffiitfiffi:I!!ltmlafflruffl:mmmeanffifml
a: a::
�t · 8 +:_, �-i-hc++-'-+++HH++·H-l-H++++++H-+++++HH++-H-l-HH4++++HH++++H-.'++++l-Hl+++l-l-HI-N++++�H++++rH�t-t-HI
::,0..
-,-i--·-,•-++-+++.-++-1 � HHH++++HH++++l-HHH++l-HHH++++HH++++t+-1-++++l-HrH++++-l-rl+t-++-H-+ � ···+rHrrt++-r-i-HH+ttl
�< ::r:j=- � +++- � ++++++-+-++- �� -++++++++++++-+-++- � H-H-++++++++++++-+-++- � H-H-1-++ � - � -+++++''k-+-+-+-++- � ++--HI
O..ID ,7 � i--'-----+-'-r- � -r++-+-t-+-1-+++-+-t-+-1+++++-Hl-t-t-H-+-t-+-+-t ��� -t-t-+-1-++++t-+-1+++++-+- � -++++·t-+-1-l-r+-1- � IC,-,.++ � r ........ '-t----t-1� ·_...
�.... !---;-:.- � -++++-t-+-irrt,+++-r+t++++t+,-+++++-t-H-+++++-HH++++-rH-H+t-t+,HH � +-ri-H+++-t-r-H+-t--rl-t-H-+-t-t--h_,_,,rr++--h 1 +++1
U::, tt--.-,+-- � ++,-++-++++1-+-1++++rH-++·t++-+-11-t-t+++-t-;-+-1++++rH � ,++++-1-+-1++++H-+-H � +· �� .+r-a++-+-1-+++-t-+-t-rh+ � +•r-l+
<o .s......,. . � , -1-->-r-1-+-H-+-H+-t-+-t-H-t-H-t-H-t-tt+tt+tt++++++-H-+-H-+-H-+tt+tt+tt+tt+tt+rtt-H+�H-T-H-T- . '-t-l-r-t+-�H+1H+1-HI
IIJ .-+·--r-'-+--++-+-H�H��+-+-t-+-1-+++-+-t-+-1+++++-H++-+->-+-+-t-+-1-+++-+-ri�-'-+++-+-Hi-+----H-�r�++�++-+-+-+-+-++++-t-+-t-H-i--�-++-+-�+++++--HI
Figure 7-26. Constant backpressure sizing factor, Kb, conventional valves-vapors and gases. By permission, Teledyne Farris Engineering Co.
448 Applied Process Design for Chemical and Petrochemical Plants
VARIABLE OR CONSTANT BACK PRESSURE SIZING FACTOR
Kv
10% OVERPRESSURE
BalanSeal Valves Only-Vapors & Gases
ii!
:,
� "' ; 1.00
.,
:,o.
� .90
><t-
�a .BO
<DJ:
Ei
J � .70
�- ��::��'e:;�URE= 100 PSIG
BACK PRESSURE= ZERO TO 80 PSIG
UC , % GAUGE B.P. = fb%-x 100 = 60% MAX.
� .50 :;::: FOLLOW DOTTED LINE. Kv - O. 88 (FROM CURVE)
a: ::: �PACITY WITH B.P. - 0.88 X RATED CAPACITY WITHOUT B. P.
II
l .40
I I I I I
0 10 20 30 40 50 60 70 80 90 100
Figure 7-27 A. Variable or constant backpressure sizing factor, Kv, at 10% overpressure, BalanSeal® valves only: vapors and gases. By per-
mission, Teledyne Farris Engineering Co.
VARIABLE OR CONSTANT BACK PRESSURE SIZING FACTOR
Kv
210/oOVERPRESSURE
BalanSeal Valves Only-Vapors & Gases
.90
.80
"
.70 ,mmfiSET PRESSU E= :1
l:l BACK PRESSURE= ZERO TO 7. PSIG
H- 0 /a GAUGE B. P. =
.60 � X 100 = 70 % MAX.
FOLLOW DOTTED i1NE. Kv =0,87 (F'ROM CURVE)
CAPACITY WITH B. P. = 0.87 X RATED CAPACITY WITHOUT B. P.
.60
..
l .40
I I I I I
0 10 20 30 40 50 60 70 80 90 100
Figure 7-278. Variable or constant backpressure sizing factor, Kv, at 21 % overpressure, BalanSeal® valves only: vapors and gases. By per-
mission, Teledyne Farris Engineering Co.
A = required orifice area, sq in. Typical Values for Cubical Expansion Coefficient*
P 1 = set pressure of valve, psig
Liquid Value
3-34.9 degree API gravity 0.0004
35-50.9 degree API gravity 0.0005
51-63.9 degree API gravity 0.0006
Ref [33a] in Appendix C cautions that if the vapor 64-78.9 degree API gravity 0.0007
pressure of the fluid at the temperature is greater than 79-88.9 degree API gravity 0.0008
the relief set/ design pressure that the valve must be 89---93.9 degree API gravity 0.00085
capable of handling the rate of vapor generation. 94-100 degree APJ gravity and lighter 0.0009
Other situations should be examined as the thermal Water 0.0001
relief by itself may be insufficient for total relief. *By permission API, Ref [33a]
Process Safety and Pressure-Relieving Devices 449
VARIABLE OR CONSTANT BACK PRESSURE SIZING FACTOR
Kw
Cl. - - --
·-
<I
z ; I•
0 1.00
0
LL.I
en .90 '.
a.; c( ' .
. (I) - '; -
ID . ........ _
>-
:Z:t- . 80
1-- J ·- ---··
-·-
-u
�� .70 EXAMPLE: - -- ·-
-
>- c( SET PRESSURE= 100 PSIG '.
1-u BACK PRESSURE= ZERO TO 40 PSIG ' . '
iJ:::) . 60 B.P.= � XI00=40% . '.
�w %GAUGE MAX . - - - . '
c( .... FOLLOW DOTTED LINE. Kw=0.88 (FR:>M CURVE)
u� .50 CAPACITY WITH B.P. =0.88 X RATED CAPACIT:t' ---
II . (FOR 10 % OVERPRESSURE, NON-CODE VALVES, MULTIPY BY Kp FACTOR 0.6 IN CAPACITY FORMULA)
� � : -r-:-,
.40 I I I I I I
'
0 10 20 30 40 50 60 70 80 90 100
% GAUGE BACK PRESSURE= BACK PRESSURE, p SIG X 100
SET PRESSURE,PSIG
Figure 7-28. Variable or constant backpressure sizing factor, Kw, for liquids only, BalanSeal® valves. Use this factor as a divisor to results of
constant backpressure equations or tables. By permission, Teledyne Farris Engineering Co.
Note: Reference of the A.PI gravity values to refinery /ZT(Sp
_
.
and petrochemical plant fluids will show that they corre- or, 1 \ - V Gr) , sq m. (7 - 27)
863. 63 F 2 Kd \ P(P - P 2)
spond to many common hydrocarbons.
Sizing Valves for Subcriiical Flow: Gas or Vap01; but not Steam Note: K,i = effective coefficient of discharge for valve= 0.975
[33AI for equations above and Equations 7-25, 26, 27
If the ratio of backpressure to inlet pressure to valve When using a balanced/bellows relief valve in the sub-
exceeds the critical pressure ratio, Pc/P 1, critical, use Equations 7-18 through 7-22; however, the
backpressure correction factor for this condition should
be supplied by the valve manufacturer [33A). For sub-crit-
ical, conventional valve:
(7 - 7)
/( . (r)(k-lJ/k]
J
k
the flow through the valve is subcritical. The required Fo = -- (r)2!k [ J - (7 - 28)
area (net, free unobstructed) is calculated for a conven- · � k-1 1-r
tional relief valve, including sizing a pilot-operated relief
valve [33A, Par 4.3.3): where: A = required effective discharge area, sq in.
F 2 = coefficient of subcritical flow, see Figure 7-29
0
T = relieving temperature of inlet gas or vapor, R
P = upstream relieving pressure, psia, = set pres-
(7 - 25)
sure + allowable overpressure + atmospheric
pressure, usually 14. 7 psia), psia
P 2 = backpressure on valve, psia
I W = required flow through valve, lbs/hr
or, A = V / ZTM sq in (7 - 26)
4645.2I�K<l V P(P-P 2) 1 • V = vapor flow required through valve, standard
cu ft/min at 14.7 psia and 60°F
450 Applied Process Design for Chemical and Petrochemical Plants
SpGr = specific gravity referred to air = 1.0. rupture disk may perform a vital safety relief function.
r = ratio of backpressure to upstream relieving Sometimes the combination of a rupture disk and pres-
pressure, P 2 /P sure-relieving valve will satisfy a prescribed situation, but
the valve cannot be relied on for instantaneous release
Emergency Pressure Relief: Fires and Explosions (response time lag of usually a few seconds).
Rupture Disks The ASME Pressure Vessel Code [ l] and the API codes
or recommended procedures [10, 13, 33] recognize and
Process systems can develop pressure conditions that set regulations and procedures for capacity design, man-
cannot timely or adequately be relieved by pressure-reliev- ufacture and installation of rupture disks, once the user
ing valves as described earlier. These conditions are pri- has established the basis of capacity requirements.
marily considered to be ( 1) internal process explosions
due to runaway reactions (see DIERS [67]) in pressure External Fires
vessels or similar containers such as an atmospheric grain
storage silo (dust explosion typically) or storage bin; (2) There have been at least six different formulas pro-
external fires developed around, under, or encompassing posed and used to determine the proper and adequate
a single process vessel or a system of process equipment, size of rupture disk openings for a specific relieving con-
or an entire plant; and (3) other conditions in which dition. The earlier studies of Sylvander and Katz [25] led
rapid/instantaneous release of developed pressure and to the development of the ASME and API recommenda-
large volumes of vapor/liquid mixture is vital to preserve tions. This approach assumes that a fire exists under or
the integrity of the equipment. For these conditions, a around the various vessels in a process. This fire may have
1.0 -
...
-...-, ·- ""
...-::...- ',!': "-"
..... .,".J,
.........
.... ',!': .... , I, .,
.... _.,
I/
....
-" .,
.....
0.9 - .... """' - ..
.. .. .,
...-i.,,,.,.. � .... ., �
,- ..... .. ·., ... .. ., ; ,
I.; ,_,,,. .... ..I .,
I/ .... ,,
..... '"' .... ., .... � "',, .,
... .,
I, ,
,
I, "' ..I , .... ,., I.,' ..... v !;'
....
., , .... ,, L,
., "' ., ., ., ....
I,
,,. .... ..... ., "' _., I, .. i.., .,
0.8 _,,,. .... .... "' ,,
,
., - _., _., _., I, i..,
',!': , ., .... .... ... ., I/
., .... ,, ,., ,., ., ,
.... ..... , ., ., ... ., l/
.,,
, .... _,,,. i.., ., ., � ., I,'
., .... .... ... ,., , ,, ,
,
, .... ., ., ... "' , , ,
.....
r- .... ,., .,
...... - <o i.., ,
,-,-
0.7 - � ...... - 'v<a - \)< "' �- "'
___ ,...
""'
// - ,. -
'1;,
�- -.{!->- ''" ----· o' - -CRITICAL FLOW LI NE
-- a
,, .....
� -- />·
I-
I
"" I
I I
0.6 I I
0.4 0.5 0,6 0.8 0.9 1.0
Figure 7-29. Values of F 2 for subcritical flow of gases and vapors. Reprinted by permission, Sizing, Selection and Installation of Pressure-
Relieving Devices in Refineries, Part I "Sizing and Selection," API RP-520, 5th Ed. July 1990 American Petroleum Institute.
Process Safety and Pressure-Relieving Devices 451
started from static discharge around flammable vapors, down of the process. Usually this is found to be about
flammable liquids released into an area drainage ditch, 20%-30% above the maximum expected peak operation
combustible gas/vapors released through flange leaks or pressure. Again, recognize the requirements for the
ruptures, over pressure, or many other potential hazards. relieving device set pressure not to exceed the actual ves-
The codes [13] suggest typical lists of potential hazards sel NIAWP at the expected relieving temperature (by cal-
and some approach to determine the types of process con- culation or pilot plant test data).
ditions that can cause a fire. A suggested extended list
(Figure 7-14) is presented earlier in this chapter and in the Heat Absorbed
following paragraphs. There are no "pat" formulas to
establish a code capacity for the volume of vapors to be The amount of heat absorbed by a vessel exposed to an
released under any one of the possible plant "failure" con- open fire is markedly affected by the size and character of
ditions. Therefore, the codes assume, based on evaluation the installation and by the environment, These conditions
of test data, that fire is under or around the various vessels are evaluated by the following equivalent formulas, in
and that absorbed heat vaporizes the contained fluid. The which the effect of size on the heat input is shown by the
informatior.. presented is taken from API-RP-520/521 lat- exponent of Aw, the vessel wetted area, and the effect of
est editions [ 10, 13, 33] and the ASME code [1]. The other conditions, including vessel external insulation is
designer should be familiar with the details in these codes. included in a factor F [33]:
Set Pressures for External Fires q = 21,000 FA"'-o.is (7-29)
The maximum allowable working pressure (MAWP) Q = 21,000 FAw+os 2 (7-30)
(discussed earlier) for the vessel or each vessel should be
the maximum set pressure for the rupture disk. Further- where q = average unit heat absorption, in BTU per hour
more, estimated flame temperatures of usually 2500°- per square foot of wetted surface.
35000F should be used to establish the reduced vessel Q = total heat absorption (input) to the wetted sur-
metal wall temperatures (recognizing the benefits of code face, in BTU per hour.
recommended fireproof insulation if properly applied to Aw = total wetted surface, in square feet.
The expression A"'-o.is is the area exposure factor
prevent dislodging by fire water hose pressures impacting or ratio. This recognizes that large vessels are less
on the insulation). The MAWP should then be re-estab- likely to be completely exposed to the flame of an
lished by calculation using the metal wall Code allowable open fire than small vessels. It is recommended
stresses at the new estimated reduced metal temperature. that the total wetted surface (A in the foregoing
This should be the maximum set pressure for the rupture formulas) be limited to that wetted surface includ-
disk provided the new lower value does not cause it to be ed within a height of 25 feet above "grade" or, in
below or too close to the usual expected process operat- the case of spheres and spheroids, to the elevation
ing temperature. Ir. that case, this author suggests that the of the maximum horizontal diameter or a height of
set pressure be 25% above the operating condition, exclu- 25 feet, whichever is greater. (A more conservative
sive of fire, not exceeding the MAWP values. approach is recommended.) The term "grade" usu-
ally refers to ground grade, but may be any level at
When a rupture disk relieves/blows/ruptures, it cre- which a sizable area of exposed flammable liquid
ates a rapid depressuring of the process system and a like- could be present [10, 33].
ly discharge of some or all vapor/liquid in the vessel(s), F = environment factor, values of which are shown in
discharging to the properly designed disposal system. Table 7-8 for various types of installation.
Therefore, great care should be given to setting the rup- Surface areas of vessel elliptical heads can be esti-
ture disk pressure because it does not have an accumula- mated by 1.15 X cross-sectional area of vessel.
tion factor, but bursts at the prescribed pressure of the
disk, taking into account the Code allowed manufactur- These are the basic formulas for the usual installation,
ing tolerances. Two-phase flow will most likely occur when with good drainage and available fire-fighting equip-
the disc (or safety-relief valve) blows (see later references ment. These formulas are plotted on Figure 7-30 showing
to explosions and DIERS work [51, 67]. curves for Q for various values of factor F. The approxi-
For unexpected runaway or process overpressure not mate amount of insulation corresponding to the factors
subject to external fire, the rupture disk set pressure, which is indicated.
is the bursting pressure, should be sufficiently higher Referring to the wetted surface, A,,., t.he surface areas of
than the expected "under acceptable control" conditions ASME flanged and dished head, ASME elliptical heads,
for the operation to avoid the frequent burst and shut hemispherical heads, etc., are often the end assemblies on
452 Applied Process Design for Chemical and Petrochemical Plants
Table 7-8 1. Liquid-full vessels (such as treaters) operate liquid
Environment Factor, F full. Therefore, the wetted surface would be the total ves-
sel surface within the height limitation.
Type of Installation Factor*
Bare vessel 1.0 2. Surge drums (vessels) usually operate about half full.
Insulated vessels+ (These arbitrary insulation condance values Therefore, the wetted surface would be calculated at 50%
are shown as examples and are in British Thermal Units per of the total vessel surface, but higher if design is based on
hour per square foot per °F) greater figure.
(a) 4.0 Btu/hr/sq ft/°F (I in thick) 0.3
(b) 2.0 Btu/hr/sq ft/°F (2 in thick) 0.15
(c) 1.0 Btu/hr/sq ft/°F (4 in thick) 0.075 3. Knockout drums (vessels) usually operate with only a
(d) 0.67 Btu/hr/sq ft/°F 0.05 small amount of liquid. Therefore, the wetted surface
(e) 0.5 Btu/hr/sq ft/°F 0.0376 would be in proportion, but to maximum design liquid
(f) 0.4 Btu/hr/sq ft/°F 0.03 level.
(g) 0.32 Btu/hr I sq ft/ °F 0.026
'Nater-application facilities, on bare vessel** 1.0 4. Fractionating columns usually operate with a normal
Depressurizing and emptying facilitiestt 1.0 liquid level in the bottom of the column and a level of
Underground storage 0.0 liquid on each tray. It is reasonable to assume that the wet-
Earth-covered storage above grade 0.03
ted surface be based on the total liquid within the height
*These are suggested values for the conditions assumed in code [33] limitation-both on the trays and in the bottom.
Par D 5.21. When these conditions do not exist, engineeringjudgment
should be exercised either in selecting a higher factor or in providing
means of protecting vessels from fire exposure as suggested in [33], 5. Working storage tanks' wetted surface is usually calcu-
par. D. 8. lated on the average inventory, but at least 25 ft height,
+Insulation shall resist dislodgement by fire hose streams. For the exam- unless liquid level can reasonably be established as high-
ples, a temperature difference of 1600°:F was used. These conductance er, then use higher value. This should be satisfactory not
values are based on insulation having thermal conductivity of
48TS/hr-ft-°F per inch at 1600°F and correspond to various thickness- only because it conforms with a probability, but also
es of insulation between l and 12 inches. because it provides a factor of safety in the time needed to
**See code for recommendations regarding water application and insu- raise the usually large volume of the liquid's sensible heat
lation. to its boiling point.
+rDcpressurtztng will provide a lower factor if done promptly, but no It is recommended that the wetted area be at least to
credit is to be taken when safety valves are being sized for fire expo-
sure. See [33], Pan i. par. D. 8.2. the height as defined in the definition of area, A.v-
By permission, API-RP-520, American Petroleum Institute, Div. of Note: This author's suggested determination of Aw val-
Refining (1967) and adapted for this current edition by this author ues may be more conservative and not conform exactly to
from later editions of the code (1976) and (1990). Items d, e, and f Code [33a.33c] recommendations. The Code [33a, Part
above from API-RP-520, 5th Ed. (1990). For complete reference, see
the latest code cited in its entirety. 1, Sect D, Par. D.4] reads, "to determine vapor genera-
tion, only that portion of the vessel that is wetted by its
internal liquid and is equal to or less than 25 feet above
a cylindrical vessel. If a formula is not available to accu- the source of flame needs to be recognized."
rately estimate the wetted surface, or the blank diameters
used for fabrication (see Appendix), which would give a 6. Based upon this author's experience in investigating
close approximation of the inside surface of the head, use many industrial fires and explosions, it is suggested that
an estimated area for the dished or elliptical heads as 1.2 X the height limit of 25 feet above "grade" or fire source
cross-section area of the vessel based on its diameter. level is too low for many process plants, and therefore, the
effect of a large external fire around equipment can
reach to I 00 feet with 75 feet perhaps being acceptably
conservative. This author would never use the 25-foot
Surface Area Exposed to Fire
limit, for example, for a horizontal butane storage "bul-
let" tank, 15 feet diameter and raised 15 feet off grade to
its bottom. The fact that any fire will engulf the entire ves-
The surface area of a vessel exposed to fire which is sel, should be considered and the wetted surface should
effective in generating vapor is that area wetted by its be the entire vessel. The same concern applies to a verti-
internal liquid contents. The liquid contents under vari- cal distillation column over 25 feet high. It is this author's
able level conditions should ordinarily be taken at the opinion that the wetted surface should be at least 80% of
average inventory, for example: See note below. the vessel height, recognizing that the tray liquid will wet
Process Safety and Pressure-Relieving Devices 453
,.
/
I I
/ I
7 I I
i
I
I
1,000
8
- 6 1-----1---1--i---i-----l--+--1-+-il-----l-"�I/ / I �/--+---l---,4- / --+--+-l-+++----1--+--1---1--1--1--1-�
N
.,._-;;./
/
'o/
5 1-----+---+--i---i-----l--+--1-�1----·t, / "�---+---+-t'--+-+-+-+-i-+-1----+--l---+--i--+-+-+-H
0
e ,__ __ _ _,___,___,_...__,_,_,'--� � .. �':; / � .. � ..-+-/r---+--,,. � /--l-l-l-t-+++-----1---+--i---+-i---+-,H-i
_._
_._
..
�/
't,�",
/_
<( 4 �-/ / �'A-+-1--l----H'-r-'-_,__--'--'-..L-J....L..Jl-----'--'--....l-.--l-....L...l....J..-'-j
I
v
u
v
�
/
.!! 3 .s: 1 / � /,, � _r+++-+----,'-- / 1---l Noles: Based on API RP-520, 1988
.. V �/ On Insulated Vessels Insulation sho!I resist
a,
(/) 2 Q: 21,000 FA·82
.. I <>) �r · .s- .f:!"1./ �.,.," I Dislodgement by Fire Hose Streams .
-0 c
�
:/
"'
�
3C � " � "- ·1 Surface Area shell include only Totally
Wetted Surface within a Height of 2!) ft.
� _
100 ,__ __ _.__.... _ _.. i .. � ·,$,·1 ,"
� ,::/ �� ,.... .... v..;:i
<( � .}: . ,./_/--+--<-<- <o., .,.._....._ __ ,___. Above Grade or in the Case of Spheres or
e 1-----+-·-+--+-" �, Spheroids to the Elevation of :he
"-1 I ..;:.1 / Maximum Horizontal Diameter.
6
/
5 1----+---' ,.!$'�/ ,'-' v / / i/ The term Grade usually Refers lo Ground
.,W
'}�
4 1-----+--- / V / Grade but may be any Level at which a
Sizable Area of Exposed Flammable
I 7 / Liquid may be Present.
/ / I 1 / / For Flom ma ble Insulation use F = 1.0 or
2 1 ,, 1 Bare Vessel Equivalent.
tQ �� � '-- -3 � l/---"4<.-'. / � -6L/..L.J8-LI- �� '-- �� '----1.3-4.,__5'--'6-'-·8L..L...L----'-2--'- 3 --1.4--L5-L6.J-J8L....W---2'----1.3_L 4 -L 5 � 6-L � 8..W I
-__.., 2
-
10,00C 100,000 1,000,000 10,000,000 100,000,000
O : Heat Absorbed, BTU I Hr.
Figure 7-30. API fonnula for heat absorbed from fire on wetted surface of pressure vessel. Prepared by pennission, Sizing, Selection and Instal-
lation of Pressure Relieving Devices in Refineries, Part I "Sizing and Seiection," API RP-520, 5th Ed. July 1990, American Petroleum Institute.
the walls and be evaporated only as long as there is liquid Each situation must be evaluated on its own merits or
to drain off the trays, but for a conservative approach, conditions and operating situation, and even its environ-
assume that there are always wetted walls in the column. ment with respect to the plant flammable processing
equipment.
For packed columns, the wetted walls are at least to the
top of the packing, with some entrainment height above Relief Capacity for Fire Exposure
that. Therefore, a vertical packed column of 60 feet of
packing above the liquid level in the sump, which has a
sump of 10 feet and a skirt of 10 feet, would be considered In calculating the relief capacity to take care of exter-
70 feet of vertical height of wetted perimeter, not count- nal fire the following equation is used:
ing the skirt. If the wetted area reached a total height of
80 feet from grade, minus the unwetted area of the skirt
height, because no liquid is in the skirt space, the 80 feet W= Q/L (7-31)
would not be used to establish the vertical height for fire
exposure, but use 60 ft + 10 ft, or 70 feet wetted height.
This is more conservative than code [33a and c], but is where W = weight rate of flow of vapors, pounds per hour
based on experience in investigating the damage levels L = latent heat at allowable pressure, BTU/lb
from fires. Q = total heat absorption from external fire, BTU/hr
454 Applied Process Design for Chemical and Petrochemical Plants
Code Requirements for External Fire Conditions 7. To provide some external protection against the
damage that an external fire can do to a pressure
Paragraph UG-125 (3) of the ASME code [I] requires relief valve or rupture disk, this author recommends
that supplemental relieving capacity be available for an that these devices be insulated after installation in
unfired pressure vessel subject to external accidental fire such a manner as not to restrict their action but to
or other unexpected source of heat. For this condition, provide some measure of reliable performance,
relieving devices must be installed to prevent the pressure even if the vessel is not insulated.
from rising more than 21 % [13] above the maximum
allowable working pressure of the vessel. The set pressure Pressure Relief Valve Orifice Areas on Vessels Containing Only
should not exceed the vessel l\'IAWP. A single relief device Gas, Unioetted Surf ace
may be used for this capacity as long as it also meets the
normal overpressure design for other possible causes of
10 percent. If desirable, multiple separate devices can be Due to gas expansion from external fire, the API code
installed to satisfy both potential overpressure situations. [I 0] provides for calculation of the pressure relief valve
For this condition, the API-RP-521 Code [13] (Figure orifice area for a gas containing vessel exposed to external
7-7A) shows an allowable 16% maximum accumulation fire on the unwetted surface:
relieving pressure above the set pressure. For external fire
conditions on a vessel, the maximum allowable accumu-
lation pressure is 21 % above the set pressure [13] for (7- 32)
both single or multiple relieving devices (Figure 7-7 A).
Based on air and perfect gas laws, vessel uninsulated,
Design Procedure and vessel will not reach rupture conditions. Review for
specific design situations [33a]
The usual procedure for determining relief area
requirements is:
where A = effective discharge area of valve, sq in.
l. Determine the external surface area exposed to fire,
as set forth by F' = operating environment factor, min value recom-
mended = 0.01 when the minimum value is
Q = 21,000 FAw+o.s 2 ( 7-30) unknown, use F' = 0.045. Can be calculated by [33c]
[ 25 :
and Table 7-8 and the paragraph on Surface Area F' = 0.1406 (Tw - T 1) 1. (7 - 33)
.
Exposed to Fire. CK d 1 1 o.6506
2. Determine the heat absorbed, Q, from Figure 7-30. A 3 = exposed surface area of vessel, sq ft
3. Calculate the rate of vaporization of liquid from P 1 = upstream relieving pressure, psiabs. This is the set
pressure plus the allowable overpressure plus the
atmospheric pressure, psiabs.
(7 - 31)
where M = Molecular weight of gas/vapor.
4. Verify critical pressure from Equation 7-7 and estab-
lish actual back pressure for relieving device. A3 = exposed surface area of the vessel, in square feet.
5. Calculate relieving area by applicable equation for P 1 = upsu-earn relieving pressure, in pounds per square
critical or non-critical flow, using the flow rate deter- inch absolute. This is the set pressure plus the allow-
mined in (3) above. (See Equation 7-10 and follow- able overpressure plus the atmospheric pressure.
ing). The area actually selected for orifice of safety C = coefficient determined by the ratio of the specific
type valve must have orifice equal to or greater than heats of the gas at standard conditions. This can be
calculated requirements. For a rupture disk applica- obtained from Equation 2 [33a] in 4.3.2.1 of API
tion, the full free open cross-sectional area of pipe Recommended Practice 520, Pan I, or Figure 7-25.
connect.ions in inlet and exit sides must be equal to K.:i = coefficient of discharge (obtainable from the valve
or be greater than the calculated area. manufacturer). K.:i is equal to 0.975 for sizing relief
6. Select a valve or rupture disk to accommodate the valves.
service application. Tw = vessel wall temperature, in degrees Rankine.
Process Safety and Pressure-Relieving Devices 455
T1 = gas temperature, absolute, in degrees Rankine, at cubic feet of vapor at stated conditions of burst pres-
the upstream pressure, determined from the fol- sure, or both.
lowing relationship: 2. Preferred material of construction, if known, other-
wise state service to obtain recommendation.
3. Type of hold-down arrangement: flanged (slip on,
weld neck, screwed, stud) union, screwed, or special.
4. Material of construction for hold-down (flange,
P� = normal operating gas pressure, in pounds per square screwed) arrangement. Usually forged carbon steel
inch absolute. is satisfactory, although aluminum or other material
T� = normal operating gas temperature, in degrees Rankine. may be required to match vessel and/or atmosphere
surrounding the disk assembly.
The recommended maximum vessel wall temperature 5. Temperature for (a) continuous operation and (b)
for the usual carbon steel plate materials is ll00°F. Where at burst pressure.
vessels are fabricated from alloy materials, the value for Teo 6. Required relief or burst pressure in vessel and the
should be changed to a more appropriate recommended back pressure on the disk, if any.
maximum [33a]. 7. Disks to be ASME Code certified.
The relief load can be calculated directly, in pounds
per hour [33a]: When the flow capacity for relief can be given to the
l disk manufacturer, together with the conditions at burst-
( Tm - TI ) 1 .25 , lbs/hr (7 - 34) ing pressure (including temperature), the manufacturer
T I.1506 can check against a selected size and verify the ability of
1
the disk to relieve the required flow.
Rupture Disk Sizing Design and Specification
Size Selection
Rupture or burst pressure of the metal disks must be
specified at least 25% to 40% greater than the normal Rupture disks are used for the same purpose as safety
nonpulsing operating pressure of the vessel or system valves and, in addition, serve to relieve internal explo-
being protected. For low pressures less than 5 to 10 psig sions in many applications. If the pressure rise can be
operating, the differences between operating pressure anticipated, then the volume change corresponding to
and set pressure of a valve or disk may need to be greater this change can be calculated by simple gas laws, and the
than that just cited. capacity of the disk at the relieving pressure is known. The
For mild pulsations, the disk bursting pressure should system must be examined and the possible causes of over-
be 1. 75 times the operating pressure; and for strong pulsa- pressure and their respective relief capacities identified
tions, use two times the operating pressure [18]. Non- before a reliable size can be determined. See Figure 7-14.
metallic impregnated graphite disks may be used to burst
at 1.34 times operating pressure as these are less subject to Calculation of Relieving Areas: Rupture Disks for Non-
fatigue. The bursting pressure must never be greater than Explosive Service
the maximum allowable working pressure of the vessel, and
proper allowance must be made for the possible pressure The vessel nozzle diameter (inside) or net free area for
variations, plus and minus, due to the manufacturer's rup- relief of vapors through a rupture disk for the usual
ture pressure range. See Table 7-2 and specific manufac- process applications is calculated in the same manner as
turers' literature. The ASME Code [l] Par. UG-127 for a safety relief valve, except that the nozzle coefficient
requires disks to burst within 5% ± of the stamped bursting is 0.62 for vapors and liquids. Most applications in this cat-
pressure at a specified disk temperature at time of burst. egory are derived from predictable situations where the
flow rates, pressures and temperatures can be established
Specifications to Manufacturer with a reasonable degree of certainty.
For rupture disk sizing the downstream pressure is
When ordering rupture disks, the following information assumed to reach the critical flow pressure although the
and specifications should be given to the manufacturer. down stream pressure initially may be much lower. Under
these conditions the flow through the "orifice" that the
l. Net inside diameter of opening leading to the flange disk produces on rupture is considered to be at critical
or holding arrangement for the disk, inches; or the flow. The assumptions of critical pressure do not apply
456 Applied Process Design for Chemical and Petrochemical Plants
where a fixed downstream side pressure into which the bursting diameter will actually burst on test and then in
disk must relieve is greater than the critical pressure. actual service.
The coefficient of discharge, K 0, is the actual flow To specify a rupture disk:
divided by the theoretical flow and must be determined
by tests for each type or style and size of rupture disk as • identify the desired bursting pressure, Pb
well as pressure-relieving valve. For rupture disks, the • list the required MR
minimum net Jww area is the calculated net area after a
complete burst of the disk, making allowance for any
structural members that could reduce the net flow area of For example, a system requiring a bursting pressure, Pb,
the disk. For sizing, the net flow area must not exceed the of 150 psig at 400°F, would have an MR range of -4% to
+7% at the operating temperature with a burst pressure
nominal pipe size area of the rupture disk assembly [l]. tolerance of ±5%. The disk supplied by a specific manu-
The bursting pressure, Pb, of the conventional tension-
loaded disk is a function of the material of which the disk facturer (MR varies with manufacturer and pressure
ranges) could have a bursting pressure as low as - (0.04)
is fabricated, as well as its thickness and diameter, and last- (150) = -6 psi, or 144 psig; or as high as ( +0.07) (150)
ly but not least in any manner, is the temperature at which = + 10.5 or 160.5 psig. If the disk is stamped at the oper-
the disk is expected to burst, and not just the temperature ating temperature at 144 psig it could burst at ±5 % or 7 .2
corresponding to the disk set pressure [37]. This type disk psi or 136.8 psig or 151.2 psig. On the other hand, if the
is best suited to be set. on Pb at least. 30% above the system disk were stamped at operating temperature to burst al
operating pressure. The reverse-buckling disk with knives 160.5 psig (its highest) then it could actually burst ±5% of
to aid the bursting are compression loaded because the this, or ±8.03 psi, giving an actual burst pressure of 168.5
dome of the disk faces the internal vessel pressure. The psig to 152.5 psig. Adapted from [37] by permission.
bursting pressure, Pb, of this disk is dependent on the
dome's geometrical shape and the characteristics of the The Code requires that the disks be burst on test by one
knife blades, but it is essentially independent of thickness of three methods using four sample disks, but not less than
and generally does not need a vacuum support [37]. It is 5% from each lot. Figure 7-32 illustrates test results for
often used when the operating pressure is as high as 0.9 burst pressure versus temperature of a disk design, all fab-
Pb. There are some potential problems or even hazards ricated from the same material, and of the same diameter.
with this design if the knives fail, come loose, or corrode, It is critical that such an examination be made to be
and the use must be examined carefully. This disk like any certain that the bursting or set pressure at this tempera-
other disk, should never be installed upside down from its ture does not exceed the lVIA,i\TP of the vessel at the
original design position. It should not be used in partial operating temperature per the ASME code [l] (see Fig-
or total liquid service. ures 7-31A and 31B).
The reverse-buckling disk, without knives but with a As allowed by code [ l ], the average of the manufactur-
pre-scored disk surface, offers some features that do not er's disks burst tests could be stamped, for example, (144
depend on the knives being in place because the thick- + 160.5)/2 = 152.3 psig with an actual ±5% of 152.3 psig
ness of the metal disk dome along the score line deter- allowed for actual burst pressure of any disk at the operat-
mines the bursting pressure of the disk. ing temperature.
The Manufacturing Range (MR) Selection of Burst Pressure for Disk, Pb (Table 7-3)
The ASME code [l] requires that a ruptured disk must It is essential to select the type or style of rupture disk
be stamped with a bursting pressure that falls within the before making the final determination of the final burst
manufacturing range. This range identifies the allowable pressure, and even this selection must recognize the pres-
range of variation from a specified burst pressure to the sure relationships between the disk's manufacturing
actual burst pressure provided by the manufacturer and range and the vessel's maximum allowable working pres-
as agreed upon with the disk user. The stamped burst sure. (Also see Figures 7-31A and 31B.)
pressure of a lot of rupture disks is the average burst pres- Table 7-9 summarizes the usual recommended rela-
sure of all the destructive tests performed per code tionship between the operating pressure of a process
requirements. The average of the tests must fall within the (should be maximum expected upper range level) and
manufacturing range (see Table 7-2). the set pressure of the rupture disk. Recognize that the set
The thickness of one material for manufacture of a pressure of the disk must not exceed the MAWP of the ves-
disk, along with the specific disk type, is the key factor in sel. (See Figures 7-31A and 31B.) The burst pressure, Pb,
establishing at what pressure range a disk of a specified can now be defined. The use of the manufacturing range
Process Safety and Pressure-Relieving Devices 457
Rupture Discs As Sole Relieving Devices Rupture Discs Used in Multiple Or For
Additional Hazard Due To External Heat
Max. Possible B.P. 105 PSI 110 PSI Max. Possible B.P. 116 PSI
<· 5% Rupture Toi. l +5% '" {
Max. Stamped B.P. 100 PSI J + 5%
MAWP <., Max. Stamped B.P. 110 PSI
105 PSI
+ Mfg. Range - + 10% MAWP 110% MAWP/
91 PSI J + 10% + 10%
Specified B.P. .......____MAWP �
}-5%
- Mfg. Range
Min. Stamped B.P. 86 PSI 95 PSI Specified B.P. 100 PSI
}-5% }
- 5% Rupture Toi.
-5% S%
Min. Possible EI.P. 82 PSI
91 PSI Min. Stamped B.P. 95 PSI
} "
-5%
Operating Pressure 86 PSI Min. Possible B.P. 90 PSI
to B.P. Percentage
Multiple Devices Additional Hazards
Max. Operating Pressure Due To External
Heat
Example Example
Mfg. Range O + 10%, - 5% Mfg. Range O + 10%, - 5%
MAWP O 100 PSI MAWP c 100 PSI
Figure 7-31A. Rupture disks as sole relieving devices. By permis- Figure 7-318. Rupture disks used in multiple or for additional haz-
sion, Fike Metal Products Div., Fike Corporation. ard due to external heat. By permission, Fike Metal Products Div.,
Fike Corporation.
(MR) discussed earlier applied to the burst pressure wi!l thus: 105 = 0.7 Pb
establish the most probable maximum Pb. Pb-min = 105/0.7 = 150 psig min rupture disk burst
The burst pressure maximum cannot exceed the pressure
l\11AWP of the vessel. Depending on the situation, it may
be necessary to work backward to the operating pressure From manufacturing range table for this type of disk, MR
maximum to see if this is usable. Table 7-9 summarizes = + 10/-5%@ 150 psig rupture pressure minimum. The
typical rupture disk characteristics noting that the maxi- maximum rupture pressure = 150 + 10% = 165 psig,
mum normal operating pressure of the system is shown as plus/minus the disk tolerance of 5%, allowing a final
a function of the rupture disk bursting pressure, Pb. maximum burst pressure of 173.2 psig.
The minimum stamped bursting pressure of the disk
Example 7-3: Rupture Disk Selection would be 150 psig + 5% tolerance = 157.5 psig.
With a -5% MR, the specified burst pressure would be
Examination of the temperature control ranges of a 157.5 + 5% = 165.4 psig.
process reactor reveals that the normal controls are to With a + 10% upper MR, the maximum stamped burst
maintain a pressure of the reacting mixture of 80 psig, pressure of the disk could be 165.4 + 10% = 181.9 psig.
while the upper extreme could be 105 psig, which would Using the code allowed tolerance for burst, the disk
be defined as the normal maximum operating pressure. could burst al 181.9 + 5% = 190.9 psig. The maximum
Select a conventional rupture disk, then from Table 7-9; allowable working pressure for the vessel cannot be less than
Pmaxop = 0.7 P1, 181.9 psig.
458 Applied Process Design for Chemical and Petrochemical Plants
Stamped Burst Pressure At Coincident Temperature
160
Method 2
150 PSI Q1 72 F
150
EXAMPLE
2" PREBULGED ALU,\41NUM
RUPTURE DISC BURST PRESSURE
150 PSI �1 n- F
DETERMINE BURST PRESSURE AT
210 F
"0
130
123 PSI. f1 240 F
120
Figure 7-32. Establishing stamped rupture disk bursting
pressure at coincident temperature, Method 2. By per-
mission, Fike Metal Products Div., Fike Corporation. TEMPERATURE. F
Table 7-9
Summary of Rupture-Disk Characteristics
Maximum
Vacuum Fragment Liquid or normal
support upon Gas partially- operating
Type of disk required? rupture? service? liquid service? pressure
Conventional Sometimes *Yes/No* Yes Yes 0.7 Pb
Pre-scored
tension-loaded No No Yes Yes 0.85 Pb
Composite Sometimes Yes Yes Yes 0.8 Pb
Reverse-
buckling with
knife blades No No Yes No 0.9 Pb
Pre-scored
reverse-buckling No No Yes No 0.9 Pb
*Depends on manufacturer's specifications ( this author).
By permission, Nazario, F. N., Chem. Eng., June 20, l 988, p. 86 [37].
From this guide to determine the bursting pressure of bursting specifications and the MR exactly the same as the
the rupture disk, it is apparent that some thought must be original order, otherwise the maximum stamped Pb could
given to the process and the equipment design and ulti- be too high for the vessel and the system not properly pro-
mate MAWP. It is not an arbitrary selection. When chang- tected against overpressure.
ing services on a vessel, the MAWP and the operating
pressures of the process must be established and then the Effects of Temperature on Disk
bursting specifications of the disk determined. \,Vhen
reordering rupture disks for a specific service lo repeat a The temperature at the burst pressure must be speci-
performance of a ruptured disk, it is important to set the fied to the manufacturer, as this is essential in specifying
Process Safety and Pressure-Relieving Devices 459
the metal or composite temperature stresses for the disk critical flow will occur, and the appropriate equations
finally supplied. Higher temperatures reduce the allow- should be used [33a].
able working stress of the disk materials. Reference [37]
shows that temperature has an effect on metals in decreas-
ing order, with the least effect on the lowest listed metal: When P 1 is increased, the flow through an open disk
increases and the pressure ratio, P 2/P 1, decreases when P2
does not change, until a value of P 1 is reached, and there
aluminum
stainless steel ( changes after 400°F) is no further increase in mass flow through the disk. The
O
nickel value of P1 becomes equal to P and the ratio is the criti-
Inconel cal pressure ratio, and the flow velocity is sonic (equals
the speed of sound).
When specifying the material at the disk temperature, the
heat loss at the disk/ disk holder as well as in a flowing Maximum velocity (sonic) of a compressible fluid in
pipe must be recognized and the assembly may need to be pipes is [9]:
insulated. This is important as it relates to the actual tem-
perature at the bursting pressure. Establishing this burst
temperature is an essential part of the system safety and (7- 35)
must not be guessed at or taken lightly.
Table 7-10 presents a temperature conversion table for �
various metals from one manufacturer for conventional or, v, = kgP 'V ( 14 4) (7- 36)
pre-bulged, tension-loaded disks with pressure on con-
cave side (not prescored) as an illustration of the effect of or, v, = 68.1 � KP'V (7 - 37)
lower or elevated temperatures referenced to 72°F on the
burst pressure of a stamped disk. For other types of disk
designs and from other manufacturers, the specific data where v, = sonic or critical velocity of a gas, ft/ sec
for the style disk must be used to make the appropriate k = ratio of specific heats, cp/ c,
g = acceleration of gravity= 32.2 ft/sec/sec
temperature correction. R = individual gas constant = MR/M = 1544/M
M = molecular weight
Rupture Disk Assembly Pressure Drop MR= universal gas constant= 1544
T = absolute temperature, R = (460 + r'F)
0
The ruptured or burst disk on a vessel or pipe system t = temperature, °F
presents a pressure drop to flow at that point, and it can P' = pressure, psia, at outlet end or a restricted location
be estimated by assuming the disk is a flat plate orifice in pipe when pressure drop is sufficiently high
[37] with a discharge coefficient, Kci, of 0.62. As an alter- V = specific volume of fluid, cu ft/lb
nate, the disk assembly can be assumed to be the equiva-
lent of a section of pipe equal to 75 nominal disk diame-
ters in length. For sonic floio [33a]:
Actual pressure ratio, P 2 /P 1, less than critical pressure
Gases arid Vapors: Rupture Disks [33a, Par.4.8]
ratio, flow is sonic or critical.
The sizing is based on use of the ASME Code [ 17] flow
coefficient:
Pc/P1 = [2/(k + l)]kl(k-l), critical pressure ratio (7-7)
K.J = 0.62 [11 (Par. UG-127) for standard metal disks, but use
K.J = 0.888 for graphite disks [70]
K.J = actual flow/theoretical flow = coefficient of discharge where Pc = critical flow throat pressure, psi a
Pb= st.amped bursting pressure, psia = burst pres-
sure + overpressure allowance (ASME Code of
To select the proper sizing equation, determine
whether the flowing conditions are sonic or subsonic 10%) plus atmospheric pressu,-e, psia
from the equations. When the absolute pressure down-
stream or exit of the throat is less than or equal to the crit- Important note: when actual system ratio, P2/P1, is less
ical flow pressure, P then the flow is critical and the des- than critical pressure ratio calculated above by Equation
O
ignated equations apply [33a]. When the downstream 7-4.0, flow is sonic. When actual P 2 /P 1 ratio is greater than
pressure exceeds the critical flow pressure, Pc, then sub- critical pressure ratio, flow is subsonic.
460 Applied Process Design for Chemical and Petrochemical Plants
Table 7-10
Temperature Conversion Table for
Conventional Rupture Disks Only
TEMPERATURE CORRECTION FACTOR IN % FROM RUPTURE PRESSURE AT 72"F.
DISK RUPTURE DISK METALS DISK RUPTURE DISK METALS
TEMP. TEMP.
•F ALUM. SILVER NICKEL MONEL INCONEL 316 S.S. •F NICKEL MONEL INCONEL 316 S.S.
-423 170 164 165 155 132 200 300 93 87 94 84
-320 152 152 144 140 126 181 310 92 87 94 84
-225 140 141 126 129 120 165 320 92 86 94 83
-200 136 138 122 126 118 160 330 92 86 94 83
-150 129 130 116 123 115 150 340 92 86 94 83
-130 127 126 116 121 114 145 350 91 85 93 82
-110 122 123 115 120 113 141 360 91 85 93 82
-100 120 122 115 119 112 139 370 91 85 93 82
- 90 120 121 114 118 112 136 380 91 85 93 82
- 80 120 120 114 117 111 134 390 90 84 93 81
- 70 119 120 113 116 110 132 400 90 84 93 81
- 60 119 119 112 115 110 130 410 90 84 93 81
- 50 119 118 112 114 109 128 420 90 84 93 81
- 40 118 117 111 113 108 125 430 89 84 93 81
- 30 117 115 110 112 108 123 440 89 83 93 80
- 20 116 112 109 111 107 121 450 89 83 93 80
- 10 115 110 108 110 106 118 460 88 83 93 80
0 114 108 107 109 105 116 470 88 83 93 80
10 113 107 106 108 105 114 480 87 83 93 80
20 111 105 105 106 104 112 490 87 82 94 80
30 110 104 104 105 103 110 500 86 82 94 79
40 108 103 103 104 102 107 520 85 82 94 79
50 106 102 102 103 102 105 540 84 82 94 79
60 103 101 101 101 101 103 560 83 81 94 79
72 100 100 100 100 100 100 580 82 81 94 78
80 100 100 100 99 100 99 600 81 81 94 78
90 99 99 99 98 99 98 620 79 80 94 77
100 98 99 99 97 99 96 640 78 80 94 77
110 97 98 98 96 99 95 660 77 79 93 77
120 97 98 98 95 98 94 680 76 79 93 76
130 96 97 97 95 98 93 700 75 78 93 76
140 95 96 97 94 98 92 720 73 77 93 76
150 94 95 96 93 97 91 740 72 77 93 76
160 93 94 96 93 97 90 760 - 76 93 75
-
170 92 93 96 92 97 90 780 - 76 93 75
180 90 92 95 92 96 89 800 75 92 75
190 89 91 95 91 96 89 820 - - 92 75
200 88 90 95 91 95 88 840 - - 92 75
-
-
210 87 89 94 90 95 88 860 - - 92 75
220 85 87 94 90 95 87 880 91 74
230 84 86 94 89 95 87 900 - - 91 74
240 82 85 94 89 95 86
250 81 84 93 89 95 86
260 93 88 94 86
270 93 88 94 85
280 93 88 94 85
290 93 87 94 84
300 93 87 94 84
NOTE. This conversion table does not apply to Type D or reverse buckling disks.
By permission, B. S. and B. Safety Systems, Inc.
Process Safety and Pressure-Relieving Devices 461
Table 7-10 Q. = required flow, cu ft/min at standard conditions of I 4.7
continued psia and 6Q°F, SCFM
Example Actual flowing conditions, ACFM
'What is rupture pressure at 500CF of a nickel disk rated 300 psi
at 72cF?
1. Consult temperature conversion table. Correction 5.596 Q, 'M
I-
factor for nickel disk at 500°F is 86%. A= CKd " V TZ (7 - 39)
2. Multiply disk rating at 72°F by correction factor:
300 x 0.86 = 258. C2.A = required flow, cu ft/min at actual conditions, ACFM
Rupture pressure of a nickel disk rated 300 psi at 72°F
is therefore 258 psi at 500°F. Stearn: Rupture disk sonic flow; critical pressure = 0.55 and
If you require a disk for a specific pressure at elevated P 2/P 1 is less than critical pressure ratio of 0.55.
or cold temperature and want to determine if it is a stan- API reference [33a] [69] dry and saturated steam,
dard disk, convert the required pressure at elevated or pressure up to 1500 psig:
cold temperature to pressure at 72°F.
w .
A = _ • , sq m. (7 - 40)
P2 = backpressure or exit pressure, psia si.s s , Pb Kn K,h
P 1 = upsu·eam relieving pressure, psia
where W = flow, lbs/hr
For sonic flow conditions [69):
K.:i = coefficient of discharge = 0.62.
K,, = correction for Napier equation = 1.0 when P 1 �
(7-10) 1515 psig = (0.1906P1 - 1000)/ (0.2292P1 - 1061)
where P1 > 1515 psia and S 3215 psia, Table 7-6.
K. 11 = superheat correction factor, see Table 7-7. For sat-
where A = minimum net required flow discharge area after urated steam al any pressure, Rs1, = 1.0
complete burst of disk, sq in. Pb = stamped bursting pressure, psia
C = sonic flow constant for gas or vapor based on ratio
of specific heats, k, Figure 7-25, when k is not known AP! for subsonic flow: gas or vapor (not steam)
use k = 1.001, or C = 315
W = required flow, lb/hr For rupture disks, pressure ratio is greater than critical
M = molecular weight pressure; mass flow: pounds/hr
K.:i = coefficient of discharge, K = 0.62 for rupture
disks, except some coefficients are different. For PjP > critical pressure ratio [2/(k t l)Jk/k - 1
example, the Zook graphite standard ASME disks
when tested mono-style, Figures 7-9B and 7-13A
have a K0 of 0.888, and when inverted, Figure 7-
l 3B have a K0 of 0. 779. Consult manufacturer for ( 7 - 41)
special disks.
0
T = flowing relieving temperature, °F + 460 = R
absolute Where C2 = subsonic flow conditions based on ratio of specific
M = molecular weight of flowing fluid heats (See Table 7-11 and equation for C 2)
Z = compressibility factor for deviation from perfect
gas if known, otherwise use Z = 1 .0 for pressures Volumetric flow, SCFM conditions
below 250 psia, at inlet conditions.
Pb = stamped bursting pressure plus overpressure
allowance (ASME l 0% or 3 psi whichever is (7 - 42)
greater) plus atmospheric pressure ( 14. 7), psi a
Volumetric flow: SCFM standard conditions (14.7 psia
and 60°F) Actual flowing conditions, ACFM
Q, (MTZ) 112 .
A= -, so 111. (7- 38) (7- 43)
6.326 CKd Pb '
462 Applied Process Design for Chemical and Petrochemical Plants
Table 7-11
Constant, C 2, for Gas or Vapor for Subsonic Flow Conditions
SUBSONIC FLOW CONDITIONS
p,;p.
k 0.95 0.90 0.85 0.80 0.75 0.70 0.65 0.60 0.55 0.50 0.45
1.001 158.1 214.7 251.9 277.8 295.7 307.4 313.7
1.05 158.4 215.5 253.3 280.0 298.7 311.2 318.4 321.0
1.10 158.7 216.3 254.7 282.0 301.5 314.8 322.9 326.4
1 .15 158.9 216.9 255.9 283.9 304.1 318.2 327.1 331.4
1.20 159.2 217.6 257.0 285.6 306.5 321.3 331.0 336.0
1.25 159.4 218.1 258.1 287.2 308.7 324.2 334.5 340.4
1.30 159.6 218.7 259.1 288.7 310.8 326.9 337.9 344.4 346.8
1.35 159.7 219.2 260.0 290.1 312.7 329.4 341.1 348.2 351.3
1.40 159.9 219.6 260.8 291.4 314.5 331.7 344.0 351.8 355.5
1.45 160.0 220.1 261.6 292.6 316.2 334.0 346.8 355.2 359.5
1.50 160.2 220.5 262.3 293.7 317.8 336.0 349.4 358.3 363.3
1.55 160.3 220.8 263.0 294.8 319.3 338.0 351.8 361.3 366.8
1.60 160.4 221.2 263.7 295.8 320.7 339.8 354.1 364.2 370.2 372.3
1.65 160.6 221.5 264.3 296.7 322.0 341.6 356.3 366.8 373.4 376.1
1.70 160.7 221.8 264.8 297.6 323.2 343.2 358.4 369.4 376.4 379.6
1.75 160.8 222.1 265.4 29J.5 324.4 344.8 360.4 371.8 379.3 383.0
1.80 160.9 222.4 265.9 299.3 325.5 346.2 362.3 374.1 382.1 386.3
1.90 161.0 222.9 266.9 300.7 327.6 349.0 365.7 378.4 387.2 392.3
2.00 161.2 223.4 267.7 302.1 329.5 351.5 368.9 382.3 391.8 397.8 400.1
2.10 161.4 223.8 268.5 303.3 331.2 353.7 371.8 385.8 396.1 402.8 405.9
2.20 161.5 224.2 269.2 304.4 332.8 355.8 374.4 389.1 400.1 407.5 411.4
2.30 161.6 224.5 269.9 305.4 334.2 357.7 376.9 392.1 403.7 411.8 416.4
k
G.! = 735
k-1
By permission Continental Disc Corp., Cat. 1-1110, p. 1.
Converting actual flow conditions to standard conditions Liquids: Rupture disk
of60°F and 14.7 psia [73]:
The test for critical or non-critical does not apply.
These equations apply to single-phase (at inlet) liquids,
non-flashing to vapor on venting, fluid viscosity is less
Q. = [{(520/14.7)) (Pac/Tac,)] (Qlct) = SCFM, 60°F and than or equal to water [69].
14. 7 psia (7-44)
ASME mass flow :
where P,c, = pressure actual, psia A= -------;:::W==== , sq m. (7-45)
.
2
Tact= temperature actual, °F + 460°F = R 2407 Kd � (Pb - P )P 1
0
<2ac, = flow at actual conditions: ACFM, at actual flowing
conditions where W = flow, lb/hr
Q, = required flow, cu ft/min at standard conditions p = Fluid density, lb/ cu ft
( 14. 7 psia at 60°F), ( 60°F + 460 = 520°R) K,i = coefficient of discharge = 0.62
Process Safety and Pressure-Relieving Devices 463
Pb = stamped bursting disk pressure plus accumulation using a 1)4..inch disc with Mone! metal. Other disk and
of 10% plus atmospheric pressure, psia valve manufacturers have their 0\'111 combination data,
P 2 = pressure on outlet side of rupture disk, psia which when available, avoids the requirement of derating
the capacity to 80% of the rated capacity of the pressure
Wt � Sp Gr relief valve. Disks (metal or graphite) that fragment
Volumetric flow : A= , sq in. (7 - 46) should neoer be used because these may become potential
38Kd � Pb-P 2
problems for the safety valve performance. Therefore, a
non-fragmenting disk should be selected, such as a
where Sp Gr = fluid specific gravity relative to water = 1.0 @ reverse acting/reverse buckling preferably pre-scored
60°F
\,Vt = liquid flow, gallons per minute design, but knife blades are a viable alternate.
Sizing for Combination of Rupture Disk and Pressure Relief Example 7-4: Safety Relief Valve for Process
Valve in Series Combination
Overpressure
When the rupture disk is installed on the inlet side of The conditions set forth on the Operational Checklist,
the pressure relief valve (see Figures 7-10, 7-11 and 7-12), Figure 7-14, are used in the example specified on the
the ASME code requires that for untested disk-valve com- specification form (Figure 7-33).
binations that the relieving capacity of the combination
be reduced to 80% of the rated relieving capacity of the
pressure relief valve [ l]. Example 7-5: Rupture Disk External Fire Condition
For flow tested combinations, see a few typical data in
Table 7-12. Note, for example, that using a Continental An uninsulated 12-ft X 36-ft horizontal storage tank
disk reverse acting knife blade rupture disc with a Crosby containing CC1 4 is to be protected from overpressure due
JOS/JBS pressure relief valve that the combined effect is to external fire by means of a rupture disk. The tank does
to multiply the rated capacity of the Crosby valve by a mul- not have a sprinkler system. Storage pressure is 5 psig and
tiplier of 0.985 for a set pressure in the 60-74 psig rauge should not exceed 10 psig. Tank is assumed to be full. k =
Table 7-12
Rupture Disk/Relief Valve Combination Capacity Factors
I TELEDYNE DRESSER KUNKLE
I DISC DISC DISC PRESSURE FERRIS 1900-30 CROSBY CROSBY CROSBY THRU LONERGAN
SET
5000
1900
2600&
TYPE SIZE MATERIAL PSIG 4500 1900-35 JOSI JBS JB JO 5999 D&OB
ZAP 1.5 Mone I 60-74 0.982 - 0.985 0.983 0.980 - -
(contd)
1.5 Mone I 75 PLUS 0.982 - 0.985 0.990 0.986 - -
1.5 Nickel 30-49 - - 0.965 - 0.975 - -
I 1.5 Nickel 50-59 0.989 0.984 0.965 - 0.975 0.988 0.966
1.5 Nickel 60 PLUS 0.985 0.984 0.992 - 0.994 0.988 0.996
ZAP 3.0 Stainless Steel 15-29 0.963 0.966 - - - - -
]o Stainless Steel 30-34 0.993 0.966 0.955 - I - -
- I
-
-
-
0.970
0.966
0.993
35-49
3.0 Stainless Steel
3.0 Stainless Steel 50-59 0.993 0.966 0.970 0.976 0.981 I - -
Extracted by permission: Continental Disc Corp., Bul. #1-1111, pg. 4. Only portion of original tables presented for illustration.
Nole: Zap is a reverse-acting rupture disk using replaceable knife blades. Patented. Other disk and valve manufacturers have tested their own combi-
nations to obtain combination capacity factors.
464 Applied Process Design for Chemical and Petrochemical Plants
I'- Spec. Dwq, No.
Job No.. _ ------
� of Po ;es
Pa qe
B/M No. Unit Price
No. Unih
SAFETY VALVE SPECIFICATIONS Item No.
DESCRIPTION
Standard Stamdard
Mako Modol Type•Back Press.
If L 6 Vapor
Size (Inlet x Oriflee No, x Outlet) ( x x Phose
�
1 75 PSIG ) 3 1 7 0
Set Pres, ( )@ 'F Full Flow Back Pross. PSIG
2.02 ?..853
Req'd Orifice Area Sq. In.: Selected Orifice Area Sq, In,
2 Screwed Cao. No Test Gaq No Liftinq Gear
Acce1aorfe1
250#-4" Raised
Inlet Nozzle: Pr•••· Clau Facin;
125 #- 6" Raised
Outlet Nonie: Preu, Clou Facing
250# 450
Mfgr'1, Roting PSIG (Mox)<. , �, 1 2 5# ( OU t 1 et) PSIG (M;n)@ 300 'F
1 2
Ref.,, to lnltfal Ve11el relief pressure. Refers to cop type, lifting gaar, gag, otc:.
MATERIALS
Cast Iron Bronze
Body and Bonnet Trim
9ronze Bellows None
Nonie and Dl1c
Carbon Stee 1, cadium plated, or equal
Spring
REMARKS
Uoo throo•way wive (YH) (No) No
PROCESS RATING DATA
I Location n ..... �"".'11,--,...�t,,....,..,. C"L.-11 Flow tt.::to � ure
• Fluid PDC Basad On Operations Vesse 1 Max.
z SyaNm Oper. Pr•••· 60 PSIG@ 347 'F: MW• 113.5
. I RM'd Cop, 22, 500 Lbs/Hr,@ 347 'F* Phase: Liquid Lbs/Cu. Ft,
Dens.•
• • . ,... Liq, Vi1co1ity* SSU :XA«u..i, lc,tiol( ]Q %: Back Pren. Corr. Factor
overpressure
...
. -
..
• R•fen to properties at S.t Prea1ure
.
u CALCULATIONS
�
..c a '
I
� � Use: A= W(Z T/M)i c KdP Kb
� Since data for c/cv not readily available, use k = 1.001 and c = 315, z = 1.0, Kb=l ,0
0
�
0
.,, p ( at relieving condition) = (75)(1.1) + 14.7 = 97.2 psi a --
• I T = 347 + 460 = 807 R
u
iii 0 "ti
z � ,,.
A = 22, 500[ ( 1) ( 807) I 113. 5] t I (315) (0.953) (97,2) (1.0) .
0
. I A = 2.055 Sq. In, �
?
�
• ,... Note that critical flow conditions apply, since relieving pressure of 97.2 psi a z
is over twice the backpressure of 14.7 psi a. 3 <T
=
--
By I Chk'd I App. I Rev. 1 Rev, J Rev,
Dot• I I I I l
Figure 7-33. Safety relief valve specification for process overpressure example.
Applied Process Design 465
1.13. Disk burst pressure to be 10 psig. Nli-\WP of vessel is Disk Area
50 psig. Discharge line back pressure is 1 psig.
( � )
Heal Input Flow is subcritical, since pl > �
pi
Using ASME flanged and dished heads (F&D) from
Appendix Tables of Blanks, the circle size is 152 in. for a
12-ft diameter tank. Then add 3-in. straight flange which
becomes 158 in. which is 158/12 = 13.166 fl diameter.
Area of this diameter for surface area of head= 136.14 sq
ft equivalent surface area of one head. For a horizontal 'vV = 106,000 lbs/hr
vessel there are two heads possibly exposed to fire. Kn= 0.62
Pb= 10 + 14.7 = 24.7 psia (10) (l.lO see Fig. 7-llA) + 14.7
External Surface Area: cylindrical area + surface area = 25.7 psia
heads (2) P2 = 15.7 psia
M = 154
= rt (12) (36) + ( l:'5§) 2 ( � ) 2 T = 460 + 202 = 662° R (B.P. of CCL 1@ 10 psig)
k=l.13
\ 12 4
1357 + 274 = 1629 sq ft (approximate) F 2 = 0.691 interpolated from Figure 7-29
Area calculated substituting in above relation:
Total Heat Input (From Figure 7-30)
A = 43.52 sq in.
6
Q = 9.0 X 10 BTU/hr. at area of 1629 sq ft
8-inch Sch. 40 pipe has a cross-sectional area of 50.0 sq in.
Solving equation: Q = 0 21,000 F A0.82 so an 8-inch frangible rupture disk will be satisfactory.
82 Disk material to be lead or lead covered aluminum.
Q = 0 21,000 ( 1.0) (1629) O = 9,036,300
BTU/hr
Example 7-6: Rupture Disk for Vapors or Gases; Non-
Fire Condition
Quantity of Vapor Released
Determine the rupture disk size required to relieve the
Latent Heat CC1 4 = 85 BTU/lb pressure in a process vessel with the following conditions:
k = 1.4.
9,000,000 .
·w = = 106, 000 lb I hr (rounded) Vessel: MAWP = 85 psig; also = disk set pressure
85
Vapor flow to relieve: 12,000 std. cu fl/min@ 60°F and
Critical Flow Pressure 14.7 psia
Flowing temperature: 385°F
Vapor mol. wt: 28
( 2 ·,k./•:k-l) ( 2 Jl.13/(1.13-1) Backpressure on discharge of disk: 30 psig
P = P --J = 24. 7 ---
c k + 1 1.13 + 1
Determine if conditions on rupLure are critical or non-
critical, based on 10% overpressure for primary relief.
Pc =27.7(0.573)=15.8psia,or
P (30+14.7)
�= =44.7/108.2=0.413
P,
- " actual= ( 14.7+1.0 J = 0.610 pl [(85)(1.10)+ 14.7]
pl (10)(1.1)+ 14.7
[--2--] 3 . . . [ 2 I:� I _
]
� = 1. · = 0.573 Critical pressure ratio: = Pc IP = -- , = 0.::>28
P ( 1.13 + l) ( l.3 - I) 1 1.4 + 1
1
466 Applied Process Design for Chemical and Petrochemical Plants
Since actual P2/P1 < critical ratio 0.528, the flow is Use Std. pipe size: 5 in. (cross sect. area= 26.01 sq in)
sonic. disk, or check manufacturer, Use inlet and discharge pipe
Critical pressure =Per= 108.2 (0.528) = 57.12 psia size = 6 in. std.
Flow area required to relieve: [33a]
Example 7-8: Liquid Overpressure, Figure 7-34
Q. ( MTZ) o.so
A=----- (7-47) A check of possible overpressure on a heat exchanger
6.32 CKdPh
handling 95% aqua ammonia in the tubes indicates that
where Q, = 12,000 SCFM tube failure is probably the condition requiring maxi-
M = 28 mum relieving capacity. The aqua is being pumped by a
C = 356, Figure 7-25 positive displacement pump. Thirty psia steam on shell
K,i = 0.62 (rupture disk) side heats (not vaporizes) the aqua. In case of tube failure
Pb = 108.2 psia the aqua would flow into the shell and soon keep the
Z = 1.0 steam from entering. Relief must prevent the shell from
T = 385 + 460 = 845°R failing. The shell is designed for a working pressure of 210
psig.
12000 [ ( 28) ( 845) ( 1.0)] OS The calculations are shown on the specification sheet,
A=----------
6.32 ( 356) ( 0.62) ( 108.2) Figure 7-34.
A= 12.22 sq in. Pressure--Vacuum Relief for Low Pres-sure Storage Tanks
Area of I.D. of 4 in. std. sch. 40 pipe = 12.7 sq in. This
should be adequate. In order to accommodate "breathing" of tanks and
other equipment due to temperature changes, pumping
Example 7-7: Liquids Rupture Disk in and out, internal vapor condensation and other situa-
tions, adequate safety vacuum relief must be provided. In
Determine the rupture disk size required to relieve the many cases both pressure and vacuum relief are needed
following operating condition: ( see Figure 7-35) . For the average product storage tank
Back pressure: 0 psig the API Guide For Tank Venting RP 2000 [26] serves to
Toluene flow: 1800 gpm, SpGr = 0.90 set minimum venting quantities for various tank capacities.
Pressure vessel: MAWP = 25 psig In addition to these tabulated values, calculations are
Relieving pressure: set pressure; use 25 psig made lo satisfy each condition of operation to insure that
Actual relief pressure = 25 + 10% = 27.5 psig there is no situation requiring more than this vent capac-
ity. Emergency vent capacity is also required to supple-
ment the normal requirement in case of external fire or
other unusual condition.
The normal venting Lo be provided must not allow
pressure or vacuum conditions to develop which could
SpGr = 0.90 cause physical damage to the tanks [26].
Fluid: Toluene, flow - 1800 gpm
Basic Venting For Low Pressure Storage Vessels
gpm ( SpGr) o.s
A = __:c.:.._ _ _ Usually reference to low pressure venting is associated
__:_
)0·3
38.0 K (P - P <l
with large storage tanks of several thousand gallons capac-
ity (ranging from a few thousand to a million); however,
� = 0.62 per API [33a], or from manufacturer
P 1 = 27.5 + 14.7 = 42.2 psia small low pressure tanks can be handled in the same
P 2 = 0 + 14.7 = 14.7 psia manner. The usual operating pressure range for the typi-
cal tank is 0.5 oz./in. to about 1.5 psig. Since low pres-
2
sure vessels have pressure ratings expressed in various
A _ 1800 I 0.90 units, Table 7-13 can be useful for conversion.
- 38 ( 0.62 )'\ ( 42.2 - 14.7) Typical large storage vessels are illustrated in Figure 7-36.
Operations associated with storage tanks should be
A= 76.40 ( 0.180) = 13. 75 sq in. required carefully analyzed, since there are several factors which
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APPLIED PROCESS DESIGN FOR CHEMICAL AND PETROCHEMICAL PLANTS, Volume 1, 3rd Edition
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