Page 1 of 8

STANDARD SPECIFICATION FOR

SAFETY / THERMAL RELIEF VALVES, RUPTURE DISCS & BREATHER VALVES

DOCUMENT NO : 44-LK-5100-00/J.02/0011-A4

Rev No.

Issue Date

12.08.08

Pages

Rev Description

Issued for Comments /

Approval

Prepared

Checked

Approved

By

By

By

RCK

GDR

BSP

JACOBS ENGINEERING INDIA PRIVATE LIMITED

DOCUMENT NO : 44-LK-5100-00/J.02/0011-A4
STANDARD SPECIFICATION FOR SAFETY / THERMAL RELIEF
VALVES, RUPTURE DISCS & BREATHER VALVES
TABLE OF CONTENTS

1.0

PURPOSE

2.0

SCOPE

3.0

TECHNICAL REQUIREMENTS

3.1
3.2
3.3

RELIEF VALVE AND DESIGN

BREATHER VALVE SIZING & DESIGN
RUPTURE DISC DESIGN

4.0

RELATED DOCUMENTATION

5.0

ATTACHMENTS

Date : 12.08.08
Page 2 of 8
Revision No. : A

JACOBS ENGINEERING INDIA PRIVATE LIMITED

_________________________________________________________________________
DOCUMENT NO :44-LK-5100-00/J.02/0011-A4
STANDARD SPECIFICATION FOR SAFETY / THERMAL RELIEF
VALVES, RUPTURE DISCS & BREATHER VALVES

1.0

Date : 12.08.08
Page 3 of 8
Revision No. : A

PURPOSE
The purpose of this specification is to define the minimum requirements of design and
manufacture of Safety / Thermal relief valves, Rupture Discs and Breather valves.

2.0

SCOPE
The scope of work shall include design, manufacture, testing and supply of Safety /
Thermal relief valves, Rupture Discs and Breather valves. The inspection requirements
shall be as per the inspection plan.

3.0

TECHNICAL REQUIREMENTS

3.1

RELIEF VALVE AND DESIGN

3.1.1

The vendor shall be responsible for the selection and sizing of the safety relief valves in
accordance with the supplied process data.

3.1.2

Safety relief valves shall be designed, manufactured and sized in accordance with the
recommendations of API RP526, API 527, API 520, API 521, ASME code for 'Boilers and
Pressure Vessels' and Indian Boiler Regulations.

3.1.3

The calculated result should be used to select a relief valve whose effective flow area is
the nearest size larger than the calculated area, as limited by the standard orifice areas
available.

3.1.4

Where Safety relief valves are provided on ASME coded boiler and pressure vessels,
they shall be manufactured in accordance with ASME VIII and shall carry the ASME VIII
code stamp.

3.1.5

Lifting lever shall be specified for steam and air service

3.1.6

The percentage accumulation in case of pressure relief / safety valves shall be as follows
Steam Service
- ASME SEC I
3%
- IBR (Before steam let-down station)
5%
- IBR (Distribution & Utilities) and
10%
ASME Section VIII
Gas, Vapour or liquid
10%
Liquid for thermal Relief
20% or less
Fire exposure on unfired vessels
21%

3.1.7

Safety Relief valves shall be of the direct spring loaded type. Pressure relief valves shall
be full nozzle full lift type except for thermal relief valves.

3.1.8

The spring in a pressure relief valve in service for pressures up to and including 250 psi
(1720 KPa) shall not be reset for any pressure more than 10% above or 10% below that
for which the valve is marked. For higher pressures, the spring shall not be reset for any
pressure more than 5% above or 5% below that for which the valve is marked.

JACOBS ENGINEERING INDIA PRIVATE LIMITED

DOCUMENT NO : 44-LK-5100-00/J.02/0011-A4
STANDARD SPECIFICATION FOR SAFETY / THERMAL RELIEF
VALVES, RUPTURE DISCS & BREATHER VALVES

Date : 12.08.08
Page 4 of 8
Revision No. : A

3.1.9

Conventional valves shall be specified for constant back pressure while bellows seal type
valves shall be specified for variable backpressure more than 10% of set pressure or for
toxic / hazardous or corrosive fluids where conservation of the fluid is of utmost
importance. Pilot operated pressure relief valves shall be used for special services and
where set pressure is closer than 10% of the operating pressure, in general.

3.1.10

All Valves shall be flanged to ANSI B16.5 R.F. serrated finish unless otherwise specified.
Flanged connection shall be for standard sizes 1" or larger. Minimum flange rating shall
be 150 # ANSI. Where permissible, screwed connections shall be used on sizes " and
below.

3.1.11

For API coded tanks pressure/vacuum relief valves shall be pallet/weight loaded, or pilot
operated. During hydrostatic testing of the equipment / pipe lines / systems Safety relief
valve shall be removed and replaced by a blind flange.

3.1.12

Valve seat tightness shall be in accordance with the requirements of API STD 527.

3.1.13

The body material shall, as a minimum, be as per piping specifications. Nozzle and disc
material shall be SS316 as a minimum with machined stainless steel guide and spindle.
Whenever semi nozzle designs are unavoidable, body material shall be at least same as
nozzle material. The spring material of pressure relief valves shall be as follows unless
otherwise specified in the datasheet, or required by the corrosive characteristics of the
service:
-29C to 250C
above 250C to 540C
below -29C
Above 540C

3.1.14

:
:
:
:

Cadmium / Nickel-plated carbon steel.

Tungsten alloy steel.
Stainless steel 316.
High Speed Steel

Pilot Operated Safety / Relief Valves

Pilot operated safety/relief valves use the process pressure acting on the topside of the
disk as the closing force. The pilot valve, which is a spring loaded valve, connects the
cavity above the disk either to the process or to the atmosphere, or a low-pressure
system. Internal sensing for pilot shall be avoided as far as possible by providing remote
pilot sense ports. The pilot operated safety/relief valve can operate at process pressure
close to the set pressure because of the high positive closing force which increases with
the process pressure. Normally pilot operated valves should be provided with soft seals,
which give a better valve tightness. The design features of a pilot operated valve allows
for larger orifice sizes than the maximum 8T10 size for spring loaded valves. A field
connection for checking the set pressure shall be provided.

3.1.15

Mechanical requirements

3.1.15.1

The design shall incorporate guiding arrangements necessary to ensure consistent

operation and tightness.

3.1.15.2

The spring shall be designed so that the full lift spring compression shall be no greater
than 80% of the nominal solid deflection. The permanent set of the spring (defined as the
difference between the free height and height measured 10 mins. after the spring has
been compressed solid three additional times after presetting at room temperature) shall
not exceed 0.5% of the free height.

3.1.15.3

The valve seat shall be fastened to the valve body such that the valve seat shall not lift. test
gag shall be provided for all pressure relief valves.

3.1.15.4

Valves shall be provided with provision for sealing of all external adjustments.

JACOBS ENGINEERING INDIA PRIVATE LIMITED

_________________________________________________________________________
DOCUMENT NO :44-LK-5100-00/J.02/0011-A4
STANDARD SPECIFICATION FOR SAFETY / THERMAL RELIEF
VALVES, RUPTURE DISCS & BREATHER VALVES

Date : 12.08.08
Page 5 of 8
Revision No. : A

3.1.15.5

On valves where the design allows liquid to collect on the discharge side of the disk, the
valve shall be provided with a drain at the lowest point.

3.1.15.6

Stems shall be of AISI 416 except if the body is austenitic stainless steel, when it shall be
of 18.8% Cr.Ni.

3.1.16

Steam service

3.1.16.1

Pressure Relief Valves on steam service shall be provided with a lifting device to ensure
the valve is free. Pressure tight packing shall be provided around the lifting lever
assembly, so that leakage will not occur when the valve is opened or under back
pressure.

3.1.16.2

The lifting device shall not hold the valve disk in the open position when the exterior lifting
force is released.

3.1.16.3

Safety Relief Valves on steam service shall meet the requirements of the Indian Boiler
Regulations.

3.1.16.4

Valves for steam service shall be flanged to ANSI B16.5. Serrated R.F. and shall have an
open bonnet i.e. only with a yoke in place of a closed bonnet. They shall be provided with
a weather hood \ when used in outdoor service.

3.1.16.5

Steam services above (750F) 399C shall be provided with a cooling spool between the
body and bonnet to minimise conduction of heat to the spring.

3.1.16.6

Vendor shall furnish sizing calculations based on IBR formula. In this connection, vendor
shall indicate the 'C' value as accepted by IBR.

3.1.17

Thermal Expansion Relief Valves

3.1.17.1

Relief valves without blow down ring shall be used for liquid thermal expansion purposes.

3.1.17.2

3/4" x 1" threaded (NPT) modified nozzle type valves with typically 0.38 cm2 orifice size
shall be specified for thermal relief. If the piping specification does not allow screwed
connection then flange connection shall be used.

3.1.18

Relief Valve Installation

3.1.18.1

Safety and Safety Relief Valves shall always be mounted in a vertical position directly on
nozzles having a well-rounded approach that provides smooth, unobstructed flow from
the vessel or line to the valve.

3.1.18.2

Safety valves shall not be mounted on nozzles having an inside diameter smaller than
the inlet connection to the valve, or on excessively long nozzles.

3.1.18.3

Discharge pipe work shall be piped upwards such that vapours or liquids are discharged
vertically.

3.1.18.4

For optimum safety valve performance, discharge piping shall be supported

independently of the valve.

JACOBS ENGINEERING INDIA PRIVATE LIMITED

DOCUMENT NO : 44-LK-5100-00/J.02/0011-A4
STANDARD SPECIFICATION FOR SAFETY / THERMAL RELIEF
VALVES, RUPTURE DISCS & BREATHER VALVES

Date : 12.08.08
Page 6 of 8
Revision No. : A

3.1.18.5

For steam service slip joint drip pan elbows should be used, with the drip pan drain piped
away to a safe location.

3.1.18.6

The installation of safety and safety relief valves shall be in accordance with the
recommendations of API RP 520 Part II.

3.1.19

Relief Valve Testing

3.1.19.1

Steam service valves shall be tested with steam. Where this facility is not available air
may be used. When steam valves are tested with air all necessary corrections for
differential in popping pressure between steam and air shall be determined by the vendor
and submitted to the purchaser for approval.

3.1.19.2

For steam service valves not covered by API Std. 527, when leak tested there shall be no
visible or audible leakage from the valve outlet when the inlet pressure is held at 95% of
the set pressure after popping and reseating.

3.1.19.3

Valves marked for general service may be tested with air.

3.1.19.4

Liquid service valves shall preferably be tested with water but may be tested with air.

3.1.19.5

Valves shall be tested to demonstrate the popping point and tightness.

3.1.19.6

Pressure relief valves shall be type tested for capacity with 5% blowdown as per ASME
Sec VIII UG 131 and actual blowdown of the individual valves shall meet the process
requirement. All Valves shall be provided with such type test certificates.

3.1.19.7

For all relief valves test records and test certificates to fully cover component materials
and the valve test details shall be provided.

3.1.20

Relief Valve Marking And Nameplates

3.1.20.1

The marks shall be placed on the valve or on a plate securely fastened to the valve. The
marks shall be made in such a way that they will not be obliterated in service.

3.1.20.2

The markings shall include the following as a minimum for Safety / Thermal Relief
Valves:-

Valve Tag number

Vendors name
Vendors design or type number (Model Number)
Size (mm)
Set Pressure kg/cmg
Orifice (standard letter designations)
Cold setting
Back pressure (constant or variable)
Capacity at overpressure
Year of manufacture
ASME or IBR symbol as required.
Clients (End user) name and Clients code no.

JACOBS ENGINEERING INDIA PRIVATE LIMITED

_________________________________________________________________________
DOCUMENT NO :44-LK-5100-00/J.02/0011-A4
STANDARD SPECIFICATION FOR SAFETY / THERMAL RELIEF
VALVES, RUPTURE DISCS & BREATHER VALVES

Date : 12.08.08
Page 7 of 8
Revision No. : A

3.2

BREATHER VALVE SIZING & DESIGN

3.2.1

The breather valves shall follow the listed specifications as a minimum during design.
There shall be sufficient margin between the set pressure of breather valve and tank's
design pressure / vacuum. Also, there should be sufficient difference between the set
pressure of N2 blanketing system and breather valve.

3.2.2

Breather valves shall generally be soft seated, dead weight type and shall have selfdraining body construction. The seating surfaces shall be shielded from condensates
and the design shall prevent tendency of pallet to stick to the seat.

3.2.3

Vacuum breakers shall, in general, be sized and designed as per API 2000.

3.3

RUPTURE DISC DESIGN

3.3.1

Rupture discs shall be reverse buckling type, in general and shall be supplied in pretorqued holder assembly which shall fit inside the inner diameter of the bolt circle of
standard flanges. Disc and holder material shall be compatible with the process fluid .
Inconel discs shall be used above 100C if compatible with the process fluid.

3.3.2

When rupture disc is used upstream of a pressure relief valve, a pressure gauge shall be
provided on the downstream of the disc to indicate any rupture of the disc in addition to
an excess flow check valve. In addition combination capacity factor of 0.9 shall be used
for sizing unless the combination has been tested and approved for any other
combination capacity factor. For such discs, a zero manufacturing tolerance shall be
considered.

3.3.3

The total tolerance of the rupture disc shall be 5% of the specified bursting pressure or
less, unless otherwise specified. This shall include both the manufacturing tolerance and
burst tolerance of the disc. All rupture discs shall be with J bolt and tell tale assembly
consisting of pressure indicator, pressure switch and excess flow check valve.
Rupture discs on ASME coded pressure vessels shall carry the ASME UD stamp.

3.3.4

Rupture Disc Testing

3.3.4.1

All discs shall be tested by bursting 2 discs of every batch with a batch being defined as a
set of discs having the same size , material and set pressure.

3.3.4.2

All rupture discs and holders shall be provided with test records and test certificates to fully
cover component materials and the disc test details.

3.3.5

Rupture Disc & Breather Valve Marking And Nameplates

3.3.5.1

The marks shall be placed on a plate securely fastened to the disc and disc holder. The
marks shall be made in such a way that they will not be obliterated in service.

3.3.5.2

The markings shall include the following as a minimum for Rupture Discs / Breather
Valves:
-

Tag number
Vendors name
Vendors design or type number (Model Number)
Size (mm)

JACOBS ENGINEERING INDIA PRIVATE LIMITED

DOCUMENT NO : 44-LK-5100-00/J.02/0011-A4
STANDARD SPECIFICATION FOR SAFETY / THERMAL RELIEF
VALVES, RUPTURE DISCS & BREATHER VALVES

Date : 12.08.08
Page 8 of 8
Revision No. : A

Set Pressure ( Set pressure for Vaccum / Gauge Pressure for Breather valves )
Set Pressure at room temperature ( Not applicable for Breather valves )
Back pressure (constant or variable) ( Not applicable for Breather valves )
Capacity at overpressure ( Not applicable for Breather valves )
Year of manufacture
Clients (End user) name and Clients code no.

3.3.5.3

ASME or IBR symbol as required. ( Not applicable for Breather valves )

4.0

RELATED DOCUMENTATION
Standard name
API RP 526
API 527
API 520
API 521
ASME CODE
SECTION VIII
IBR

5.0

ATTACHMENTS
Nil

Description
Flanged steel safety relief valves.
Commercial seat tightness of safety Relief Valves with metal to metal
seats
Design and installation of pressure relieving systems in refineries parts I
& II.
Guide for pressure relief and depressurising systems.
Boiler and Pressure vessel code Div.1 and Div. 2
Indian Boiler Regulations.