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V Pressure-Relief Valves

5.1. Introduction to PRVs

A pressure-relief valve (PRV) is a self-operating valve
that is installed in a process system to protect against
overpressurization of the system.
PRVs can be used for both gas and liquid services,
although the design varies with each.
PRVs are actuated (opened and closed) by one of the
2 common methods:
1. System actuation (direct-acting PRV) where the process
pressure acts on one side of the closure element, while a
predetermined spring provide a mechanical load on
other side of closure element as shown in Fig. 1.
2. Pilot actuation (Pilot PRV) in which a pilot-valve
mechanism monitors the system pressure and triggers
the main valve to open when the pressure exceeds the
limit, Fig. 2
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Fig. 2 Pilot PRV

Fig. 1
Direct-acting PRV

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PRV open of two ways:

1. Full lift: When the overpressurization causes the closure
element to open slightly, the valve opens to the full-open
position immediately and allows for immediate depressurization of the line.
2. Modulating lift: In which the valve only partially opensjust enough to relive the overpressurization but not enough
to depressurize the line entirely.

PRVs are divided into 2 families according to application:

1. Relief valves are used in liquid service and
2. Safety valves are used in gas or vapor services.

Generally, gas services are designed to allow some

overpressurization, because of the inherent compressibility
of the gases, before the PRV opens.
PRVs are commonly found in inlet size of 0.25 in (DN 6) to
20 in (DN 500).
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5.2. PRVs Design

Because of the critical nature of relief and safety valves,
their design is strictly regulated by local, national, regional,
and international codes.
Internationally, ISO 4126 has been adopted to monitor
design and performance standards for PRVs.
Other institution that concern on code and standard for
PRVs are:
HPGCL (High Pressure Gas Control Law) - Japan
TUV (Technicsher Ueberwachungs Verein) - Germany
API, ASME - USA

Closure element of the PRVs consist of the disk (pallet) and

the nozzle.
A number of disk and nozzle seating arrangement are
found, but the most common is metal-seated design in
which the disk has an inverted groove for the nozzle.
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PRV has 2 ports:

1. Inlet port as pressure-bearing side of the closure element
2. Outlet port which is the downstream pressure (or
atmospheric pressure, if vented)

The outlet port is always larger than the inlet to

accommodate the large flow associated with a blowdown.
PRVs use typically a 90o angle body design. One-piece or
two-piece bodies are common. With two piece designs
having the versatility of changing the direction of the outlet
in any one of four quadrants.
Above the body is the bonnet, which supports and enclose
the spring and spring compression.
Two types of bonnets are common: open bonnet, Fig. 3 and
closed (pressurized) bonnet, Fig. 4.
Open bonnet is used in high-temperature applications and
closed bonnet is used in mild temperature.
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Fig. 3 PRV
with open bonnet

Fig. 4 PRV
with closed bonnet
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5.3. PRVs Operation

PRVs are designed to stay closed during the operating
pressure, which is defined as the service pressure.
At this point, the downward force on disk produced by
spring is greater than the upward force produced against
the disk.
The downward force can be increased by back pressure
or can be reduced by service temperature by affecting
the spring.
Each PRV has a defined setting pressure, which is the
point where the overpressurization of the system
overcome the spring force holding the disk to the nozzle
and PRV begins to open.
The seating-pressure differential is a term used to
express the difference between the operating and setting
pressure.
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Opening Pressure
Blowdown
Seating Pressure
Differential

Setting Pressure
Reseating Pressure
Operating (Service)
Pressure

Generally, for spring-operated PRVs (according to Section I of the ASME Code):

Opening pressure: 3% Max (above setting pressure)

Seating pressure diff: 1-5% for gas and 5-20% for liquid (of operating pressure)

Blowdown pressure: between 2 to 4 percent below the setting pressure.

Fig. 5 Schematic relationship between some pressure terms

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For gas services, the seating pressure differential is usually

set between 1 and 5%, while in liquid services it is set
between 5 to 20 percent.
Opening pressure is a pressure that cause the PRV to
fully open. This pressure usually greater than setting
pressure.
As the overpressurization decreases, the pressure will reach
a point where the downward force of the spring overcomes
the upward force, causing the disk to lower and finally seat.
The pressure where the disk reseats is called reseating
pressure.
Blowdown is defined as the difference in pressure between
setting and reseating pressures.
Some users prefer the blowdown to be of a short duration
for production efficiency. However, the valve can become
somewhat unstable if the blowdown is too short.
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Ideally, the solution is determined by the application itself. If

the lost of production is the main concern, shorter blowdown
is recommended. If blowdowns are infrequent a longer
one is preferable to ensure PRVs stability.
Blowdown may be adjusted by a number of means: by
installing upper blowdown ring or using separate nozzle
threaded in body or by adding a throttling regulator to
regulate the forces acting on the back side of the disk.
Spring-operated PRVs fall under Section I of the ASME Code,
which establishes that full rated discharge must take place at
a maximum pressure of 3 percent above the PRVs setting
pressure.
On the other hand, the blowdown is required to be between
2 to 4 percent below the setting pressure. If the PRV is set
below 100 psi (6.9 bar), the reseating pressure is required to
be between 2 to 4 psi (between 0.1 and 0.3 bar).
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5.4. PRVs Installation

Before installation takes place, the PRV should be inspected
to ensure that is has been certified by an approved
accreditation institution (ASME or others).
The PRV should have a seal attached with the proper
approval stamps or other identification marks.
If the PRV is provided with a lifting lever, the user should
never use it as a convenient device to lift lever, since this
action may cause the seating surfaces to rub against each
others and cause a potential leak path. Lifting by the lever
can also cause the PRV to rotate causing a safety hazard.
A good practice is to use a light-gauge wire or tape to attach
the handle to the bonnet in order to prevent an accident.
PRVs are normally installed with the bonnet up, although
other orientations are sometimes possible.
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The outlet port is connected to the tank or other receiving

vessel. In most cases, the discharge piping is upward.
In all cases, the discharge piping should be anchored
adequately to prevent excessive vibration.
Space should exist to allow for access to the PRV and to
remove it, if necessary.
After the PRV has been installed, the system should be
started up and tested to the setting pressure point to see if
the PRV can operate correctly as it is intended.
If the set opening or reseating pressure is incorrect, the MIs
should be checked for possible calibration procedures.
Many settings are very sensitive, and large movements of
the setting can upset the operation of the PRV.
If necessary, user can asked the manufacturers service
technicians or an authorized service operation to complete
the calibration.
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Fig. 6 Safety valve testing unit

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5.5. PRVs Troubleshooting

The PRVs should be inspected periodically to ensure proper
operation.
As part of monthly troubleshooting, the PRV should be
opened with the lifting lever or through planned system
overpressurization.
The most common problem with PRVs is a tendency for the
closure element to pulsate when it is opening or in the open
position chatter during opening or flutter in open position.
The most common cause of these problems are:
Oversized valve (mostly)
Close proximity of a piece of process equipment that causes
pressure fluctuations or process turbulence
Back pressure may be higher than the PRV is set for
The opening pressure differential may be set at such a low
setting that standard leakage flow is enough to open the valve.
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A pressure loss may be taking place between the compressor or

pump and the PRV.
The PRV may be designed for maximum flow, but pressure
variations are only minor, or not allowing the PRV to move to
the full-open position.

Common cause of valve leakage in a PRV are:

A worn disk or nozzle (especially in high-use situations)

A damage disk or nozzle,
A valve that chatter due to it operates too close to set pressure
Piping stresses that may affect the alignment of the valve body
and closure element.

High blowdown is a problem with adjustment of the PRV

itself, although it can be increased by the presence of drops
of liquid in the gas or vapor or the buildup of the back
pressure over time.

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5.6. PRVs Servicing

Because of the critical nature of PRVs, their servicing and
adjustments should be made by a trained and certified
technician.
Generally, PRV adjustments are extremely sensitive and
even minor maladjustments can upset the operation of PRV.
The best procedure to follow is to refer to the manufacturers
printed maintenance literature before making any
adjustments.
All moving and pressure-retaining parts should be checked
for signs of wear, galling, or damage. Process buildup should
be removed and parts are cleaned.
After reassembling, the PRV should the be returned to
service in the process line and start-up procedure performed,
including overpressurization, to ensure that the PRV operates
at the correct setting pressure and blowdown.
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If a PRV has been completely rebuilt, the best procedure to

follow is to perform a pressure test with the PRV.
The ASME code requires that each PRV be tested for correct
operation by use of a steam test.
This test should be conducted by ASME-approved facilities
and technicians and should mirror the basic operating
conditions of the actual service.

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Reference
Skousen, P.L., Valve Handbook, McGraw-Hill, USA,
1998.
Fisher, Control Valve Handbook, Fisher Control
International, USA, 2001.

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