Beruflich Dokumente
Kultur Dokumente
DESIGN
Parts
Nozzle - The pressure containing element which constitutes
the inlet flow passage and includes the fixed portion of the
seat closure. The nozzle can be of two designs: Full-nozzle or
Semi-nozzle.
Relief Valve - An automatic pressure relieving device can be an open lever or a packed lever (fully enclosed design).
actuated by the static pressure upstream of the valve,
Balanced Bellows - A bellows designed so that the effective
opening in direct proportion to the pressure increase.
It is used primarily for liquid service. area of the bellow is equivalent to that of the valve seat, there-
by canceling out the additive effect of the backpressure. Bal-
Safety Relief Valve - An automatic pressure relieving anced bellows are used for the following reasons: Backpres-
device suitable for use as either a safety or relief valve, sure is excessive or variable, fluid is highly viscous or slurry, or
depending on application. the fluid is corrosive to the upper works of the valve.
backpressure.
BASICS OF
- 48 -
BASICS OF RELIEF VALVES, CONTD.
DESIGN
Built-up Backpressure - Pressure which develops at
Maximum Allowable Working Pressure (MAWP) - The
the valve outlet as a result of flow after the pressure relief
maximum gauge pressure permissible in a vessel at a desig-
valve has opened.
nated temperature.
Lift - The actual travel of the disc away from the closed
Overpressure - The pressure increase over the set pressure
position when a valve is relieving.
of a pressure relief valve, usually expressed as a percentage
of the set pressure. Chatter - Abnormal, rapid reciprocation movement of the
disc on the seat of a pressure relief valve.
Accumulation - The pressure increase over the maximum
allowable working pressure (MAWP) of the vessel during dis-
charge through the pressure relief valve usually expressed as
a percentage of the set pressure.
RELIEF VALVES
BASICS OF
DUAL RING CONTROL
Safety Valves are pressure relief devices actuated by inlet Spence Figure 31 Safety Valves Dual Ring Control allows
static pressure and characterized by rapid opening or for finer adjustment of the popping action and length of
pop action. The difference between Safety Valves from blowdown. This allows exceptional flow efficiency and
different manufacturers is how well they do this. maximum lifting force while minimizing system energy loss.
- 49 -
SIZING GUIDELINES
SAFETY RELIEF VALVES
PROCESS CONTROL
DESIGN
Section E for approximate sizing formulas
5. When calculating the maximum possible flow through the
regulator, in all cases your sizing should be based on the 3 4
largest orifice size available in the pipe size of the regulator
. It may be possible that an originally supplied reduced TYPE ED PRESSURE
REGULATOR
orifice can be changed in the field to a full port orifice with-
out any consideration to the effect on the capacity of the
Pressure Relief Valve.
FIGURE C
6. In determining the maximum flow through the pressure 3. If an intermediate pressure line is taken off between the
SIZING GUIDELINES
reducing valve when the valve fails, the failure mode should pressure reducing valves then this line and the final low
be considered when the valve plug has reached 100% full side shall be protected by pressure relief valves sized on
travel . the basis of the high side pressure and the largest possible
orifice size of the first pressure reducing valve in the line
B. Parallel Pressure Reducing Stations (National Board Inspection Code ANSI/NB-23, Appendix G,
1. When sizing a pressure relief valve in a parallel pressure 1999) plus the bypass or the maximum possible flow
reducing station, the conditions listed above in (A) should through the downstream pipe , whichever is less. Consi-
all be met. deration should be given to the maximum capacity of the
FIG. 41 SAFETY source .
RELIEF VALVE
FIG. 41 SAFETY
RELIEF VALVE 9
6 7
1 2
8
TYPE ED PRESSURE 1
5
REGULATOR
2 7
3
3 4
TYPE ED PRESSURE
REGULATOR
4
TYPE ED PRESSURE 5
REGULATOR
FIG. 41 SAFETY
6 RELIEF VALVE
FIGURE B FIGURE D
- 51 -
SIZING GUIDELINES CONTD
SAFETY RELIEF VALVES
PROCESS CONTROL
4. If an intermediate by-pass line is designed in between the E. When Flow Coefficients Are Not Known
pressure reducing valves then the final low side shall be For sizing Spence regulators and/or control valves:
protected by a pressure relief valve sized on the basis of
See Main Valve Sizing Formulas on page 68
the high side pressure and the largest possible orifice size
of the first of the two pressure reducing valves plus the See CV Data beginning on page 69
bypass valves , and or the maximum possible flow For all other manufacturers valves where flow coefficients are
through the downstream piping , whichever is less. Consi- not known, the following may be approximated.
deration should be given to the maximum capacity of the It is possible that the flow coefficients K and K1 may not be
source . known and in such instances for approximating the flow, a
5. Size SRV for pressure drop across regulator using regulator factor of 1/3 may be substituted for K and 1/2 for K1.
high side pressure and the safety relief valve set pressure. The formulas in E above then become:
FIG. 41 SAFETY W = 1/3AC for the capacity through the pressure reducing
RELIEF VALVE
valve and
9 W = 1/2A1 for the capacity through the by-pass valve
1 8
WHERE:
W = steam flow, in lbs/hr through the pressure reducing valve
2 3 7
A = internal area in sq. in. of the inlet pipe size of the
pressure reducing valve (See Pipe Data Table)
5 A1 = internal area in sq. in. of the pipe size of the bypass
TYPE ED around the pressure reducing valve (See Pipe Data Table)
4 TYPE ED PRESSURE C = flow of saturated steam through a 1 sq. in. pipe at
6
PRESSURE REGULATOR various pressure differentials (See Steam Capacity Table)
REGULATOR
C1 = flow of saturated steam through a 1 sp. In. pipe at
various pressure differentials (See Steam Capacity Table)
Caution should be exercised when substituting these factors
FIGURE E
DESIGN
for the actual coefficients since this method will provide approx-
D. Two Stage Parallel Pressure Reducing Station imate values only and the capacities so obtained may in fact
be lower than actual. It is recommended that the actual flow
1. Sizing is based whenever any condition from (B) and any coefficient be obtained from the pressure reducing valve
condition from (C) applies. manufacture and reference books be consulted for the flow
2. In addition, all sizing should be based on maximum coefficient of the by-pass valve (National Board Inspection
capacity from sources. Code ANSI/NB-23, Appendix G, 1998).
Nominal Approx.
PIPE DATA TABLE
- 52 -
CAPACITY OF SATURATED STEAM TABLE
DESIGN
450 43330 40730 38150 35260 31980 28080 23290 16680
400 40760 38220 35680 33050 29980 26380 21870 15760
350 33120 30690 27910 24570 20460 14790
300 33240 28140 25610 22620 18860 13630
250 28150 25650 23200 21000 17100 10800
200 21350 18250 15350 10900
175 18250 16000 12600
150 18250 16200 13400
125 18780 13600
110 13600
SATURATED STEAM
100 13600
85 13600
CAPACITY OF
75 13600
60 13630
- 53 -
SAFETY VALVE SIZING BY COMPUTATION
SAFETY RELIEF VALVES
PROCESS CONTROL
FORMULA KEY
A = Actual discharge area through the valve at developed lift, Ksh = Steam superheat correction factor (use 1.00 for saturated
inches2 See formulas below steam) See Table E4 on page 57
C = Constant for gas or vapor based on ratio of specific heats Kv = Capacity correction factor for viscosity
Cp/Cv See Tables E2 and E3 beginning on page 55 See Graph E8 on page 60
G = Specific gravity of fluid (Relates the densities of a fluid to that Kw = Liquid capacity correction factor for backpressure service
of a standard fluid) See Table E2 on page 55 balanced bellows valves only See Graph E9 on page 60
1.0 for water @70F and air at 14.7 psia and 60F M = Molecular weight See Table E2 on page 55
Kb = Dimensionless number used to correct for the reduction in P = Stamped set pressure + overpressure + 14.7 psia
capacity due to effect of backpressure: See Spence Testing Specification Chart page 61
For conventional valves: See Graph E5 on page 58 P = [Stamped set pressure + 3 psi or 10% (whichever is greater)]
For balanced bellows valves: See Graph E6 on page 59 backpressure, psi
Kd = Coefficient of discharge (including 90% de-rating) P1 = [Stamped set pressure + 3 psi or 25% (whichever is greater)]
See Table E1 on page 55 backpressure, psi
Kn = Napier steam correction factor for set pressures between T = Absolute temperature at inlet, R (degrees F + 460)
1423 and 2900 psig:
W = Rated capacity, Steam (lbs/hr), Air (SCFM),
<1423 psig Kn = 1.00
Gas or Vapor (lbs/hr or SCFM), Liquid (GPM)
.1906P 1000
>1423 psig Kn = ____________ Z = Compressibility factor corresponding to T and P for gas and
.2292P 1061
vapor (If unknown, use 1.0)
Kp = Correction factor for overpressure See Table E7 on page 59
= 1.0 at 25% overpressure
A = W
_________________ A = W
_____________
51.45 KdPKshKbKn 51.45 KdPKb
AIR (SCFM)
__ LIQUID10% OVERPRESSURE
A = WT
__________ (GPM) CODE
__
418 KdPKb A = W___
G
________________
38.0 KdP KvKw
GAS OR VAPOR
__ __(SCFM)
__ LIQUID25% OVERPRESSURE
A = WGTZ
_____________
(GPM) NON
__ CODE
1.175 CKdPKb A = G
W___
_________________
38.0 KdP1 KpKvKw
All sizing equations are in compliance with API 520 Part I 1997. all applicable required coefficients. Neither Spence Engineering
Please refer to that document for further information on sizing. Company nor its agents assume any liability for improperly
The user is responsible for verifying that these are the currently sized valves.
accepted formulae and for contacting the manufacturer(s) for
- 54 -
TABLE E1SPENCE VALVE COEFFICIENTS (Kd)
DESIGN
N-Butane 1.18 335 58.12 2.006
Iso-Butane 1.19 336 58.12 2.006
Carbon Dioxide 1.29 346 44.01 1.519
Carbon Monoxide 1.40 356 28.01 .967
Chlorine 1.35 352 70.90 2.447
Ethane 1.19 336 30.07 1.038
Ethyl Alcohol 1.13 330 46.07 1.590
Ethylene 1.24 341 28.03 0.968
Freon 11 1.14 331 137.37 4.742
Freon 12 1.14 331 120.92 4.742
TABLE E1
TABLE E2
Freon 22 1.18 335 86.48 2.985
Freon 114 1.09 326 170.93 5.900
Helium 1.66 377 4.02 0.139
Hydrochloric Acid 1.41 357 36.47 1.259
Hydrogen 1.41 357 2.02 0.070
Hydrogen Chloride 1.41 357 36.47 1.259
Methane 1.31 348 16.04 0.554
Methyl Alcohol 1.20 337 32.04 1.106
Natural Gas 1.27 344 19.00 0.656
Nitric Oxide 1.40 356 30.00 1.036
Nitrogen 1.40 356 28.02 0.967
Nitrous Oxide 1.31 348 44.02 1.520
Oxygen 1.40 356 32.00 1.105
Propane 1.13 330 44.09 1.522
Propylene 1.15 332 42.08 3.60
Sulfur Dioxide 1.27 344 64.04 2.211
- 55 -
TABLE E3GAS CONSTANT (C)
SAFETY RELIEF VALVES
PROCESS CONTROL
k C
1.00 315
1.02 318
1.04 320
1.06 322
1.08 324
1.10 327
1.12 329
1.14 331
1.16 333
1.18 335
1.20 337
1.22 339
The relationship of (C) to (k) is expressed
1.24 341 by the following equation:
1.26 343 _______________
(
1.28 345
k+1
_____
2 k1
1.30
1.32
347
349
C = 520 k _____
k+1 )
1.34 351
1.36 352
1.38 354
DESIGN
1.40 356
1.42 358
1.44 359
1.46 361
1.48 363
1.50 364
1.52 366
1.54 368
1.56 369
1.58 371
TABLE E3
1.60 372
1.62 374
1.64 376
1.66 377
1.68 379
1.70 380
2.00 400
2.20 412
- 56 -
TABLE E4SUPERHEAT CORRECTION FACTOR (Ksh)
DESIGN
700 506 1.00 0.99 0.97 0.96 0.94 0.93 0.91 0.90 0.89 0.88 0.87 0.86 0.85 0.84 0.83 0.82 0.81 0.81 0.80 0.79 0.79 0.78 0.77 0.77 0.76
750 513 1.00 1.00 0.98 0.96 0.95 0.93 0.92 0.90 0.89 0.88 0.87 0.86 0.85 0.84 0.83 0.83 0.82 0.81 0.80 0.79 0.79 0.78 0.77 0.77 0.76
800 520 1.00 0.99 0.97 0.95 0.94 0.92 0.91 0.90 0.88 0.87 0.86 0.85 0.84 0.84 0.83 0.82 0.81 0.80 0.80 0.79 0.78 0.78 0.77 0.76
850 527 1.00 0.99 0.98 0.96 0.94 0.93 0.92 0.90 0.89 0.88 0.87 0.86 0.85 0.84 0.83 0.82 0.81 0.81 0.80 0.79 0.78 0.78 0.77 0.76
900 533 1.00 1.00 0.99 0.97 0.95 0.93 0.92 0.90 0.89 0.88 0.87 0.86 0.85 0.84 0.83 0.82 0.81 0.81 0.80 0.79 0.79 0.78 0.77 0.77
950 540 1.00 0.99 0.97 0.95 0.94 0.92 0.91 0.89 0.88 0.87 0.86 0.85 0.84 0.83 0.82 0.82 0.81 0.80 0.79 0.79 0.78 0.77 0.77
1000 546 1.00 0.99 0.98 0.96 0.94 0.93 0.91 0.90 0.89 0.87 0.86 0.85 0.84 0.83 0.83 0.82 0.81 0.80 0.79 0.79 0.78 0.77 0.77
1050 552 1.00 1.00 0.99 0.97 0.95 0.93 0.92 0.90 0.89 0.88 0.87 0.86 0.85 0.84 0.83 0.82 0.81 0.80 0.80 0.79 0.78 0.77 0.77
1100 558 1.00 0.99 0.98 0.95 0.94 0.92 0.91 0.89 0.88 0.87 0.86 0.85 0.84 0.83 0.82 0.81 0.81 0.80 0.79 0.78 0.78 0.77
1150 563 1.00 0.99 0.98 0.96 0.94 0.92 0.91 0.90 0.88 0.87 0.86 0.85 0.84 0.83 0.82 0.81 0.81 0.80 0.79 0.78 0.78 0.77
1200 569 1.00 0.99 0.98 0.97 0.95 0.93 0.91 0.90 0.89 0.87 0.86 0.85 0.84 0.83 0.82 0.81 0.81 0.80 0.79 0.78 0.78 0.77
1250 574 1.00 0.99 0.97 0.95 0.93 0.92 0.90 0.98 0.88 0.87 0.85 0.85 0.84 0.83 0.82 0.81 0.80 0.79 0.79 0.78 0.77
TABLE E4
1300 579 1.00 0.99 0.98 0.96 0.94 0.92 0.91 0.98 0.88 0.87 0.86 0.85 0.84 0.83 0.82 0.81 0.80 0.79 0.79 0.78 0.77
1350 584 1.00 0.99 0.98 0.96 0.94 0.93 0.91 0.90 0.88 0.87 0.86 0.85 0.84 0.83 0.82 0.81 0.80 0.80 0.79 0.78 0.78
1400 588 1.00 1.00 0.99 0.97 0.95 0.93 0.92 0.90 0.89 0.88 0.86 0.85 0.84 0.83 0.82 0.81 0.81 0.80 0.79 0.78 0.78
1450 593 1.00 0.99 0.97 0.95 0.94 0.92 0.90 0.89 0.88 0.86 0.85 0.84 0.83 0.82 0.81 0.81 0.80 0.79 0.78 0.78
1500 597 1.00 0.99 0.97 0.96 0.94 0.92 0.91 0.89 0.88 0.87 0.86 0.84 0.84 0.83 0.82 0.81 0.80 0.79 0.78 0.78
1600 606 1.00 0.98 0.97 0.96 0.94 0.93 0.91 0.89 0.88 0.86 0.85 0.84 0.83 0.82 0.81 0.80 0.79 0.78 0.78 0.77
1700 615 1.00 0.99 0.97 0.96 0.95 0.93 0.91 0.89 0.88 0.86 0.85 0.84 0.83 0.82 0.81 0.79 0.79 0.78 0.77 0.77
1800 622 0.99 0.98 0.97 0.95 0.93 0.91 0.89 0.88 0.86 0.85 0.84 0.82 0.81 0.80 0.79 0.79 0.78 0.77 0.76
1900 630 1.00 0.98 0.97 0.96 0.93 0.91 0.89 0.88 0.86 0.85 0.84 0.82 0.81 0.80 0.79 0.78 0.78 0.77 0.76
2000 636 1.00 0.98 0.96 0.93 0.91 0.89 0.87 0.86 0.84 0.83 0.82 0.81 0.80 0.79 0.78 0.77 0.76 0.76
2100 644 1.00 0.98 0.95 0.93 0.91 0.89 0.87 0.86 0.84 0.83 0.82 0.81 0.79 0.78 0.77 0.77 0.76 0.75
2200 650 1.00 0.98 0.95 0.93 0.91 0.89 0.87 0.85 0.84 0.82 0.81 0.80 0.79 0.78 0.77 0.76 0.75 0.74
2300 658 1.00 0.98 0.95 0.93 0.91 0.89 0.87 0.85 0.84 0.82 0.81 0.79 0.78 0.77 0.76 0.75 0.75 0.74
2400 663 0.98 0.95 0.93 0.91 0.89 0.87 0.85 0.83 0.82 0.80 0.79 0.78 0.77 0.76 0.75 0.74 0.73
2500 669 0.98 0.95 0.93 0.90 0.88 0.86 0.84 0.83 0.81 0.80 0.78 0.77 0.76 0.75 0.74 0.73 0.72
2600 675 1.00 0.96 0.93 0.90 0.88 0.85 0.84 0.82 0.80 0.79 0.77 0.76 0.75 0.74 0.73 0.72 0.71
2700 680 1.00 0.95 0.90 0.88 0.85 0.83 0.81 0.79 0.78 0.76 0.75 0.74 0.73 0.72 0.71 0.70
2800 686 1.00 0.95 0.90 0.88 0.85 0.82 0.80 0.78 0.76 0.75 0.74 0.73 0.72 0.71 0.70 0.69
2900 691 1.00 0.90 0.87 0.84 0.82 0.80 0.78 0.76 0.75 0.73 0.72 0.71 0.70 0.69 0.68
- 57 -
GRAPH E5SUPERIMPOSED (CONSTANT)
SAFETY RELIEF VALVES
PROCESS CONTROL
90
80
70
60
k = 1.1
50 k = 1.3
k = 1.5
k = 1.7
Example
40
30
20
10
0
DESIGN
0 10 20 30 40 50 60 70 80 90 100
FORMULA KEY
Pb = Backpressure, psia Pb
% of absolute backpressure = ________ x 100
Ps = Set Pressure, psia Ps + Po
Po = Overpressure, psi
GRAPH E5
SOLUTION:
(70+10+14.7)
% of absolute backpressure = _____________ x 100 = 76
(100+10+14.7)
Kb (follow dotted line) = .89 (from curve)
Capacity with backpressure = .89 (rated capacity without backpressure
Note: This chart is typical and suitable for use only when the conventional pressure relief valves that have their spring setting
make of the valve or the actual critical flow pressure point for adjusted to compensate for the superimposed backpressure.
the vapor or gas is unknown; otherwise, the valve It should not be used to size Balanced Bellow type valves (see
manufacturer should be consulted for specific data. This next page).
correction factor should be used only in the sizing of Information from API 520 Part I, 1997
- 58 -
GRAPH E6SUPERIMPOSED OR VARIABLE
0.90
10
%
ov
er
pr
es
0.80 su
re
0.70
0.60
0.50
0 5 10 15 20 25 30 35 40 45 50
DESIGN
FORMULA KEY
Pb
% of gauge backpressure = ____
Pb = Backpressure, psia x 100
Ps
Ps = Set Pressure, psia
Note: The curves above represent a compromise of the values correction factor. These curves are for set pressure of 50 psig
recommended by a number of relief valve manufacturers and and above. They are limited to backpressure below critical flow
may be used when the make of the valve or the actual critical pressure for a given set pressure. For subcritical flow back-
flow pressure point for the vapor of the gas is unknown. When pressure below 50 psig, the manufacturer must be consulted
make is known, the manufacturer should be consulted for the for values of Kb . Information from API 520 Part I, 1997
1.10
GRAPH E7CAPACITY
GRAPH E6
GRAPH E7
1.00
0.60
Kp
0.50
0.40
0.30 Note: The curve on the left shows that, at 25% or less over-
pressure, capacity is affected by the change in lift, the change
0.20 in orifice discharge coefficient and the change in over-pressure,
Above 25% overpressure, capacity is affected only by the
0.10 change in over-pressure. Valves operating at low overpressure
tend to chatter, therefore, over-pressures of less than 10%
0 should be avoided.
10 15 20 25 30 35 40 45 50 Information from API 520 Part I, 1997
% Overpressure
- 59 -
1.0 GRAPH E8CAPACITY
0.9 CORRECTION FACTOR
0.8 DUE TO VISCOSITY
When a relief valve is sized for viscous liquid service, it
0.7
is suggested that it first be sized for nonviscous type
Kv application in order to obtain a preliminary required
0.6 discharge area, (A). The next larger manufacturers
standard orifice orifice size should be used in deter-
0.5 mining the Reynolds number from either of the
formulae below.
After the value of R is determined, the factor Kv is
0.4
obtained from the graph on the left. Kv is applied to
correct the preliminary required discharge area. If the
0.3 corrected area exceeds the chosen standard orifice
10 20 40 50 100 200 400 1,000 2,000 4,000 10,000 20,000 100,000 area, the above calculation should be repeated using
R = Reynolds number the next larger standard orifice size.
Information from API 520 Part I, 1997
FORMULA KEY
A = Effective discharge area, inches2
G = Specific gravity of the liquid (referred to as water) at the flowing
R = Q(2800G)
________
__ or R =
12,700Q
________
__
temperature, G = 1.00 at 70F
A UA
Q = Flow rate at the flowing temperature, GPM Second equation not recommended for viscosities
= Absolute viscosity at the flowing temperature, centipoises less than 100 Saybolt Universal seconds.
U = Viscosity at the flowing temperature, Saybolt Universal seconds
DESIGN
0.95
Pb
% of gauge backpressure = ____ 0.90
x 100
Ps
0.85
0.80
Kw
0.75
FORMULA KEY
0.70
Pb = Backpressure, psia
0.65
Ps = Set Pressure, psia
0.60
0.55
0.50
0 10 20 30 40 50
Note: The curve above represents values recommended should be consulted for the applicable correction factor.
various manufacturers. This curve may be used when the Information from API 520 Part I, 1997
manufacturer is not known. Otherwise, the manufacturer
- 60 -
SPENCE SRV TESTING SPECIFICATIONS
SAFETY RELIEF VALVES
PROCESS CONTROL
Spence Safety and Relief Valves (unlike some competitors valves) are tested and conform to API 527. These Spence Testing
Specifications are in conformance with applicable ASME Code and API 527.
DESIGN
71 and higher 3% N/A * 10%
SPECIFICATIONS
20 and higher 4 inches HG N/A * 6 inch HG
LEAK TESTING (in accordance with API 527) Test Pressures - < 50 psig test at 5 psig below set pressure
> 50 psig test at 90% of set pressure
Service Set Pressure psig Size Acceptable Leakage rate
Metal Seats
Steam 15 higher All No audible or visible leakage for 1 min
Air 15 1000 < .307 sq in orifice 40 bubbles/min
> .307 sq in orifice 20 bubbles/min
Liquid 15 higher < 1" inlet 10 cc/hr per inch of inlet size
1" inlet 10 cc/hr
Soft Seats
Steam 15 higher All No audible or visible leakage for 1 min
Air 15 1000 < .307" orifice size 0 bubbles/min
> .307" orifice size 0 bubbles/min
Liquid 15 higher < 1" inlet size 0 cc/hr per inch of inlet size
1" inlet size 0 cc/hr
- 61 -
SUMMARY OF ASME CODES & STANDARDS
The American Society of Mechanical Engineers (ASME) The three codes that pertain to Spence Pressure Relief Valves
through its committees have established Boiler and Pressure are as follows:
Vessel codes for safety through rules and formulae indicating Section I (Power Boilers) - This is a construction code
good practice. covering power, electric and miniature boilers and high
The National Board of Boiler and Pressure Vessel Inspectors temperature boilers used in stationary service. This section
(NB) verify, administer and enforce the ASME codes wherever includes power boilers used in locomotive, portable and
the codes have been adopted. traction service.
The ASME Codes are broken down into the following sections: Section IV (Heating Boilers) - This is another construction
Sec I - Power Boilers code covering the design, fabrication, installation and inspec-
Sec II - Material Specifications tion of steam heating, hot water heating and hot water supply
Sec III - Nuclear Power Plant Components boilers which are directly fired by oil, gas, electricity or coal.
Sec IV - Heating Boilers (Low Pressure Steam & Hot Water) Section VIII (Pressure Vessels) - Basic rules for the con-
Sec V - Non-destructive Examination struction, design, fabrication, inspection and certification of
Sec VI - Recommended Rules for Care & Operation of pressure vessels. These rules have been formulated on the
Heating Boilers basis of design principles and construction practices appli-
Sec VII - Recommended Rules for Care of Power Boilers cable to vessels designed for pressures up to 3000 PSI.
Sec VIII - Pressure Vessels Stamping and coding are also covered in this section.
Sec IX - Welding and Brazing Qualifications
Sec X - Fiberglass Reinforced Plastic Pressure Vessels
Sec XI - Rules for in service Inspection of Nuclear Power
Plant Components
The appropriate symbols (below) are required on all ASME coded Pressure Relief Valves:
DESIGN
- 62 -
COMPARISON OF ASME SECTION I TO SECTION VIII
CRITERIA SECTION I SECTION VIII
Set Point Tolerances < 70 2 psig < 70 2 psig
>70 & < 300 3% > 70 3%
> 300 & < 1000 10 psig (ASME Section VIII, UG-126 (d), 1995)
> 1000 1%
(ASME Section I, PG-72.1, 1995)
Blowdown Tolerances < 67 4 psig No blowdown requirement in service.
> 67 & < 250 6%
> 250 & < 375 15 psig
> 375 4%
minimum blowdown for all valves:
2 psi or 2%, whichever is greater
(ASME Section I, PG-72.2, 1995)
Capacity Certifications Full lift at no greater than 3% or 2 psig, Full lift at no greater than 10% or 3 psig,
(whichever is greater) above the set pressure (whichever is greater) above the set pressure
without chattering. The published rated without chattering. The published rated
capacity is 90% of the average capacity of capacity is 90% of the average capacity of
the valves tested. the valves tested.
(ASME Section I, PG-69.1.4 & 69.2.1, 1995) (ASME Section VIII, UG-131 (c)(1) & (d)(1), 1995)
Lifting Device Lifting devices are required to enable lifting the Lifting devices are required to enable lifting the
disc while 75% of the set pressure is present. disc while 75% of the set pressure is present
(ASME Section I, PG-73.1.3, 1995) for Air, Steam & Hot Water (over 140F).
(ASME Section VIII, UG-136 (a)(3), 1995)
Sealing of Adjustments All external adjustments are to be (wire) All external adjustments are to be (wire)
sealed to prevent changing the adjustment sealed to prevent changing the adjustment
without breaking the seal. It also serves to without breaking the seal. It also serves to
DESIGN
identify the manufacturer or his authorized identify the manufacturer or his authorized
assembler making the adjustment. assembler making the adjustment.
(ASME Section I, PG-73.1.8, 1995) (ASME Section VIII, UG-136 (a)(7), 1995)
Markings on Valve The markings shall be placed on the valve The markings shall be placed on the valve
or on a nameplate securely fastened to the or on a nameplate securely fastened to the
valve by the manufacturer or assembler. The valve by the manufacturer or assembler. The
markings shall include: the ASME Code V markings shall include: the ASME Code UV
symbol, the name of the manufacturer and symbol, the name of the manufacturer and
assembler, model number, inlet size, set assembler, model number, inlet size, set
ASME SECTION I TO
pressure, rated capacity, year built and the pressure (if applicable, the CDTP),rated capa-
VIII COMPARISON
NB symbol. city in lbs/hr of steam, gal/min of water, SCFM
(ASME Section I, PG-110, 1995) or lb/min of air, year built and the NB symbol.
(ASME Section VIII, UG-129) (a), 1995)
Materials Seats, discs, springs and sliding surfaces Seats, discs, springs and sliding surfaces
shall be of corrosion resistant material and shall be of corrosion resistant material and
listed in ASTM specifications. Bodies and listed in ASTM specifications. Bodies and
bonnets must be listed in ASME Section II. bonnets must be listed in ASME Section II.
(ASME Section I, PG-73.2, 1995) (ASME Section VIII, UG-136 (b), 1995)
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INSTALLATION, MAINTENANCE & TROUBLESHOOTING
SAFETY RELIEF VALVES
PROCESS CONTROL
GUIDELINES
Spence Pressure Relief valves are safety devices designed to should be mounted downstream from any device at a
protect pressurized vessels, lines or systems during an distance sufficient to avoid turbulence.
overpressure event. The recommendations below are general 12. In a pressure reducing valve station, it is recommended
and it is the responsibility of the user to assure that installation that the pressure relief valve be installed a minimum of
and maintenance are in accordance with the applicable ASME 20 pipe diameters from the outlet of the pressure
Codes, API 520 Part II, local jurisdictional requirements and reducing valve to avoid turbulent flow and an unstable
any other requirements. Neither Spence Engineering nor its condition.
agents assume any liability for valves improperly installed,
maintained or troubleshot. 13. When Pressure Relief Valves are left on line during an
extended shutdown, the valves should be inspected and
A. INSTALLATION - SINGLE VALVE re-tested due to the potential of corrosion, fouling or
tampering.
1. Installation must be performed by qualified service
personnel only. Inlet Piping
2. Pressure relief devices intended for use in compressible 14. The opening through all pipe, fittings, and nonreclosing
fluid service shall be connected to the vessel in the vapor pressure relief devices (if installed) between a pressure
space above any contained liquid or to piping connected vessel and its pressure relief valve shall have at least the
to the vapor space in the vessel that is to be protected. area of the pressure relief valve inlet. (ASME Section VIII,
Pressure relief devices intended for use in liquid service UG-135 (b)(1), 1998).
shall be connected below the normal liquid level (ASME 15. The flow characteristics of the upstream system shall
Section VIII, UG-135 (a), 1998). be such that the cumulative total of all nonrecoverable
3. The operating pressure of the system should be a inlet losses shall not exceed 3% of the valve set pressure
minimum of 20% or 10 PSI, whichever is greater, below (ASME Section VIII, Appendix M-7(a), 1998)
the set pressure of the valve. The set pressure of each Outlet Piping
pressure relief valve must be in conformance with 16. Discharge pipes shall be at least of the same size as
DESIGN
pressure limits of the system and of the limits specified in the pressure relief valve outlet (ASME Section VIII,
the appropriate ASME codes. Appendix M-8(a), 1998).
4. Valves must be installed in an upright position with the 17. Where feasible, the use of a short discharge pipe or
spindle vertical. (ASME Section VIII, Appendix M, 1998). vertical riser, connected through long-radius elbows from
Mounting valves in any other position will cause each individual device, blowing directly to the
additional friction on the guiding surfaces and the valve atmosphere, is recommended (ASME Section VIII,
performance will be affected. Mounting valves in other Appendix M-8(a), 1998). Discharge piping should be
positions may allow dirt and other foreign substances to designed to place the minimum load on the valve under
accumulate in the valve and adversely affect the valve all conditions of valve operation. See 16 of this Section.
action.
18. When the nature of the discharge permits, whereby
5. The connection to the vessel should be provided with a condensed vapor in the discharge line, or rain, is
INSTALLATION
11. The valve should be normally placed close to the Stop Valves
protected equipment so that the valve will be fed 22. ASME Section I - No valve of any description shall be
properly under flowing conditions. However, valves placed between the required safety valve or safety relief
- 64 -
INSTALLATION, MAINTENANCE & TROUBLESHOOTING
DESIGN
their outlet areas. The effect of the back-pressure that
may be developed when certain valves operate must be c. Valve seating surface could be worn or damaged.
considered (ASME Section VIII, Appendix M-8 (b), 1998). Please contact your local Pressure Relief Valve Repair
Facility.
4. It is recommended that the smaller orifice valve be set at
the lower set pressure and that it is installed up stream 4. If a valve is chattering it may be the result of the
of the other valves. following:
a. Improper piping at valve inlet or outlet. See the
C. MAINTENANCE appropriate ASME Codes and the Spence Installation
1. Valves are set and sealed to prevent tampering, Guidelines. See page 67
guarantee is void if any seal is broken. The setting, b. Valves are oversized. Review the Spence Sizing
adjustment or repair should be done only by an Guidelines. See page 68
INSTALLATION
GUIDELINES
Authorized Pressure Relief Valve repair facility.
c. Back-pressure may be present which may not have
2. The valves should be checked periodically to see that been accounted for in the original sizing. Review Sizing
they are not clogged or seized due to dirt or other Formulas. See page 68
foreign matter and that they will operate satisfactorily.
d. Valve holes may be plugged. Check to make sure all
3. Installation conditions should be reviewed, seals should holes are not plugged and any shipping plugs have
be checked to verify that they are not broken and no been removed.
unauthorized adjustments have been made.
e. Valve may be worn or damaged. Please contact your
4. Valves may be manually operated by means of the lifting local Pressure Relief Valve Repair Facility.
lever only when the system pressure is at least 75% of
5. If a valve is not popping at the set pressure as stamped
the nameplate set pressure. A Pressure Relief Valve
on the nameplate, the following should be checked:
should never be lifted without 75% of the nameplate set
pressure. a. All Pressure Relief Valves have tolerance built into the
set pressure. Review the Spence Engineering Testing
5. Pressure Relief Valves should be re-tested as part a
Specifications and/or the appropriate ASME codes to
normal routine inspection program. The intervals
ensure the valve is operating within the allowed
between tests can vary in accordance with the severity
tolerances.
of the service condition. Guidelines for inspection are
provided in the API Inspection Code and the National b. Make sure the gauge reading the pressure is properly
Board Inspection Code. However, consideration should installed and calibrated. Compensate for the water leg
be given to your local jurisdictional policies, your between the valve and gauge.
insurance company polices and/or your company c. Review the inlet piping to make sure that the inlet
policies. piping is at least the area of the Pressure Relief Valve
- 65 -
INSTALLATION, MAINTENANCE & TROUBLESHOOTING
SAFETY RELIEF VALVES
PROCESS CONTROL
GUIDELINES - CONTD
inlet. Review the inlet piping to ensure no other
pressure drops can occur. See the Spence Installation
Guidelines. See page 67
d. Review the outlet piping to ensure that backpressure
has been accounted for in the original sizing and
selection of the valve. See the Spence Installation
Guidelines. See page 67
e. Valve may be worn or damaged. Please contact your
local Pressure Relief Valve Repair Facility.
6. If a valve is not closing or has an excessive blowdown,
the following should be checked:
a. It is possible that dirt or foreign material is lodged
under the seat. Perform the check as outlined in part 2
of this Section.
b. Operating pressure may not be reduced below the
reseating pressure of the valve. Reduce the operating
pressure of the system to 50% of the normal operating
pressure and then slowly bring the system back to the
normal operating pressure. Make sure that a minimum
operating to set point differential is maintained
according the guidelines specified in the Spence Sizing
Guidelines. See page 68
c. Valve may be worn or damaged. Please contact your
DESIGN
- 66 -
PLANNING MAIN VALVE INSTALLATION
A. PLANNING THE INSTALLATION C. DESIGN GUIDELINES TO MINIMIZE NOISE
1. Locate the valve in a straight run of horizontal pipe. See Fig. 1. 1. Size the regulator to provide a maximum inlet velocity of
2. Allow headroom above the valve for access through the blind about 10,000 FPM.
flange. Provide clearance for stem withdrawal underneath. 2. Determine the regulator outlet velocity. if it would exceed
3. Prevent water hammer and erratic operation by installing 30,000 FPM, use a Spence muffling orifice or a second stage
traps to provide proper drainage before and after the valve, regulator.
and before secondary PRV or control valve. 3 Expand regulator outlet piping to limit discharge line velocity
4. Avoid damaging affects of scale and dirt in pipe lines by to about 10,000 FPM.
using a strainer as shown in Fig. 1 . 4. Avoid abrupt changes in pipe size. Limit pipe diameter
5. Provide a 3-valve by-pass to facilitate inspection without changes to two pipe sizes per stage of expansion. Do not
interrupting service. use eccentric reducers.
6. To eliminate excessive noise and erratic regulation with 5. Directional changes in downstream piping should be made
steam and other compressible fluids enlarge the delivery only after the line size has been increased. Use long radius
pipe size to effect a reasonable flow velocity at the reduced fittings; avoid bull-head tee connection.
pressure. A tapered transition is recommended. If possible, 6. Provide as much straight run of pipe on both sides of
avoid a sharp turn close to the regulator outlet and a bull- regulator as possible:
headed tee connection to the low pressure main. a - 10 pipe diameters minimum to the inlet.
7. Install initial and delivery pressure gauges to indicate b - 20 pipe diameters minimum of expanded line size from
performance. If the pressure rating of the delivery system or the outlet.
connected equipment is less than the initial steam pressure, 7. Size all piping components, including strainer and stop valves
provide a safety valve. for a maximum flow velocity of about 10,000 FPM (Exception:
B. CONTROL PIPE An outlet stop valve mounted at the regulator outlet should
1. Use 1/4 pipe for this line which connects the pilot diaphragm be equal in size to the regulator). In areas where low sound
chamber to the desired point of pressure control. See Fig. 1. levels are specified, reduce this limit by 25% to 50%.
2. Take the control at a point of minimum turbulence. Avoid 8. To limit noise transmission through the buildings structure.
control immediately at the valve outlet or after a turn. When keep the regulator and piping at least 3 feet away from solid
DESIGN
the delivery pipe expands in size select a spot at least 4 pipe surfaces. Use sound-isolating piping supports.
diameters beyond the point of enlargement. 9. Apply high density insulation to the regulator body, piping and
3. Pitch away from pilot to avoid erratic operation and fouling. system components. Insulation reduces heat loss significantly
Eliminate water pockets. and can provide moderate (3-6 dB) local noise attenuation.
4. Locate delivery pressure gauge in control pipe to show 10. Use a Spence noise suppressor to reduce the propagation
pressure actually reaching pilot diaphragm. of noise via the downstream piping.
VALVE INSTALLATION
3. Strainer 9. Drip Pan Elbow
PLANNING MAIN
4. PRV Type 10. Vent Stack
5. Bypass Pipe 11. Low Pressure Trap
6. Bypass Valve 12. High Pressure Trap
10
1
6
5
10 d1
2 4 2 20 d2
7
d1 d2
3 Min. 4 d2
11
12
- 67 -
MAIN VALVE SIZING BY COMPUTATION
FORMULA KEY
Cv = Valve Coefficient
PS = P1 (.96 .28 P ) P when P < P
v
v 2 v
EDR = Equivalent Direct Radiation (Sq. Ft.) P C
F = Pipe Area Factor (see Pipe Factors Table) q = Liquid Flow Rate, U.S. gpm
ft = Feet Q = Flow Rate, SCFH
G = Specific Gravity T = Absolute T (T + 460)R
P = Pressure Drop,P1 P2 psi TSH = Steam Superheat (F) =
P1 = Inlet Pressure, psia (psi + 14.7) Total Steam Temp. Saturated Steam Temp.
P2 = Reduced Pressure, psia (psi + 14.7) v = Specific Volume FT3/#
Pc = Pressure at Thermodynamic Critical Point, V = Velocity, FPM
psia (water = 3206 psia) W = Steam Flow, #/Hr.
Pv = Vapor Pressure, psia Ws = Flow, #/Hr. Superheated Steam
To avoid interpolation or solve problems beyond the scope of the table, valve sizes may be determined by calculation as follows:
Cv LOADS
SUBCRITICAL CRITICAL GPM X Temp. Rise (F)
WATER W=
2
SATURATED P2 > .58 P1 P2 < .58 P1 GPM
STEAM: W FUEL OIL W= X Temp. Rise (F)
Cv= W 4
Cv=
2.1 P (P1 + P2)
DESIGN
VELOCITY
LIQUID: P2 > P1 .85 PS P2 < P1 .85 PS Wv
STEAM V = 2.4
PG PG
A
Cv= q Cv= .93q
S
PIPE FACTORS
FOR STANDARD
(SCHEDULE 40) PIPE
SIZE FACTOR SIZE FACTOR
FLOW 1
/8 .55 1
3 /2 95
14
/ 1.0 4 122
STEAM W = .0433 x V x F 3/8
v 1.8 5 192
1
/2 2.9 6 278
AIR & GASES Q = .0259 x V x F x P1 3/4
T 5.1 8 481
1 8.3 10 758
LIQUIDS q = .0054 x V x F 11/4 14 12 1076
11/2 20 14 1301
2 32 16 1699
21/2 46 18 2151
3 71 20 2673
- 68 -
REGULATOR CV DATA
Valve E E2 E5,E6 C20 C34 D D34 D50 N6 Series
Size Normal Normal Normal Full Full 2000
Full Normal Full 60% 50%
50% 75% 50% 75%
14
/ .25
38
/ .65 1.5 .32
1
/2 1.5 1.4 2.1 2.8 .32 2.2 .4-5.22
34
/ 4.8 2.7 4.0 5.4 7.6 5.7 7.6 3.3 5.3 6.85
1 7.5 4.4 6.6 8.8 11.7 10.0 11.7 7.5 5.5 3.3 4.9 9.2 9.15
14
1/ 10.4 7.0 10.6 14.1 18.9 13.4 18.9 14.0 12.5 7.5 5.0 14.3 14.3
11/2 14.6 9.9 14.8 19.8 27.4 19.8 27.4 20.0 17.3 10.4 10.1 20.8 15.1
2 17.6 15.5 23.3 31 44 25 43 30 24 14.4 10.8 37.5 17.2
- 69 -
21/2 12 18 24 22 33 44 68 35 67 47 36 21.6 60
3 22 33 43 37 56 74 96 59 95 69 53 32
4 39 59 78 55 82 109 143 120 159 115 86 52
5 58 87 115 85 127 169 202 176 258 186 139 84
6 76 114 151 124 186 248 255 228 350 250 196 118
8 125 187 249 222 333 444 465 366 665 436
10 189 283 377 353 530 706 748 525 1018 700
12 316 474 631 557 835 1113 1118 952 1611 1083
BOSS Cv TABLE
Valve Size Full Port Cv 40% Red. Cv Seco-Sonic Cv Seco-Cav Cv
2 65 26 48 32
212 90 36 70 40
3 125 50 97 63
4 205 82 156 103
6 435 174 349 217
8 760 304 579 304
CONTROL VALVE
Cv DATA
- 70 -