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SAFETY VALVES
AND
BURST DISCS
TRAINING MANUAL
COURSE EXP-MN-SM085
Revision 0
Field Operations Training
Mechanical Maintenance
Safety Valves and Burst Discs
EQUIPMENT
SAFETY VALVES AND BURST DISCS
CONTENTS
1. OBJECTIVES ..................................................................................................................4
2. THE FUNCTIONS OF SAFETY VALVES ........................................................................5
2.1. INTRODUCTION.......................................................................................................5
2.2. OPERATION .............................................................................................................6
2.3. STANDARDS ............................................................................................................9
3. THE PRINCIPAL CATEGORIES ...................................................................................10
3.1. SPRING VALVE/ HIGH PRESSURE SAFETY VALVE ...........................................10
3.1.1. Different types .................................................................................................12
3.1.1.1. Screw plug valve ........................................................................................12
3.1.1.2. Thermal expansion valve ...........................................................................13
3.1.1.3. Regulator valve ..........................................................................................14
3.1.1.4. Safety valve with operating lever................................................................15
3.2. PILOT OPERATED VALVE.....................................................................................16
3.3. TANK VENT VALVE................................................................................................17
3.4. PRESSURE REDUCING VALVE ............................................................................18
3.5. BURST DISC ..........................................................................................................19
4. APPLICATIONS OF VALVES........................................................................................20
4.1. SPRING VALVE ......................................................................................................20
4.1.1. Pressure Safety Valve (PSV) ..........................................................................20
4.1.2. Pressure Relief Valve (PRV) ...........................................................................20
4.2. TANK VENT VALVE................................................................................................21
4.3. BURST DISC ..........................................................................................................22
4.3.1. Arrangement of burst discs..............................................................................22
4.3.1.1. Conventional burst disc ..............................................................................22
4.3.1.2. Back pressure or anti-vacuum mountings ..................................................23
4.3.1.3. Reversed burst disc ...................................................................................24
4.4. ADVANTAGES AND DISADVANTAGES................................................................25
5. PRINCIPLE OF OPERATION........................................................................................26
5.1. TERMINOLOGY USED...........................................................................................26
5.2. SPRING VALVE ......................................................................................................26
5.2.1. Valve installed on gases or steam. ..................................................................27
5.2.2. Valve installed on liquids .................................................................................28
5.3. VALVE WITH ADJUSTING RINGS .........................................................................29
5.4. PILOT-OPERATED VALVE ....................................................................................31
5.5. TANK VENT VALVE................................................................................................32
5.6. BURST DISC ..........................................................................................................33
5.6.1. Conventional burst disc ...................................................................................33
5.6.2. Reversed burst disc.........................................................................................33
5.6.3. Warning note ...................................................................................................33
6. REPRESENTATION AND DATA ...................................................................................35
1. OBJECTIVES
2.1. INTRODUCTION
Its operation must be exceptional and its position must remain normally closed.
Industrial capacities are characterised by a maximum operating pressure which must not
be exceeded. This is the pressure used as a basis for calculating the strength of the
component materials used in the capacity.
Adjustment:
Spring
Counterweight
Discharge:
Channelled
Training Manual : EXP-MN-SM85-EN
Last Revision: 20/03/2008 Page 5 of 55
Field Operations Training
Mechanical Maintenance
Safety Valves and Burst Discs
2.2. OPERATION
Safety valves evacuate any excess energy from the system to be protected in order to limit
the maximum pressure in the protected device to a level which is acceptable for it.
A safety valve is a safety component whose operation is exceptional. Its normal position is
the closed position. The valve is designed to evacuate a gas flow because, for an equal
volume, more (pneumatic) energy is evacuated in the gas phase than in the liquid phase.
keeps the flames away from the wall of the tank protected by the valve. The top end of this
vent is also protected by a shutter, which prevents water or foreign matter from entering
the valve / vent tube assembly.
When two valves are used, they are usually installed on a twinning valve.
This enables either a single valve to be put in service (with the other valve isolated) or both
valves at the same time (index in the intermediate position).
When the two valves are operated simultaneously (in which case
neither valve provides 100 % of the required flow-rate), the position of
the twinning valve (intermediate position) must be guaranteed by a
safety chain or a lead seal.
When necessary, these devices enable a valve to be removed for a check, an inspection
or replacement, without completely emptying the tank.
2.3. STANDARDS
Standards concerning safety valves, applicable both in France and at our subsidiaries,
must be taken into account before any operation or before carrying out any work on these
devices. The main standards concerned are listed below.
EC Directive 97-23 (Directive CE 97-23) from the European Parliament and the
Council Meeting held on 29 May 1997:
Safety devices for gas pressure regulation stations and installations - Safety
valves for service pressures up to 100 bars
Safety devices for protection against excessive pressure - Part 1: safety valves
Safety devices for protection against excessive pressures - Part 7: common data
A body in cast steel connected to the capacity to be protected and to the exhaust
system.
A seat, screwed into the body, of which the upper section is carefully machined in
order to provide sealing.
An adjusting ring which is screwed to the seat and can be operated from the
exterior by a worm screw.
A lift ring which is screwed to the adjusting ring and can be operated from the
exterior by a worm screw.
A valve guide which rests on the upper part of the body through a seal.
A disc valve which slides in the valve guide and is held against the seat by the
spring, thus providing sealing.
A stop maintained against the upper side of the valve guide and against which
the disc valve stops when it opens.
A pin, the spring and its washer constituting the system which forces the plug
against the seat.
An adjusting screw and its nut, allowing the spring tension to be adjusted
A jacket, resting on the top of the valve body through a seal and fixed by bolts,
which protects the spring
A bonnet screwed to the top of the jacket and connected to it by a sealing which
prevents any modification of the valve setting.
BONNET
ADJUSTING NUT
SPRING WASHER
SPRING
PIN
JACKET
VALVE GUIDE
STOP
DISC VALVE
TO EXHAUST
SYSTEM LIFT RING
ADJUSTING
RING
SEAT
BODY
1 Bonnet
3 Plug
4 Baseplate
5 Disc valve
6 Valve carrier ring
7 Valve carrier
8 Guide
9 Stop screw
10 Retaining ring
11 Rod
15 Adjusting screw
16 Adjusting screw nut
17 Plug screw
18 Plug screw seal
19 Plug seal
20 Bonnet seal
21 Stop screw seal
22 Spring washer
23 Spring
37 Nameplate
Two safety valves per tank are generally fitted either to a change-over valve or to a
manifold, which allows one of the valves to be isolated while ensuring that the other
operates
This arrangement allows valve maintenance to be performed without shutting down the
equipment
ATMOSPHER
CAPACITY SIDE
FROM GAS SYSTEM
Note:
Pressure reducing valve reserved for compressed air; steam and gases, which
are compressible,
Connection:
Between flanges
Advantages:
Fluid-tight
Disadvantage:
4. APPLICATIONS OF VALVES
A PRV opens under the pressure of the internal fluid, usually in proportion to the increase
in pressure
or as a relief device
Capsule type mounting supports have two rings assembled by screws and fitted between
two pipe flanges which do not provide sealing between the disc and the rings. Sealing
requires the assembly to be tightened between pipe flanges.
Some discs are thick enough to tolerate a total vacuum without support.
The vacuum support, shown by the points, is always placed under the disc.
The disc is mounted in a support which has, on its downstream side, a diagonal
arrangement of sharp blades.
If an overpressure occurs, the disc reverses and is cut or torn by the blades to ensure
relief.
ADVANTAGES DISADVANTAGES
Vent valve
5. PRINCIPLE OF OPERATION
It is the result of 2 dynamic forces caused by the velocity of the fluid and the rise in static
pressure.
As soon as it returns to below the set pressure of the valve, the spring keeps the disc
valve against its seat.
The outlet orifice is extended by a vertical vent which helps dilution and in the case of
ignition keeps the flames away from the wall of the tank that the valve protects.
The upper part of the vent is itself protected by a cover which prevents water or foreign
objects from entering the valve/vent pipe assembly.
The weight of this cover is calibrated so that it lifts under the pressure.
D D
P1 > P2 + kx
4 4
kx: action of spring (adjustable)
P1 and P2: pressures acting on each side of the valve. Weight of parts ignored
The effect of the spring can be replaced by that of a counterweight but this is no longer
used.
Normal Operation:
Valve closed:
Process pressure: P2
Spring pressure: P1
The gases succeed in entering the valve faces for Pressures < 1 to 2 % of the set
pressure.
If the Pressure P2 continues to rise, the valve opens to the fully open position:
The disc valve comes against the stop and the overpressure escapes to the
exhaust system
Normal Operation:
Valve closed:
Process pressure: P2
Spring pressure: P1
The principle is identical to the previous case as far as the "hiss" stage
The role of this type of valve is to allow rapid opening in order to avoid this phenomenon -
rapid closure in order to avoid loss of pressure in the capacity and bouncing of the disc
valve on the seat.
The disc valve having started to lift, the gases enter the chamber 1 and can only escape
through the annular space formed by the outer edge of the adjusting ring and the edge of
the disc valve. This space is adjustable by moving the ring. If the space is tightened, the
speed of the gas is reduced, while the pressure increases. The bearing area is also
increased and the pressure on it creates a force which is able to overcome the action of
the spring, promoting a sudden lifting of the disc valve.
The valve set to the MAOP "fizzes". The adjusting ring is too low.
It rises distinctly but the closing is slow and results in a loss of pressure: The adjusting ring
is too high.
Training Manual : EXP-MN-SM85-EN
Last Revision: 20/03/2008 Page 29 of 55
Field Operations Training
Mechanical Maintenance
Safety Valves and Burst Discs
If we raise the baffle, its outer edge comes closer to that of the Valve Carrier and we have
the same phenomenon of pressure increase in chamber 2 as previously. If the baffle and
the ring are set "HIGH", the spring will be unable to overcome the total of the forces
exercised by P2 + chambers 1 & 2.
To create a rapid drop and return to P2 < P pressure setting, the baffle must be set lower.
PHASE 1
PHASE 2
PHASE 3
PHASE 4
the disc valve on the Gas System side is pressed against its seat
2
ATMOSPHER
CAPACIT
A conventional burst disc is a component which does not re-close. It is designed to burst at
a predetermined pressure in order to protect systems or isolated facilities against
unacceptable conditions of pressure or vacuum.
Discharge from the burst disc continues until the pressure reaches equilibrium.
The intensity of burst can be very high and impose reaction forces.
Certain types of disc are not suitable for hydraulic applications (reversed dome
disc).
The re-use of discs is not recommended after they have been removed.
7. OPERATION OF VALVES
In all cases, an equipment must only be commissioned with these valves if the certificate
dates from less than 90 days, after which the maintenance rules take effect.
Each valve is fitted with a nameplate showing these characteristics, and an additional plate
showing the date of the last pressure setting. These plates are INDISPENSABLE.
All valves have data sheets and certificates, which must ABSOLUTELY be kept for
inspection.
The pressure setting of a valve, i.e. the pressure at which it starts to open must not be
higher than the maximum operating pressure.
When the internal pressure of the tank is less than the set pressure of the valve, the spring
keeps the disc valve against its seat.
If the pressure exceeds the set pressure of the valve, the disc valve rises and allows the
excess energy to escape.
Verify
WORKSHOP overhaul Clean
Remove
Refit
Refitting to unit
Check the external state of corrosion, particularly for offshore sites, and lubrication of nuts
and bolts for easier dismantling for inspection.
Burst discs do not generally require maintenance because they have no moving parts.
7.2.3. Disposal
Used components must be disposed of in accordance with local and national regulations.
7.3.1. Assembly
Place the discharge side of the support on a bench with the throat upwards.
Check that all surfaces are clean and smooth and that the radius is not damaged.
Check the information shown on the disc label (identification no., burst pressure,
operating temperature).
Fit the pressure side part of the support into the discharge side part.
Assembly
o Standard assembly
Insert and tighten the assembly screws which fix the two parts of the support.
These screws must not be overtightened.
Note: No sealing ring must be fitted between the disc and the discharge side of the
support. Sealing rings may be fitted between the disc assembly and the pressure side of
the support. If these are required, they must be supplied by MARSTON.
7.3.2. Installation
Check that the information shown on the disc and support labels is correct for the
position in question.
When installing the assembly between flanges, check the position and direction of
the disc
Sealing rings must be fitted between the support and the system flanges.
Tighten the flange bolts gradually in order to ensure that the system does not
leak.
The tightening torque of the flange bolts does not affect the performance of the
disc.
All valves connected to the flare systems can be closed, separately or in groups, by means
of an isolation valve.
Open in operation.
This valve is equipped with a locking system (chain and padlock) which protects the safety
valve against operation.
The safety system is operated in accordance with the CGS 05-05 Instruction entitled:
"Isolation of safety valves".
7.4.1. Subject
The purpose of this procedure is to define the actions to be undertaken in order to check
the condition and correct operation of safety devices installed on equipment under
pressure which are monitored by the Corrosion-Inspection department.
It also deals with the intervention frequency and the management of monitoring.
7.4.2. Scope
This procedure applies to safety devices which are intended to protect equipment under
pressure against overpressures or underpressures:
spring valves,
pilot-operated valves,
burst discs
Ministerial Order of 15 March 2000 concerning the operation of equipment under pressure
Before being installed on site, all new valves must be identified by the Central File
Manager of the inspection department. He enters the manufacturing characteristics in the
CMMS.
The valve is then sent to an approved repairer who performs a triggering test and fits a
sealed metal nameplate bearing the following engraved information:
station identifier
equipment identifier
pressure setting
Nature
check of the general condition of the valve and associated equipment (change-
over valves, pipework)
verification of sealing
Frequency
For valves installed on equipment under the normal regulatory system, the
inspection takes place when the unit is being prepared for shutdown, during the
12 months prior to the shutdown.
For valves installed on equipment covered by a P.C.S., the inspection takes place
during the external examinations specified in the procedure.
For valves installed on common systems, inspection takes place at the same time
as the systems inspection.
100% of the valve population is delivered to the workshop per batch (Scheduled
Shutdown)
Nature
dismantling
check of components
Overhaul report
Frequency
Circumstances
The specifications for workshop valve overhauls includes a systematic bench test
BEFORE any other verification
In all cases, an invitation must be sent to the inspector responsible. The test must be
monitored by an inspector or its designated representative.
In-service triggering is taken into account in all cases except when the pressure recorded
was not more than 10% higher than the pressure setting of the valve, in which case the
incident is closed
The Operator records all cases of valve triggering: significant facts" of the control room
and issues a failure notice in SAP.
When such an incident occurs, it also notifies the inspector responsible for the site via e-
mail.
If the valve has closed again correctly, it archives the pressure recording (if the pressure
was recorded) corresponding to the incident
The zone inspector validates the failure notice in the SAP computer application and follows
up the work order until its closure.
If this is not the case, the inspector asks for the valve to be removed for workshop
overhaul.
If the valve continues to leak, the inspector asks for it to be removed for workshop
overhaul.
This case is characterised by the ESP monitoring pressure transmitter threshold being
exceeded without triggering the valve. The Operator is informed by an alarm on its
management system.
The Operator records the event in the "daily log: significant events" of the control room.
When such an incident occurs, it also notifies the inspector responsible for the site via e-
mail and creates a failure notice in Unisup.
The zone inspector validates the failure notice in the SAP computer application and follows
up the work order until its closure.
1) SIC issues a malfunction form to search for the causes and induced effects
2) during the daily meetings
3) the inspector attends the test
4) and countersigns the malfunction form after on-site verification that refitting was compliant
5) either in the technical dossier for the equipment, or in the file provided for that purpose for
piping
(1) full list of valves to be overhauled plus list of valves to be tested before removal
(2) the inspector attends testing for 10% of the designated valves
(3) by countersigning the original list
(4) either in the technical dossier for the equipment, or in the file provided for that purpose for piping
As shown in the procedure and the logical diagrams, monitoring follows precise
rules with which compliance is mandatory
8. EXERCISES
1. What does PSV mean?
Safety device?
Regulation device?
10. A check shows that the pressure is at 110% of the normal pressure setting: what
should I do?
Stop
Continue to 120%
Yes
No
9. LIST OF FIGURES
Figure 1: Examples of valves...............................................................................................5
Figure 2: Operation of safety (relief) valves .........................................................................6
Figure 3: Spring-type safety valve .......................................................................................6
Figure 4: Example of safety valves on a twinning valve.......................................................7
Figure 5: Diagram of a twinning valve..................................................................................7
Figure 6: Safety valves on a twinning valve .........................................................................8
Figure 7: 4-valve manifold....................................................................................................8
Figure 8: Examples of spring valves ..................................................................................10
Figure 9: Composition of a spring valve.............................................................................11
Figure 10: Screw plug valve...............................................................................................12
Figure 11: Thermal expansion valve..................................................................................13
Figure 12: Example of thermal expansion valve ................................................................13
Figure 13: Regulator valve.................................................................................................14
Figure 14: Example of a regulator valve ............................................................................14
Figure 15: Valve with operating lever.................................................................................15
Figure 16: Examples of valve with operating lever.............................................................15
Figure 17: Example of pilot-operated valve........................................................................16
Figure 18: Pilot-operated valve ..........................................................................................16
Figure 19: Tank vent valve.................................................................................................17
Figure 20: Diagram of a tank vent valve ............................................................................17
Figure 21: Pressure reducing valve ...................................................................................18
Figure 22: Burst disc ..........................................................................................................19
Figure 23: Examples of PSV's ...........................................................................................20
Figure 24: Examples of PRV's ...........................................................................................20
Figure 25: Tank vent valve.................................................................................................21
Figure 26: Burst disc (1).....................................................................................................22
Figure 27: Burst disc (2).....................................................................................................22
Figure 28:Semi-nozzle type arrangement ..........................................................................22
Figure 29: Full-nozzle type arrangement ...........................................................................23
Figure 30: Burst disc - back pressure and anti-vacuum support ........................................23
Figure 31: Arrangement of a semi-nozzle reversed disc....................................................24
Figure 32: Spring valve ......................................................................................................26
Figure 33: Operation of a simple valve ..............................................................................28
Figure 34: Valve with adjusting ring ...................................................................................29
Figure 35: Operation of a pilot-operated valve...................................................................31
Figure 36: Tank vent valve.................................................................................................32
Figure 37: Reversed burst disc ..........................................................................................33
Figure 38: Representation of valves on a PID ...................................................................35
Figure 39: ROSA PSV data sheet sample .........................................................................36
Figure 40: Pressure setting bench .....................................................................................37
Figure 41: Adjusting a valve...............................................................................................37
Figure 42: Example of identification...................................................................................43
Figure 43: Logical diagram for removal/refitting.................................................................47
Figure 44: Logical diagram for issue from store.................................................................48
Figure 45: Logical diagram for removal in store.................................................................49