Pressure Relief Devices ASME and API Code Simplified

by Malek, Mohammad

• ISBN13: 9780071455374
• ISBN10: 007145537X
• Edition: 1st
• Format: Hardcover
• Copyright: 2005-10-27
• Publisher: McGraw-Hill Education

Summary

Within the boiler, piping and pressure vessel industry, pressure relief devices are considered one of the most important safety components. These Devices are literally the last line of defense against catastrophic failure or even lose of life. Written in plain language, this fifth book in the ASME Simplified series addresses the various codes and recommended standards of practice for the maintenance and continued operations of pressure relief valves as specified by the American Society of Mechanical Engineers and the American Petroleum Institute. Covered in this book are: preventive maintenance procedures, methods for evaluation of mechanical components and accepted methods for cleaning, adjusting and lubricating various components to assure continued operation and speed performance as well as procedures for recording and evaluating these items.

Author Biography

Mohammad A. Malek, P.E. is chief boiler inspector for the State of Florida. He has more than 27 years of experience in boiler design, construction, inspection, maintenance, and repair of boilers and pressure vessels. Mr. Malek is a member of the American Society of Mechanical Engineers, and National Board of Boiler and Pressure Vessel Inspectors. He has authored ASME Sections IV & VI to the book titled Companion Guide to ASME Boiler and Pressure Vessel Code edited by K.R. Rao and published by ASME. He has written numerous articles on boilers and pressure vessels. He serves on four ASME technical committees

Table of Contents

Preface	xv
Fundamentals of Pressure Relief Devices	1	(22)
Brief History	1	(1)
Pressure Vessels	2	(5)
Boiler accidents	3	(2)
Pressure vessel accidents	5	(2)
Pressure Relief Devices	7	(1)
Reclosing-Type Pressure Relief Devices	8	(4)
Pressure relief valves	8	(1)
Safety valves	8	(2)
Relief valves	10	(2)
Safety relief valves	12	(1)
Pressure Vacuum Relief Valves	12	(2)
Pressure vacuum vent valves	13	(1)
Pressure relief valves	14	(1)
Vacuum relief valves	14	(1)
Nonreclosing Pressure Relief Devices	14	(4)
Rupture disks	15	(1)
Breaking pin devices	16	(1)
Buckling pin devices	17	(1)
Shear pin devices	17	(1)
Fusible plug devices	18	(1)
Codes and Standards	18	(2)
U.S. codes	18	(1)
International codes	19	(1)
Jurisdictional Authority	20	(3)
Pressure Relief Valves	23	(30)
Safety Relief Valves	24	(20)
Conventional pressure relief valves	24	(5)
Pilot-operated pressure relief valves	29	(9)
Balanced bellows pressure relief valves	38	(4)
Power-actuated pressure relief valves	42	(1)
Temperature-actuated pressure relief valves	43	(1)
Relief Valves	44	(2)
Safety Valves	46	(1)
Major Components	47	(1)
Accessories	48	(3)
Specifications	51	(2)
How to order a conventional pressure relief valve	51	(1)
Specification sheets	51	(2)
Safety Valves	53	(16)
Working Principle	53	(3)
Classification of Safety Valves	56	(5)
Classification based on actuation	56	(2)
Classification based on lift	58	(1)
Classification based on seat design	59	(1)
Classification based on type of lever	59	(1)
Classification based on bonnet design	60	(1)
Major Components	61	(1)
Accessories	62	(1)
Safety Valve Locations	62	(3)
Pressure-reducing station	63	(1)
Pharmaceutical factory with jacketed pans	64	(1)
Specifications	65	(4)
Specification sheet	66	(1)
Specifying a safety valve	67	(2)
Rupture Disks	69	(20)
Brief History	70	(1)
Working Principle	70	(1)
Application of Rupture Disks	71	(3)
Primary relief	72	(1)
Secondary relief	73	(1)
Combination relief	73	(1)
Types of Rupture Disks	74	(6)
Conventional rupture disks	74	(2)
Scored tension-loaded rupture disks	76	(1)
Composite rupture disks	76	(1)
Reverse-acting rupture disks	77	(2)
Graphite rupture disks	79	(1)
Major Components	80	(1)
Accessories	80	(3)
Specifications	83	(1)
How to specify a rupture disk	83	(1)
Specification sheet	83	(1)
Rupture Pin Relief Valves	83	(1)
Comparison of rupture pins and rupture disks	84	(1)
Buckling Pin Relief Valves	84	(5)
Valve characteristics	86	(1)
Specifications	87	(2)
Materials	89	(20)
Pressure Relief Valves	89	(14)
Materials	90	(4)
Bill of materials	94	(2)
Material selection	96	(7)
Rupture Disks	103	(6)
Bill of materials	103	(1)
Material selection	103	(6)
Design	109	(20)
Fundamentals of Design	111	(5)
Seat disk lift	111	(1)
Back pressure	112	(2)
Bonnet	114	(1)
Valve nozzle	115	(1)
Design Factors	116	(2)
Flow area	116	(1)
Curtain area	117	(1)
Discharge area	117	(1)
Other design factors	117	(1)
Pressure Requirements	118	(2)
System pressures	118	(2)
Relieving device pressures	120	(1)
Design Considerations	120	(1)
Design of Parts	121	(1)
Body	121	(1)
Bonnet	121	(1)
Nozzle	121	(1)
Disk	122	(1)
Spindle	122	(1)
Adjusting ring	122	(1)
Adjusting screw	122	(1)
Huddling chamber	122	(1)
Spring	122	(1)
Testing and Marking	122	(1)
Hydrostatic test	123	(1)
Marking	123	(1)
Rupture Disks	123	(6)
Basic design	123	(2)
Operating ratios	125	(1)
Pressure-level relationship	125	(1)
Certified KR and MNFA	126	(3)
Manufacturing	129	(22)
Manufacture of Pressure Relief Valves	130	(11)
Test laboratories	131	(2)
Capacity certification	133	(5)
Capacity certification in combination with rupture disks	138	(1)
Testing by manufacturers	139	(1)
Inspection and stamping	140	(1)
Manufacturer's data reports	141	(1)
Manufacture of Rupture Disks	141	(10)
Manufacturing ranges	144	(1)
Rupture tolerances	144	(1)
Capacity certification	145	(1)
Production testing	146	(1)
Marking	147	(2)
Manufacturer's data reports	149	(2)
Sizing and Selection	151	(28)
Pressure Relief Valves	151	(25)
Valve sizes	152	(1)
Required sizing data	153	(2)
API sizing	155	(1)
Sizing for vapors and gases	156	(7)
Sizing for liquids	163	(4)
Sizing for air	167	(1)
Sizing multiple valves	168	(2)
Saturated-water valve sizing	170	(1)
RRV and rupture disk combinations	171	(3)
Sizing for thermal expansion of trapped liquids	174	(1)
Sizing for mixed phases	175	(1)
Rupture Disks	176	(3)
Sizing method	177	(2)
Safety Valves for Power Boilers	179	(26)
Operational Characteristics	182	(1)
Code References	182	(1)
Design Requirements	182	(7)
Mechanical requirements	183	(1)
Material selection	184	(1)
Boiler safety valves	184	(2)
Superheater safety valves	186	(3)
Reheater safety valves	189	(1)
Organic fluid vaporizer safety valves	189	(1)
Capacity Requirements	189	(10)
Relieving capacity	190	(3)
Capacity checking	193	(2)
Capacity certification	195	(4)
Testing by Manufacturers	199	(1)
Inspection and Stamping	199	(1)
Certificate of Conformance	200	(1)
Operation	201	(1)
Selection of Safety Valves	201	(4)
Ordering information	202	(1)
Specifying safety valves	202	(3)
Pressure Relief Valves for Heating Boilers	205	(20)
Code References	207	(1)
Design Requirements	207	(9)
Safety valve requirements for steam boilers	208	(3)
Safety relief valve requirements for hot water boilers	211	(2)
Safety and safety relief valves for tanks and heat exchangers	213	(1)
T&P safety relief valves for hot water heaters	213	(2)
Mechanical requirements	215	(1)
Material selection	216	(1)
Locations	216	(1)
Manufacture and Inspection	216	(2)
Valve markings	217	(1)
Manufacturer's Testing	218	(1)
Capacity Requirements	219	(6)
Calculation of capacity to be stamped on valves	219	(3)
Fluid medium for tests	222	(1)
Capacity tests of T&P safety relief valves	222	(1)
Capacity tests for safety and safety relief valves	222	(1)
Test record data sheets	223	(2)
Pressure Relief Devices for Pressure Vessels	225	(30)
Introduction	225	(6)
Types of pressure vessels	227	(2)
Pressure vessel codes	229	(2)
Pressure relief devices	231	(1)
Pressure Relief Valves	231	(16)
Operational requirements	233	(1)
Code references	234	(1)
Design requirements	234	(8)
Capacity certification	242	(2)
Testing by manufacturers	244	(1)
Inspection and certification	245	(2)
Rupture Disks	247	(8)
Operational characteristics	249	(1)
Code references	249	(1)
Design requirements	249	(1)
Capacity certification	250	(1)
Testing by manufacturers	251	(1)
Inspection and certification	252	(3)
Pressure Relief Devices for Nuclear Systems	255	(16)
Nuclear Reactors	256	(8)
Boiling-water reactors	257	(2)
Pressurized-water reactors	259	(5)
Overpressure Protection Reports	264	(2)
Content of report	264	(1)
Certification of report	265	(1)
Review of report	265	(1)
Filing of report	266	(1)
Code Requirements	266	(1)
Relieving Capacity	267	(1)
Operating Requirements	267	(1)
Capacity Certification for Pressure Relief Valves	268	(1)
Marking, Stamping, and Data Reports	268	(3)
Pressure relief valves	269	(1)
Rupture disks	269	(2)
Pressure Relief Devices for Transport Tanks	271	(18)
Classes of Vessels	272	(1)
Pressure Relief Devices	272	(4)
Determining pressure relief requirements	274	(1)
Code references	275	(1)
Installation requirements	275	(1)
Requirements for Pressure Relief Valves	276	(6)
Types of pressure relief valves	276	(1)
Design requirements	277	(2)
Materials requirements	279	(1)
Manufacturing	280	(1)
Marking and certification	281	(1)
Production testing	282	(1)
Requirements for Rupture Disks	282	(5)
Design requirements	283	(1)
Materials requirements	284	(1)
Manufacturing	284	(1)
Marking and certification	285	(1)
Production testing	286	(1)
Installation requirements	286	(1)
Requirements for Breaking Pin Devices	287	(2)
Pressure Relief Devices for Petroleum Industries	289	(18)
Refining Operations	290	(2)
Protection of Petroleum Equipment	292	(1)
Protection of Tanks	292	(2)
Fire Sizing	294	(8)
Fire sizing standards	295	(1)
Fire sizing for liquid hydrocarbons	295	(4)
Fire sizing for vessels containing gases	299	(3)
Seat Tightness Test	302	(5)
Testing with air	302	(2)
Testing with steam	304	(1)
Testing with water	305	(2)
Installation	307	(26)
Installation of Pressure Relief Valves	308	(20)
Preinstallation handling and testing	308	(1)
Inlet piping	309	(7)
Discharge piping	316	(7)
Power piping systems	323	(1)
Isolation valves	324	(3)
Vent piping	327	(1)
Drain piping	327	(1)
Bolting and gasketing	328	(1)
Installation of Rupture Disks	328	(5)
Preparation for installation	330	(1)
Inspection	330	(1)
Installation guidelines	330	(3)
Operation	333	(12)
General Guidelines for Operation	333	(2)
Visual Examination	335	(1)
Safety Valve Operation	336	(5)
Hand lift operation	336	(2)
Operation testing	338	(2)
Precaution for hydrostatic test	340	(1)
Safety Relief Valve Operation	341	(1)
Valve tightness test	341	(1)
Lift and blowdown	342	(1)
Testing	342	(1)
Operator's Responsibilities	342	(3)
Maintenance	345	(18)
Valve Specification Records	346	(1)
Maintenance Procedures	346	(2)
Pretest	347	(1)
Disassembly	347	(1)
Repairs	347	(1)
Assembly	347	(1)
Valve testing	348	(1)
Types of Maintenance	348	(4)
Routine maintenance	348	(2)
In-line maintenance	350	(2)
Preventive maintenance	352	(1)
Testing	352	(2)
Setting	353	(1)
Blowdown adjustment	353	(1)
Seat tightness test	354	(1)
Causes of Improper Performance	354	(4)
Rough handling	354	(1)
Corrosion	354	(1)
Damaged seating surfaces	355	(1)
Failed springs	356	(1)
Improper setting and adjustment	356	(1)
Plugging and sticking	357	(1)
Misapplication of materials	357	(1)
Improper discharge piping test	358	(1)
Troubleshooting	358	(1)
Spare Parts	358	(3)
Storage	361	(2)
Inspection	363	(14)
Authorized Inspectors	364	(1)
Types of Inspections	365	(3)
Inspection of new installations	366	(1)
Routine inspection	366	(1)
Shop inspection	366	(1)
Visual on-stream inspection	367	(1)
In-service testing	367	(1)
Unscheduled inspection	368	(1)
Safety Valve inspection	368	(3)
Safety Relief Valve inspection	371	(1)
Rupture Disk inspection	372	(1)
Records and Reports	373	(4)
Repairs	377	(12)
Repairers	377	(2)
Repair of Pressure Relief Valves	379	(7)
Visual Inspection as received	379	(2)
Preliminary test as received	381	(1)
Disassembly	381	(1)
Cleaning parts	382	(1)
Inspection	382	(1)
Machining	383	(1)
Lapping	383	(1)
Adjusting rings	384	(1)
Bearing points	384	(1)
Assembly	384	(1)
Testing	384	(1)
Sealing	385	(1)
Repair Nameplates	386	(1)
Documentation	386	(3)
Shop Testing	389	(14)
Test Media	390	(1)
Testing with air	390	(1)
Testing with nitrogen	390	(1)
Testing with water	390	(1)
Testing with steam	391	(1)
Test Stands	391	(6)
Test stand with air system	391	(3)
Multipurpose test stand	394	(2)
Portable tester	396	(1)
Testing	397	(4)
Set pressure	397	(1)
Blowdown	398	(1)
Seat tightness test	399	(2)
Test Reports	401	(1)
Rupture Disk Testers	401	(2)
Terminology	403	(4)
Terminology for Pressure Relief Valves	403	(2)
Terminology for Rupture Disks	405	(2)
Appendix A. 1914 ASME Boiler Code	407	(6)
Appendix B. Spring-Loaded Pressure Relief Valve Specification Sheet	413	(2)
Appendix C. Pilot-Operated Pressure Relief Valve Specification Sheet	415	(2)
Appendix D. Rupture Disk Specification Sheet	417	(2)
Appendix E. ASME Application for Accreditation	419	(6)
Appendix F. ASME-Accredited Testing Laboratories	425	(2)
Appendix G. Physical Properties of Gas or Vapor	427	(4)
Appendix H. Superheat Correction Factor	431	(2)
Appendix I. Dimensions of Flanges	433	(4)
Appendix J. Pipe Data	437	(2)
Appendix K. Manufacturer's Data Report Form NV-1	439	(2)
Appendix L. Corrosion Resistance Guide	441	(8)
Appendix M. Water Saturation Pressure and Temperature	449	(2)
Appendix N. Value of Coefficient C	451	(2)
Appendix O. Unit Conversions	453	(8)
Bibliography	461	(2)
Index	463