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Well Test Manual 3

Section 30

Instrumentation – Pilot Relief

Valves
Table of Contents
Introduction and Objectives…………………………………………… 30-2
Introduction to Relief Valves…...……………………………………… 30-3
Series 400 Modulating Valve……………………………………….…. 30-6
Installation and Startup Instruction………………………………… 30-12
Important Note regarding Operations………………………………… 30-16

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Introduction
The section contains information on Pilot Relief Valves

Objectives
After completing this section, you should be able to

• Understand the Specification of the Pilot Relief Valve.

• Understand the workings of Pilot Relief Valve.
• Know how to install Pilot Relief Valve.

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Pilot Relief Valves

Introduction
A pressure relief valve is a safety device designed to protect a pressurized
vessel or system during an overpressure event. An overpressure event refers
to any condition which would cause pressure in a vessel or system to
increase beyond the specified design pressure or maximum allowable working
pressure (MAWP).
Since pressure relief valves are safety devices, there are many Codes and
Standards written to control their design and application. The purpose of this
discussion is to familiarize you with the various parameters involved in the
design of a pressure relief valve and provide a brief introduction to some of
the Codes and Standards which govern the design and use of pressure relief
valves. Excerpts of various applicable Codes and Standards are included in
other sections of this handbook.
Many electronic, pneumatic and hydraulic systems exist today to control fluid
system variables, such as pressure, temperature and flow. Each of these
systems requires a power source of some type, such as electricity or
compressed air in order to operate. A pressure relief valve must be capable of
operating at all times, especially during a period of power failure when system
controls are nonfunctional. The sole source of power for the pressure relief
valve, therefore, is the process fluid.

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Once a condition occurs that causes the pressure in a system or vessel to

increase to a dangerous level, the pressure relief valve may be the only
device remaining to prevent a catastrophic failure. Since reliability is directly
related to the complexity of the device, it is important that the design of the
pressure relief valve be as simple as possible.
The pressure relief valve must open at a predetermined set pressure, flow a
rated capacity at a specified overpressure, and close when the system
pressure has returned to a safe level. Pressure relief valves must be designed
with materials compatible with many process fluids from simple air and water
to the most corrosive media. They must also be designed to operate in a
consistently smooth and stable manner on a variety of fluids and fluid phases.
These design parameters lead to the wide array of Crosby products available
in the market today and provide the challenge for future product development.

Spring Loaded Design

The basic spring loaded pressure relief valve has been developed to meet the
need for a simple, reliable, system actuated device to provide overpressure
protection. Figure F2-1 shows the construction of a spring loaded pressure
relief valve. The valve consists of a valve inlet or nozzle mounted on the
pressurized system, a disc held against the nozzle to prevent flow under
normal system operating conditions, a spring to hold the disc closed, and a
body/bonnet to contain the operating elements. The spring load is adjustable
to vary the pressure at which the valve will open.

Spring Loaded Pressure Relief Valve

Figure F2-1

Figure F2-2 is a simple sketch showing the disc held in the closed position by
the spring. When system pressure reaches the desired opening pressure, the
force of pressure acting over Area A1 equals the force of the spring, and the
disc will lift and allow fluid to flow out through the valve.

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When pressure in the system returns to a safe level, the valve will return to
the closed position. When a pressure relief valve begins to lift, the spring force
increases. Thus system pressure must increase if lift is to continue. For this
reason pressure relief valves are allowed an overpressure allowance to reach
full lift. This allowable overpressure is generally 10% for valves on unfired
systems. This margin is relatively small and some means must be provided to
assist in the lift effort.

Trim Areas Diagram

Figure F2-2

Most pressure relief valves, therefore, have a secondary control chamber or

huddling chamber to enhance lift. A typical configuration is shown in Figure
F2-3. As the disc begins to lift, fluid enters the control chamber exposing a
larger area A2 of the disc (Figure F2-2) to system pressure. This causes an
incremental change in force which overcompensates for the increase in spring
force and causes the valve to open at a rapid rate. At the same time, the
direction of the fluid flow is reversed and the momentum effect resulting from
the change in flow direction further enhances lift. These effects combine to
allow the valve to achieve maximum lift and maximum flow within the
allowable overpressure limits. Because of the larger disc area A2 (Figure F2-
2) exposed to system pressure after the valve achieves lift, the valve will not
close until system pressure has been reduced to some level below the set
pressure. The design of the control chamber determines where the closing
point will occur.
The difference between the set pressure and the closing point pressure is
called blowdown and is usually expressed as a percentage of set pressure.

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Pressure Relief Valve Trim

Figure F2-3

The design of the control or huddling chamber involves a series of design

tradeoffs. If the design maximizes lift effort then blow down will be long. If the
design objective is to minimize blow down, then the lift effort will be
diminished. Many pressure relief valves are, therefore, equipped with a nozzle
ring which can be adjusted to vary the geometry of the control chamber to
meet a particular system operating requirement (Figures F2-2 and F2-3).

Series 400* Modulating Valve

The Series 400 modulating valve, with non-flowing pilot, incorporates an

advanced design in pilot operated valves. Under process conditions, both
pilot and main valve can be tight as high as 98 percent of set pressure. The
main valve lifts proportionally, according to demand, restricting product loss to
only that which must be relieved to prevent process pressure from exceeding
the code allowance.

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The Series 400 valve is well suited for gas and/or liquid services, including
dirty and/or wet services. The modulating action is strongly preferred for liquid
relief because it eliminates the destructive effects of ‘liquid hammer.’ The
Series 400 valve is available with the following: effective orifice areas of 0.110
through 38.96 inch2 [0.710 through 251.3 cm2] valve inlet sizes 1-inch
through 8-inch [25 mm through 200 mm], set pressure between 15 and 1480
psig [1.03 and 102.0 barg], and continuous service temperatures from -65°F
to +500°F [-54°C to +260°C].

Features and Benefits

• Unique Field Test Capability. Allows accurate set pressure verification with
valve in service. No system isolation valve or rupture disc required.
• Reduced Product Loss and Pollution. Soft seats for premium tightness
before and after relief cycles. Modulating action relieves minimum product to
prevent overpressure.
• ASME Section VIII Code Stamp. Certified National Board capacities for
both gas and liquid service assures user of independent third party flow rate
verification.
• Suited for Dirty or Wet Service. Non-flowing pilot minimizes entrance
of dirt and formation of hydrates in pilot. Due to low velocities within the pilot
and supply tubing, most particles will drop out upstream of pilot inlet screen.
Optional cartridge type pilot filter is available for extremely dirty services.
• Rugged Bracket Pilot Mounting.
Extremely rigid mounting protecting against vibration and careless handling.
Shake table proven.
• Reduced Noise. Modulating action minimizes flow and resultant noise
during normal system upset, reducing noise abatement costs.
• Increased System Output. Because of valve tightness to 98 percent of set
pressure, the system can be operated nearer set pressure without valve
leakage, resulting in greater system throughput.
• Reduced Maintenance Costs. Soft seats greatly extend service life, making
costly and time-consuming metal seat lapping unnecessary.
• Ease of Adjustment. Single adjustment for set pressure allows accurate
and dependable setting.
• Balanced Design. Proper valve operation and lift are unaffected by
back pressure. Costly and fragile metal bellows are not required.
• Patent Protected

Operation
With no system pressure, the pilot inlet seat is open and the outlet seat is
closed.
As pressure is admitted to the main valve inlet, it enters the pilot through a
filter screen. Pressure is then transmitted through passages in the feedback
piston, past the inlet seat, into the main valve dome, which causes the main
valve piston to remain closed.

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As system pressure increases and approaches valve set pressure, it acts

upward on the sense diaphragm, with the feedback piston also moving
upward to close the inlet seat. This seals in the main valve dome pressure,
since the outlet seat is also closed. A small, further increase in system
pressure opens the outlet seat, partially venting the main valve dome
pressure. This reduced dome pressure acts on the unbalanced feedback
piston to reduce feedback piston lift, tending to ‘lock in’ the dome pressure.
Thus, at any stable inlet pressure, there will be no pilot flow (i.e., zero
leakage).
As inlet pressure rises above set pressure, dome pressure reduction will
provide modulating action of the main valve piston proportional to the process
upset. The spool/feedback piston combination will move, responding to
system pressure, to alternately allow pressure in the main valve dome to
increase or decrease. This moves the main valve piston to the exact lift that
will keep system pressure constant at the required flow. Full main valve lift,
and therefore full capacity, is achieved with relatively little overpressure. As
system pressure decreases below set pressure, the feedback piston moves
downward and opens the inlet seat to admit system pressure to the dome.
This closes the main valve. Due to the extremely small pilot flow, the pilot on
gas/vapor valves normally discharges to atmosphere through a weather and
bug proof fitting. Pilots for liquid service valves have their discharge piped to
the main valve outlet.

Specifications
• Non-flowing pilot.
• Single point set pressure adjustment.
• Replaceable main valve seat, located on piston to take wear.
• Feedback mechanism in pilot, independent of primary pressure sensing
mechanism, to ensure smooth modulation of main valve.
• Indicator button for field test capability.
• Field replaceable main valve nozzle.

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Iso-Dome* Series 400 Valve

The Iso-Dome accessory for the 400 pilot provides protection of the critical
pilot internals from the process media. The pilot is actuated by the process
fluid and is ASME Section VIII Code stamped for gas and liquid service. The
Iso-Dome 400 pilot is available with the following: effective orifices areas of
0.110 through 38.96 inch2 [0.710 through 251.3 cm2 ], valve inlet sizes 1-inch
through 8-inch [25 mm through 200 mm], set pressure between 15 and 1480
psig [1.03 and 102.1 barg], and continuous service temperature from -65°F to
+500°F [-54°C to +260°C].

Features and Benefits

• Critical Pilot Internals and Main Valve Dome Protected from Process
Media. Expands the application of pilot operated valve technology.
• Valve is Fail-safe. Meets ASME code requirements.
• Allows System Operating Pressure to be Near Set Pressure. SRV
tightness is maintained, resulting in greater system throughput.
• All Adjustments are Factory Sealed. Just add the clean gas supply for
simple and inexpensive field installation.
• Modulating Action. Minimizes fugitive emissions, product release, product
loss, and noise.
• Valve Operation Insensitive to Back Pressure. Costly and fragile metal
bellows not required.
• Unique Field Test Capability. Set pressure may be verified while valve
remains in service protecting the system. No system isolation valve or rupture
disc required.

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INSTALLATION & START-UP INSTRUCTIONS

TYPE 423,433,473 NO-FLOW MODULATING ACTION PlLOT

1. PRINCIPLE OF OPERATION
The Anderson-Greenwood Pilot Operated Pressure Relief Valves use the
principle of back-loading the top, large area, of a differential area piston with
line pressure to hold it closed below set pressure. At set the pilot valve
actuates, partially evacuating the dome (volume above piston) and the piston
lifts permitting discharge from the main valve. When process pressure
decreases the pilot repressurizes the main valve dome, closing the main
valve.

2. CONNECTIONS
Piping to the inlet of the safety valve should meet the general requirements
set forth in the AMERICAN PETROLEUM INSTITUTE RECOMMENDED
PRACTICE 520, PART 11. This document recommends inlet piping pressure
losses not exceed 3% o f the set pressure, discharge piping be properly
braced t o withstand reactive thrust forces when the safety valve relieves and
the safety valve be properly supported t o withstand system vibration. main
valve.

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3. PREINSTALLATION HANDLING
Dirt can be damaging and cause a safety relief valve t o become inoperative.
Valves which are not installed immediately should have the inlet and outlet
connections closed off. All safety valves should be handled with care and not
subject t o heavy shocks.

Procedure
A. Remove cap from field test fitting and connect flex hose from test gas
bottle.
B. Close vent valve "C" on gas bottle, open block valve "A" t o slowly
pressurize pilot and observe test pressure gage.
C. Set pressure i s where the pressure gage stops increasing and test gas
rapidly vents from field test indicator port . Caution: Stand clear of indicator
port during test to avoid contact with high pressure gas
D. To remove set up, close block valve "A", open vent valve "C" and install
cap on field test fitting .

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4. MAINTENANCE
Maintenance should be performed on a regular basis. Depending on the
service conditions, an inspection/maintenance on an annual basis is the
recommended maximum time interval.

5. INSTALLATION
The installation of the safety valve should be in accordance with the
recommendations set forth in the American Society of Mechanical
Engineers, Section VIII, Appendix M Pressure Vessel Code. This document
recommends the safety valve be installed in the upright position, as
shown in Figure 1.

6. PRESSURIZING THE VALVE

There must be pressure at the valve inlet to establish a differential in force
across the piston and "load" it in the closed position. Pressure must pass
through the pilot supply tube and pilot and exert force on the top of the piston.
On normal plant start-up the valve loads itself as plant pressure increases. It
is not uncommon that slight leakage past the main seat occurs until system
pressure reaches two or three pounds.

7. USE OF BLOCK VALVES UNDER THE SAFETY VALVE

Block valves are often used under safety valves in order to isolate them when
maintenance is required. When putting the safety valve in service be sure the
block valve is fully opened. If the block valve is opened after start-up, the
safety valve may briefly vent past the main valve seat before the dome gets
pressurized; it will then close.

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8. USE OF REMOTE PRESSURE PICK-UP

When remote pressure pick-up is used the pilot supply tube is connected to a
remote location rather than to the inlet neck of the valve. A block valve for
shut off in the remote pilot sense line is not recommended. If one is used, it
must be opened before pressurizing the system.

NOTE : Remove pressure pick-up piping must have the equivalent flow
area of 318" tubing for lengths up to 100 feet. For lengths greater than
100 feet, larger tubing or pipe should be used.

9. OTHER USES OF A SAFETY REZIEF VALVE

A safety relief valve should be used only to protect a system from
overpressure during a pressure upset. It should not be used as a control valve
that is required to operate continuously. It should not be used as a pipe fitting
or transition piece in a piping system.

10. FIELD TEST INSTRUCTIONS

The set pressure of valves equipped with a field test accessory can be
checked with the valve installed, in operation, using a test set up similar to
that shown in Figure 2. This procedure accurately checks the set pressure; it
will not be an accurate check of the reseat pressure.
The main valve will not open using the procedure described here. If the main
valve must be opened, slowly increase the test gas pressure beyond set point
until the valve opens. To close the valve, close block valve "A" on the test gas
bottle and open vent valve "C".

NOTE:
Field Service
The pilot assembly is not intended to be field serviceable; doing so will void
the set point certification.
Field service is limited to the main valve, filter, and accessories. Many
potential problems may be prevented by frequent draining and cleaning of the
filter and dipper tube.
If not present, add the heavy dome spring(s) which assist in the initial low
pressure seal.

Nitrogen charge system

If a valve starts to leak during pressure testing or while in service a Nitrogen
charge can be applied to the dome to energize the main valve piston. To
preserve full functionality, the rig up of the nitrogen to the relief valve must be
done as per the attached drawing. Deviation or omissions from the complete
system as shown may impede the relief valve function.
Each component of the nitrogen charge system performs a specific task. The
small orifice needle valve limits the N2 flow rate from overrunning the pilot
vent capability. The rupture disc guards in case of regulator failure. The back
flow preventer ensures that the pilot senses the greater pressure of the
nitrogen supply or process fluid.

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Nitrogen pressure must not exceed 1/2 relief valve set pressure. Rupture disc
setting must not exceed 70% of relief set point.
Prior to applying the nitrogen dome charge check the following:-
1. Check relief valve filters for debris.
2. Check the SS tubing and dipper tube for leaks, damage, or plugging.
3. Check main valve seat and piston. Replace as necessary.
If any valve continues to leak, remove leaking valve from service and send it
to an approved AGCO service shop for further inspection and testing.

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