Catalog # 77-1006

Safety Relief Valves

Rupture Disks Combined with

Safety Relief Valves

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 Instructions Longer Periods Between Major Valve Overhauls - Because the valve
Rupture Disks with Safety Relief Valves

The ASME Pressure Vessel Code permits the use of a rupture internals are not normally exposed to process contamination,
disk device at both a safety relief valve inlet and outlet. This they remain in “like new” condition, allowing longer periods
combination, once considered a luxury, has proven itself to save between major overhauls.
money through:­
Less Expensive Valve Material Can Be Used - The large initial cost
• Zero process leakage to the atmosphere of the safety relief valve can be reduced by ordering the valves
• Longer periods between major valve overhauls from less expensive metal and isolating it with a rupture disk.
• Valves can be tested in place As an example, if a Hastelloy® valve is normally required, use a
carbon steel valve with Hastelloy® rupture disk, with 65% savings
• Less expensive trim material can be used (average). The savings will buy the rupture disk.
• Valve life is extended by isolating internal valve parts
from corrosive environments When to Use a Rupture Disk, Relief Valve
Combination
This bulletin has been published to give you the facts, the
Pressure relief systems protect life and property from dangerous
advantages, applications, and the ASME Code that governs
overpressure events within process pressure systems, serving as
rupture disks and safety relief valves.
an important safeguard in establishing a safe, Code compliant,
Advantages of Rupture Disks Used in industrial working environment.
Combination with Safety Relief Valves Pressure relief valves, rupture disks, or combination of both,
Zero Process Leakage to the Atmosphere - An important reason for function as the pressure relief system, discharging excessive
isolating safety relief valves with rupture disks is to prevent the pressure. Individually, a rupture disk is an excellent choice for
process from leaking into the atmosphere. On conventional safety overpressure protection. However, a rupture disk / relief valve
relief valves, API Standard 526 states that for an orifice size of F combination will sometimes be the u­nrivaled choice when:
and smaller, the maximum allowable leakage rate is 40 bubbles
/ minute (approximately 6 cubic feet per 24 hours). The rupture 1) A leak tight seal of the system is needed because the system
disk used at the inlet of the relief valve acts as a solid metal contains a corrosive or hazardous substance and there is a
barrier between the process and the valve to eliminate leakage. concern that a relief valve may leak.

Allows Safety Relief Valves to be Tested in Place - When a rupture 2) The system contains highly viscous substances that
disk is used to isolate a safety relief valve, the set pressure of the may clog the relief valve over time causing it to become
valve can be tested in place. With a reverse buckling rupture disk inoperable. The installation of a rupture disk upstream
installed at the valve inlet, the safety relief valve can be tested serves as a barrier between the process and the relief valve.
on the spot by one man with a portable pressure source. To
3) Cost savings - BS&B rupture disks are 100% leak proof
accomplish this without shutting down the process, air or other
serving as a solid metal barrier between the valve and the
suitable gas, is injected into the chamber between the rupture
process. The disk prevents product buildup from adhering
disk and the safety relief valve inlet. Pressure is increased until the
to mechanical components of the valve. Since the process
operator hears the valve pop or simmer. Test pressure should not
media will not come in contact with internal surfaces and
exceed 110% of the marked burst pressure of the disk.
parts of the valve, the valve will remain in new condition
Valve Life is Extended - Safety relief valve life extension is the until called upon to activate.
third major advantage for using a disk / valve combination. The
rupture disk acts as a solid metal barrier between the valve and
the process. The disk prevents product buildup from adhering to
mechanical components of the valve that otherwise would affect
valve performance and safety of the system. Since the process
media will not come in contact with internal surfaces and parts
of the valve, it will remain in new condition until activated by an
overpressure event.

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Safety Relief Valve Isolation

Safety Relief Valves

BS&B recommends the Sta-Saf® lineup of reverse buckling rupture
disks when isolating safety relief valves. Sta-Saf products cover
most ranges of safety relief valve pressures ranging from 5 psig
(0.34barg) to 2000 psig (138barg).
Sta-Saf disks offer the user a vacuum resistant, solid metal rupture Safety Relief Valve
disk designed for non-fragmentation and ultimate leak-tightness.
Each Sta-Saf rupture disks is installed in a pre-torqued SRB-7RS
safety head that allows the rupture disk to be removed from
service, inspected, cleaned, and reinstalled without resetting the
torque. Pretorqued SRB-7RS
safety head fits between
The following is a guide to selecting rupture disks for each standard flanges
application:
1. New Construction Valve Inlet Isolation
Sta-Saf system recommended: The Sta-Saf lineup of rupture disks
are available in models: Sigma EXL, Sigma, SKR, SRD, RLS, JRS, FRS,
S-90, and LPS depending on burst pressure required and service
conditions. The disk and safety head fits between flanges, assuring
correct installation by means of a J-bolt and disk centering pins.

Application Summary Chart A Sigma EXL rupture disk

Figure 1
Application Inlet Outlet installed in an SRB-7RS
New construction Sta-Saf AV Disk or Sta-Saf safety head
Retro free vent Sta-Saf AV Disk or Sta-Saf
Retrofit fixed SVI AV Disk or Sta-Saf
Outlet piping SVI AV Disk or Sta-Saf
Liquid service Sigma, RLS, SKR, LPS AV Disk or Sta-Saf

Figure 2: The S-90 rupture disk is one of eight rupture

Figure 2 disk models within the Sta-Saf family including three
safety heads that provide the user a multitude of
options for isolating safety relief valves. Standard
Example: S-90 rupture disk installed
features of the Sta-Saf family include:
into an SRB-7RS safety head • Sizes from 1 to 40 inches (25 to 1000mm)
• Up to 95% operating ratio
• Pressures from 5 to 2,000 psig (0.7 to 138 barg)
• Vacuum resistant
• Solid metal, leak-tight construction
• Designed for non-fragmentation
• Models for all process environments
• Saf (structural apex forming) technology

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 Figure 3 Application Considerations
Rupture Disks with Safety Relief Valves

Figure 3(b) type AV disk fits

To better understand the use of rupture disks to isolate safety
between standard flanges relief valves, compare the advantages and disadvantages of each
relief device.
Safety Relief Valve
• Metal seated valves leak – loss of products as well as
pollution of the atmosphere
• High cost
• High maintenance required – since the process goes
through the valve, it must be checked periodically for
correct operation. The system must be shut down
Figure 3(a) SVI disk slips • Adjustable
easily into inlet piping
• Recloses after pressure relief

Rupture Disk
• Leak tight
• Low cost
• Low maintenance required
2. Retrofit - Inlet to Valve (gas / vapor service) • Fixed setting
For isolating safety relief valves already in service with rigid • Non-reclosing
discharge piping, the SVI rupture disk assembly is recommended • Disposable – must be replaced after each operation
(figure 3a). The SVI is a reverse buckling S-90 rupture disk welded
into a one piece metal assembly. Supplied with affixed gasket Rupture Disk / Safety Relief Valve Combination
for immediate assembly, the SVI easily slips into the inlet piping. • Leak-tight
Advantages include:
• Moderate cost
• No safety head required
• Medium maintenance required
• Fits into inlet piping
• Non-fragmentation • Adjustable
• Available in sizes 1.5 to 8 inches (40 to 200mm) • Recloses after pressure relief
• Valve is reusable, disk is disposable
3. New Constructions or Retrofit Valve Outlet Isolation
With tighter EPA regulations causing safety relief valves to be
manifolded rather than discharged to the atmosphere, it is
important to isolate the safety relief valve outlet (as well as the
inlet) with a rupture disk to prevent “backflow” corrosion.
The type AV low pressure rupture disk is the perfect fit for the
job (figure 3b). The AV disk requires no safety head, comes with
affixed gasket and fits between standard flanges (figure 3b).
Advantages for valve outlet isolation:
• Low burst pressures available
• Bursts at equal pressure in both directions (1:1 ratio)
• Cannot be installed wrong, both sides are identical
• Available in sizes 2 to 72 inches (50 to 1800mm)
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 The BS&B rupture disk metal tab (pictured to the right) shows stamped lot number,
disk size, and rated rupture pressure at temperature.

Safety Relief Valves

BS&B rupture disks are manufactured in accordance with the requirements of
international codes and standards when specified including: ASME Section VIII
(UD stamped) and Section III and EU Pressure Equipment Directive (CE marking
EN 4126-2: Bursting disk safety devices).

Reprinted from ASME 2015 BPVC, Section VIII-Division 1, by permission of the American Society of
Mechanical Engineers. All rights reserved. No further copies can be made without written permission.

ASME Pressure Vessel Code Section VIII, Footnotes to ASME Code

45 A safety valve is a pressure relief valve actuated by inlet static pressure and
Division 1, 2015 Edition: characterized by rapid opening or pop action. A relief valve is a pressure relief
Rupture Disks and Safety Relief Valves Defined valve actuated by inlet static pressure which opens in proportion to the increase
in pressure over the opening pressure. A safety relief valve is a pressure relief
UG-126: Pressure Relief Valves45 valve characterized by rapid opening or pop action, or by opening in proportion
(Meeting the Requirements of ASME CODE, 2015 Section VIII - Division 1) to the increase in pressure over the opening pressure, depending on application.
A pilot operated pressure relief valve is a pressure relief valve in which the major
(a) Safety, safety relief, and relief valves shall be of the direct relieving device is combined with and is controlled by a self-actuated auxiliary
spring loaded type. pressure relief valve.
46 A rupture disk device is a nonreclosing pressure relief device actuated by inlet
(b) Pilot operated pressure relief valves may be used, provided
that the pilot is self-actuated and the main valve will open static pressure and designed to function by the bursting of a pressure containing
disk. A rupture disk is the pressure containing and pressure sensitive activation
automatically at not over the set pressure and will discharge component of a rupture disk device. Rupture disks may be designed in several
its full rated capacity if some essential part of the pilot should configurations, such as plain flat, prebulged, or reverse buckling. A rupture disk
fail. holder is the structure that encloses and clamps the rupture disk in position.
47 The manufacturing design range is a range of pressure within which the
(c) The set pressure of a pressure relief device shall not be
adjusted outside the range of set pressure specified by marked burst pressure must fall to be acceptable for a particular requirement
as agreed upon between the rupture disk manufacturer and the user or his
the device manufacturer. The initial adjustment shall be designated agent. The manufacturing design range must be evaluated in
performed by the Manufacturer, his authorized representative, conjunction with the specified burst pressure to ensure that the marked burst
or an Assembler, and a valve data tag shall be provided that pressure of the rupture disk will always be within applicable limits of UG-13 4.
identifies the set pressure capacity and date. The valve shall be Users are cautioned that certain types of rupture disks have manufacturing
sealed with a seal identifying the Manufacturer, his authorized ranges that can result in a marked burst pressure greater than the specified
burst pressure.
representative, or the Assembler performing the adjustment.
48 The specified disk temperature supplied to the rupture disk manufacturer
(d) The set pressure tolerances, plus or minus, of pressure relief shall be the temperature of the disk when the disk is expected to burst.
valves shall not exceed 2psi (15kPa) for pressures up to and 49 A lot of rupture disks is those disks manufactured of a material at the same
including 70 psi (500kPa) and 3% for pressures above 70 psi time, of the same size, thickness, type, heat, and manufacturing process
(500kPa). including heat treatment.

UG-127: Nonreclosing Pressure Relief Devices

(a) Rupture Disk Devices46
General. Every rupture disk shall have a marked burst pressure
established by rules of UG-137 (d)(3) within a manufacturing
design range47 at a specified disk temperature48 and shall be
marked with a lot49­­ number. The burst pressure tolerance at the
specified disk temperature shall not exceed +2 psi (+ 15kPa) for
marked burst pressure up to and including 40 psi (300 kPa) and +
5% for marked burst pressure above 40 psi (300kPa). ­­
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 Meeting ASME Code Capacity of
Figure 4
Rupture Disks with Safety Relief Valves

Combination
In order to meet the ASME code, the capacity of the Safety Relief Valve
combination of the safety relief valve and rupture
disk must be determined one of two ways:
A) Flow test the combination to arrive at a
“certified combination capacity factor”.
Testing must be done in accordance with
Excess flow
Paragraph UG-132 and approved by the valve
National Board of Boiler and Pressure Vessel Rupture disk
Inspectors. Safety head

Rupture disk / relief valve combinations with Flange

flow tests will be allowed a relieving capacity
of the valve multiplied by a correction factor
obtained from actual flow tests of the rupture
disk/relief valve combination. A typical piping arrangement is shown in figure 4. The telltale
indicator consists of a pipe nipple, tee, an excess flow (flow check
The combination capacity factor shall be used as a multiplier valve), and pressure gauge. The outlet side of the excess flow
to derate the ASME rated relieving capacity of the safety valve has a threaded connection. If free venting is not desirable,
relief valve in all sizes of the design. a discharge line can be installed to permit dispersion of product
to a safe location.
Refer to BS&B Catalog 77-1006A for “Combination Capacity
Factors” After the relief system has been operated by pressure and the
B) UG-127(a)(3)(b)(2), In lieu of testing, a factor of 0.90 must safety relief valve reseats, the prevailing line pressure will force
be applied to the capacity of the relief valve. the ball in the excess flow valve to its seat. This permits the line
pressure to be indicated on the gauge. After a replacement disk is
Rupture disk / relief valve combinations, which have installed, the chamber between the disk and relief valve is again
not been flow tested as a combination, must be rated in voided of pressure and gauge reading is at zero.
allowable relieving capacity to 90% of the rated relieving
capacity stamped of the valve. Another common method is to use a pressure switch instead of a
pressure gauge. If pressure builds above the disk cavity, it sets off
Note: If a rupture disk device is to be used with a relief valve, then an an alarm device at the site or at a remote location. This pressure
additional nameplate must be installed on the relief valve or safety increase could be leakage allowing pressure buildup above
head. The nameplate must show the valve type, the disk holder the disk and thus increasing the pressure required to burst the
type, the type of disk and the flow capacity of the combination, rupture disk. It could also be caused by the rupture disk bursting.
UG-129 (c).
If a closed system is used with pressure gauge, tricock or other
Meeting ASME Code: Arrangement of Piping types of telltale indicators, the relief system is then dependent
ASME Code requires that the space between a rupture disk upon a visual or manual check to determine if pressure is present
device and a safety relief valve be provided with a pressure in the cavity between the two relief devices elevating the burst
gauge, tricock, free vent or suitable telltale indicator, UG-127(a) pressure of the disk.
(3)(b)(4).

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Meeting ASME Code: Rupture Disks Installed (4) the opening provided through the rupture disk device

Safety Relief Valves

on the Outlet (Discharge) Side of the Valve after breakage is sufficient to permit a flow equal to the
rated capacity of the attached pressure relief valve without
UG-127 exceeding the allowable overpressure;
A rupture disk device may be installed on the outlet side54 of
(5) any piping beyond the rupture disk cannot be obstructed by
a pressure relief valve which is opened by direct action of the
the rupture disk or fragment
pressure in the vessel provided:
(6) the system is designed to consider the adverse effects of any
(1) the pressure relief valve will not fail to open at its proper leakage through the pressure relief valve or through the outlet
pressure setting regardless of any back pressure that can side rupture disk device, to ensure system performance and
accumulate between the pressure relief valve disk and the reliability. 56
rupture disk. The space between the pressure relief valve disk
(7) the bonnet of a balancing bellows or diaphragm type pressure
and the rupture disk shall be vented or drained to prevent
relief valve shall be vented to prevent accumulation of pressure
accumulation of pressure, or suitable means shall be provided
in the bonnet.
to ensure that an accumulation of pressure does not affect the
proper operation of the pressure relief valve. 55
Footnotes to ASME Code
(2) the pressure relief valve is ample in capacity to meet the 54 This use of a rupture disk device in series with the pressure relief valve is

requirements of UG-125(c); permitted to minimize the loss by leakage through the valve of valuable or of
noxious or otherwise hazardous materials, and where a rupture disk alone or
(3) the marked burst pressure of the rupture disk at the specified disk located on the inlet side of the valve is impracticable, or to prevent corrosive
disk temperature plus any pressure in the outlet piping shall gases from a common discharge line from reaching the valve internals.
not exceed the design pressure of the outlet portion of the 55 Users are warned that many types of pressure relief valves will not open at

pressure relief valve and any pipe or fitting between the valve the set pressure if pressure builds up in the space between the pressure relief
and the rupture disk device. However, in no case shall the valve disk.
marked burst pressure of the rupture disk at the specified disk 56 Some adverse effects resulting from leakage may include obstructing the

temperature plus any pressure in the outlet piping exceed the flow path, corrosion of pressure relief valve components, and undesirable bursts
of the outlet side rupture disk.
maximum allowable working pressure of the vessel or the set
pressure of the pressure relief valve.

Reprinted from ASME 2015 BPVC, Section VIII-Division 1, by permission of the American Society of Mechanical Engineers. All rights reserved. No further
copies can be made without written permission.

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Rupture Disks with Safety Relief Valves

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8 ©2017 BS&B Innovations, Limited. Printed Jan. 2017
© 2015Mar25#77-1006 BS&B Safety Systems, L.L.C