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ENGINEERING STANDARD

Title:

SAFETY AND RELIEF VALVES

Approvals:

Sponsor

Standard No. :
420
Page
:
1 of 13
Issue Date
:
April, 2006
Director, Control Systems
Director, Specialty
& Electrical Engineering
Engineering

Name

J. Pittman

M. A. Tibbitts

M. R. Hoffman

Signature

ON FILE

ON FILE

ON FILE

Date

05/04/06

05/05/06

06/02/06

TABLE OF CONTENTS
Page
1.0

SCOPE................................................................................................................................... 2

2.0

CODES, STANDARDS AND REFERENCES .................................................................. 2

3.0

PSV CALCULATIONS AND SIZING BASIS .................................................................. 3

4.0

PSV SELECTION, MATERIALS AND CONSTRUCTION........................................... 4

5.0

SETTING RANGES............................................................................................................. 4

6.0

BLOWDOWN....................................................................................................................... 5

7.0

TIGHTNESS......................................................................................................................... 5

8.0

IDENTIFICATION.............................................................................................................. 6

9.0

TESTING AND INSPECTION........................................................................................... 6

10.0

SHIPMENT........................................................................................................................... 6

11.0

INSTALLATION ................................................................................................................. 7

12.0

ACUTELY TOXIC SERVICE APPLICATIONS ............................................................ 7

EXHIBIT 1 - SSR Requirements and Form .......................................................................................... 9


RECORD OF REVISIONS................................................................................................................... 13

Standard No:
420
SAFETY AND RELIEF VALVES

Issue Date:
April, 2006

Page
2 of 13

1.0

SCOPE

1.1

This Standard, in conjunction with the Vendor Preference List and specification for the
specific project, shall define the minimum Lyondell requirements for frequently used safety
and relief valves.

1.2

Relief System Manual shall be used as an Engineering Guideline in conjunction with this
Standard.

1.3

Where approvals are indicated in this Standard, this refers to Lyondell or its designated
representative.

1.4

Any discrepancy between this Standard and other contract or procurement documents or
specifications, unless specifically indicated as an exception, shall be submitted by the
Contractor/Manufacturer/Supplier to the Buyer for a written ruling.

1.5

All measurements are expressed in the U.S. Conventional System of Measurement, followed
by, in parenthesis, the equivalent SI units (metric). All SI units are for reference only and
shall not be interpreted as a precise conversion.

1.6

Any proposed deviation from this Standard shall be submitted in writing to Lyondell for
review and approval. It is the responsibility of the individual(s) who request a deviation to
submit a request form in a timely manner and in accordance with Lyondell Procedure SEP
107B, Preparation of Addenda to and Deviations from Lyondell Engineering Standards.

2.0

CODES, STANDARDS AND REFERENCES


The latest editions of the following Codes and Standards in effect on the date of contract
award shall be used, except as otherwise specified.

2.1

Lyondell Engineering Standards and Guidelines


ES 320
EG 4012

2.2

Corporate Management System Procedures


TEC-03-P1
TEC-03-P4

2.3

Piping
Relief System Manual

Process Hazards Analysis and Risk Assessment


Relief Valve Availability for Risk Assessment

American Petroleum Institute (API)


API RP 520, Parts 1 & 2
API RP 521
API 527
API 2000

2.4

Recommended Practice for the Design and Installation of


Pressure-Relieving Systems in Refineries
Guide for Pressure Relief and Depressurizing Systems
Commercial Seat Tightness of Safety Relief Valves with Metalto-Metal Seats
Venting Atmospheric and Low-Pressure Storage Tank

American Society of Mechanical Engineers (ASME)

Standard No:
420
SAFETY AND RELIEF VALVES

ASME Code Section I


ASME Code Section VIII
3.0

Issue Date:
April, 2006

Page
3 of 13

Power Boilers
Pressure Vessels

PSV CALCULATIONS AND SIZING BASIS


NOTE: RELIEF DEVICE DOCUMENTATION REQUIREMENTS ARE NOT TO BE
AMENDED OR REDUCED BY PLANT OR PROJECT ADDENDA.

3.1

The basic format requirement for this documentation is that all calculations and analyses shall
be clear, legible, and presented in a manner that an engineer, who is not intimately familiar
with the system, will be able to follow. The documentation shall contain a sufficient
narrative to allow a viewer understanding of the basic assumptions and reasoning for
determining the relief loads. Both quantitative and qualitative analyses shall be included.
The sources of all data shall be identified.
Documentation shall show all calculations and the basis of calculations for all plant safety
valves. These documents shall bear the approval signature of the assigned Lyondell process
engineer. As a minimum, the documentation shall include the following:

3.1.1

A sketch of the pressure relief device and the system in which it is installed. The sketch shall
show all the equipment protected by the pressure relief device.

3.1.2

A copy of the calculations for the relief load analysis and sizing.

3.1.3

A copy of the computations for the pressure relief device specification and sizing.

3.1.4

A sketch of the pressure relief devices installation, showing all details required for a proper
installation.

3.1.5

A copy of the pressure loss calculations for sizing the pressure relief devices inlet and outlet
piping and the calculations associated with piping supports.

3.1.6

Copies of all drawings, performance curves, equipment data sheets, etc., which were used in
the evaluation of the system.
All relief cases shall be summarized on a data sheet as found in the Relief System Manual.
This form provides a summary of the equipment being protected, its design conditions, and
the relief cases that were considered in developing the sizing case. Quantitative values of
flows, operating conditions, and fluid physical properties for each relief case shall be
provided. This form also provides space to list the required pressure relief device areas for
each case and to summarize the devices selected for the service.

3.1.7

A completed Instrument Society of America (ISA) data sheet or equivalent.

3.2

All spring loaded and pilot operated safety and relief valves shall be of the manufacturers
current standard type. Materials and design shall conform to the latest revisions of the
applicable section of the ASME Code and all local, applicable regulations.

Standard No:
420
SAFETY AND RELIEF VALVES

Issue Date:
April, 2006

Page
4 of 13

3.3

The proper ASME Code stamp shall appear on all valves used to protect pressure vessels:
(UV) or (V), as required by the Code.

4.0

PSV SELECTION, MATERIALS AND CONSTRUCTION

4.1

The use of direct spring operated pressure relief valves is strongly recommended. Pilot
operated pressure relief valves should be utilized only when a direct operated pressure relief
will not meet the application requirements. Where pilot operated pressure relief valves are
used Lyondell EG 4012 shall be reviewed for guidance in the specification and application of
the valve.

4.2

In general, relief valves shall have cast carbon steel bodies with stainless steel nozzle, disc,
guide, spindle, and bellows (when required). Spring material shall be compatible with the
fluid temperature. Alloy steel bodies or trim that is other than stainless steel shall be used
when required by operating conditions or ES 320.

4.3

For pressure vessels, valves that are 1 in. and larger shall be a type having a nozzle bushing
that extends through and beyond the base of the inlet bolting flange and forms the gasketbearing surface for the inlet flange.

4.4

Inlet and outlet flange ratings are specified to cover the temperature and pressure
requirements. In general, they will agree with the piping specification. Screwed valves may
have screwed bonnets and be used where small orifice areas are required, such as thermo
relief valves. Screwed valves shall be the modified nozzle type.

4.5

Safety and relief valves shall be furnished with top guide and disc or disc holder, flat seats
and discs, and optically ground seating surfaces.

4.6

For hard-to-hold fluids, an O-ring type or other soft seated type valve may be used with
Lyondells approval. Temperature and corrosion shall be checked as limiting factors.

4.7

All safety and relief valves shall meet or exceed ES 320 for materials and piping joints.

4.8

All safety and relief valves in the process service shall be flanged.

4.9

Screw-type valves are permitted in utility services, such as water, air, and inert gas service,
within the ANSI temperature-pressure rating for the class of 150 lb flanges.

4.10

To ensure chemical compatibility, all valve internal gasket types must be specified on the
instrument specification sheet for bellows style relief valves. Metal gaskets should meet or
exceed the metallurgy requirements of the valve. Non-metal gaskets (such as the bellows
gasket) material should be derived from the valve outlet piping specification gasket
requirements. Flexible graphite should be specified for piping specifications that require
flexible graphite or graphite filled spiral wound gaskets. Filled PTFE needs to be specified
for piping specifications that require filled PTFE sheet or PTFE filled spiral wound gaskets.
The vendor supplying relief devices to Lyondell must meet the requirements outlined in the
Lyondell relief device specification sheets.

5.0

SETTING RANGES

Standard No:
420
SAFETY AND RELIEF VALVES

Issue Date:
April, 2006

Page
5 of 13

5.1

Safety and relief valves shall have the springs supplied and adjusted for the initial set
pressure, as specified in the data sheets.

5.2

Relief valve springs shall be selected so that an adjusted range of 10% of the original set
pressure is possible on the valves whose settings are 250 psig (1.72 MPa), maximum.

5.3

Relief valves set higher than 250 psig (1.72 MPa) shall have a range adjustment of 5% of
the set pressure.

5.4

Set pressure tolerances shall be in accordance with ASMEs Unfired Pressure Vessel Code,
as follows:

5.4.1

Set pressures at 70 psig (.48 MPa) or less2 psi

5.4.2

Set pressures above 70 psig (.48 MPa)3%

5.5

If multiple relief valves are used (instead of one), set pressures are to be staggered to prevent
valve chattering.

5.6

Percent accumulation, used in calculating the sizes of relieving devices, shall be as follows,
unless specified otherwise in the Project Design Basis:
Percent

Service

3
10
21

Steam service where the ASME Boiler Code applies


Gas or vapor service and liquids
Fire exposure on unfired pressure vessels

5.7

Bellows-type valves, when specified, shall have the bellows rated for the set pressure plus
accumulation.

6.0

BLOWDOWN

6.1

Blowdown (the difference between set pressure and reseating pressure) for all vapor relief
valves, other than those covered by the ASME Code, Section I, shall be that which is
normally provided by the vendor. If a different blowdown is required, it shall be reviewed
with Lyondell.

6.2

For power boilers, blowdown shall be in accordance with the ASME Code, Section I,
paragraph PG 72.

7.0

TIGHTNESS

7.1

Vendors tightness, when specified, shall meet the tightness test as set forth in API 527. For
pressures greater than 1,000 psi (6.9 MPa), review with Lyondell.

7.2

Absolute bubble tightness, when specified, shall require that the valve be absolutely bubbletight at 95% set pressure. Special lapping costs to secure the above shall be stated by the
vendor in the proposal when specified in the data sheets.

Standard No:
420
SAFETY AND RELIEF VALVES

Issue Date:
April, 2006

Page
6 of 13

8.0

IDENTIFICATION

8.1

Each valve shall be furnished with a stainless steel nameplate that is permanently fastened
with stainless steel screws or rivets, engraved or metal-stamped in accordance with the
ASME Code, Section VIII, Division I, paragraph UG 129. Additional markings may be
required to include the bench set (cold set) pressure.

8.2

When a temperature correction factor is used to compensate test stand conditions, the cold set
pressure (even if it is equal to the set pressure, the operating relief pressure, and the operating
temperature) shall be stamped on the nameplate, or on a separate stainless steel tag that is
permanently fastened to the valve in the same manner as the nameplate.

9.0

TESTING AND INSPECTION

9.1

Inspecting, testing, and setting of all relief valves shall be performed by the manufacturer in
the shop prior to shipment.

9.2

Records of the final, approved settings and testing shall be forwarded to Lyondell when
inspection, per paragraph 9.1, is completed.

9.3

Prior to installation, all safety and relief valves shall be tested in a shop designated and
approved by Lyondell. This is a safety practice that takes into account the possibility of a
pressure set point error at the factory or a deviation from the pressure setting or seat leakage,
due to the transit rigor encountered by the valves on their way from the factory to their point
of use.

9.4

The local shop shall tag or stamp all new safety and relief valves with the valve number,
vessel number, set pressure, cold differential test pressure and, when required, the date the
device was installed. A companion tag shall be attached to the flange on which the device is
mounted, which shall have the valve number, vessel number, and set pressure. These tags
shall be in addition to the vendors tag or nameplate.

9.5

Lyondell shall maintain, at the plant and/or field office where the pressure-relieving device is
located, a permanent and progressive record showing the serial or identification number, the
location, the pressure setting, spring size, the date of installation in service, and the dates of
testing.

9.6

Exhibit 1 contains Lyondells Supplier Surveillance Requirements. These requirements


identify the minimum attributes to be addressed during surveillance of the Supplier by
Lyondell or Lyondells designated representative when such surveillance is performed.

10.0

SHIPMENT

10.1

Machined or threaded surfaces that will be exposed to the atmosphere in shipment or storage
shall be coated with an easily removable rust preventative.

10.2

Flanged faces shall be protected by covers that are securely fastened to the flanges. Openings
shall be covered to prevent dirt from entering the valve interior.

Standard No:
420
SAFETY AND RELIEF VALVES

Issue Date:
April, 2006

Page
7 of 13

10.3

Ends of the threaded valves shall have threaded protectors, which will exclude dirt.

10.4

Color coding of the valves, when required by Lyondell, shall be in accordance with the
detailed valve specification sheet.

11.0

INSTALLATION

11.1

Installation shall conform to the latest revision of the applicable section of the ASME Code
and the applicable division of Industrial Safety, State Safety, and other local safety codes.

11.2

API RP 520 and API RP 521 shall be used as guides in designing and installing pressurerelieving systems.

11.3

The use of balanced bellows-type valves shall be considered under the following conditions:

11.3.1

Variable back pressure

11.3.2

Corrosive or viscous fluids on the downstream side

11.3.3

Where there is any possibility of contamination

11.4

Installation of rupture discs, safety heads, or relief valve isolators shall be in accordance with
the ASME Code, Section VIII, Division I, paragraph UG 127, UG 133, UG 134, and the
manufacturers installation instructions.

11.5

Where rupture discs, safety heads, or relief valve isolators are specified to be installed on the
inlet side of safety or relief valves, an opening (1/4 in. minimum) shall be provided in the
outlet flange of the device or in the inlet nozzle bushing of the safety or relief valve. This
opening shall be provided for the mandatory installation of a corrosion-resistant vent, excess
flow valve, and pressure gauge. All connections and material shall be in accordance with the
applicable pipe specification.

11.6

Where rupture discs, safety heads, or relief valve isolators are specified to be installed on the
outlet side of safety or relief valves, an opening (1/2 in. minimum) shall be provided in the
inlet flange of the device for venting to a closed system. Relief valves in this service shall
normally be balanced bellows type valves.

11.7

For venting atmospheric and low-pressure storage tanks, API 2000, latest edition, shall be
used as a guide.

11.8

Safety of personnel shall be considered in locating atmospheric discharge stacks; as a


minimum requirement, the discharge stacks shall extend to 10 ft (3 m) above the highest
operating platform within a 25 ft (7.6 m) radius.

11.9

Where discharge stacks are vented vertically to the atmosphere, a drain hole shall be provided
in the bottom of the stack.

12.0

ACUTELY TOXIC SERVICE APPLICATIONS

Standard No:
420
SAFETY AND RELIEF VALVES

12.1

Issue Date:
April, 2006

Page
8 of 13

Relief valves utilized in Acutely Toxic material service, as defined in ES 320, shall be
balanced bellows type with the valve outlet piped to a closed vent system and subsequent safe
location such as a scrubber or flare system. These safety relief vales shall be provided with a
rupture disc installed on the inlet side of the relief valve. A mandatory telltale assembly
consisting of an opening (1/4 in. minimum) located in the outlet flange of the disc device
holder or in the inlet nozzle bushing of the relief valve, an excess flow check valve, and
pressure switch or transmitter shall be installed. The outlet side of the excess flow valve shall
be piped back to the relief valve discharge piping vent header. The output of the pressure
switch or transmitter shall be alarmed in the control room to notify operators that the rupture
disk has failed or the rupture disk/relief valve has opened.
These acutely toxic service rupture disk/pressure relieve valve systems shall be installed as
redundant pairs with the proper isolation valves to allow on-line maintenance of the system.
Where failed or leaking rupture disk are detected they shall be replaced immediately.

Standard No:
420
SAFETY AND RELIEF VALVES

Issue Date:
April, 2006

Page
9 of 13

EXHIBIT 1
INSTRUCTIONS FOR USE OF SUPPLIER SURVEILLANCE REQUIREMENTS
1.0

PURPOSE
The Supplier Surveillance Requirements (SSR) represent Lyondells minimum requirements
for monitoring the Supplier during fabrication of equipment.
The SSR does not modify or supersede the technical requirements specified for the equipment
contained in the main body of the Lyondell Standard. The Lyondell Standard specifies the
minimum requirements to be met by the Supplier for fabrication, inspection, testing,
documentation, preparation for shipment, etc.

2.0

SCOPE
The SSRs apply to the surveillance of shop fabrication of Category I and II, Equipment;
Class 1, 2, and 3, Packaged Equipment. These categories and classes are defined by the
references listed in Paragraph 4.0 of this attachment. The extent that these requirements are
applied to Category III and IV equipment; Class 4, 5, and 6, Packaged Equipment, shall be
determined by the Responsible Engineer on a case by case basis using engineering judgment.

3.0

DEFINITIONS
Hold Point: An activity requiring release from Lyondell or Lyondells representative before
the Supplier may proceed in performing the activity.
Quality Surveillance Representative (QSR): An individual representing Lyondell who is
assigned to perform surveillance of the Supplier.
Responsible Engineer: Lyondell Engineer assigned to the project who is responsible for the
engineering phase of the equipment.
Review Documentation: Review of procedures, records, and other specified documents to
determine compliance with the referenced Standard(s).
Supplier: The organization fabricating/manufacturing the equipment.
Verify by Inspection: Visual Inspection to: (a) verify document approval status, (b) check
fabrication for conformance to requirements.
Witness Point: An activity that may be observed by Lyondell or its representative. Unless
otherwise specified, the supplier is required to notify Lyondell or its representative at least
five days prior to activity performance.

4.0

REFERENCES

4.1

Lyondell Quality Assurance Standard 551 (Criticality Rating Requirements for Engineered
and Packaged Equipment)

Standard No:
420
SAFETY AND RELIEF VALVES

Issue Date:
April, 2006

Page
10 of 13

4.2

Lyondell Procedure CPP 601

(Packaged Equipment)

5.0

INSTRUCTIONS

5.1

The SSR contains attributes (denoted with an X) which must be verified, as a minimum,
when surveillance of the Suppliers shop fabrication activities is required. Where an X is
not shown for a given attribute on the existing SSR, the attribute must be reviewed by the
Responsible Engineer. The Responsible Engineer must either specify a surveillance function
(as denoted with an X) in the Function column of the SSR or identify the attribute as not
applicable (N/A) in the Supplemental Information column of the SSR.

5.2

Additional requirements may be added by the Responsible Engineer, when appropriate, based
on the engineering issues related to the specific equipment being fabricated. The additional
requirements shall be identified with an (*) in No. column to distinguish these types of
requirements from Lyondells minimum requirements.

5.3

The surveillance requirements indicated on the SSR for Suppliers of Category III and IV
Equipment; Class 4, 5, and 6 Packaged Equipment, may be modified by the Responsible
Engineer based on engineering judgment. (This does not imply any modification of the
technical requirements contained in the main body of the Lyondell Standard, only the
intensity of surveillance over the Suppliers activities).

LYONDELL
SSR No. 420

Date:
Rev:

SUPPLIER SURVEILLANCE REQUIREMENTS


Item: Safety & Relief Valves

Lyondell Approval:

Page

Equipment Description:

11 of 13

Critical Equip. Category:

Prepared by:
Specifications/Codes/Standards:
Lyondell ES 420
API 520

No.

Surveillance Functions:
1 - Verify by Inspection
2 - Witness Point
3 - Hold Point
4 - Review Documentation
Attribute

Function
2
3

Supplier/Contractor:
Lyondell P.O./Contract:

Supplemental Information

Pre-Fab Meeting

Drawings & Calculations

Approved by Lyondell.

Verify Data Sheet

Approved by Lyondell.

Verify Materials of Construction

Verify Latest DWG's/Calc's/Data Sheet/Spec

Verify Size/Rating/Capacity

Dimensional
Component Parts (See Note 1)
Outline

Visual Inspection
Component Parts
Assembled Unit

Test Gauge Calibration

10

Verify Test Stand Setup

11

Testing

12

Verify Correct Tagging

13

Final Documentation Review

14

Prep Shipment

15

Release for Shipment

16
17
18
19
20
21
22

SSR No. 420

Item: Safety & Relief Valves

Lyondell Approval:

Page

Equipment Description:

12 of 13

Critical Equip. Category:

Prepared by:
Specifications/Codes/Standards:
Lyondell ES 420
API 520

No.

Surveillance Functions:
1 - Verify by Inspection
2 - Witness Point
3 - Hold Point
4 - Review Documentation
Attribute

23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Remarks:

Legend: (X) Mandatory Surveillance Function performed by QSR.


(*) Attributes specifically added for this Purchase Order.
Where (X) is not shown, this function needs to be specified on a case basis

Function
2
3

Supplier/Contractor:
Lyondell P.O./Contract:

Supplemental Information

Standard No:
420
SAFETY AND RELIEF VALVES

Issue Date:
April, 2006

Page
13 of 13

RECORD OF REVISIONS
(as compared to February, 2000 issue)
Updated this Standard to provide requirements for Acutely Toxic materials, requirements for gasket
materials and recommendation to use direct spring opposed relief valves.
2.2

Added paragraph and renumbered subsequent paragraphs.

4.0

Renamed section.

4.1

Added new paragraph and renumbered subsequent paragraphs.

4.10

Added new paragraph.

11.5

Revised paragraph for clarity.

11.6

Revised paragraph for clarity.

12.0

Added new section.

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