Pressure Relief Valve (PRV) New Set Pressure

for Pressure Vessel Based on New MAWP

Hadi Veyse – CCR Supervisor

Terminology

MAWP:
Maximum Allowable Working Pressure (MAWP) is maximum gauge pressure permitted at the top of
a pressure vessel in its operating position for a designated temperature. This pressure is based on
calculations using the minimum (or average pitted) thickness for all critical vessel elements,
(exclusive of thickness designated for corrosion) and adjusted for applicable static head pressure
and non-pressure loads (e.g., wind, earthquake, etc.). The MAWP may refer to either the original
design or a rerated MAWP obtained through an FFS assessment.

Rerating:
A change in either the design temperature rating, the MDMT or the MAWP rating of a vessel. The
design temperature and MAWP of a vessel may be increased or decreased because of a rerating.
Derating below original design conditions is a permissible way to provide for additional corrosion
allowance.
Rerating is most commonly necessitated by:
 A change in operating conditions for the process.
 Deterioration (i.e., the occurrence of corrosion or cracking) that affects vessel integrity and
reliability for the original design pressure and temperature, and a repair cannot be economically
justified.
MAWPoriginal (Design Pressure) Calculation Procedure

Original Maximum Allowable Working Pressure of Pressure Vessel Based on Shell

Thickness:

t required = t name plate − C. A.

2SEt required
MAWPoriginal =
D − 0.8t required

trequired is the required thickness at the same location or component as the actual measurement
computed by the design formulas (e.g., pressure and structural) before corrosion allowance and
manufacturer's tolerance are added.
Corrosion Allowance (C.A.) is additional material thickness available to allow for metal loss during the
service life of the vessel component.
D is outside diameter of cylindrical shell course under consideration.
S is maximum allowable stress value at temperature.
E is weld joint efficiency.
MAWPprojected (rerated) Calculation Procedure

Rerated Maximum Allowable Working Pressure of Pressure Vessel Based on Shell

Thickness:

When the MAWP is recalculated, the wall thickness (projected thickness) used in these computations
shall be the actual thickness as determined by inspection minus twice the estimated corrosion loss
before the date of the next inspection. If the pressure vessel is being rerated, the new MAWP shall
be the rerated MAWP:

t projected = t actual − 2 Crate ∗ Iinternal

2SEt projected
MAWPprojected =
D − 0.8t projected

Crate is the governing corrosion rate.

Iinternal is the interval of the next internal or on-stream inspection.
tactual is the actual thickness measured at the time of inspection for a given location or component.
tprojected is the thickness used in computations shall be the actual thickness as determined by
inspection minus twice the estimated corrosion loss before the date of the next inspection.
D is outside diameter of cylindrical shell course under consideration.
S is maximum allowable stress value at temperature.
E is weld joint efficiency.
Corrosion Rate Determination

Corrosion rate for thinning damage mechanisms is determined by the difference between two
thickness readings divided by the time interval between the readings. The determination of corrosion
rate may include thickness data collected at more than two different times. Suitable use of short-
term versus long-term corrosion rates shall be determined by the inspector. Short-term corrosion
rates are typically determined by the two most recent thickness readings whereas long-term rates
use the most recent reading and one taken earlier in the life of the equipment. These different rates
help identify recent corrosion mechanisms from those acting over the long-term.

The long-term (LT) corrosion rate shall be calculated from the following formula:

t initial – t actual
Corrosion Rate Long Term =
time years between t initial and t actual

The short-term (ST) corrosion rate shall be calculated from the following formula:

t previous – t actual
Corrosion Rate Short Term =
time years between t previous and t actual

tinitial is the initial thickness at the same CML as tactual. It is either the first thickness measurement at
this CML or the thickness at the start of a new corrosion rate environment.
tactual is the actual thickness measured at the time of inspection for a given location or component.
tprevious is the thickness at the same location as tactual measured during one or more previous
inspections.
Parts of a Conventional Spring Loaded Safety Valve – Flanged
Parts of a Balanced Bellows Spring Loaded Safety Valve – Flanged
 Practical Case

Calculate Pressure Relief Valve (PRV) New Set

Pressure for ABAN Separator Based on New MAWP
ABAN Separator Name Plate
ABAN Separator Construction Code

The present code PD 5500, formerly BS 5500 evolved partly from the well-known BS 1500 in the
1950’s and BS 1515 first published in 1965; the latter permitted higher level allowable stresses and
more advanced rules. In 1969, following a report from the Committee of Enquiry into the Pressure
Vessel Industry, the British Standards Institution brought all the pressure vessel interests together
under one general committee in order to rationalize the activity.
Ultrasonic Thickness Measurement
Ultrasonic Thickness Measurement

Point Value, mm Point Value, mm Point Value, mm Point Value, mm Point Value, mm Point Value, mm Point Value, mm Point Value, mm Point Value, mm Point Value, mm Point Value, mm Point Value, mm

1 45.08 51 48 101 22.78 151 24.84 201 22.48 251 21.6 301 23.17 351 32.68 401 54.41 451 54.84 501 55.08 551 23.12

2 45.15 52 48.3 102 29.85 152 33.41 202 21.59 252 25.83 302 18.2 352 22.31 402 55.99 452 53.91 502 55.05 552 55.61

3 44.8 53 47.7 103 54.03 153 33.8 203 25.14 253 26.16 303 19.6 353 31.05 403 54.2 453 55.06 503 55.43 553 21.64

4 44.22 54 47.9 104 54.02 154 23.38 204 28.72 254 25.83 304 20.29 354 55.81 404 54.64 454 54.84 504 55.01 554 19.52

5 44.4 55 48.13 105 22.76 155 24.27 205 21.32 255 21.28 305 22.77 355 32.13 405 31.66 455 55.21 505 55.28 555 21.99

6 44.5 56 47.7 106 55.04 156 21.17 206 21.56 256 20.98 306 21.82 356 55.64 406 55.09 456 55.25 506 54.42 556 31.52

7 44.85 57 48.66 107 55.08 157 31.48 207 26.09 257 22.5 307 21.01 357 55.21 407 54.85 457 55.08 507 54.83 557 23.61

8 44.3 58 48.01 108 55.19 158 21.17 208 24.83 258 31.44 308 31.82 358 55.37 408 55.26 458 55.06 508 55.28 558 24.47

9 43.26 59 47.6 109 55.45 159 32.1 209 26.54 259 20.46 309 21.76 359 55.81 409 54.63 459 55.43 509 55.21 559 25.35

10 43.06 60 47.75 110 22.4 160 21.21 210 31.07 260 19.4 310 18.44 360 55.43 410 54.67 460 54.99 510 55.17 560 30.52

11 45.12 61 54.85 111 55.38 161 21.04 211 27.18 261 20.65 311 18.52 361 55.44 411 24.25 461 55.25 511 55.23 561 20.75

12 44.48 62 54.79 112 55.01 162 22.15 212 21.09 262 23.91 312 18.53 362 55.25 412 54.42 462 54.86 512 55.01 562 23.65

13 49.25 63 55 113 55.22 163 23.81 213 22.95 263 23.6 313 19.64 363 55.44 413 54.79 463 55.04 513 55.03 563 26.89

14 49.01 64 54.6 114 20.47 164 22.85 214 18.71 264 21.36 314 22.61 364 55.41 414 54.28 464 55.24 514 55.03 564 20.51

15 47.73 65 55.01 115 20.28 165 24.65 215 22.35 265 22.36 315 22.88 365 55.43 415 55.02 465 55.02 515 55.06 565 27.99

16 47.45 66 55.01 116 21.77 166 16.65 216 22.34 266 23.4 316 33.12 366 55.38 416 55.01 466 55.19 516 54.82 566 28.41

17 47.76 67 54.58 117 26.25 167 16.56 217 30.09 267 23.2 317 23.02 367 26.98 417 55.38 467 54.99 517 55.24 567 23.85

18 48.96 68 54.85 118 24.11 168 22.04 218 28.53 268 22.39 318 22.3 368 55.43 418 55.42 468 54.22 518 54.99 568 28.07

19 47.76 69 54.88 119 22.09 169 22.7 219 19.53 269 19.25 319 21.45 369 54.46 419 54.81 469 55.08 519 54.79 569 28.62

20 47.5 70 54.76 120 20.05 170 22.85 220 21.88 270 35.62 320 22.4 370 54.39 420 55.38 470 53.85 520 55.24 570 27.37

21 47.94 71 55.04 121 55.44 171 22.56 221 26.4 271 18.25 321 21.72 371 54.4 421 55.01 471 55.02 521 54.83 571 37.23

22 47.84 72 55.01 122 55.65 172 22.5 222 24.65 272 21.62 322 23.35 372 54.63 422 55.17 472 54.78 522 54.98 572 28.86

23 47.64 73 55.24 123 54.37 173 18.08 223 20.95 273 22.22 323 22.37 373 54.24 423 54.85 473 53.75 523 54.91 573 26.96

24 47.53 74 55.45 124 23.94 174 21.97 224 25.34 274 32.51 324 23.54 374 54.2 424 54.82 474 54.85 524 54.79 574 27.96

25 51.44 75 55.23 125 22.88 175 27.56 225 22.01 275 19.14 325 30.09 375 55.07 425 53.68 475 54.45 525 54.91 575 23.34

26 52.06 76 55.43 126 22.83 176 26.86 226 22.65 276 18.67 326 31.89 376 54.02 426 54.82 476 55.06 526 54.64 576 23.53

27 51.83 77 55.41 127 55.24 177 27.12 227 22.87 277 18.61 327 30.58 377 53.83 427 55.51 477 55.08 527 54.24 577 28.41

28 51.61 78 54.41 128 55.61 178 18.56 228 19.65 278 23.67 328 33.86 378 55.03 428 55.04 478 54.78 528 55.02 578 25.13

29 52.07 79 54.43 129 55.39 179 22.4 229 22.88 279 55.84 329 55.81 379 55.05 429 55.03 479 54.18 529 55.62 579 25.48

30 52.06 80 54.8 130 55.29 180 55.46 230 21.17 280 55.81 330 56.06 380 54.42 430 55.23 480 55.04 530 54.78 580 25.71

31 52.01 81 55.01 131 55.26 181 55.66 231 29.75 281 20.48 331 55.88 381 54.64 431 55.46 481 54.45 531 54.89 581 25.23

32 52.04 82 54.8 132 55.64 182 14.89 232 29.5 282 21.52 332 29.51 382 54.88 432 54.71 482 54.64 532 54.85 582 24.48

33 52.06 83 54.85 133 55.45 183 21.7 233 32.94 283 23.15 333 25.67 383 54.22 433 54.01 483 55.08 533 54.82 583 24.05

34 51.7 84 55.23 134 55.85 184 31.17 234 19.53 284 20.04 334 29.01 384 54.84 434 55.01 484 55.25 534 54.43 584 22.81

35 52.24 85 55.48 135 21.98 185 21.12 235 31.86 285 19.97 335 31.63 385 54.27 435 55.41 485 54.69 535 54.62 585 32.71

36 51.9 86 55.38 136 22.71 186 20.4 236 25.26 286 23.28 336 31.55 386 54.28 436 55.21 486 54.63 536 55.23 586 23.28

37 51.65 87 55.37 137 22.66 187 24.9 237 23.46 287 22.86 337 27.17 387 54.8 437 54.47 487 54.62 537 55.26 587 24.41

38 51.64 88 20.41 138 19.44 188 24.92 238 29.5 288 56.01 338 24.52 388 54.22 438 53.98 488 54.63 538 55.04 588 24.95

39 52.07 89 55.04 139 20.66 189 31.92 239 28.36 289 55.82 339 24.37 389 54.49 439 54.57 489 55.01 539 55.02 589 31.01

40 52.01 90 52.63 140 19.5 190 18.3 240 18.74 290 55.85 340 25.6 390 54.48 440 54.81 490 55.29 540 55.08 590 54.44

41 51.46 91 54.6 141 18.88 191 17.1 241 55.86 291 33.89 341 24.31 391 54.43 441 54.26 491 54.61 541 55.2

42 51.64 92 52.39 142 24.99 192 17.18 242 19.4 292 21.23 342 19.8 392 54.63 442 54.42 492 54.82 542 55.42

43 52.23 93 54.87 143 19.24 193 24.82 243 25.15 293 24.36 343 55.24 393 55.05 443 54.22 493 55.03 543 27.4 Minimum
44 51.11 94 28.02 144 21.86 194 28.69 244 25.2 294 25.31 344 55.41 394 55.18 444 54.89 494 54.25 544 55.49

45 52.24 95 55.02 145 33.52 195 21.9 245 21.12 295 35.03 345 25.14 395 54.46 445 55.03 495 54.88 545 23.76

46 52.23 96 54.96 146 34.72 196 18.48 246 18.3 296 19.51 346 30.26 396 54.88 446 54.84 496 55.26 546 29.81

47 52.4 97 55.37 147 22.88 197 20.63 247 20.08 297 24.35 347 27.04 397 54.61 447 55.09 497 55.05 547 54.19

48 52.46 98 55.26 148 55.19 198 20.45 248 16 298 31.05 348 29.24 398 54.39 448 55.07 498 55.17 548 55.25 14.89
49 47.65 99 24.96 149 23.02 199 25.41 249 25.18 299 23.08 349 29.1 399 55.02 449 54.89 499 55.71 549 55.07

50 47.78 100 25.18 150 22.76 200 21.74 250 24.46 300 19.55 350 55.8 400 55.07 450 55.08 500 55.45 550 24.06
Construction Code Design Margin Determination
Maximum Allowable Stress Determination

Maximum Allowable Stress, S:

 Method I (ASME BPVC. II. D. C − 2021, Table 1A)

 Method II (ASME BPVC. II. D. C − 2021, Table U and Table Y − 1)

Maximum Allowable Stress Determination

 Method I (ASME BPVC. II. D. C − 2021, Table 1A):

M1 = Design Margin of Construction Code PD 5500 (B. S. 1515) = 2.35

M2 = Design Margin of Construction Code ASME Section VIII Division 1 = 3.5

𝐌𝐌𝟐𝟐 𝟑𝟑. 𝟓𝟓
𝐒𝐒 = 𝐒𝐒 @ 𝟏𝟏𝟏𝟏𝟏𝟏 °𝐅𝐅 ∗ = 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐 ∗ = 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐. 𝟐𝟐𝟐𝟐𝟐𝟐 𝐩𝐩𝐩𝐩𝐩𝐩
𝐌𝐌𝟏𝟏 𝟐𝟐. 𝟑𝟑𝟑𝟑
Maximum Allowable Stress Determination

 Method I (ASME BPVC. II. D. C − 2021, Table 1A):

Maximum Allowable Stress Determination

 Method I (ASME BPVC. II. D. C − 2021, Table 1A):

Maximum Allowable Stress Determination

 Method I (ASME BPVC. II. D. C − 2021, Table 1A):

Maximum Allowable Stress Determination

 Method II (ASME BPVC. II. D. C − 2021, Table U and Table Y − 1):

M1 = Design Margin of Construction Code PD 5500 (B. S. 1515) = 2.35

𝐒𝐒𝐮𝐮 𝟐𝟐 𝟕𝟕𝟕𝟕𝟕𝟕𝟕𝟕𝟕𝟕 𝟐𝟐
𝐒𝐒 = 𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌 𝐚𝐚𝐚𝐚𝐚𝐚 𝐒𝐒𝐲𝐲 = 𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌𝐌 𝐚𝐚𝐚𝐚𝐚𝐚 𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒𝟒 = 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐. 𝟐𝟐𝟐𝟐𝟐𝟐 𝐩𝐩𝐩𝐩𝐩𝐩
𝐌𝐌𝟏𝟏 𝟑𝟑 𝟐𝟐. 𝟑𝟑𝟑𝟑 𝟑𝟑
Maximum Allowable Stress Determination

 Method II (ASME BPVC. II. D. C − 2021, Table U and Table Y − 1):

Maximum Allowable Stress Determination

 Method II (ASME BPVC. II. D. C − 2021, Table U and Table Y − 1):

Maximum Allowable Stress Determination

 Method II (ASME BPVC. II. D. C − 2021, Table U and Table Y − 1):

Maximum Allowable Stress Determination

 Method II (ASME BPVC. II. D. C − 2021, Table U and Table Y − 1):

Maximum Allowable Stress Determination

 Method II (ASME BPVC. II. D. C − 2021, Table U and Table Y − 1):

MAWPoriginal (Design Pressure) Calculation

t required = t name plate − C. A. = 2.0625 − 0.0625 = 2 inch

𝟐𝟐𝟐𝟐𝟐𝟐𝐭𝐭 𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫 𝟐𝟐 ∗ 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐. 𝟐𝟐𝟐𝟐𝟐𝟐 ∗ 𝟏𝟏 ∗ 𝟐𝟐

𝐌𝐌𝐌𝐌𝐌𝐌𝐏𝐏𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨(𝐜𝐜𝐜𝐜𝐜𝐜𝐜𝐜𝐜𝐜𝐜𝐜𝐜𝐜𝐜𝐜𝐜𝐜𝐜𝐜) = = = 𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏 𝐩𝐩𝐩𝐩𝐩𝐩
𝐃𝐃 − 𝟎𝟎. 𝟖𝟖𝐭𝐭 𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫𝐫 𝟗𝟗𝟗𝟗 − 𝟎𝟎. 𝟖𝟖 ∗ 𝟐𝟐

𝐌𝐌𝐌𝐌𝐌𝐌𝐏𝐏𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨𝐨 𝐧𝐧𝐧𝐧𝐧𝐧𝐧𝐧𝐧𝐧𝐧𝐧𝐧𝐧𝐧𝐧𝐧𝐧 = 𝟏𝟏𝟏𝟏𝟏𝟏𝟏𝟏 𝐩𝐩𝐩𝐩𝐩𝐩

MAWPprojected (rerated) Calculation

Assumptions:

Maximum Temperature = 175 °F

mm inch
Crate = 0.1 = 0.004
year year
Iinternal = 10 years

Minimum t actual = 14.89 mm = 0.586 inch

t projected = t actual − 2 Crate ∗ Iinternal = 0.586 − 2 ∗ 0.004 ∗ 10 = 0.506 inch

𝟐𝟐𝟐𝟐𝟐𝟐𝐭𝐭 𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩 𝟐𝟐 ∗ 𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐𝟐. 𝟐𝟐𝟐𝟐𝟐𝟐 ∗ 𝟏𝟏 ∗ 𝟎𝟎. 𝟓𝟓𝟓𝟓𝟓𝟓

𝐌𝐌𝐌𝐌𝐌𝐌𝐏𝐏𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩 = = = 𝟑𝟑𝟑𝟑𝟑𝟑 𝐩𝐩𝐩𝐩𝐩𝐩
𝐃𝐃 − 𝟎𝟎. 𝟖𝟖𝐭𝐭 𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩 𝟗𝟗𝟗𝟗 − 𝟎𝟎. 𝟖𝟖 ∗ 𝟎𝟎. 𝟓𝟓𝟓𝟓𝟓𝟓
Set Pressure and Accumulation Limits for Pressure-relief Devices
Pressure Level Relationships for Pressure-relief Valves
ABAN Separator PRVs EXISTING Set Pressure (Wrong Values)

PRV-01A Set Pressure = 93 bar = 1349 psi

PRV-01B Set Pressure = 86.16 bar = 1250 psi

ABAN Separator PRVs NEW Set Pressure (Correct Values)

Device Installations Maximum PRV Set Pressure

Single PRV MAWPprojected 315 psi

First PRV MAWPprojected 315 psi

2 PRVs (One Working, One Standby)
Second PRV MAWPprojected 315 psi

First PRV MAWPprojected 315 psi

Non-fire Case
Additional PRVs 1.05 * MAWPprojected 331 psi

Multiple (More Than 1 PRV) First PRV MAWPprojected 315 psi

Fire Case Additional PRVs 1.05 * MAWPprojected 331 psi

Supplemental PRV 1.1 * MAWPprojected 347 psi

References

 API 510
 API 570
 API STANDARD 520
 API 579-1/ASME FFS-1
 ASME BPVC.VIII.1
 ASME BPVC.II.D.C
 NACE SP21464
Thanks for your attention