Chapter 8

API 576 Inspection of Pressure-

Relieving Devices
8.1 Introduction to API 576
This chapter is about learning to become familiar with the
layout and contents of API 576: Inspection of Pressure-
Relieving Devices. Similar to API 572, API 576 is a well-
established document (it is still on its 2000 edition) with its
roots in earlier documents published by the American
refining industry. It is more a technical guide document
rather than a code, as such, but it does perform a useful
function in supporting the content of API 510.
Note the following four points about API 576:
Point 1. It is a well-detailed and comprehensive technical
document. Unlike some API codes, which have a very
selective approach to their subject, API 576 is one of the
best in the quality of the technical information it provides.
It is an excellent guide to the practical aspects of pressure-
relieving devices.
Point 2. API 576 introduces specific API terminology on the
types of pressure-relieving devices. These relate to the
definitions used for the following terms: safety valve, relief
valve and safety relief valve. These API definitions are
technically consistent in themselves but can be different to
those used in other codes (e.g. BS/EN/DIN).
Point 3. Similar to API 572, it refers to a few related codes
that are not in the API 510 exam syllabus (mainly API 527
covering seat leakage testing; see API 576 section 2 on page
1 of the code). As with previous related codes, you need to
know that these additional codes exist but you do not need
to study them for the API 510 examination.
And finally, the most important point. Like API 572, API 576
is all text and technical descriptions, accompanied by

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explanatory photographs of a fairly general nature. It

contains no calculations. This means that many examina-
tion questions about API 576 in the API 510 certification
exam may be closed book. The downside to this is that API
576 contains many separate technical facts, giving a large
scope for the choice of exam questions.
Again, similar to API 572, appendix A of API 576 contains
specimen work order/inspection report sheet/test record
formats. While these undoubtedly contain sound guidance
on the format of reports they are not a particularly suitable
subject matter for multiple choice exam questions.
All this means that you need to concentrate firmly on the
technical (rather than administrative) content of API 576. We
will look at some of the more important areas as we work
through the code.
8.2 API 576 sections 3 and 4: types (definitions)
of pressure-relieving devices
Remember that API 576 uses specific definitions for the
various types of pressure-relieving devices and that these may
not correspond with those in other codes (or your own
knowledge and experience). API 576 sees the situation as
shown in Fig. 8.1.
Don’t worry if you find this a bit confusing. Read the
following points, which attempt to clarify the situation:
NOTE THESE POINTS ABOUT PRV TERMINOLOGY
. Note the first annotation on Fig. 8.1; it shows the term
PRV as a generic definition covering most practical types
of pressure-relieving device, excluding bursting discs. We
will use this term PRV in this context throughout the rest
of this chapter.
. Now read API 576 section 4.2: safety valve. Note how the
‘pure’ type of safety valve described refers, in the main, to
valves used for steam service (it doesn’t actually say this,
but that is what it means).

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Figure 8.1 Pressure-relieving device definitions

. Now read API 576 section 4.3: relief valve. Note how the
‘pure’ type of relief valve described refers, in the main, to
valves used for liquid service (again, it doesn’t actually say
this, but this is what it means).
. Now read API 576 section 4.4: safety relief valve. Can you
see why this has been introduced? Think of it as a generic
definition, encompassing both the ‘pure’ types of safety
valve and relief valve. The reason for API 576 introducing
this term safety relief valve is to take into account the fact
that many proprietary designs of PRV can be used on gas/
vapour or liquid service and so can be considered (with a
bit of imagination) as both a safety valve and a relief valve,

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depending on application. Now you see why it is

important not to confuse the terminology.
Keep these definitions in mind as you work through the rest
of this API 576 chapter and they should start to become
clearer.
8.3 Types of pressure-relieving device
Section 4 of API 576 describes the different types of pressure-
relieving device. Note how this is supplemented by the
various terminology definitions in section 3.
Protective device types: API 576
There are a large number of different types of protective
device.
Spring-loaded valves
. Normal relief valves
. Safety valves
. Balanced safety relief valves (bellows)
. Pilot operated relief valves
Rupture discs (not re-useable)
. Conventional
. Scored tension
. Reverse acting
. Graphite
Vacuum valves
. Dead weight (more often seen on tanks)
. Pilot operated valves (diaphragm)
. Spring and dead weight
As we are mostly concerned with internal pressure, we shall
concern ourselves mostly with spring-loaded safety valves
and rupture discs. Before we look at protective devices, we
will look at the various internal pressures that can exist inside
a vessel. These are summarized in Fig. 8.2.

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Figure 8.2 Pressure term definitions

Normal maximum operating pressure. This is a bit confusing.

It is, essentially, the design pressure based on the ASME VIII
code.
Maximum allowable working pressure (MAWP). This is equal
to or greater than the nominal design pressure (it is based,

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again, on ASME VIII and a common calculation parameter

included in the API 510 examination syllabus).
Accumulation. This is the pressure above MAWP or design
pressure (values defined in ASME VIII).
Overpressure. This may be expressed as either:
. The pressure above the set pressure of a PRV at which full
discharge flow is achieved (mass flow kg/s or lb/s).
. A percentage of set pressure.
. The same as accumulation (when based on MAWP).
Note that the actual set pressure of the valve or disc is vital to
the performance of the vessel. If it is set too low (at or just
above the operating pressure) the valve will lift frequently. If
it is set too high (above MAWP) the vessel may become over-
pressurized. There are a lot of terms for the different
operational characteristics of a PRV, which are given in
API 576 section 3.4. Two terms that deserve further
explanation are back pressure and cold differential test
pressure (CDTP):
. Back pressure is the pressure that is present downstream of
the discharge pipe of the PRV. It can either be present all
the time or can build up as the result of flow as the PRV
opens. For example, if a valve has a set pressure of 100 psi
and is vented into a system that is operating at 25 psi, the
valve will not operate until 125 psi.
. Cold differential test pressure (CDTP) is used for PRVs on
‘hot’ duty and is an adjusted pressure at which the valve
opens on a test stand at room temperature. The CDTP is
corrected for both temperature and back pressure.
API 576 section 4: pressure-relieving valve types
Section 4.3: relief valves
Relief valves (see Fig. 8.3) are direct spring-loaded valves
that begin to open when the set pressure is reached. They
open progressively and do not exhibit a pop action. Full lift is

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obtained with an overpressure of 10 % or 25 % depending on

the type of valve. The valve will close after blowdown is
complete but at a pressure lower than the set pressure. They
are sometimes called thermal relief valves as they may relieve
small pressure increases caused by thermal expansion of
process liquid.
Normally, relief valves have a closed bonnet to prevent the
release of product that is toxic, corrosive, flammable or
expensive. For tightness of the seat, resilient O-rings can be
fitted to replace the conventional metal-to-metal seat.
Applications: mostly used on incompressible liquids.
Limitations: relief valves should not be used on the following
services:

Figure 8.3 A thermal relief valve

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. Vapour services including steam, air and gas.

. Systems that discharge into a closed header unless the
back pressure build-up has been allowed for.
. As a bypass or pressure control valve.
Section 4.7: pilot-operated pressure relief valves
In this type, an auxiliary pressure relief valve called the pilot
actuates the main valve. The pilot may be mounted on the
same connection as the main valve or separately. The pilot
valve opens normally at the set pressure and in turn operates
the main valve. Figure 8.4 shows the principle.
Applications:
. Used when a high set pressure and large relief area are
required. This type of PRV can be set to a maximum
flange rating.
. The differential pressure between the operating and set
pressures is small.
. Large low-pressure storage tanks.
. Where very short blowdown is necessary
. To replace bellows type valves to overcome the problems
of high back pressure.
. Where pressure can be sensed in one position and the
process is relieved at another.
. Where frictional pressure losses in the inlet or outlet
pipework are high.
Limitations: Pilot PRVs have limitations on systems where:
. Service duty is dirty (unless filters are fitted in the system).
. High viscosity fluids (small passages in the pilot valve slow
down the flow rate).
. The process fluids may form polymers, which cause
blockages.
. High temperatures where seals, O-rings or diaphragms
may not be suitable.
. The process may attack the seals, O-rings or diaphragms.
. Corrosion build-up affects the operation of the pilot valve.

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Figure 8.4 Pilot operated PRV

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Rupture disc devices

Rupture (or bursting) discs comprise a thin disc of material
that has a known bursting pressure, held within a special
holder. The actual disc can be made in a number of different
configurations (see Fig. 8.5):
. Domed
. Reverse acting
. Flat

Figure 8.5 Rupture disc types

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Conventional (often called direct acting) discs. The pressure

acts on the concave side of the disc.
Scored tension loaded rupture disc. The pressure acts on the
concave side but the disc is cut or scored by mechanical
means during fabrication and is made of thicker material.
The objective is to achieve a more accurate, reliable burst
pressure.
Composite rupture disc. These are flat or domed, made in
metallic or non-metallic material, with multipiece construc-
tion. The top section is slit and the burst pressure is
controlled by the combination of the top and the underlying
sections.
Reverse-acting rupture disc. These are domed but the pressure
is on the convex side. The disc can be ruptured by a number
of methods:
. Shear
. Knife blades
. Knife rings
. Score lines
Graphite rupture disc. A flat disc of graphite impregnated
with a binder material. It bursts by bending or shear.
8.4 API 576 section 5: causes of improper
performance
This section of API 576 contains reasons for pressure-
relieving devices (mainly PRVs) failing to work properly. The
section is not particularly well structured but does contain
good technical details. Much of the section is taken up with
the corrosion/damage mechanisms that affect PRVs. Here is
a summary of the content.
Section 5.1: corrosion
Because PRVs are on the same duty as the pressure vessels
they protect, they are subject to the many causes of corrosion

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that also occur in the vessels. Some typical (refinery industry)

examples given in section 5 are:
. Acid attack on carbon steel due to a leaking valve seat
. Acid attack on a stainless steel inlet nozzle
. Chloride corrosion on a stainless steel nozzle
. Sulphide corrosion on a carbon steel disc
. Chloride corrosion on a stainless steel disc
. Pitting corrosion on stainless steel bellows
. Sour gas (H2S) attack on a monel rupture disc
By careful selection of the correct materials within a PRV,
most corrosion problems can be overcome. The correct
maintenance of the valve also stops any potential leakage
allowing corrosive processes into those parts that could
rapidly deteriorate.
As previously mentioned, bellows are used to give
protection to the valve spring and discharge side of the
valve. Also, placing a rupture disc directly under a PRV gives
added protection to the valve components.
Section 5.2: damaged seating surfaces
Because there is metal-to-metal contact between the valve
disc and nozzle, this area must be extremely flat, as any
imperfections will lead to a process leak. The seating surfaces
must be lapped to produce a finish of two to three light bands
(0.000 034 8 in). Figure 8.6 shows the principle.
Section 5.3: failed springs
Safety valve springs fail in two distinct ways:
Gradual weakening, which can cause the valve to open ‘light’.
This may be caused by:
. Improper material choice for the spring
. Operating at temperatures too high for the material
. Corrosion, leading to cracks and failure

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Figure 8.6 PRV seat lapping

Catastrophic failure of the spring, so that the valve opens and

jams, preventing it from closing. The normal cause of this
type of failure is stress corrosion cracking (SCC).
Section 5.4: improper setting and adjustment
Several factors can affect the setting and adjustment of a
PRV:
. Not following the manufacturer’s instructions.
. Testing the valve with the wrong medium. Water, air or
nitrogen is frequently used:
. Gases generally produce a definite ‘pop’ and are
generally used for vapour service.
. Water is generally used for liquid service.

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. Steam service should be tested with steam, to replicate

its temperature and flow characteristics.
. Incorrect pressure gauge calibration. Gauges should be
tested with a calibrated dead weight tester. The test
pressure should fall within the middle third of the test
gauge.
. Blowdown rings not correctly set.
Section 5.5: plugging and sticking
When working on a fouling fluid, the inlet pipe to a PRV can
become completely blocked. The fouling can be caused by a
large number of refining industry processes that give solid
particles such as coke and iron sulphide.
Section 5.6: misapplication of materials
Occasionally, the material of construction of a PRV is not
suitable for the process duty. Hydrogen sulphide and
chloride attack are typical examples.
Section 5.7: improper location, history or identification
A valve may not provide the required protection if is not
located at the correct location. A record should be
maintained of the history of the valve including the
specification, any repairs, installation details, etc.
Section 5.8: rough handling
PRVs are manufactured and maintained to a commercial seat
tightness standard given in API 527. Rough handling may
change the set pressure or otherwise cause damage to the
valve.
Section 5.9: improper differential between operating and set
pressures
In use, a PRV should be kept tightly closed by having a
reasonable margin of difference between the operating and
set pressures. The design of the system governs the operating
and set pressures, and references to the guidelines are found
in ASME VIII.

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8.5 API 576 section 6: inspection and testing

This section contains the main inspection and test activities
traditionally used on PRVs. It describes (in roughly
chronological order) the stages shown in Fig. 8.7.

Figure 8.7 PRV inspection and test activities

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8.6 API 576 familiarization questions

Q1. API 576 section 3.3.1: system pressures
The amount by which the pressure in a vessel rises above MAWP
when the pressure-relieving device is fully open and discharging
is known as?
(a) Back pressure build-up &
(b) Accumulation &
(c) CDTP &
(d) Blowdown &

Q2. API 576 section 3.3.3: system pressures

Generally speaking, which of the following is true for a pressure
vessel (according to API 576)?
(a) MAWP is always the same as design pressure &
(b) MAWP is normally greater than design pressure &
(c) MAWP is normally lower than design pressure &
(d) MAWP = design pressure – back pressure &

Q3. API 576 section 3.4: device pressures

What is back pressure?
(a) Pressure in the PRV inlet line &
(b) Pressure in the PRV discharge line before the PRV lifts &
(c) Pressure in the PRV discharge line after the PRV lifts &
(d) The sum of (b) and (c) above &

Q4. API 576 section 3.4.7: CDTP

Cold differential test pressure (CDTP) is:
(a) The pressure at which a PRV is set to lift on the test
stand &
(b) The pressure at which a PRV is set to lift under service
(hot) conditions &
(c) ‘Set pressure’ + 10 % &
(d) ‘Set pressure’ + back pressure &

Q5. API 576 section 4.1: pressure relief valves (PRV)

In API 576, the term ‘PRV’ refers to:
(a) Only valves that exhibit a defined ‘pop’ action &
(b) Only valves that do not exhibit a defined ‘pop’ action &
(c) Only those valves defined as ‘safety’ relief valves
(API 576 section 4.4) &
(d) All of the above. PRV is a generic term &

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Q6 API 576 section 4.2.2: safety valve limitations

Can safety valves be used in corrosive service without being
isolated from the process fluid by a rupture disc on the inlet side?
(a) No, it is not recommended &
(b) Yes, as long as the seat is corrosion-resistant &
(c) Yes, as long as it has an enclosed bonnet &
(d) Yes, as long as the fluid is compressible &

Q7. API 576 section 4.3: relief valve

What is the fundamental difference between the opening
characteristic of a relief valve compared to that of a safety valve?
(a) A relief valve has a lower measured lift &
(b) A relief valve opens without a ‘pop’, in proportion to
the pressure increase over the opening pressure &
(c) A relief valve contains a huddling chamber, giving a
proportional opening &
(d) A relief valve should not be used on liquids &

Q8. API 576 section 4.9.3: rupture disc limitations

Which of the following damage mechanisms (DMs) would be
unlikely to affect conventional rupture discs, causing premature
failure?
(a) Fatigue &
(b) Stress corrosion cracking &
(c) Creep stress failure &
(d) Brittle fracture &

Q9. API 576 section 5.3: failed springs

Failed PRV springs are almost always caused by:
(a) Plastic deformation (‘set’) of the spring due to
continual use &
(b) Fatigue &
(c) Brittle fracture &
(d) Surface corrosion and/or stress corrosion cracking &
Q10. API 576 section 5.5: plugging and sticking
Which of the following is unlikely to be a cause of sticking of a
valve disc in its guide?
(a) Machining of components outside their tolerance limits &
(b) Use on process fluids such as coke or catalysts &
(c) Use of a balanced (bellows-type) PRV &

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(d) Galling of mating components &

Q11. API 576 section 5.8: PRV handling
Rough handling of a PRV can result in problems with seat
leakage. The standard used to specify PRV leakage is?
(a) API 576 &
(b) API 596 &
(c) API 527 &
(d) API 572 &
Q12. API 576 section 5.8.1: handling during shipment
In order to minimize the chances of damage to PRV seating
surfaces, PRVs should be shipped:
(a) In an upright position &
(b) Lying on their side (firmly secured to a pallet) &
(c) With the spring fully compressed &
(d) With the spring fully extended &

Q13. API 576 section 6.2.1: safety aspects of PRV

inspection
Before removing PRVs from the plant, it is an important safety
requirement to check that:
(a) The spring is released &
(b) The connecting pipework and any block valves are
adequately supported &
(c) They are ‘pre-pop’ tested first &
(d) The discharge connection to atmosphere is blanked off &

Q14. API 576 section 6.2.8: as-received pop pressure

During its first as-received pop test, a PRV opens at 120 %
CDTP. It is tested a second time and opens at 105 % CDTP (a
pressure considered acceptable under the applicable code).
Which pop pressure result should be used as the basis of
determining the inspection interval for this PRV?
(a) 105 % CDTP &
(b) 105 % CDTP ± 10% &
(c) 120 % CDTP &
(d) CDTP &

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Q15. API 576 section 6.2.8: ‘as-received’ pop

pressure
When is it acceptable for a user to waive the ‘as-received’ pop
test on a very dirty PRV and still be in compliance with API 576?
(a) Never &
(b) If the PRV is the balanced (bellows) type &
(c) If the PRV has not been in HF service &
(d) If the inspection interval is immediately reduced, and
then assessed again at the next inspection &

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