Partner Reported Opportunities (PROs) PRO Fact Sheet No. 605 for Reducing Methane Emissions 

Replace Burst Plates with Secondary 

Relief Valves 

Technology/Practice Overview 

Description 

Rupture Discs, or “Burst Plates,” are a 

low capital cost alternative to pressure 

relief valves, for the protection of process 

equipment when gas pressures rise to 

levels exceeding the maximum allowable 

operating pressure. These burst plates 

are for one-time use only. If the 

calibrated metal membrane (burst plate)

is broken by excessive gas pressure, 

significant amounts of methane, along 

with volatile organic compounds (VOCs), 

and hazardous air pollutants (HAPs),

vent to the atmosphere until the device

is manually blocked-in and the broken

plate replaced with a new plate. 

One Partner has reported installing 

secondary pressure relief valves (PRVs)

on burst plates to reduced methane 

emissions. The pressure relief valve will

open when the burst plate breaks, and 

then automatically close when the gas 

pressure returns to safe levels. 

Installing PRVs on top of burst plates 

has the dual benefits of reducing fugitive 

leaks while the burst plate is intact, and

minimizing gas release during pressure 

surges. 

Operating Requirements 

The PRVs have to pass the ASME Code

26 and Department of Transportation’s

pressure relief valve requirements. 

Applicability 

PRVs added in conjunction with burst

plates are most advantageous at 

unmanned sites that may be prone to 

pressure surges. 

Methane Emissions 

The methane emissions reductions can 

be estimated using vendor’s data, which

is readily available for any size burst 

Estimated 

Gas Price 

Annual 

Methane 

Savings 

Value of 

Annual

 Gas Savings* 

Estimated 

Implementation 

Cost 

Incremental 

Operating Cost 

Payback 

(months) 

$7.00/Mcf 500 Mcf $3,700 $2,000 $100 7 Months 

$5.00/Mcf 500 Mcf $2,700 $2,000 $100 10 Months 

$3.00/Mcf 500 Mcf $1,600 $2,000 $100 16 Months 

Economic and Environmental Benefits 

Economic Evaluation 

Additional Benefits 

 Avoidance of catastrophic events in gas service lines 

Estimated annual methane emission reductions 500 Mcf per rupture 

Methane Savings 

* Whole gas savings are calculated using a conversion factor of 94% methane in pipeline quality natural gas. 

Compressors/Engines 

Dehydrators 

Directed Inspection & 

Maintenance 

Pipelines 

Pneumatics/Controls 

Tanks 

Valves 

Wells 

Other 

Applicable Sector(s) 

Production 

Processing 

Transmission 

Distribution 

Other Related PROs: 

Test and Repair Pressure Safety 

Valves, PRO No. 602 

Install Flares, PRO No. 904 
 

 

PRO Fact Sheet No. 605 Continued 

Replace Burst Plates with Secondary Relief Valves (Cont’d) 

plate and pressure rating (e.g., 8,000 scf per minute for a

2-inch burst plate operating at 150 psig). 

Economic Analysis 

Basis for Costs and Emissions Savings 

Methane emissions reductions of 500 Mcf per year apply 

to a single incident of rupturing a 2-inch burst plate on a 

150 psig system and venting gas continuously for 1 hour 

until manually blocked in and replaced. 

The average methane content of natural gas varies by natural gas 

industry sector. The Natural Gas STAR Program assumes the 

following methane content of natural gas when estimating 

methane savings for Partner Reported Opportunities. 

Production 79 % 

Processing 87 % 

Transmission and Distribution 94 % 

Methane Content of Natural Gas 

The implementation costs are assumed to be $2,000 for

purchasing and installing a pressure relief valve. 

Discussion 

The primary benefit of this PRO is to save natural gas.

An additional benefit is the avoidance of catastrophic 

events in gas service lines. The capital costs are based on 

installing a pressure relief valve on top of a rupture disk. 

The maintenance costs are for inspecting the valve once a 

year for leakage. The payback is based on the vented gas 

savings. 

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