PRESSURE RELIEF VALVES

Sizing of Pressure Relief Valves

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Outline
 Sizing Codes
 Significance of sizing
 Workflow of sizing
 Process data entry
 Valve type selection logic
 Sizing for gases/ vapors (overpressure) - API
 Sizing for gases/ vapors (overpressure) - ASME section VIII
 Sizing for gases/ vapors Fire (Gas Filled vessel)
 Sizing for liquids (API - valves not requiring capacity certification)
 Sizing for liquids (ASME - valves with capacity certification)
 Sizing for liquids Fire (Liquid filled vessel)
 Sizing for steam - ASME section I
 Sizing for steam - ASME section VIII

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Outline

 Sizing for steam – API

 Sizing for steam - IBR
 Sizing for mixed phase
 Selection of multiple valves
 Valve size and rating selection
 Total relieving capacity of selected PRV
 Cold bench set pressure/ Cold differential test pressure

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Sizing Codes

• API standard 520, Part I: Sizing and selection

• API standard 521: Pressure-relieving and depressuring systems

• API standard 526: Flanged steel pressure relief valves

• ASME Section VIII: Rules of construction of pressure vessels

• ASME Section I: Rules of construction of power boilers

• ASME PTC 25-2018: Pressure relief devices performance test codes

• IBR: Indian Boiler Regulation 1989

API 520 is applicable to sizing and selection of pressure relief devices used in
refineries and related industries for equipment that has a MAWP of ≥ 15 psig.

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Significance of sizing

• PRVs are sized to ensure their adequacy for the process conditions.

• PRV size is an important input of datasheet preparation for procurement of

PRVs.

• Based on the PRV sizes, pipe sizes, equipment nozzle sizes are finalized.

• Reduced requirement of vendor for sizing inputs. Only in rare cases, vendors’
sizes differ from the in-house sizing.

• Reduced project execution time due to independency from vendors and the
ability to carry out concurrent engineering.

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Workflow of sizing

P&IDs and process datasheets are available

Review of process data

• Availability of all process data and its correctness.
• Overpressure values must be as per applicable codes.
Piping Material Specifications are available

Process data entry

Selection of type of pressure relief valve

Sizing and finding out the governing case

Valve size and rating selection

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Process data entry
• Fluid phase: Liquid, gas/ vapour, steam, mixed phase

• Basis of selection and sizing code:

 Gases: API or ASME for over-pressure. API for fire case gas filled vessel.

 Liquids: Overpressure – API option is of capacity un-certified valves. ASME

option for capacity certified valves.

 Fire liquid filled vessel: Liquid overpressure API and ASME section-VIII.

 Steam: ASME section-I or IBR for boiler etc. API or ASME section-VIII for
others.

 Mixed phase: Only overpressure as per API-520s Leung-Omega method.

• Required relieving capacity. Not required for ‘fire – gas filled vessel’.

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Process data entry (continued)
• Process data specific to fluid phase is entered.

• Operational conditions:

 set pressure, relieving temperature (not required for fire case – gas filled
vessel), percent overpressure.

 Operating pressure and back pressure required for valve type selection.

• For gas filled vessels under fire, vessel wall temperature and surface area are
required.

• Inlet and outlet pipe class are required for valve material selection.

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Valve type selection logic
A. Conventional
Operating pressure (max.) ≤ 90% of set pressure and either:
• Steam service, or
• Constant back pressure ≤ 90% of set pressure
• Variable back pressure is small

B. Bellows
Operating pressure (max.) ≤ 90% of set pressure and
variable back pressure ≤ 50% of set pressure

C. Pilot Operated
Operating pressure (max.) > 90% of set pressure and/ or
variable back pressure > 50% of set pressure

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Valve type selection logic followed in EIL
A. Conventional
Operating pressure (max.) ≤ 90% of set pressure and either:
• Steam service, or
• Constant back pressure ≤ 90% of set pressure, or
• Variable back pressure ≤ 10% of set pressure, subject to:
Operating pressure (max.) < 90% of (set pressure- back pressure)

B. Bellows
Operating pressure (max.) ≤ 90% of set pressure and either
variable back pressure ≤ 10% of set pressure, but:
Operating pressure ≥ 90% of (set pressure- back pressure), or
10% of set pr. < variable back pressure ≤ 50% of set pressure

C. Pilot Operated
Operating pressure (max.) > 90% of set pressure and/ or
variable back pressure > 50% of set pressure

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Common parameters used in sizing

A calculated area, in sq. in.

W required relieving mass flow capacity, in lb/hr
Q required relieving volume flow capacity, in US gal/min
Kd discharge coefficient
PS set pressure, in psig
P1 relieving pressure, in psig (psia in gas/ vap. and steam equation)
P2 total back pressure, in psig (psia in gas/ vap. equation)
T relieving temperature, in °R (i.e. °F + 460)
Kc combination correction factor. If there is an upstream rupture disc, then Kc
is 0.9 (where combination does not have certified value), else 1.
Z compressibility factor
M molecular weight
k specific heat ratio (Cp/Cv)
Gl specific gravity of the liquid at the flowing temperature
μ absolute viscosity in centipoises (cP)

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Sizing for gases/ vapors (overpressure) - API
Determine flow is critical or subcritical.
Critical flow pressure ratio:

Pcf critical flow nozzle pressure, in psia

P1 relieving pressure, in psia

k specific heat ratio (Cp/Cv)

Critical flow, if P2 ≤ Pcf

Subcritical flow, if P2 > Pcf
For k = 1.4, Pcf / P1 is approx. 0.53 i.e. critical flow nozzle pressure is
approximately 53% of relieving pressure.

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Sizing for gases/ vapors (overpressure) – API (contd.)
Sizing for critical flow for gases/ vapours:
Kd is 0.975
Kb is back pressure correction factor
Kc is combination correction factor
Where
C is a function of ratio of ideal gas
Specific heats (k = Cp/Cv) at inlet
relieving temperature. Use C = 315, if k
cannot be established.

For conventional valves and pilot operated valves, Kb is equal to 1.0.

For balanced bellows valves, Kb is taken from API-520

For balanced valves, same equation to be used for subcritical flow, but Kb to be
taken from manufacturer.

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Sizing for gases/ vapors (overpressure) – API (contd.)
Sizing for subcritical flow for gases/ vapours, conventional and PORV:

Where

Kd is 0.975
Kc is combination correction factor

F2 coefficient of sub-critical flow.

P1 relieving pressure, in psia
P2 total back pressure, in psia
r ratio of back pressure to relieving pressure, P2/P1

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Sizing for gases/ vapors (overpressure) – API (contd.)
Alternative sizing for conventional and PORV in subcritical flow:
Kd is 0.975
Kb is back pressure correction factor
Kc is combination correction factor
Where
C is a function of ratio of ideal gas
Specific heats (k = Cp/Cv) at inlet
relieving temperature. Use C = 315, if k
cannot be established.

Kb is taken from API-520

This method is only for pilot operated valves and conventional, whose spring
settings are adjusted for superimposed back pressure.
Caution: This method shall not be used for bellows valves

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Sizing for gases/ vapors (overpressure) – ASME section VIII
A. ASME certified capacity
In case the PRV vendor follows UG-131(d) and conducts capacity certification tests, certified
capacity tables are used. Individual PRV’s stamped capacity cannot exceed 90% of the average
capacity determined after testing.
Solve for k x A using certified capacity
B. ASME certified discharge co-efficient
Instead of individual capacity certification mentioned above, UG-131(e) may be followed for
determination of discharge coefficient Kd for a particular model. This Kd is calculated by
multiplying 0.9 with the average Kd determined from testing and cannot be greater than 0.878,
i.e. 0.9 x 0.975.

As the official relieving capacity or discharge co-efficient, determined through ASME testing
methods is slightly de-rated, this may prevent vendors from meeting the purchaser’s PRV sizes
that are calculated considering discharge coefficient as 0.975 as per API-520.

To compensate, most vendors offer PRVs whose actual orifice areas are slightly greater than
API-526 standard orifice areas.
www.nationalboard.org

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Sizing for gases/ vapors – Fire (gas filled vessel)
Wetted surface upto 7.6 m above the source of flame
As per 5.15.1.1 of API 521, only that portion of the vessel that is wetted by its internal liquid and
is equal to or less than 7.6 m (25 ft) above the source of flame is considered to determine
vapour generation.
This limit of 7.6 m above fire pool is not applicable to spheres, where area of the entire bottom
hemisphere is to be considered.

Relieving temperature
Relieving temperatures are often above the design temperature of the equipment being
protected. If the elevated temperature is likely to cause vessel rupture, additional protective
measures should be considered. Relieving temperature is calculated as:

T1 relieving temperature, expressed in °R

pn operating pressure, in psia
Tn operating temperature, in °R

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Sizing for gases/ vapors – Fire (gas filled vessel) (contd.)
Required orifice area:

Where A’ is the exposed surface area of the vessel, in sq. ft. F’ can be determined as:

Tw is Vessel Wall temperature, in ◦R

Calculation of C is as given in gas sizing.

Caution: If operating pressure to set pressure difference is too high, reduction in

set pressure may be required.

The selected PRV’s relieving capacity is calculated as:

qm,relief is in lb/hr

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Sizing for liquids (API - valves not requiring capacity certification)

These valves, when used in liquid service, required high overpressure (25 %) to achieve full lift
and stable operation, since liquids do not provide the expansive forces that vapors do.

This method assumes an effective coefficient of discharge, Kd =0.62, and 25 % overpressure.

An additional capacity correction factor, Kp, is needed for relieving pressures other than 25 %
overpressure (e.g. Kp is 0.6 for 10% overpressure).

Kd is 0.62
KW is back pressure correction factor
Kc is combination correction factor
KV is viscosity correction factor
KP is overpressure correction factor

If backpressure is atmospheric, Kw is 1. Bellows valves in backpressure service will

require the correction factor determined from API-520.
Conventional and pilot-operated valves require no special correction (Kw = 1)
For overpressures other than 25 %, Kp is determined from API-520.

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Sizing for liquids (API - valves not requiring capacity certification)
Determining Viscosity correction factor KV:

Step-1: The liquid is assumed as non-viscous and hence value of KV is considered as one (1)
for calculating the preliminary ‘calculated area’.

Step-2: The preliminary ‘calculated area’ is used to select the preliminary ‘selected area’ as
per API-526.

Step-3: This ‘selected area’ is used in the following equation for calculating Reynold’s number.

Step-4: The Reynold’s number is then used to calculate KV from the following from API-520.

Step-5: This value of KV is substituted back into the area equation to recalculate the final
‘calculated area’.

If it is more than the ‘selected area’ in step-2, step- 2 to 5 to be repeated.

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Sizing for liquids (ASME - valves with capacity certification)

Liquid service valves, capacity certified as per ASME code, are required to reach full rated
capacity at 10% or less overpressure

Kd is 0.65
KW is back pressure correction factor
Kc is combination correction factor
KV is viscosity correction factor

Kw is as defined in liquid API sizing.

KV is as defined in liquid API sizing.

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Sizing for liquids Fire (liquid filled vessel)

The sizing equations are same as those for liquid overpressure (API and ASME),
but with overpressure 21%.

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Sizing for steam – ASME section I
Area equation is:

A = W / (51.5 * P1 * KD * KN * KSH)

A calculated area, in sq. in

P1 relieving pressure, in psia
KD discharge coefficient
KSH superheat correction factor
KN correction factor for the Napier equation, is calculated as below:
If P1 ≤ 1500, then KN = 1
If 3200 > P1 > 1500, then KN = [(0.1906 * P1) – 1000] / [(0.2292 * P1) – 1061]

KSH is calculated from table given in API-520.

Kb is not considered since in steam service only conventional valves are

considered.

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Sizing for steam – ASME section VIII

The sizing equation is same as ASME section-I, except that overpressure is

considered 10% instead of 3% for calculation of P1.

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Sizing for steam – API

The sizing equation is same as ASME section-VIII, except that KD is considered

0.975 instead of ASME certified discharge coefficient.

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Sizing for steam – IBR
For boiler drums, desuperheaters, steam lines before pressure reducing station,
Discharge capacity is calculated as per regulation 293 (a), (b), (c):

E=CAP

A Calculated area, in sq. mm

E Rated discharge capacity of saturated steam in kg/hr
P The highest set pressure of any safety valve mounted on boiler in bar
absolute
The value of C for a full lift valve as per Regulation no. 293 can be taken as 0.24.
However, for some manufacturers who have got coefficient ‘C’ approved by IBR
as per Appendix L, value can be taken as 0.46

Bore of the seat of safety valve installed on boiler shall not be less than 19 mm
(i.e. Minimum ‘G’ orifice) as per Regulation no. 281.

Overpressure: 5% of set pr. (as per Regulation no. 294)

Blowdown: 2.5%~5% of set pr. (as per Regulation no. 295)
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Sizing for mixed phase
Following mixed-phase relieving scenarios are envisaged in API-520 annexure-
C:
Table: Two phase Liquid/ Vapour Relief Scenarios for PRVs

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Selection of multiple valves

A. Due to calculated area > T orifice

Number of valves to be increased till the sum of orifice area for all the valves is more than the
calculated area.

B. Due to set pressure and relieving temperature combination

beyond limits
For higher orifice designations, the pressure ratings allowed as per API-526 are relatively lower
than those allowed for lower orifice designations (e.g. maximum allowed inlet rating for ‘T’ orifice
is 300#, for ‘M’ orifice is 900# but for ‘G’ orifice is 2500#).

In case the set pressure and relieving pressure are beyond the selected orifice designation’s P-
T limits, the calculated area is divided by a divisor whose initial value is 2 to get the reduced
calculated area which is further used to select the new, reduced, orifice designation. This
process of dividing the initial calculated areas by progressively increased divisors, continues
until the set pressure and relieving pressure are within the latest orifice designation’s P-T limits.

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Valve size and rating selection

A. Selection from API 526 P-T tables

B. Different tables for Spring loaded valves and Pilot Operated

C. If PRV rating from table < pipe rating, increase PRV inlet/ outlet rating

D. If PRV rating from table > pipe rating, retain it and review pipe rating

E. For fire case, PRV rating need not consider relieving temperature

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Total relieving capacity of selected PRV

• This is the maximum flow rate of process fluid that the selected valve can
relieve with full opening.

• The process conditions for calculating the total relieving capacity are
identical to those considered while sizing the PRV (i.e. relieving temperature,
relieving pressure, fluid properties, etc).

• The same equation used earlier for calculating the required area is now used
for calculating the flow with area being considered as the selected PRV’s
ASME certified or rated discharge coefficient and orifice area.

• For fire-gas filled vessel case, the relieving capacity is calculated with a
separate equation as discussed.

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Cold bench set pressure/ Cold differential test pressure (CDTP)

CDTP includes corrections for service conditions of backpressure, relieving

temperature or both.

For conventional valves, CDTP = (Set pressure – backpressure) * KBENCH

For valves other than conventional, CDTP = Set pressure * KBENCH

KBENCH = 1 for T ≤ 120 °C;

= 1.03 for 120 °C < T ≤ 540 °C;
= 1.05 for T > 540 °C

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