SIZING OF PRESSURE RELIEF VALVES

The guidelines for sizing/specifying pressure relief valves were checked

from Safety Design Practices by Exxon, Lieberman, BP guidelines, Ludwig,
UOP Manual, API etc. After thorough review, it was found that the API RP
520 guidelines for sizing of pressure relief valves are comprehensive and
widely by almost all the manufacturers. Only those guidelines/commonly
used terms, which are useful for the process engineers, have been
summarized below.

Maximum Allowable Working Pressure (MAWP):

As defined in the construction codes for pressure vessels, the maximum

allowable working pressure depends on the type of material, its thickness
and the service conditions set as the basis for design. The vessel may not
be operated above this pressure or its equivalent at any metal
temperature other than that used in its design. Consequently, for that
metal temperature, it is the highest pressure at which the primary pressure
–relief valve is set to open.

Set Pressure:

The set pressure, in psig, is the inlet pressure at which the pressure relief
valve is adjusted to open under service conditions. In a relief or safety
relief valve on liquid service, the set pressure is the inlet pressure at which
the valve starts to discharge under service conditions. In a safety or safety
relief valve in gas or vapor service, the set pressure is the inlet pressure at
which the valve pops under service conditions.

Accumulation:

Pressure increase over the maximum allowable working pressure of the

vessel during discharge through the pressure relief valve (expressed as a
percent of that pressure or in psi) is called accumulation.

Overpressure:

Pressure increase over the set pressure of the relieving device is

overpressure. It is the same as accumulation when the relieving device is
set at the MAWP of the vessel. The overpressure may be greater than the
allowable accumulation if the valve is set lower than the vessel MAWP.
Likewise, if multiple relief valves are installed, some with staggered set
pressures above the vessel MAWP, the overpressure for the staggered
valves will then be less than the allowable accumulation.
Blowdown:

Blowdown is the difference between the set pressure and the reseating
pressure of a pressure relief valve, expressed as percent of the set pressure
or in psi.

Backpressure:

Pressure on the discharge side of safety relief vales is backpressure.

Operational Difficulties and Required Relief Capacities:

The following table lists the principal operations difficulties giving rise to the
relief capacities indicated. Not all the causes will occur simultaneously;
therefore, the relief or safety relief valve should be sized for the condition
or conditions that require the greatest relief. This table to be referred
while deciding the relief capacity for any particular operational
contingency.

Required Relief Capacity

Relief Valve
No. Condition
for Safety Relief valve for vapor relief
Liquid Relief
Maximum
Total incoming steam and vapor, plus
liquid
1 Closed outlets on vessels that generated therein under normal
pump-in
operation
rate
Total incoming steam and vapor, plus
Cooling water failure to that generated therein under normal
2 ---
condenser operation, less vapor condensed by
side stream reflux
Total vapor to condenser at reliving
3 Top-tower reflux failure ---
conditions
Difference between vapor entering
4 Side stream reflux failure ---
and leaving section
5 Lean oil failure to absorber --- None
Accumulation of non Same effect in towers as for items no.
6 ---
condensables 2 and no. 8 in other vessels
Entrance of highly volatile
material:
a. Water into hot oil --- For towers - usually not predictable.
b. Light hydrocarbons --- For heat exchangers – assume an
7
into hot oil. area twice the internal cross
sectional area of one tube to provide
for the vapor generated by the
entrance of the volatile fluid.
Overfilling storage or surge Maximum
8 ---
vessel liquid
 pump-in
rate
Failure of automatic
controls:
a. Tower pressure --- Total normally uncondensed vapor.
controller to closed
9 position
b. All valves to closed No No operational requirement.
position, except operational
water and reflux requirement
valves.
Abnormal heat or vapor
input:
a. Fired heaters or --- Estimated maximum vapor
10 steam boilers. generation including non-
condensable from overheating.
b. Split re-boiler tube --- Steam entering from twice the cross-
sectional area of one tube.
Not controlled by conventional relief
11 Internal explosion --- devices, but by avoidance of
circumstances.
Estimated vapor generation from
12 Chemical reaction --- both normal and uncontrolled
conditions.
Hydraulic expansion:
a. Cold fluid shut in Normal size ---
13 b. Lines outside Normal size ---
process area shut
in.
Estimate by the method given in
14 Exterior fire ---
Section 6.
Power failure (Steam, --- Study the installation to determine
electric or other) : the effect of power failure. Size relief
valve for the worst condition that can
occur.
a. Fractionator --- All pumps could be down, with the
result that reflux and cooling water
would fail. Size valves as in item No 2.
b. Reactors --- The agitation or stirring would stop
15
and the quench or retarding stream
would fail. Size valves for product
generation from a runaway reaction.
c. Air-cooled --- Fans would fail. Size valves for the
exchangers difference between normal and
emergency duty.
d. Surge vessels Max liquid ---
inlet rate
Amount of Heat Absorbed:

The amount of heat absorbed by a vessel exposed to open fire is

markedly affected by the size and character of the installation and by the
environment. It is calculated by following formulae.

q = 21000 FA –0.18

Q = 21000 FA 0.82

Where;

q = average unit heat absorption, in British thermal units per hour per
square foot of wetted surface.

Q = Total heat absorption (input) to the wetted surface, in British thermal

units per hour.

A = total wetted surface, in square feet. (The expression A –0.18 , or 1/A 0.18,
Is the area exposure factor or ratio. This ratio recognizes the face
that large vessels are less likely to be completely exposed to the
flame of an open fire than are small vessels.)

F = environment factor, values of which are shown in Table given below

for various types on installation.

Environment Factors are given in Table 3 on page 10 of API RP 520-Part I.

The aforementioned formulas, upon application of the value of factor (F =
1.0) for a bare vessel, become :

q = 21000 A –0.18

Q = 21000 A 0.82

It is recommended that the total wetted surface (A in the foregoing

formulas) is at least that wetted surface included within a height of 25 feet
above grade or - in the case of spheres and spheroids – at least the
elevation of the maximum horizontal diameter or a height of 25 feet,
whichever is greater. The term, “Grade” usually refers to ground grade,
but may be at any level at which a sizable fire could be sustained.
Surface Area Exposed to Fire

The surface area wetted by its internal liquid contents is effective in

generating vapor when it is exposed to fire. The liquid content under
variable level conditions should ordinarily be taken at the average
inventory, namely :

1. Liquid – Full Vessels (such as treaters) operate liquid full. Therefore,

the wetted surface would be the total vessel surface within the
height assumed to be affected by a fire as recommended above.
2. Surge Drums (Vessels) usually operate about half full. Therefore, the
wetted surface would be calculated at 50 percent of the total
vessel surface.
3. knockout Drums (Vessels) usually operate with only a small amount
of liquid. Therefore, the wetted surface would be in proportion.
4. Fractionating Columns usually operate with normal liquid level in the
bottom of the column and a level of liquid on each tray. It is
reasonable to assume that the wetted surface be based on the
total liquid in the bottom and in the tray within the height assumed
to be affected by a fire as recommended above.
5. Working storage tanks wetted surface is usually calculated on the
average inventory. This calculation should be satisfactory not only
because it conforms with a probability, but also because it provides
a factor of safety in the time needed to raise the usually large
volume of the liquid’s sensible heat to its boiling point. It is
recommended that the wetted area be at least to the height
specified above.

Sizing for Gas or Vapor Relief:

Safety and safety relief valves I gas or vapor service may be sized by
use of one of the following formulas :
___ ___
A = W√ TZ / CKP1Kb√ M

____
A = V√ TZM / 6.32 CKP1Kb

____
A = V√ TZG / 1.175 CKP1Kb

Where,

A = required effective discharge area of the valve in square inches.

W = required flow through valve, in pounds per hour.

C = coefficient determined by ratio of the specific heats of the gas or

vapor at standard conditions. This can be obtained from fig. 2,
fig. B-2 or Table B-1.

K = effective coefficient of discharge = 0.975 for use in formulas C-1, C-

2 and C-3.

V = required flow through valve, in standard cubic feet per minute at

14.7 pounds per square inch absolute and 60 degree Fahrenheit.

P1 = upstream relieving pressure, in pounds per square inch absolute.

This is the set pressure plus the allowable overpressure, plus the
atmospheric pressure, in pounds per square inch absolute.

Kb = capacity correction factor due to backpressure. This can be

obtained from fig. C-1, which applied to conventional safety-relief
valves, or from fig. C-2, which applies to balanced bellows valves.

M = molecular weight of the gas or vapor.

T = absolute temperature of the inlet vapor, in degrees Fahrenheit +

460.

Z = compressibility factor for the deviation of the actual gas from a

perfect gas, a ratio evaluated at inlet conditions. This can be
obtained from fig 3 or fig. B-3.

G = specific gravity of gas referred to air = 1.00 at 60 degrees

Fahrenheit and 14.7 pounds per square inch absolute.

Sizing for Gas Expansion Due to External Fire:

The discharge areas for safety and safety-relief valves on gas-

containing vessels exposed to open fires can be determined by use of
the following formula:

A= F’A3
√P1

Where,
 A = effective discharge area of the valve in square inches.

F’ = an operating factor determined from figure C-3.

A3 = exposed surface area of the vessel, in square feet.

P1 = upstream relieving pressure, in pounds per square inch absolute.

This is the set pressure plus the allowable overpressure, plus the
atmospheric pressure, in pounds per square inch absolute.

Sizing for Liquid Relief:

Safety-relief valves in liquid service may be sized by the use of the

following formulas, a conversion from a basic liquid flow formula.
__ ________
Required A = gpm √G / 38.0 KKpKwKv √1.25p-pb

Where,

gpm = flow rate at the selected percentage of overpressure, in U.S.

gallons per minute.

A = effective discharge area of the valve in square inches.

K = coefficient of discharge, which should be obtained from valve

manufacturer. If K is unknown, a conservative value of 0.62 is
recommended.

Kp = capacity correction factor due to overpressure. Many, if not most,

relief valves in liquid service are sized on the basis of 25 %
overpressure, in which case Kp = 1.0. The factor for other
percentages of overpressure can be obtained from figure C-4.

Kw= capacity correction factor due to backpressure. If the

backpressure is atmospheric, the factor can be disregarded or Kw
= 1.0. Conventional valves in backpressure service require no
special correction: Kw = 1.0. Balanced bellows valves in back
pressure service will require the correction factor as determined
from Figure C-5.

Kv = capacity correction factor due to viscosity due to viscosity. For most

applications, viscosity may not be significant, in which case Kv =
1.0.
p = set pressure at which relief valve is to begin opening, in pounds per
square inch gauge.

pb = back pressure in pound per square inch gauge

G = specific gravity of the liquid at the flowing temperature referred to

water = 1.0 at 70 degrees Fahrenheit.

Sizing of Steam Relief

For safety-relief valves in steam service, the required area may be

estimated from following formula :

A = W / 50 P1KSH

W = flow rate, in pounds per hour.

A = required effective discharge area of the valve in square inches.

P1 = upstream relieving pressure, in pounds per square inch absolute. This

is the set pressure plus the allowable overpressure, plus the
atmospheric pressure, in pounds per square inch absolute. The ASME
Power Boiler Code applications are permitted only 3 percent
overpressure. Other applications may need to confirm to the ASME
Pressure Vessel Code, wherein greater overpressure is permitted.

KSH = correction factor due to amount of superheat in the steam. This can
be obtained from Table C-2. For saturated steam at any pressure,
the factor KSH = 1.0. To determine valve capacities, apply the KSH
factor to the manufacturer’s published saturated steam capacities.
Allowable Overpressure

The Allowable Overpressure for various services is given below.

PROTECTED ALLOWABLE ACCUMULATION

FLUD
EQUIPMENT Single Valve Multiple Valve Fire
Pressure Vessels 10% 16% 21%
Heat Exchangers 10% 16% 21%
Liquid Storage Tanks 10% 16% 21%
Pumps 10% to 25%
Process Lines 10% to 25%
Pressure Vessels 10% 16% 21%
Vapor Heat Exchangers 10% 16% 21%
& Gas Compressors 10% 16% --
Process Lines 10% 16% --
Steam Boilers 3% 6% --
Steam
Steam Lines 10% 16% --

Orifice Letter Designations:

Orifice letter designations are given based on the orifice area as shown
below.

ORIFICE ORIFICE AREA ARIFICE AREA

DESIGNATION CM2 IN2
D 0.71 0.110
E 1.26 0.196
F 1.98 0.307
G 3.24 0.503
H 5.6 0.785
J 8.30 1.287
K 11.80 1.838
L 18.40 2.853
M 23.20 3.600
N 28.00 4.34
P 41.10 6.38
Q 71.30 11.05
R 103.20 16.0
T 167.70 26.00
Sample Problem:

A relief valve (73-SV-1234) is required to protect a vessel (73-D-07)

containing HC vapors, MW=44. The required capacity at 28.1 Kg/cm2 set
pressure plus 10% accumulation is 15,876 Kg/hr and temperature is 399 °C.
Calculate required discharge area of the valve in square inches.

Solution :
___ ___
A = W√T Z / CKP1Kb√M

W = 15876 Kg/hr = 35000.6 lb/hr

T = 399 °C = 1209.87 °R

M = 44

P1 = [28.1 + (28.1 x 0.1)] x 14.22 + 14.7

= 454.24 psia

Z = 0.89 from figure 3

K = 0.975

Kb = 1.0 from figure C-1

C = 302 from figure B-2

_____________
A = 35000.6 x √1209.87 x 0.89 / 302 x 0.97 x 454.24 x 1.0 x √44

= 1.295 in2

= 8.35 cm2

Orifice designation is ‘K’

 HINDUSTAN PETROLEUM CORPORATION LIMITED
SAFETY VALVE SPECIFICATION SHEET

General Tag No. 73-SV-1234

Protected vessel no./Line no. 73-D-07
Safety / Relief valve Safety Valve
Valve Type Full nozzle full lift
Bonnet type
Conventional/ Bellows/Pilot Conventional
operated
Inlet connection
Outlet connection
Cap over adjusting bolt
Lifting gear type
Test gag Yes
Material Body & bonnet
Nozzle & disc.
Spring
Bellows
Options

Basis Code
Basis of selection Closed Outlet
Service Fluid & state HC vapor
Conditions Corrosive compounds H2S
Required capacity, kg/hr. 15876
Mole. wt./SG at relieving 44 / -
temp.
Operating pressure, kg/cm2g 22
Operating / Relieving temp, C 399 / 399
Valve discharge to Atmosphere
Back pressure kg/cm2g 0
Set pressure, kg/cm2g 28.1
Cold bench test pressure,
kg/cm2g
Overpressure, % 10
Compressibility factor 0.89
Ratio of specific heats Cp/Cv 1.13
Viscosity at relieving temp.
Orifice Calculated area, cm2 8.35
Selected area, cm2 11.8
No. of valves required 2 (1 spare)
Orifice designation K
Total area, cm2
Actual capacity, kg/hr.
Model no.
IBR certification Not required
Rev. Description Prepd Chekd Apprd Date
PRESSURE RELIEF VALVES