Sr. No.

Description Design Practice Reference

1 PSV Sizing for Blocked Liquid Discharge Condition API 520 Part 1 Sec 3.8, 7th Edition

2 PSV Sizing for Blocked Gas Discharge Condition API 520 Part 1 Sec 3.6, 7th Edition

3 PSV Sizing for Fire Case of Liquid Filled Vessel API 521 Par 5.15

4 PSV Sizing for Control Valve Fail Open Case API 521, Section 5.10, 2007 edition

5 Relief Valve Sizing for Thermal Expansion API 521 Par 5.14

6 Restriction Orifice Sizing for Gas Flow Perry's Handbook

7 Restriction Orifice Sizing for Liquid Flow Perry's Handbook

8 Single Phase Flow Line Sizing Tool Darcy-Weisbach Equation

9 Gas Control Valve Sizing Tool Fisher's Equation

Guidelines
API recommended practices for the use of Safety Relief Valves in Petroleum & Chemical industries - mostly used are:
1. API Recommended Practice 520 Part I - Sizing, Selection & Installation of Pressure relieving devices in Refineries.
2. API Recommended Practice 520 Part II – Installation of pressure relief systems in Refineries.
3. API Recommended Practice 521 – Guide for Pressure-Relieving and Depressuring Systems.
4. API Standard 526 - Flanged Steel Pressure Relief Valves
5. API Recommended Practice 527 - Seat Tightness of Pressure Relief Valves
6. API Standard 2000 - Venting Atmospheric and Low-Pressure Storage Tanks: Non-refrigerated and Refrigerated
7. API Standard 2001- Fire Protection in Refineries.

The designed pressure relieving devices should be certified and approved under Code,
1. ASME- Boiler and Pressure Vessel Code Section I, and Section VIII, Pressure Vessels.
2. ASME- Performance Test Code PTC-25, Safety and Relief Valves.

Notes

The following Excel Sheet serves for training and preliminay design purposes and process specifications but the final design must always be
checked by a subject matter expert and guaranteed for service by an authorized manfucturing vendor.
 PSV Sizing - Blocked Liquid Discharge [Requiring Capacity Certification]
Equipment No. V-100 PSV SIZING RESULTS
Relief Service Crude Oil Selected Standard Orifice Area [Based on API 526] 6.38 inch2

Reason for Relief Blocked Liquid Discharge Selected Orifice Designation P -

PSV INPUT CALCULATIONS

Parameter Value Unit Parameter Value Unit

Flow through vessel / Relieving Rate 300,000 kg/h Flow Rate [Q] 5,556 lit/min

Liquid Density (for specific gravity calc) 900 kg/m3 Specific Gravity [SG] 0.9 -

Liquid Viscosity 450.0 cP Relieving/Upstream Pressure [P1] 1,980 kPag

RV Set Pressure 18.00 barg Downstream Pressure [P2] 400 kPag

Over Pressure 10 % Percent of Gauge Back Pressure 22.2 %

Back Pressure at Relief Valve Discharge 4.00 barg Coefficient of Discharge [Kd] 0.65 -

Rupture Disc Installed Upstream of RV Yes Combination correction factors for use of rupture discs [K C] 0.9 -

Type of Relief Valve Balanced Bellow Correction Factor due to back pressure[KW] 0.96 -

2,795 mm2
Initial Orifice Area Sizing (no viscosity correction) [Kv = 1.0] [AR]
4.33 inch2

Reynolds Number [R] 3,951 -

Correction Factor due to Viscosity [KV] 0.96 -
Orifice Area based on corrected viscosity [Acorr] 4.51 inch2

Selected Orifice Designation P -

Selected Standard Orifice Area [Aselect] [ Based on API 526] 6.38 inch2

Notes
1. Conventional and pilot operated valves require no special correction for Kw (correction due to back pressure)

2. Balanced Bellow type valves should be selected if back pressure is a variable

3. Upstream Relieving Pressure = Set Pressure + Allowable Over Pressure

4. Section VIII, Division I, of the ASME Code requires that capacity certification be obtained for pressure relief valves designed for liquid service.
 PSV Sizing - Blocked Gas Outlet [Non Fire Case]
Equipment No. V-100 PSV SIZING RESULTS
Relief Service Fuel Gas FLOW CONDITION BEHAVIOUR SUBCRITICAL FLOW
Reason for Relief Blocked Gas Discharge Selected Standard Orifice Area [Based on API 526] 3.60 inch2

Selected Orifice Designation M -

PSV INPUT CALCULATIONS - CRITICAL FLOW

Parameter Value Unit Parameter Value Unit

Flow through vessel / Relieving Rate [W] 15,000 kg/h Mass Flow [W] 33,069 lb/h
Ratio of Specific Heats [k = C P/CP-R] 1.30 - Coefficient [C] 347 Unit

Gas Compressibility Factor [Z] 0.85 - Relieving/Upstream Pressure [P 1] 94.5 psia

Gas Molecular Weight [MW] 65.0 lb/lbmol Relieving Temperature of Inlet gas to PSV [T] 627 Rankine
Relieving Temperature 75 C
0 Coefficient of Discharge [Kd] 0.975 -

RV Set Pressure 5.00 barg Percent of Gauge Back Pressure 80.0 %

Over Pressure 10 % Correction Factor due to back pressure[KB] 1.00 -

Back Pressure at Relief Valve Discharge 4.00 barg Combination correction factors for use of rupture discs [K C] 1.00 -

Rupture Disc Installed Upstream of RV No CALCULATIONS - SUB CRITICAL FLOW

Type of Relief Valve Conventional Downstream Pressure [P2] 72.7 psia

FLOW CONDITION BEHAVIOUR Ratio of Back Pressure to Upstream Relieving Pressure [r] 0.77 -

Critical Flow Pressure Ratio 0.55 - Coefficient of Subcritical Flow [F2] 0.86 -
Upstream Relieving Pressure [P1] 94.5 psia PSV SIZING RESULTS - BASED on API 526
51.5 psia Calculated Orifice Area [Acalc] 3.39 inch2
Critical Flow Nozzle Pressure [P cf]
2.5 barg Selected Orifice Designation M -
FLOW CONDITION BEHAVIOUR SUBCRITICAL FLOW Selected Standard Orifice Area [A select] [ Based on API 526] 3.6 inch2

Notes
1. Conventional and pilot operated valves require no special correction for K w (correction due to back pressure)

2. Balanced Bellow type valves should be selected if back pressure is a variable

3. Upstream Relieving Pressure = Set Pressure + Allowable Over Pressure
4. Section VIII, Division I, of the ASME Code requires that capacity certification be obtained for pressure relief valves designed for liquid service.
 PSV Sizing - Fire Case - Liquid Filled Vessel
Equipment No. V-100 PSV SIZING RESULTS
Relief Service Vapour FLOW CONDITION BEHAVIOUR CRITICAL FLOW
P&ID No. xx-xx-xx-xx Selected Standard Orifice Area [Based on API 526] 0.11 inch2
Reason for Relief Liquid Filled vessel [Fire Case] Selected Orifice Designation D -

EQUIPMENT INPUT PSV INPUT CALCULATIONS - CRITICAL FLOW

Parameter Value Unit Parameter Value Unit Parameter Value Unit

Tank Diameter [D] 4.50 m Relieving Rate [W] 4,352 kg/h Mass Flow [W] 9,594 lb/h

Tank Length [T/T] [L] 21.00 m Ratio of Specific Heats [k = C P/CV] 1.39 - Coefficient [C] [SQRT(lbm.lbmol.R/lbf.hr] 355 Unit
Tank with Boot Yes - Gas Compressibility Factor [Z] 0.53 - Relieving/Upstream Pressure [P1] 1,769 psia

Boot Diameter 1.20 Gas Molecular Weight [MW] 79.3 lb/lbmol Relieving Temperature of Inlet gas to PSV [T] 989.6 Rankine

Boot Height 2.00 Relieving Temperature 277 C

0 Coefficient of Discharge [Kd] 0.975 -
Mounting Horizontal - RV Set Pressure 100.00 barg Percent of Gauge Back Pressure 3.5 %

Vessel and Boot Head Hemispherical - Over Pressure 21 % Correction Factor due to back pressure[KB] 1.00 -

Tank Elevation w/o considering Boot [H] 5.5 m Back Pressure at Relief Valve Discharge 3.5 barg Combination correction factors for use of rupture discs [KC] 1.00 -

Tank Elevation with Boot [H] 2.9 m Rupture Disc Installed Upstream of RV No CALCULATIONS - SUB CRITICAL FLOW
Operating Liquid Level [HLL/NLL] [F] 4.0 m Type of Relief Valve Conventional Downstream Pressure [P2] 65 psia

Drainage & Fire Fighting Measures Available - FLOW CONDITION BEHAVIOUR Ratio of Back Pressure to Upstream Relieving Pressure [r] 0.04 -

150 kJ/kg Critical Flow Pressure Ratio 0.53 - Coefficient of Subcritical Flow [F2] 0.14 -
Latent Heat of Vaporization
64 BTU/lb Upstream Relieving Pressure [P1] 1,769 psia PSV SIZING RESULTS - BASED on API 526
Is the Vessel Insulated Yes - 938 psia Calculated Orifice Area [Acalc] 0.04 inch2
Critical Flow Nozzle Pressure [Pcf]
Thermal Conductivity of Insulation 3.00 W/m.K 62.8 barg Selected Orifice Designation D -
% Piping Exposed to Fire 20 % FLOW CONDITION BEHAVIOUR CRITICAL FLOW Selected Standard Orifice Area [Aselect] [ Based on API 526] 0.11 inch2
Environmental Factor [F] 0.0399 -

CALCULATIONS - CRITICAL FLOW

Parameter Value Unit
K1 [ISO 23521] 6.90 m
K1 [Effective Total Height of Liquid Surface] 6.90 m
E1 [ISO 23521] 4.00 m
E1 [Initial Liquid Level] 4.00 m
β 141.1 degrees
292.64 m2
Wetted Surface Area [Awet]
3,150.0 f2
Heat Load [Q] 618,730 BTU/hr

9,594 lb/h
Vapour Flow Rate
4,352 kg/h

Notes
1. Conventional and pilot operated valves require no special correction for K w (correction due to back pressure)

2. Balanced Bellow type valves should be selected if back pressure is a variable

3. Upstream Relieving Pressure = Set Pressure + Allowable Over Pressure

4. Section VIII, Division I, of the ASME Code requires that capacity certification be obtained for pressure relief valves designed for liquid service.

5. The wetted area computed with hemispherical ends is considered approximately equal to wetted area with elliptical heads since margin is added to account for piping. The difference is expected to be accomodated in the margin
 PSV Sizing - Control Valve Fail Open
Equipment No. V-100 PSV SIZING RESULTS
Relief Service Fuel Gas FLOW CONDITION BEHAVIOUR CRITICAL FLOW
Reason for Relief Control Valve Fail Open Selected Standard Orifice Area [Based on API 526] 26.00 inch2
Selected Orifice Designation T -
CONTROL VALVE INPUT PSV INPUT CALCULATIONS - CRITICAL FLOW
Parameter Value Unit Parameter Value Unit Parameter Value Unit
6.49 barg Flow through vessel / Relieving Rate [W] 61,012 kg/h Mass Flow [W] 134,508 lb/h
Control Valve Inlet Pressure [P1]
109 psia Ratio of Specific Heats [k = CP/CV] 1.25 - Coefficient [C] 342 Unit
4.63 barg Gas Compressibility Factor [Z] 0.98 - Relieving/Upstream Pressure [P1] 90.4 psia
Control Valve Outlet Pressure [P2]
82 psia Gas Molecular Weight [MW] 19.4 lb/lbmol Relieving Temperature of Inlet gas to PSV [T] 551 Rankine
Control Valve Inlet Temperature [T1] 35.0 0
C Relieving Temperature [CV Outlet] 32.7 C
0 Coefficient of Discharge [Kd] 0.975 -
Gas Molecular Weight [MW] 19.37 kg/kmol RV Set Pressure 4.50 barg Percent of Gauge Back Pressure 0.0 %
Ratio of Specific Heats [k = CP/CV] 1.25 Over Pressure 16 % Correction Factor due to back pressure[KB] 1.00 -
Control Valve Cv 768.0 - Back Pressure at Relief Valve Discharge 0.00 barg Combination correction factors for use of rupture discs [KC] 1.00 -
Gas Compressibility Factor [Z] 0.9791 Rupture Disc Installed Upstream of RV No CALCULATIONS - SUB CRITICAL FLOW
CALCULATIONS Type of Relief Valve Balanced Bellow Downstream Pressure [P2] 14.7 psia
Parameter Value Unit FLOW CONDITION BEHAVIOUR Ratio of Back Pressure to Upstream Relieving Pressure [r] 0.16 -
Pressure Drop [ΔP] 27 psia Critical Flow Pressure Ratio 0.56 - Coefficient of Subcritical Flow [F2] 0.31 -
Pressure Drop Ratio [x] 0.25 - Upstream Relieving Pressure [P1] 90.4 psia PSV SIZING RESULTS - BASED on API 526
Piping Geometry Factor [Fp] 1.00 - 50.2 psia Calculated Orifice Area [Acalc] 23.55 inch2
Critical Flow Nozzle Pressure [Pcf]
Ratio of Specific Heat Factor [Fk] 0.89 - 2.4 barg Selected Orifice Designation T -
Rated Pressure Drop Factor [xT] 0.81 - FLOW CONDITION BEHAVIOUR CRITICAL FLOW Selected Standard Orifice Area [Aselect] [ Based on API 526] 26 inch2
Expansion Factor [Y] 0.885 -
Flow Behaviour across Control Valve SUB CRITICAL -
Mass Flow through Control Valve 61,012 kg/h

Notes
1. Conventional and pilot operated valves require no special correction for Kw (correction due to back pressure)
2. Balanced Bellow type valves should be selected if back pressure is a variable
3. Upstream Relieving Pressure = Set Pressure + Allowable Over Pressure
4. Section VIII, Division I, of the ASME Code requires that capacity certification be obtained for pressure relief valves designed for liquid service.
 Relief Valve Sizing - Thermal Expansion
Equipment No. V-100 PSV SIZING RESULTS
Relief Service Fuel Gas Selected Standard Orifice Area NPS 3/4" x NPS 1"
Reason for Relief Thermal Expansion RV Flow Rate [m3/h] 1.91

INPUT Notes

Parameter Value Unit 1. Since the flowrates are very small for Thermal expansion cases the safety valve size of

850 kg/m3 NPS 3/4" x NPS 1" (DN 20 x DN25) should be sufficient as per API 521 Par. 5.14.2
Density of Liquid (ρ)
53.1 lb/f3
API Gravity 35.0 0
API
1000.0 kJ/s
Total Heat Transfer Rate [H]
3,412,140 BTU/hr

2.00 kJ/kg.K
Specific Heat of Trapped Fluid [C]
0.4777 BTU/lb 0F
Cubic Expansion Coefficient [B] 0.00050 1/0F
Specific Gravity (SG) 0.850 -

RESULTS
8.40 USGPM
RV Flow Rate
1.91 m3/h
 RO Sizing - Gas Flow
Equipment No. V-100 RO SIZING RESULTS
Relief Service Fuel Gas FLOW CONDITION BEHAVIOUR CRITICAL FLOW
RO Tag No. xx-RO-xxx GAS FLOW 6803.0 kg/h

Reason for Relief RO Gas Flow BLOWDOWN ORIFICE SIZE 15.2 mm

RO INPUT CRITICAL FLOW CALCULATIONS

Parameter Value Unit Parameter Value Unit
Gas Flow [W] 6,803 kg/h Upstream Pressure [P1] 63.00 bara
Gas Molecular Weight [MW] 24.52 kg/kmol Downstream Pressure [P2] 8.00 bara
Ratio of Specific Heats [k = CP/CV] 1.18 - Upstream Temperature [T1] 360.8 K
Upstream Pressure [P1] 61.99 barg Upstream Gas Specific Gravity [SG] 0.85 -
Downstream Pressure [P2] 7.0 barg Critical Expansion Factor (Ycr) 0.69 -
Upstream Temperature [T1] 87.7 °C Blowdown Orifice Diameter [d] (Ftp = 1) 15.22 mm
Upstream Gas Density [ρ1] 1.09 kg/m3 β [d/D] 0.3092 -

Gas Compressibility factor [Z] 0.88 - Corrected Ftp 1.0019 -

Orifice Coefficient [C] 0.84 - Corrected Blowdown Orifice Diameter [dcorr] 15.20 mm

Upstream Diameter [D] 49.22 mm Orifice Area [A] 182 mm2

FLOW CONDITION BEHAVIOUR SUB CRITICAL FLOW CALCULATIONS
Critical Flow Pressure Ratio 0.57 - Parameter Value Unit
63.0 bara Pressure ratio [r] 0.127 -
Upstream Relieving Pressure [P1]
62.0 barg Expansion Factor [Y] 0.248 -
Critical Flow Nozzle Pressure [Pcf] 34.8 barg Blowdown Orifice Area [A] 2622 mm2
FLOW CONDITION BEHAVIOUR CRITICAL FLOW Blowdown Orifice Diameter [d] 57.8 mm

Notes
1. P1 & P2 is computed in Pascals (Pa)
 RO Sizing - Liquid Flow
Equipment No. V-100 RO SIZING RESULTS
Relief Service Condensate Orifice Mass Flow 36,261 kg/h

RO Tag No. xx-RO-xxx Orifice Volumetric Flow 0.012 m3/h

Reason for Relief RO Liquid Flow

RO INPUT CALCULATIONS
Parameter Value Unit Parameter Value Unit
Liquid Density [ρ1] 850 kg/m 3 Upstream Pressure [P1] 1.44 bara
Upstream Pressure [P1] 0.43 barg Downstream Pressure [P2] 1.01 bara
Downstream Pressure [P2] 0.00 barg 1,963 mm2
Orifice Area [A]
Pressure Ratio [P2/P1] 0.70 - 0.001963 m2
Orifice diameter [d] 50.0 mm Orifice Mass Flow 10.07 kg/s

Orifice Coefficient [C] 0.60 - Orifice Volume Flow 0.0119 m3/s

Notes
1. P1 & P2 is computed in Pascals (Pa)

2. In case, Orifice Flow Rate is Known, Use 'Goal Seek' to backcalculate the orifice diameter required
 Single Phase Line Sizing
Piping No. x"-xxx-xxx RO SIZING RESULTS
Service Condensate Pressure Drop [ΔP] 0.0002 bar
From Equipment V-100 Fluid Velocity 0.05 m/s
To Equipment V-200 Flow Behaviour Turbulent -

Friction Factor Equation Colebrook -

PIPE INPUT CALCULATIONS

Parameter Value Unit Parameter Value Unit
Pipe Inner Diameter 102.26 mm Pipe Roughness [ε] 0.00005000 m
Pipe Length 100 m Pipe ID (D) 0.10226 m
Pipe Roughness 50.0 μm Pipe Cross Sectional Area [A] 0.00821 m2
Flowrate 950.0 kg/h Dynamic Viscosity [μ] 0.000 kg/m.s
Liquid Viscosity [Dynamic] 0.36 cP Volumteric Flow [Q] 1.37 m3/h
Liquid Density 693.0 kg/m3 Fluid Velocity [V] 0.05 m/s

FRICTION FACTOR [f] CALCULATIONS Reynold's Number [NRe] 9,072 -

Laminar Flow - Friction Factor [f] Flow Behaviour Turbulent -
Parameter Value Unit Pipe Roughness /Pipe ID [ε/D] 0.00049 -
Laminar Flow [f] 0.0071 - Friction Factor Equation Colebrook

Turbulent Flow - Churchill Equation Friction Factor [f] Friction Factor [f] 0.0324 -
Term A 1.30E+19 - 0.02360 kPa
Pressure Drop [ΔP]
Term B 7.36E+09 - 0.00024 bar
Churchill Equation - Friction Factor [f] 0.0327 - Pressure Drop per 100m [ΔP/L] 0.00024 bar/100 m
Turbulent Flow - Colebrook Equation Friction Factor [f]
Churchill Equation - Friction Factor [f] 0.0324 -

Notes
1. P1 & P2 is computed in Pascals (Pa)
2. If NRe <= 2100 - Use Laminar Flow Friction Factor
2. If NRe <= 4000 - Use Churchill Equation
3. If NRe > 4000 - Use Colebrook Equation
4. Pressure Drop is estimated using Darcy-Weisbach Equation
 Gas Control Valve Sizing
Equipment No. V-100

Service Fuel Gas

CONTROL VALVE INPUT

Parameter Value Unit
6.49 barg
Control Valve Inlet Pressure [P1]
109 psia
4.63 barg
Control Valve Outlet Pressure [P2]
82 psia
Control Valve Inlet Temperature [T1] 35.0 0
C
Gas Molecular Weight [MW] 19.37 kg/kmol
Ratio of Specific Heats [k = CP/CV] 1.25 -
Control Valve Cv 768.0 -
Gas Compressibility Factor [Z] 0.9791 -

CALCULATIONS
Parameter Value Unit

Pressure Drop [ΔP] 27 psia

Pressure Drop Ratio [x] 0.25 -
Piping Geometry Factor [Fp] 1.00 -
Ratio of Specific Heat Factor [Fk] 0.89 -
Rated Pressure Drop Factor [xT] 0.81 -

Expansion Factor [Y] 0.885 -

Flow Behaviour across Control Valve SUB CRITICAL -
Mass Flow through Control Valve 61,012 kg/h

Notes

Sizing is based on Fisher Equation for Gas Flow

 Tank LAH & LAHH Calculator

Parameter Value Unit

Tank Diameter [D] 14 feet

Tank Height [H] 18 feet

Normal Liquid Level [NLL] 6 feet Overfill 18.00 feet

Pump in Flow [Q] 250 USGPM

2,771 f3
Total Volume of Tank [Vtotal]
20,728 U.S Gallons LAHH 14.74 feet

Time to fill from Overfill to LAHH 15 min

Tank flow in 15 minutes 3,750 U.S Gallons

16,978 U.S Gallons

LAHH to Overfill Volume
2,270 f3 LAH 8.23 feet

Liquid Alarm HH [LAHH] 14.74 f

Time to fill from Overfill to LAH 45 min

Tank flow in 45 minutes 11250 U.S Gallons NLL 6.00 feet

9,478 U.S Gallons

LAH to Overfill
1267 f3

Liquid Alarm H [LAH] 8.23 f Tank Bottom 0.00 feet

Summary

Liquid Alarm HH [LAHH] 14.74 f Legend Input Data

8.23 f
Liquid Alarm H [LAH]
2.23 f
LAH to NLL