4.

Relief Valve Sizing

Topics to be Covered
General Sizing
Sizing Procedure
API KA vs. ASME KA
Gas / Vapor Sizing Sonic Flow
Equations, Variables, Units of Measure
Gas Properties
Back Pressure
Rupture Disc
Gas / Vapor Sub-Sonic Flow
Equations, Variables, Units of Measure
Pressure & Vacuum
Topics to be Covered
Steam Sizing
Equations, Variables, Units of Measure
Sec. VIII vs. Sec I
Sonic vs. Subsonic
Liquid Sizing
Equations, Variables, Units of Measure
Back Pressure
Fire Sizing
API 521 Unwetted Vessels
API 521 Wetted Vessels
API 2000
Must Consider The
One Worst Case Scenario
Blocked Discharge
External Fire
Thermal Expansion
Runaway Reaction
Tube Rupture In Heat Exchanger
Basic Sizing Procedure
Establish Set Pressure of PSV
Determine Required Relief Capacity
Select PSV Size That Will Flow At Least
That Capacity At The Relieving Pressure
In 1962, the ASME Section VIII Code
Was Revised, Requiring That K
Be Used In Sizing Calculations
(10% Safety Factor) Instead of K
D

K = K
D
x 0.90
API & ASME KA Values
The NB Red Book is a Bi-Annual
publication of the Pressure Relief Device
Certifications by the National Board of
Boiler and Pressure Vessel Inspectors.
The NB allows advertised deviations
from the Red Book K and A values,
however
Advertised KA s ASME KA
(per NB Red Book)
Since 1962, most PRV manufacturers
have Overstated their K values,
and Understated their A values.
API vs ASME Orifice Areas
AGC JOS-E Series
API DESIGNATION
API EFFECTIVE AREA
(SQ IN)
ASME / NB CERT.
AREA (SQ IN)
D 0.110 0.124
E 0.196 0.221
F 0.307 0.347
G 0.503 0.567
H 0.785 0.887
API vs ASME Orifice Areas
AGC JOS-E Series
API DESIGNATION
API EFFECTIVE AREA
(SQ IN)
ASME / NB CERT.
AREA (SQ IN)
J 1.287 1.453
K 1.838 2.076
L 2.853 3.221
M 3.600 4.065
N 4.340 4.900
API DESIGNATION
API EFFECTIVE AREA
(SQ IN)
ASME / NB CERT.
AREA (SQ IN)
P 6.380 7.205
Q 11.05 12.47
R 16.00 18.06
T 26.00 29.35
API vs ASME Orifice Areas
AGC JOS-E Series
Example of Different Manufacturers KA Values
J Orifice (API = 1.287 in
2
)
NATIONAL BOARD CATALOG
K KA K KA
0.859
0.953
1.287
[8.303]
0.855
0.95
0.877
0.975
A, in
2
[cm
2
] A, in
2
[cm
2
]
1.287
[8.303]
1.287
[8.303]
1.226
[7.910]
1.223
[7.888]
1.255
[8.095]
1.228
[7.925]
1.279
[8.252]
1.312
[8.464]
1.430
[9.226]
1.496
[9.652]
1.496
[9.652]
FARRIS
POPRV
CONSOLID.
DSOPRV
AGC
POPRV
API & ASME KA Values
API Preliminary Sizing
ASME Models Actual Valve Performance
API Uses API 526 Standard Orifice Areas
ASME Uses NB-18 Actual Certified Orifice Areas
API Coefficients of Discharge
Gas / Vapor = 0.975
Liquid = 0.650
ASME Coefficients of Discharge
Use De-rated Value (K) for sizing
Varies from Manufacturer to Manufacturer and Model Type to
Model Type
Advertised KA s ASME KA
Gas / Vapor Sizing
ENGLISH UNITS
OR
METRIC UNITS
OR
SONIC Flow - Generally When Set Pressure > 15 psig [1.03 barg]
c b
K K CKP
MTZ V
A
1
02 . 17
=
c b
K K CKP
MTZ V
A
1
32 . 6
=
M K K CKP
TZ W
A
c b 1
=
M K K CKP
TZ W
A
c b 1
316 . 1
=
VOLUMETRIC FLOW
MASS FLOW
Formula Symbols
SYMBOL
A
P
1
V
W
Z
C
K
D
K
K
b
K
c
T
M
DESCRIPIPTION
Calculated Orifice Area
Inlet Flowing Pressure [P
1
= P
set
+ P
over
P
loss
+ P
atm
]
Volumetric Flow Rate
Mass Flow Rate
Compressibility Factor (if unknown, assume Z = 1.0)
Gas Constant (if unknown, assume C = 315)
Actual Coefficient of Discharge
ASME Coefficient of Discharge [K=0.90 x K
d
]
Back Pressure Correction Factor
Rupture Disc Combination Correction Factor
Relieving Temperature
Molecular Weight
Units
SYMBOL
A
P
1
V
W
Z
C
K
D
K
K
b
K
c
T
M
ENGLISH
in
2
psia
SCFM
lb/hr
---
---
---
---
---
---
R = F + 460
---
METRIC
cm
2
bara
Nm
3
/hr
kg/hr
---
---
---
---
---
---
K = C + 273
---
Compressibility Factor, Natural Gas, 0.60 SG
PRESSURE, psig [barg]
1.2
1.1
1.0
0.5
0.9
0.8
0.7
0.6
0 500
[34]
1000
[69]
1500
[103]
2000
[138]
2500
[172]
3000
[207]
3500
[241]
4000
[276]
4500
[310]
5000
[345]
MW = 17.40
(0.6 sp gr)
T = F [C]
500 [260]
400 [204]
300 [149]
200 [93]
100 [38]
0 [-18]
Gas Constant
RATIO OF SPECIFIC HEATS, k
C
400
380
360
340
320
1.0 1.2 1.4 1.6 1.8 2.0
1
1
1
2
520

+
|
.
|

\
|
+
=
k
k
k
k C
Typical Properties of Gases
ACETYLENE 26 343 1.26
AIR 29 356 1.40
AMMONIA 17 348 1.31
ARGON 40 378 1.67
BENZENE 78 329 1.12
BUTADIENE 54 329 1.12
CARBON DIOXIDE 44 345 1.28
CARBON MONOXIDE 28 356 1.40
ETHANE 30 336 1.19
ETHYLENE 28 341 1.24
FREON 22 86 335 1.18
HELIUM 4 377 1.66
HEXANE 86 322 1.06
Gas
Molecular
Weight
C
Factor
k , Ratio Of
Specific Heats
Typical Properties of Gases (contd)
HYDROGEN 2 357 1.41
HYDROGEN SULFIDE 34 349 1.32
METHANE 16 348 1.31
METHYL MERCAPTON 48 337 1.20
N-BUTANE 58 326 1.09
NATURAL GAS (SG=0.60) 18.9 344 1.27
NITROGEN 28 356 1.40
OXYGEN 32 356 1.40
PENTANE 72 323 1.07
PROPANE 44 330 1.13
PROPYLENE 42 332 1.15
STEAM 18 348 1.31
SULPHUR DIOXIDE 64 346 1.29
VCM 62 335 1.18
Gas
Molecular
Weight
C
Factor
k , Ratio Of
Specific Heats
Back Pressure
Correction Factor
1.00 1.00
0.90 0.90
0.80 0.80
0.70 0.70
0.60 0.60
0.00 0.00
00 10 10 20 20 30 30 40 40 50 50
% Built-Up Back Pressure (gauge) % Built-Up Back Pressure (gauge)
At 110% of
Set Pressure
At 110% of
Set Pressure
~
Unbalanced Conventional Direct Spring PRV Unbalanced Conventional Direct Spring PRV
Back Pressure
Correction Factor
Balanced Bellows Direct Spring PRV Balanced Bellows Direct Spring PRV
1.00 1.00
0.90 0.90
0.80 0.80
0.70 0.70
0.60 0.60
0.50 0.50
00 10 10 20 20 30 30 40 40 50 50
% Back Pressure (gauge) % Back Pressure (gauge)
At 110% of
Set Pressure
At 110% of
Set Pressure
Effect of Back Pressure on Lift
of Pressure Relief Valve Types
100
90
80
70
60
50
0 10 20 30 40 50 90 100
%

R
a
t
e
d

L
i
f
t
Conventional
Spring Operated
PRV
Pilot Operated PRV
(Standard)
Balanced Bellows
Spring Operated PRV
% Back Pressure (gauge) % Back Pressure (gauge)
A Perfect Nozzle (K
D
= 1.0)
100
% Back Pressure
%

R
a
t
e
d

C
a
p
a
c
i
t
y
80
60
40
20
0
0 20 40 60 80 100
k=1.3
53%
P
1
P
2
Back Pressure Correction Factor
AGC Piston POPRV (Gases)
K
b
= Absolute Pressure Ratio
0.0
k = 1.0
k = 1.2
k = 1.4
k = 1.6
k = 1.8
k = 2.0
0.0 0. 2 0.4 0.6 1.0
0.8
1.0
0.8
0.6
0. 4
0.2
P2
P1
PSV With Rupture Disc
At Inlet
Do PSV Calculation, then
Apply Combination Factor for that
Model PSV & Model/Material of RD*
As Established by the NB Testing.
*Listed in back of NB Red Book
OR
De-rate PSV Capacity by 10%.
PRV With Rupture Disc
At Outlet
No PSV De-Rating Necessary
Gas / Vapor Sizing
ENGLISH UNITS
OR
METRIC UNITS
OR
SUBSONIC Flow - Generally When Set Pressure < 15 psig [1.03 barg]
1
12510 P FK
MTZ V
A
D
=
1
4645 P FK
MTZ V
A
D
=
M P FK
TZ W
A
D 1
735
=
M P FK
TZ W
A
D 1
558
=
VOLUMETRIC FLOW
MASS FLOW
Formula Symbols
SYMBOL
A
P
1
V
W
Z
K
D
M
T
F
DESCRIPIPTION
Calculated Orifice Area
Inlet Flowing Pressure [P
1
= P
set
+ P
over
P
loss
+ P
atm
]
Volumetric Flow Rate
Mass Flow Rate
Compressibility Factor (if unknown, assume Z = 1.0)
Actual Coefficient of Discharge
Molecular Weight
Relieving Temperature
Subsonic Flow Factor
Units
SYMBOL
A
P
1
V
W
Z
K
D
M
T
F
ENGLISH
in
2
psia
SCFM
lb/hr
---
---
---
R = F + 460
---
METRIC
cm
2
bara
Nm
3
/hr
kg/hr
---
---
---
K = C + 273
---
Subsonic Flow Factor
(
(
(

|
|
.
|

\
|

|
|
.
|

\
|

=
+
k
k
k
P
P
P
P
k
k
F
1
1
2
2
1
2
1
For Pressure:
P1 = Inlet Flowing Pressure [P
1
= P
set
+ P
over
P
loss
+ P
atm
]
P2 = Pressure at Valve Outlet [P
2
= P
back
+ P
atm
]
For Vacuum:
P1 = Atmospheric Pressure [P
1
= P
atm
]
P2 = Pressure at Valve Outlet [P
2
= P
vacuum set
+ P
under
+ P
atm
]
k = ratio of specific heats
WHERE:
F
Factor
0.55
0.50
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
1.00 0.90 0.80 0.70 0.60 0.50 0.40
k = 1.90
k = 1.40
k = 1.00
F
= Absolute Pressure Ratio
P2
P1
AGC Series
90 & 9000
Steam Sizing
ENGLISH UNITS
METRIC UNITS
SONIC Flow - Generally When Set Pressure > 15 psig [1.03 barg]
1
5 . 51 P K K KK
W
A
b P S
=
1
5 . 52 P K K KK
W
A
b P S
=
Formula Symbols
SYMBOL
A
P
1
W
K
K
S
K
P
K
b
DESCRIPIPTION
Calculated Orifice Area
Inlet Flowing Pressure [P
1
= P
set
+ P
over
P
loss
+ P
atm
]
Mass Flow Rate
ASME Coefficient of Discharge
Superheat Correction Factor
High Pressure Correction Factor (over 1600 psig)
Back Pressure Correction Factor
Units
SYMBOL
A
P
1
W
K
K
S
K
P
K
b
ENGLISH
in
2
psia
lb/hr
---
---
---
---
METRIC
cm
2
bara
kg/hr
---
---
---
---
K
S
Superheat Correction Factor
Set
Pres.
psig
15
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
350
400
450
500
Sat.
Steam
o
F
250
259
287
308
324
338
350
361
371
380
388
395
403
409
416
422
436
448
460
470
Total Steam Temperature,
o
F
280
1.00
1.00
300
1.00
1.00
1.00
320
1.00
1.00
1.00
1.00
340
0.99
0.99
1.00
1.00
1.00
1.00
360
0.99
0.99
0.99
0.99
1.00
1.00
380
0.98
0.98
0.99
0.99
0.99
1.00
1.00
1.00
1.00
400
0.98
0.98
0.98
0.98
0.99
0.99
0.99
1.00
1.00
1.00
1.00
1.00
420
0.97
0.97
0.97
0.97
0.98
0.98
0.98
0.99
0.99
0.99
0.99
1.00
1.00
1.00
1.00
440
0.96
0.96
0.96
0.96
0.97
0.97
0.97
0.98
0.98
0.98
0.99
0.99
0.99
0.99
1.00
1.00
1.00
460
0.95
0.95
0.95
0.95
0.96
0.96
0.96
0.96
0.97
0.97
0.97
0.98
0.98
0.98
0.99
0.99
1.00
1.00
480
0.94
0.94
0.94
0.94
0.94
0.95
0.95
0.95
0.95
0.96
0.96
0.96
0.97
0.97
0.97
0.98
0.99
0.99
1.00
1.00
520
0.93
0.93
0.93
0.93
0.93
0.94
0.94
0.94
0.94
0.94
0.94
0.95
0.95
0.96
0.96
0.96
0.97
0.97
0.98
0.99
[ENGLISH]
500
0.93
0.93
0.93
0.93
0.93
0.94
0.94
0.94
0.94
0.95
0.95
0.95
0.95
0.96
0.96
0.96
0.97
0.98
0.99
0.99
K
S
Superheat Correction Factor
SET
PRES.
barg
1.03
1.38
2.76
4.14
5.52
6.90
8.27
9.65
11.0
12.4
13.8
15.2
16.6
17.9
19.3
20.7
24.1
27.6
31.0
34.5
SAT.
STEAM
o
C
121
126
142
153
162
170
177
183
188
193
198
202
206
210
213
217
225
231
238
243
TOTAL STEAM TEMPERATURE,
o
C
138
1.00
1.00
149
1.00
1.00
1.00
160
1.00
1.00
1.00
1.00
171
0.99
0.99
1.00
1.00
1.00
1.00
182
0.99
0.99
0.99
0.99
1.00
1.00
193
0.98
0.98
0.99
0.99
0.99
1.00
1.00
1.00
1.00
205
0.98
0.98
0.98
0.98
0.99
0.99
0.99
1.00
1.00
1.00
1.00
1.00
216
0.97
0.97
0.97
0.97
0.98
0.98
0.98
0.99
0.99
0.99
0.99
1.00
1.00
1.00
1.00
227
0.96
0.96
0.96
0.96
0.97
0.97
0.97
0.98
0.98
0.98
0.99
0.99
0.99
0.99
1.00
1.00
1.00
238
0.95
0.95
0.95
0.95
0.96
0.96
0.96
0.96
0.97
0.97
0.97
0.98
0.98
0.98
0.99
0.99
1.00
1.00
249
0.94
0.94
0.94
0.94
0.94
0.95
0.95
0.95
0.95
0.96
0.96
0.96
0.97
0.97
0.97
0.98
0.99
0.99
1.00
1.00
260
0.93
0.93
0.93
0.93
0.93
0.94
0.94
0.94
0.94
0.95
0.95
0.95
0.95
0.96
0.96
0.96
0.97
0.98
0.99
0.99
271
0.93
0.93
0.93
0.93
0.93
0.94
0.94
0.94
0.94
0.94
0.94
0.95
0.95
0.96
0.96
0.96
0.97
0.97
0.98
0.99
[METRIC]
K
P
- High Pressure Correction Factor
Pressure, psig [barg]
1.25
1.15
1.05
0.95
1500
[103.4]
1900
[131.0]
2300
[158.6]
2700
[186.2]
3100
[213.8]
3500
[241.3]
K
P
0.1906P - 1000
0.2292P - 1061
K
P
=
Steam Sizing Notes
Sec. VIII Use 10% over pressure
Sec. I Use 3% over pressure
Sonic Flow Use Steam Equations
Sub-Sonic Flow Use Gas/Vapor Equations
Liquid Sizing
ENGLISH UNITS
METRIC UNITS
B A V W
L
P P K KK
G V
A

=
38
B A V W
L
P P K KK
G V
A

=
094 . 5
Formula Symbols
SYMBOL
A
P
A
P
B
V
L
G
K
K
W
K
V
DESCRIPIPTION
Calculated Orifice Area
Inlet Flowing Pressure [P
1
= P
set
+ P
over
P
loss
]
Outlet Flowing Pressure [P
2
= P
back
]
Required Capacity
Specific Gravity
ASME Coefficient of Discharge [K=0.90 x K
d
]
Back Pressure Correction Factor
Viscosity Correction Factor
NOTE: Temperature is not required to calculate orifice area.
Units
SYMBOL
A
P
A
P
B
V
L
G
K
K
W
K
V
ENGLISH
in
2
psig
psig
gpm
---
---
---
---
METRIC
cm
2
barg
barg
m
3
/hr
---
---
---
---
Liquid Thermal Expansion Relief
GC
BH
V
L
500
=
V
L
=
B =
H =
G =
C =
Liquid Flow Rate, gpm
Cubicle Expansion Coefficient per F
Total Heat Transfer Rate, BTU/hr
Specific Gravity
Specific Heat, BTU/lbF
Per API 521, Section 3.14
Fire Sizing
The Procedure Used In Fire Sizing Depends On The Codes
And Engineering Practices Applied At Each Installation.
Some Procedures That May Be Used For Fire Sizing:
The Procedure Used In Fire Sizing Depends On The Codes
And Engineering Practices Applied At Each Installation.
Some Procedures That May Be Used For Fire Sizing:
Recommended Practices For The Design
And Installation Of Pressure Relieving
Systems In Refineries. (SET > 15 psig [1.03 barg])
Venting Atmospheric And Low Pressure
Storage Tanks (SET < 15 psig [1.03 barg])
Design Of Lp Gas Installations
Storage And Handling Liquefied Petroleum
Gasses (National Fire Protection Association)
Stationary Storage Tanks
Recommended Practices For The Design
And Installation Of Pressure Relieving
Systems In Refineries. (SET > 15 psig [1.03 barg])
Venting Atmospheric And Low Pressure
Storage Tanks (SET < 15 psig [1.03 barg])
Design Of Lp Gas Installations
Storage And Handling Liquefied Petroleum
Gasses (National Fire Protection Association)
Stationary Storage Tanks
API RP 521
API 2000
API 2510
NFPA 58
CGA S-1.3
API RP 521
API 2000
API 2510
NFPA 58
CGA S-1.3
API 521 (Fire) Unwetted Vessels
1
'
P
A F
A
S
=
A =
F =
A
S
=
P
1
=
Calculated PSV Orifice Area, in
2
Relates to Bare Vessel Metal
Temperature at Relief (if unknown, F=0.042)
Exposed Surface Area of Vessel, ft
2
Relieving pressure, psia
[P
1
= P
set
+ P
over
P
loss
+ P
atm
]
Per API 521, Section 3.15
API 521 (Fire) Unwetted Vessels
F Operating Factor

F

G
a
s

F

G
a
s
700
600
500
400
300
200
100
0
0.005 0.015 0.025 0.035 0.045 0.055
k = 1.001
k = 1.4
Operating Factor, F'
Conservative
( )
6506 . 0
1
25 . 1
1
1406 . 0
'
CKT
T T
F
wall

=
Minimum
T
wall
, R
T
1
, R
API 521 (Fire) Wetted Vessels
( )
82 . 0
000 , 21
wet
A F Q =
Q =
F =
A
wet
=
Total Heat Input to Wetted Surface, BTU/hr
Environmental Factor
Total Wetted Surface Area, ft
2
Per API 521, Section 3.15
( )
82 . 0
500 , 34
wet
A F Q =
Prompt Fire-Fighting Efforts &
Adequate Drainage
Exists
Prompt Fire-Fighting Efforts &
Adequate Drainage
Does Not Exists
Step 1
Vertical
Vessel
Horizontal
Vessel
Sphere
Max.
Dia.
25 ft.
Ground
API 521 (Fire) Wetted Vessels
Total Vessel Wetted Surface Area, ft2, Up to 25 ft. Above
Ground Level or, (in the Case of a Sphere) to the
Elevation of Largest Diameter - Whichever Is Greater.
API 521 (Fire) Wetted Vessels
VESSEL F
Bare (Un-Insulated) 1.0
Insulated
Conductance Value: 4 btu/hr/ft
2
/F 0.3
2 0.15
1 0.075
Earth Covered, Above Grade 0.03
Bare With Water Spray 1.0
Underground 0.0
VESSEL F
Bare (Un-Insulated) 1.0
Insulated
Conductance Value: 4 btu/hr/ft
2
/F 0.3
2 0.15
1 0.075
Earth Covered, Above Grade 0.03
Bare With Water Spray 1.0
Underground 0.0
API 521 (Fire) Wetted Vessels
vap
H
Q
W =
W =
Q =
H
vap
=
Required Valve Capacity, lb/hr
Total Heat Input to Wetted Surface, BTU/hr
Latent Heat of Vaporization, BTU/lb
EXAMPLES: AMMONIA 589
BENZENE 169
BUTANE 166
CO
2
150
ETHANE 210
ETHYLENE 208
METHANE 219
PROPANE 183
WATER 970
EXAMPLES: AMMONIA 589
BENZENE 169
BUTANE 166
CO
2
150
ETHANE 210
ETHYLENE 208
METHANE 219
PROPANE 183
WATER 970
Step 2
API 521 (Fire) Wetted Vessels
M K K CKP
TZ W
A
c b 1
=
M K K CKP
TZ W
A
c b 1
316 . 1
=
ENGLISH METRIC
Use Vapor Equations to Calculate Required
Orifice Area.
Use the Boiling Temperature of the Liquid
(Flash to Vapor) for T .
Use Relieving Temperature for orifice sizing.
Use Operating Temperature for soft good
selection.
If unknown, we suggest using 200F [93C]
Step 3
API 2000 (Fire)
82 . 0
1107FA V =
V =
F =
A =
Venting Requirement, ft
3
/hr, air (60F)
Environmental Factor (if unknown, F=1.0)
Exposed Surface Area of Vessel, ft
2
Set Pressure < 15 psig [1.03 barg]
API 2000 (Fire) - Surface Area s 2800 ft
2
A, ft
2
20
30
40
50
60
70
80
90
100
120
140
160
180
200
250
300
SCFM
AIR
352
527
702
878
1053
1228
1403
1580
1780
2100
2450
2800
3167
3517
2983
4417
A, ft
2
350
400
500
600
700
800
900
1000
1200
1400
1600
1800
2000
2400
2800
over 2800
SCFM
AIR
4800
5200
5900
6533
7133
7700
8217
8733
9283
9783
10,233
10,650
11,033
11,733
12,367
use formula
Using the calculated, required,
relief valve capacity and set
pressure, use air capacity tables
(10% overpressure) in catalogs
to select orifice area and
valve size. For set pressures
15 psig and below, be sure
to use the actual K
D
Reference: API 2000, Sections 1.5.2 and 2.3
ASME K
0.90
K
D
=