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How To Perform PSV Sizing?

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Pressure relief valves and other relieving devices are crucial for protecting piping, valves, fittings,
and equipment from pressures exceeding their design limits. Proper selection, use, location, and
maintenance of these devices are vital to ensure the safety of personnel and equipment, as well
as to comply with industry codes and regulations.

Relief valves must be designed to open rapidly and fully and must be adequately sized to handle
the total flow of gases and liquids that could potentially cause an overpressure situation. These
valves alleviate pressure by routing the fluid stream to a safe location, where it can be either
vented to the atmosphere or safely burned using a flare system.

The importance of relief valves cannot be overstated, as safety switches can fail or be bypassed
for operational reasons. Thus, these devices serve as a critical last line of defense in maintaining
safe operating conditions.

To save time, PSV sizing can be carried out by excel tools or Software applications in conjunction
with Codes and Standards.

Applicable Code & Standards

 API 520 (Parts I & II) Guidelines for PSV sizing, selection, and installation.
 API 521 Recommendations for designing pressure-relieving and de-pressuring systems.
 ASME BPVC Section VIII, Division 1 Requirements for pressure vessel design and PSV
inclusion.
 ISO 4126 Standards for pressure relief device requirements and performance.
 NFPA 30 Guidelines for pressure relief in flammable and combustible liquid handling.
 EN 4126 (European Standard): Requirements for designing and testing pressure relief
devices.

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Key Considerations

Set Pressure and Overpressure Allowance Ensure PSV begins to open at the set pressure and
allows for overpressure accumulation (typically 10% for non-fire, 21% for fire scenarios).

Relieving Conditions Calculate relieving pressure and temperature.

Flow Capacity Ensure the PSV can handle maximum expected flow rates.

Fluid Properties Use accurate fluid properties for precise calculations.

Backpressure Account for constant and variable backpressure.

Two-Phase Flow Special calculations are needed for two-phase flow scenarios.

Types of Valves

 Conventional Relief Valve

 Balanced-Bellows Relief Valve
 Pilot-Operated Relief Valve

As per API 520

 Low and Stable Backpressure (<10% of set pressure) Use Conventional Relief Valve.
 Moderate to High and Variable Backpressure (10% - 50% of set pressure) Use
Balanced-Bellows Relief Valve.
 High and Highly Variable Backpressure (up to 100% of set pressure) Use Pilot-
Operated Relief Valve.

General Overview of the PSV Sizing Process

Determine the Set Pressure

Set pressure is typically at or slightly above the maximum allowable working pressure (MAWP) of
the system.

Identify the Overpressure Scenario

Common scenarios: blocked outlet, thermal expansion, fire exposure, equipment failure, process
upsets.

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Calculate the Required Relief Rate

Calculate the amount of fluid to be relieved to prevent excessive pressure, involving complex
thermodynamic and fluid dynamic calculations.

Select the Appropriate PSV Type

Choose between spring-loaded, pilot-operated, etc., based on application, fluid characteristics,

and operating conditions.

Determine the Required Orifice Size

Use the calculated relief rate to determine the PSV orifice size, considering factors like
backpressure, temperature, viscosity, and compressibility.

Check Against Industry Standards

Ensure compliance with standards such as ASME Boiler and Pressure Vessel Code, API standards,
and other regulations.

Account for Backpressure

Consider the impact of backpressure on PSV performance, as high backpressure can reduce
effective relief capacity.

Verify and Document

Cross-check PSV sizing with manufacturer’s data, document calculations and the selection process
for compliance and future reference.

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Fire Exposure Scenario (API Method):

For vessels exposed to fire, use the API 521 guidelines. The relief rate due to fire can be
estimated by:

Example Calculation: Sizing a PSV for Gas Service in a Fire Scenario

Here’s a step-by-step process for sizing a Pressure Safety Valve (PSV) for a gas service in a fire
scenario:

1. Determine the Set Pressure

Set Pressure: Usually set at or slightly above the maximum allowable working pressure (MAWP)
of the vessel.

Example:

MAWP of the vessel = 150 psi

Set Pressure: 150 psi

2. Identify the Overpressure Scenario

Scenario: Fire exposure

Overpressure Allowance: For fire scenarios, typically 21% over the set pressure is allowed.

Relieving Pressure: Set pressure + 21% of set pressure

150 psi + ( 0.21 × 150 psi ) = 181.5 psi

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3. Calculate the Required Relief Rate

Use API 521 guidelines for fire sizing.

Formula for gas relief rate due to fire:

Example Data:

Fire factor (F): 21,000 BTU/hr-ft² (typical for vessels)

Wetted surface area (A): 100 ft²

Molecular weight (W): 18 (for ammonia)

Relieving temperature (T): 600°R (140°F + 460 for Rankine)

4. Select the Appropriate PSV Type

Consideration: High backpressure in fire scenarios.

Selection: Pilot-operated PSV or balanced-bellows PSV for high backpressure tolerance.

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5. Determine the Required Orifice Size

API 520 Formula for orifice size:

Example Data:

Flow coefficient (C): 356 (for air at standard conditions)

Effective coefficient of discharge (Kd): 0.975

Relieving pressure (P): 181.5 psi (gauge) = 181.5 + 14.7 = 196.2 psia

Compressibility factor (Z): 1 (assume ideal gas)

6. Check Against Industry Standards

Ensure the selected PSV size and type comply with ASME and API standards.

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7. Account for Backpressure

Example: If backpressure is high, verify the pilot-operated or balanced-bellows PSV can handle it
without performance degradation.

8. Verify and Document

Cross-check: Confirm calculations with manufacturer’s data.

Document: Keep records of all calculations and assumptions for compliance and future reference.

Task: Design the safety PSV for a vessel to protect it from fire events based on API standards.

Design the safety PSV for a vessel to protect it from fire events based on API standards.

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Step: 01

Start a New Case

Step: 02

Add components

Nitrogen n-Pentane

CO2 n-Hexane

H2S n-Heptane

Methane n-Octane

Ethane n-Nonane

Propane E-Mercaptan

n-Butane

Step: 03

Select Peng Robinson as a property package

Step: 04

Enter in to the Simulation Environment and add the Material Stream and input the following
parameters:

Feed Composition Feed Conditions

Nitrogen 0.01 n-Pentane 0.03

Temperature [C] 66
CO2 0.07 n-Hexane 0.05
Pressure [kPa] 4238
H2S 0.08 n-Heptane 0.03 Molar Flow
[kgmole/h] 4218
Methane 0.47 n-Octane 0.04

Ethane 0.07 n-Nonane 0.05

Propane 0.05 E-Mercaptan 0.01

n-Butane 0.04

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Step: 05

Add a valve after the stream with a Delta P 0.0034 Kpa

Step: 06

Add a two phase separator after the valve

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Step: 07

Click on Pressure Relief option to switch to Safety Analysis environment.

Step: 08

Add a PSV on vapor outlet

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Step: 09

Select PSV in a navigation menu on the left and input the design temperature and pressure.

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Step: 10

Select PRD Data option Select Relief Valve Type Conventional  Select Body Material
Stainless Steel.

Step: 11

Go to Scenario option Create Scenario  Select Type Fire Case And Check Sizing Case.

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Step: 12

 Select Scenario in a navigation menu on the left.

 Select scenario reference stream: Click Select button  Select the stream (Vap) for the
case.
 Select Relieving Phase – Method : Direct Integration (HEM)
 Select Calculation Method: Unwetted (API)

Step: 13

 Select Vessel Type Vertical (Incl. Bottom Head)

 Select Head Type Hemispherical
 Insert Diameter 3.658 m, Vessel Tan/Tan 11.58 m, Elevation 1.524 m

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Step: 14

 Select the orifice size , Selected Orifice >= Calculated Orifice

Step: 15

 Click Fluid Properties option to view fluid properties.

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Step: 16

 Click Relief Composition option to view components fractions in the relief.

Step: 17

 Select PSV in a navigation menu on the left Rating to view scenario details.

On Analysis: Recommended Orifice size is 5.064 cm2 (H)

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