By Rahul Deshpande

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Safety valves – Features and sizing
Safety relief valves are the last line of defense to
protect personnel and equipment from the
consequences of energy and mass accumulation
greater than what is allowed by design limit.
Safety relief valves are commonly installed one or more
of following reasons :
 Safety of operating personnel w.r.t. overpressure

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 Prevention of destruction of capital investment
due to overpressure.
 Conservation of material loss during & after an
upset which produces temporary overpressure.
 Minimizing of unit downtime caused by
overpressure.
 Prevention of damage to downstream equipment
due to overpressure being transmitted through
connecting equipment and piping.

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 Necessity of compliance with local, state and
national regulations.
Following API stds. Are referred for safety valve
relief sizing :
 API 520 : For sizing selection and installation of
pressure relieving devices
 API 521 : Guide for pressure relieving and
depressurizing systems

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Nomenclature
 Relief valves :
A relief valve is a spring loaded pressure relief valve
actuated by static pressure upstream of valve. The
valve opens normally in proportion to the pressure
increase over the opening pressure. The relief valves
are used primarily for incompressible fluids. Relief
valve capacities are usually rated at 10-25%
overpressure depending on application.

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 Safety valves :
A safety valve is spring loaded pressure relief valve
actuated by static pressure upstream of the valve and
characterized by rapid opening or pop-up action. A
safety valve is normally used for compressible fluids.

 Conventional pressure relief valve :

A conventional pressure relief valve is spring loaded
pressure relief valve whose performance characteristics
are directly affected by changes in back pressure on the
valve.

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 Balanced pressure relief valves :
A balanced pressure relief valve is a spring loaded
pressure relief valve that incorporates means for
minimizing effect of back pressure on the performance
characteristics.
 Pilot operated pressure relief valves :
A pilot operated pressure relief valve is a pressure relief
valve in which main valve is combined with and
controlled by an auxiliary pressure relief valve.

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 Set pressure :
The set pressure is the inlet gauge pressure at which
pressure relief valve is set to open under service
conditions.

 Cold differential test pressure :

The cold differential test pressure is the pressure at
which pressure relief valve is adjusted to open on test
stand. It includes correction for the service conditions
of back pressure and temperature both.

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 Back pressure :
Back pressure is the pressure that exists at the outlet of
pressure relief device as a result of pressure in the
discharge system. It is sum of superimposed back
pressure and built-up back pressure.

 Blow down :
Blow down is the difference between set pressure and
closing pressure of pressure relief valve expressed as %
of set pressure or in pressure units.

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 Accumulation :
Accumulation is the pressure increase over the
maximum allowable working pressure of the vessel
during discharge through pressure relief device
expressed in pressure units or %.
Maximum allowable accumulations are established by
applicable codes for operating and fire contingencies.

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 Overpressure :
Overpressure is the pressure over the set pressure of
relieving devices expressed in pressure units or %. It is
same as accumulation when relieving device is set at
maximum allowable working pressure of the vessel.
Causes of overpressure :
Following are various causes of overpressure. Not all
causes will appear simultaneously therefore, the
pressure relief valve should be sized for the condition
or the conditions that required largest relief area. The
pressure relief valves are not required on each vessel or
group of vessels that may be isolated by control valves
or other valves.

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 Causes :
- Closed outlet on vessels
- Reflux failure
- Inadvertent valve opening
- Check valve malfunction
- Utility failure
- Electrical or mechanical failure
- Loss of instrument air or electric power
- Abnormal heat input from reboiler
- Heat exchanger tube failure

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 - External fire
- Hydraulic expansion

 Causes of overpressure :
- Utility failure – The consequences that may develop from
loss of any utility service must be carefully evaluated. The
normal utility services that could fail are :
 Cooling water
 Instrument air
 Steam
 Fuel oil
 Inert gas
 Electric power

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 Closed outlet on vessel :
The inadvertent closure of block valve on outlet of
pressure vessel while plant is on-stream may expose
the vessel to pressure that exceeds maximum allowable
working pressure. The pressure relieving device is
required if block valve is not locked open. Closure of
such valve can result in overpressure.

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 Inadvertent valve opening :
The inadvertent valve opening of any valve from source
of high pressure such as high pressure steam or
process fluids should be considered.

 Check valve malfunction :

The failure of check valve to close must also be
considered. E.g. where fluid is pumped into process
system that contains gases or vapor at significantly
higher pressure than design rating of that equipment
upstream of the pump, cessation of flow accompanied
by failure of check valve at discharge line will result in
reversal of liquid’s flow and serious overpressure may
result.

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- Electric or mechanical failure –
The failure of electrical or mechanical equipment
that provides cooling or condensation in process
streams can cause overpressure in process vessel.
- Loss of instrument air or electric power –
The complexity of instrument automation on process
unit requires the provision of reliable and continuous
source of air or electric power or both , for dependable
operation. To minimize the like hood of overpressure,
each control valve should have its fail safe
characteristics properly established as integral part of
plant design.

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 Abnormal heat input from reboiler :
Reboilers are designed with specific heat input. When
they are new or recently cleaned, additional heat input
above normal design can occur. In case of failure of
temperature control, excess vapor generation can lead
to built up of pressure.
 Heat exchanger tube failure :
In shell and tube heat exchanger, tubes are subject to
failure from number of causes including thermal
shock, vibration and corrosion.

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Whatever the cause, the result is the possibility that
high pressure stream will over pressurize equipment
on low pressure side of exchanger. Economical design
usually dictates that high pressure stream flow
through tubes, since this can result in thinner shell,
but this is not always the case. The possible pressure
rise must be ascertained to determine whether
additional pressure relief would be required if flow
from tube rupture were to discharge into low pressure
stream.

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 External fire :
Any pressure vessel in operating plant that handles or
processes flammable liquid or gases may be exposed to
fire at some time in its life. The hazard may exists even
though contents of the vessel itself are not flammable,
therefore, for pressure vessel that contain liquids, a
pressure relief Safety valve should be provided to
relieve overpressure generated by fire heat input.

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- External fire –

Effect of fire on wetted surface of vessel :

If the critical pressure of the fluid exceeds the
relieving pressure , radiation to the wetted surface of
partially filled vessel (assuming no thermal insulation
will be absorbed as sensible heat , the vessel and liquid
temperatures will be increased and will essentially be
equal. At boiling point the radiation will be absorbed
by liquid almost totally as latent heat. ) The heat
absorption and consequent vapor generation will
cause overpressure in the vessel to be until it reaches
the relieving pressure of pressure relief valve.

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- Effect of fire on un-wetted surface of vessel :
Un-wetted surface exposed to fire do not have the
benefit of latent heat absorption of liquid to mitigate
the rise in metal temperature. When only vapor is
present to absorb heat internally, the wall temperature
can rise rapidly which may soon lead to vessel rupture.
Pressure relief valve may provide protection only for
short period, other devices would be required to
prevent vessel rupture.

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 Hydraulic expansion :
Hydraulic expansion is the increase in liquid volume
caused by an increase or decrease in temperature. It
can result from several causes , the most common
which are following –
 Piping or vessels are blocked in while they are filled
with cold liquid and are subsequently heated by heat
tracing, coils or ambient heat gain or fire.
 An exchanger is blocked in on cold side with flow in
hot side.
 Piping or vessel are blocked in while they are filled
with liquid at near ambient temperature and are
heated by direct solar radiation.

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Determination of individual rates
 Blocked outlet :
To protect the vessel or system from overpressure,
when all outlets on the vessel or system is blocked, the
capacity of relief device must be at least as great as
capacity of source pressure. If all outlets are not
blocked, the capacity of unblocked outlet may
properly be considered. The source of overpressure
includes pumps, compressors, high pressure supply
headers and process heat. In case of heat exchangers, a
closed outlet can cause thermal expansion or possibly
vapor generation.

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The quantity of material to be relieved should be
determined at conditions that correspond to set
pressure plus over pressure instead of normal
operating conditions. The required valve capacity is
often reduced appreciably when this difference in
condition is considered.

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 Heat transfer equipment failure :
A tube rupture is considered to be a sharp cut in one
tube. The high pressure fluid is assumed to flow
through openings that are equal to twice the cross
sectional area of one tube. The flow considered should
include flow through the tube opening in the tube
sheet and flow through broken tube.
In determining the flow rate , allowance should be
made for any liquid that will flash to vapor either as
pressure reduction.

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 Cooling failure :
The relief requirement is total incoming vapor rate to
the condenser recalculated at temperature that
corresponds to new vapor composition at set pressure
plus overpressure and heat input prevailing at time of
relief.
 Partial condensing :
The relief requirement is the difference between
incoming and outgoing vapor rate at relieving
conditions. The incoming vapor rate should be
calculated on the same basis as that
for total condensing case. If the composition or rate of
reflux is changed , the incoming vapor rate to
condenser should be determined for new conditions.

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 Failure of process stream automatic control :
When the transmission signal to final control element
fails, the control devices assume either a fully open or
fully closed or to last position.
For inlet control valves, if fail position is “close”,
overpressure relieving device may not be required.
However, if fail position is “open”, relieving flow rate is
the difference between maximum flow and normal
flow.
For outlet control valves, that fails in “closed” position,
entire flow shall be considered for sizing pressure
relieving device.

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 Hydraulic expansion :
Since every application will be relieving the liquid, the
capacity of relieving device will be small. A ¾” x 1”
relief valve is commonly used.

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 External fire case :
The surface area wetted by vessel’s internal liquid
contents is effective in generating vapors, when area is
exposed to fire. To determine vapor generation, only
that portion of the vessel that is wetted by its internal
liquid and is equal to or less than 25ft (7.62 m.) above
the source of flame needs to be recognized.

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Heat absorption across the wetted surface of the vessel
:
The amount of heat absorbed by vessel exposed to
open fire is affected by type of fuel feeding the fire, the
degrees to which vessel is enveloped by flames and
fireproofing measures.

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Pressure Relief Valve Sizing Calculations –
Critical Gas Flow Service
 Sample Problem Statement
Design a pressure relief valve for the following service.
Protected equipment : Separator vessel Relief service : Fuel Gas
Reason for relief : Blocked gas discharge
Relieving Rate : 10,000 kg/hr
Gas Density : 4.1 kg/m3
Ratio of specific heats for the gas (CP/CV) : 1.35 Compressibility
factor of gas = 0.95
Relieving temperature = 20°C
Set pressure : 5 barg
Accumulation : 10%
Back pressure at relief valve discharge : 0.5 barg
Type of relief valve : Conventional

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 Solution
This sample problem for relief valve sizing calculation
can be solved in following steps, which are based on
pressure relief valve sizing procedures described in API
RP 520 Part I. The first step is to determine whether
the gas flow type is critical or sub-critical.

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 Step1 The first step is to determine if the flow
conditions are critical. For this purpose the critical
flow pressure (Pcf) downstream to the relief valve has
to be calculated using the following equation from API
RP 520 Part I,
Pcf = P1 x (2 / k+1)^(k/k-1)
P1 : Relieving pressure upstream to relief valve in bara
P1 = 6.51 bara (including 10% accumulation)
k : Ratio of specific heats of the gas .. (CP/CV)
k = 1.35
Pcf : Critical flow pressure for the given flow
conditions in bara Pcf = 3.5 bara

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 If the pressure downstream or back pressure of the
relief valve is lower than the critical flow pressure,
then the flow is said to be of critical type.
 In the present case, back pressure (1.5 bara) < Pcf (3.5
bara). Hence the flow is of critical type.

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 Step2 Next step is to use the relief valve sizing
procedure given in the API 520 part I for critical flow
type gas relief valve. The following equation is used, …
(1)

 A = (W/CxKdxP1x Kbx Kc) x sqrt (TxZ / M)

 A : orifice are requirement in mm2

 W : flowrate in kg/hr W = 10,000 kg/hr
 T : Temperature in Kelvin T = 273.16 + 20 = 293.26 K
 Z : compressibility factor of gas Z = 0.95
 C : coefficient

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 C = 520 x (sqrt (k x (2/k+1)^(k+1/k-1))
here, C = 351.6
P1 : Relieving pressure upstream to relief valve in bara
P1 = 6.51 bara (including 10% accumulation)
Kd : Coefficient of discharge Kd = 0.975 for gas service
Kb : capacity correction factor due to back pressure Kb
= 1 (for conventional relief valves with near
atmospheric backpressure)
KC : combination correction factor for use of rupture
discs KC = 1 (for absence of rupture disc upstream to
the valve, 0.9 for RV+RD)
Plugging this data into equation (1), the minimum
required orifice area for the relief valve is

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 A = 22.0 cm2

 Step3
 The next higher available orifice area should be
selected for the pressure relief valve to be actually
installed. Referring to the table of standard orifice
sizes from API 526- Table 1, Next high available orifice
area is selected to be A = 23.20 cm2 and the
corresponding designating letter is ‘M’. Available valve
size is ’4M6′, which correspond to different nozzle
sizes for suction and discharge nozzles of the pressure
relief valve.

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Pressure Relief Valve Sizing Calculations –
Subcritical Gas Flow Service
 Sample Problem Statement
 Design a pressure relief valve for the following service. Protected
equipment : Separator vessel
 Relief service : Fuel Gas
 Reason for relief : Blocked gas discharge
 Relieving Rate : 10,000 kg/hr
 Gas Density : 4.1 kg/m3
 Ratio of specific heats for the gas (CP/CV) : 1.55 Compressibility factor
of gas = 0.95
 Molecular weight of gas = 20 gm/mole
 Relieving temperature = 20°C Set pressure : 4.5 barg
 Accumulation : 10%
 Back pressure at relief valve discharge : 2.1 barg
 Type of relief valve : Balanced bellows

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 Solution This sample problem for relief valve sizing
calculation can be solved in following steps, which are
based on pressure relief valve sizing procedures
described in API RP 520 Part I. The first step is to
determine whether the gas flow type is critical or sub-
critical.

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 Step1
 The first step is to determine if the flow conditions are
critical or sub-critical. For this purpose the critical
flow pressure (Pcf) downstream to the relief valve has
to be calculated using the following equation from API
RP 520 Part I,
 Pcf = P1 x [ 2/k+1]^(k/k-1)

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P1 : Relieving pressure upstream to relief valve in bara
P1 = 5.96 bara (including 10% accumulation)
k : Ratio of specific heats of the gas .. (CP/CV) k = 1.55
Pcf : Critical flow pressure for the given flow
conditions in bara
Pcf = 3.0 bara
If the pressure downstream or back pressure (3.113
bara) of the relief valve is greater than the critical flow
pressure (3.0 bara), then the flow is said to be of sub-
critical type. In the present case, back pressure (3.113
bara) > Pcf (3.0 bara). Hence the flow is of sub-critical
type.

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 Step2 Next step is to use the relief valve sizing
procedure given in the API 520 part I for sub-critical
flow type gas relief valve. The following equation is
used,
A = (17.9 x W / F2 x Kd x Kc) x sqrt [ (ZT/MP1(P2-P1)]

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 A : orifice are requirement in mm2
W : flowrate in kg/hr W = 10,000 kg/hr
T : Temperature in Kelvin T = 273.16 + 20 = 293.26 K
Z : compressibility factor of gas Z = 0.95
M : Molecular weight of the gas M = 20 gm/mole
P1 : Relieving pressure upstream to relief valve in bara
P1 = 5.96 bara (including 10% accumulation)
P2 : back pressure downstream to relief valve in bara P2 =
3.11 bara
Kd : Coefficient of discharge Kd = 0.975 for gas service
KC : combination correction factor for use of rupture disc
KC = 1 (for absence of rupture disc upstream to the valve)

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 F2 : Coefficient of sub-critical flow
F2 = sqrt [ (k/k-1)x (r)^(2/k) x (1-(r)^(k-1)/k) / (1-r)]
k : Ratio of specific heats of the gas .. (CP/CV) k = 1.55
r : ratio of back pressure to relieving pressure
r = P2/P1 = 0.58 hence, F2 = 0.5985
Plugging this data into equation (1), the minimum
required orifice area for the relief valve is calculated to
be, A = 34.07 cm2

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 Step3
The next higher available orifice area should be
selected for the pressure relief valve to be actually
installed. Referring to the table of standard orifice
sizes given in API 526 –table 1, next high available
orifice area is selected to be A = 41.20 cm2 and the
corresponding designating letter is ‘P’. Available valve
size is ’4P6′, which corresponds to different nozzle
sizes for suction and discharge nozzles of the pressure
relief valve.

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Pressure relief valve nozzle orifice
areas in square inch
Orifice designation API area

D 0.11
E 0.196
F 0.307
G 0.503
H 0.785
J 1.287
K 1.838
L 2.853
M 3.60
N 4.34
P 6.38
Q 11.05
R 16.0
T 26.0
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Safety valve sizing for fire case
 Basis : API 520 (External fire condition)
 Equation :
Q = 21000 x F x A^0.82
Where, A = Area exposed to the fire, ft^2
F = Environment factor
Q = Heat absorption to wetted surface, Btu/h
Where adequate drainage and fire fighting equipments do not exist, we
have to use the following equation –
Q = 34500 x F X A^0.82
For vertical non-insulated vessel following case study data is assumed :
Vessel dia = 2m.
Liquid level = 2m.
Vessel elevation = 5m. (From bottom tan line)

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Maximum fire height = 7.62m. (API 521 maximum fire
height 25ft.(7.62m))
Wetted height (H) = 2.0m.
Wetted area calculations
Vessel radius = R = D/2 = 1m.
Vessel wetted area = shell + head
= 2xPixRxH + 0.345 x Pi x 2R^2
= 14.74 m^2. = 158.3 ft^2 (For vertical vessel)

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Using the equation ,
Q = 21000 x F x A^0.82
As F = 1 for non-insulated vessel, we get
Q = 21000 x 1 x 158.3^0.82
= 1336013 Btu/h
If latent heat of vaporization of liquid = 205.26 Btu/lb
Amount of liquid vaporized = 1336013/205.26
= 6509 lb/h = 2952 kg/h
Therefore, design capacity of safety valve = 2952 kg/h

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Horizontal vessel : Fire case
Given data :
Vessel dia = 1.70m.
Boot dia = 0m.
Liquid level = 1.36 m.
Vessel elevation = 3 m.
Maximum fire height = 7.62 m.(API 521 maximum fire
height = 25ft. (7.62m.))
Weighted height = 1.36 m. (H)
Length = 5.1 m.

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 Wetted area calculations : Vessel radius (R = D/2 =
0.85 m.)
Head wetted fraction (f) –
(R^2cos^-1(1-H/R) – (R-H)x sqrt (2RH-H^2) / Pi x R^2 =
0.86
Vessel wetted area (shell + heads)
2RLcos^-1(1-H/R) + 2f x 0.345 x Pi x (2R)^2
= 24.571 m^2
Boot wetted area
Pi x D x H + 0.345 x Pi x D^2
= 0 m^2

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 Total wetted area = 24.571 m^2 = 264.476 ft^2
Using the equation, we get,
Q = 21000 x 1 x 264.476^0.82
= 2035054 btu/h
Amount of liquid vaporized = 2035054 / 205.26 =
9914.5 lb/h = 4496.4 kg/h
Safety valve required design capacity = 4497 kg/h

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Blocked outlet case
 The calculations are based on the following formula :
Residence time = Volume (m^3) / Volumetric flow rate
(m^3/h)
In normal case, volumetric flow rate is given by pump
rated flow rate applicable to column / vessel. You need
to consider the volume in between HLL/HHLL to top
TL elevation of the item.

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If you get the residence time less than 30 min. (which
is considered as a std. time for panel operator’s
intervention), relief valve discharge = pump rated flow
rate. However, if you get the residence time more than
30 min., you need not have to perform the calculations
and make a remark that “sufficient time is available for
operator’s intervention.”

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Control valve malfunction case
 The system is having two independent control valve in
series(first and second @ 600 mts apart) for
controlling pressure to the downstream unit. The
downstream unit supplies the gas to two independent
units via a branched process line. The PSV is located
downstream of the second PCV.
The requirement of PSV is due to the pressure
limitation from the downstream unit and also the wide
variation of the incoming supply pressure
figures(chances of pressure surges deviation from
almost normal operation).

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 Please consider the control valve upstream pressure as
the maximum operation pressure and control valve
downstream pressure as relief valve set pressure. With
this (delta P), you need to estimate the flow rate based
on control valve sizing calculation formula by utilizing
the software or by the Fluid Control Institute
Formula(FCI, USA).
Control valve FCI Cv calculation formula of liquid
service , Cv = 1.17 x Q x (sqrt.(sp.gravity of the
liquid)/(pressure drop across control valve)) Whereas,
Q =m3/h , Pressure drop = kg/cm2

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 FCI, USA Important formulas for calculations - a)
Steam service : Delta P < 0.5P1
Cal Cv = W x K / (13.67 x sqrt(Delta P (P1+P2)) W =
kg/h and Pressure = kg/cm2a
b) Steam service : Delta P > 0.5P1
Cal Cv = W x K / (11.9 x P1)
W = kg/h and Pressure = kg/cm2a
In these formulas, K = 1 for saturated condition and K
= 1+(0.0013+steam temp.,deg.C) for superheated
temperature.

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 c) Vapour service Delta P< 0.5P1
Cal Cv = (V/1460) x (sqrt (MW x T / Delta P(P1+P2))
V = Nm3/h, MW = Molecular weight, T = deg.K and
Pressure = kg/cm2a
Delta P > 0.5P1
Cal Cv = (V/1270) x (sqrt(MW x T) / P1 P1 = kg/cm2a ,
V =Nm3/h and T = deg.K
Please remember the following conversions for your
day-today calculations, which you will need to
calculate the flow rates :
(Nm3/hr / 22.414) x (Mol.weight) = kg/hr
(kg/h x 22.414) / (Mol.weight) = Nm3/h.

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Tube rupture case
 In case of tube rupture case, please consider the orifice
sizing calculation formula.
You can utilize the formula which is given in Crane's book.
Orifice dia = Tube ID
Pressure P1 = Maximum operating pressure of high
pressure fluid service (abs.)
Pressure P2 = Relief valve overpressure i.e. set pressure x
1.1+abs.conversion factor (like in case of psi units, it is 14.7)
With this Delta P, you can estimate the relief rate. This
relief rate is considered as a single hole puncture in the
tube which you need to multiply with two(2) in calculation
considering that the tube may rupture from both the sides.

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 Q = 236 d1^2 x C x sqrt (ΔP / ρ)
In this equation,
Q = Rate of flow, in GPM
d1 = Tube ID, in inches
C = Flow coefficient for orifice (0.6)
ΔP = Differential pressure, psi
ρ = Weight density of fluid, lb/ft^3

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