Pembinaan Pemeriksaan Teknis,

Pengujian Katup Pengaman dan

Pemutusan Segel Migas 2019
PSV SIZING

Irmayanti Lusia
irmayanti@Kotaminyak.co.id
Codes & Standards
 American Society of Mechanical Engineers
• The ASME establishes rules of safety governing the design, the fabrication and the
inspection during construction of boilers and unfired pressure vessels, and interprets
these rules when questions arise regarding their intent.
• Different Sections of ASME Code deal with the manufacture of safety valves:
• ASME Code Section I
• ASME Code Section II
• ASME Code Section III
• ASME Code Section VIII
ASME Section I
• This is a construction code covering power, electric and miniature boilers and
high temperature boilers used in stationary service above 15 psig.
• 3% maximum overpressure at rated capacity.
• Blowdown requirements:
– Pset < 67 psi 4 psi
– Pset ≥ 67 and ≤ 250 psi 6% of set pressure
– Pset > 250 and ≤ 375 psi 15 psi
– Pset > 375 psi 4% of set pressure
• Set pressure tolerance:
– Pset  70 psig +/- 2 psi
– 70 psi < Pset  300 psi +/- 3 psi
– 300 psi < Pset < 1000 psi +/- 10 psi
– Pset  1000 psi +/- 1%
• Must have lifting lever and nameplate showing rated capacity in lb/hr
steam
ASME Section II
 This is a construction code listing materials suitable for the construction of
safety valves according to ASME Code.
– Part A: Ferrous Materials Specifications
– Part B: Nonferrous Materials Specification
– Part C: Specifications for Welding Rods, Electrodes & Filler Materials
– Part D: Properties (Customary or Metric)
 In order for a part to be used in the construction of a safety valve,
the material must appear in ASME Code Section II*.

* Materials found in ASME Code Cases are allowable to the limits specified in the code case.
 ASME Section VIII
• This is a construction code covering the basic rules for the construction, design,
fabrication, inspection and certification of unfired pressure vessels above 15 psig.
• Maximum accumulation at rated capacity:
– 10% (or 3 psi) single valve
– 16% (or 4 psi) multiple valves (non-fire)
– 21% overpressure due to fire
• No mandatory blowdown; however, adjustable blowdown valves must meet 7%
during test for certification
• Set pressure tolerance:
– Pset  70 psi +/- 2 psi
– Pset > 70 psi +/- 3%
• Lifting lever for water (>140ºF [60ºC]), air or steam service
• Nameplate showing rated capacity in SCFM air, US-GPM water or lb/hr steam
ASME VIII
Set Pressure Tolerance
UP TO 70 PSIG [4.83 barg] SET ---- ± 2 psig [0.14 barg]

OVER 70 PSIG [4.83 barg] SET ---- ± 3%

NAMEPLATE

SET PRES.
ASME Section VIII

CAN APPLY ONLY TO VALVES

SET 1.03 barg [15 psig] & HIGHER
 PRV Requirements
(reference Para. UG-136(a)(3))

ASME REQUIRES A LIFT LEVER

FOR SERVICES ON:
• AIR
• STEAM
• HOT WATER (> 140°F)
[> 60°C]
National Board of Boiler & Pressure Vessel
Inspectors (NB)
• The NB represents the enforcement agency who assures adherence
to provisions of the ASME boiler and pressure vessel codes.
• The NB:
• Sets inspection standards
• Qualifies inspectors
• Works for owners, insurers
• Maintains records (Red Book – NB-18)
• Looks into violations
• Covers repair (VR Stamp)
 NB Method of Certifying Capacity
• At an “ASME Approved” flow facility, flow each of 9 total valves
at 110% of Set Pressure (3 valve sizes, 3 set pressures)
• Establish the “KD” for each test valve (considering the flow
conditions and each measured orifice area)

FLOW OF THE TEST VALVE

KD =
FLOW OF A “PERFECT NOZZLE”
KA Factor
During certification

• A is measured
• Smallest section in the
flow path (throat)

• Actual flow is compared

to theoretical flow
through perfect nozzle
(K=1)

• Wactual/Wtheory= Kactual

• K=0.9 x Kactual
NB Method of Certifying Capacity
• Calculate the average “KD” for the 9 test valves
• No test valves “KD” can deviate more than ±5% from the average

• Establish the ASME “K”

K = Average KD x 0.90
• The nozzle coefficient “K”, and orifice area “A” are published for
all certified SV in the NB “Red Book”
Orifice Area

AN = AREA OF DN
(NOZZLE DIAMETER),
OR
AC = CIRCUM. OF DN X LIFT,
[“CURTAIN AREA”]
WHICHEVER
IS SMALLER

LIFT
 National Board NB-18 ‘Red Book’

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  ASME KA
(per NB Red Book)

www.nationalboard.org
National Board NB-18 ‘Red Book’
National Board NB-18 ‘Red Book’
 NB-18 viewed on line or downloaded
 All data on each and every valve (& RD) certified per ASME codes (I, III &
VIII)

K=Kd x 0.90

Actual
Areas
American Petroleum Institute (API)
API publishes several standards dealing with safety valves:
• API 520 Part 1 – Sizing & Selection of Pressure Relief Devices

• API 520 Part 2 – Installation of Pressure Relief Devices

• API 521 – Guide for Pressure-Relieving & Depressurizing Systems

• API 526 – Flanged Steel Safety Relief Valves

• API 527 – Seat Tightness of Pressure Relief Valves

 API 520
API 520 Part 1
• Applies to the sizing and selection of pressure relief devices for equipment with an
MAWP of 15 psig or greater.
• Protection of unfired vessels
• Basic definitions
• Operational characteristics of pressure relief devices
• Sizing procedures, equations and methods
API 520 Part 2
• Covers methods of installation for pressure relief devices on equipment with an MAWP of
15 psig or greater.
 API 520 Part 2
• According to API 520 Part 2, inlet piping must be sized so that non-recoverable pressure
losses from vessel to pressure relief valve inlet flange do not exceed 3% of set pressure.

Pressure Drop ≤ 3% of Pset

API 520 Part 2
• Install the PRV in an upright, vertical position

OUTLET

INLET

AVOID
 API 521
• API 521 is designed to aid in the selection of the system that is most appropriate for the
risks and circumstances involved in various installations.

• This standard provides guidelines for:

• Examining the principal causes of overpressure

• Determining individual relieving rates

• Including fire vapor generation and fire gas expansion

• Selecting and designing disposal systems

 API 526
• API 526 is a purchasing specification for flanged steel pressure relief valves. Requirements
are given for spring loaded pressure relief valves and pilot-operated relief valves.
• API 526 has standardized the following items:
1. Orifice designation and area
2. Valve size and pressure rating, inlet and outlet  
3. Materials
4. Pressure-temperature limits 
5. Center-to-face dimensions, inlet and outlet
• Inspection and shop tests

• Identification and preparation for shipment


 API 527
• API 527 describes tests to determine the seat tightness of metal and soft-seated pressure
relief valves. Valves of conventional, bellows, and pilot-operated designs are covered.
Acceptable leakage rates are defined.
• It contains criteria for:
• Testing with air
• Testing with steam
• Testing with water
• Testing with air – another method
API 527 Leak Test For Gas

1/2”
[13 mm]

1/4”
[6.4 mm] 90% OF SET PRES.
I.D.
 API 527 for Gas Service
Metal Seat Leakage At 90%
Set Pressure, psig Of Set Pressure, Bubbles/Minute
[barg]
“D” thru “F” Orifice “G” thru “T” Orifice
15 - 1000 [1.03 - 69] 40 20
1500 [103] 60 30
2000 [138] 80 40
2500 [172] 100 50
3000 [207] 100 60
4000 [276] 100 80
6000 [414] 100 100
Soft Seat Leakage At 90% Of Set
Pressure, Bubbles/Minute
15 - 6000 [1.03 - 414] 0
Required Nameplate Data
Terminology
 Safety Device Classification
Pressure Relief Devices

Reclosing Devices Non-reclosing Devices

Rupture Disc
Loading Principle

Direct-load Controlled
Pin-actuated Device

Controlled Safety Pressure Relief System

Spring Weight
loaded loaded Pilot-Operated Safety Valve
Function

Relief Safety Safety Snap-acting Modulating

Valve Valve Relief Valve
 Terminology
• Pressure Relief Valve
 A pressure relief device, either direct loaded or controlled, is designed to open and
relieve excess pressure and to re-close and prevent the further flow of fluid after normal
conditions have been restored.
– Relief Valve – Liquid Service
– Safety Valve – Vapor/Gas Service
– Safety Relief Valve – Either Liquid or Vapor/Gas Service
Loading Principle: Spring Loaded
• A pressure relief valve in which the opening and closing of the valve is controlled by a
spring.
Loading Principle: Weight Loaded
• A pressure relief valve in which the opening and closing of the valve is controlled by a
weight.
Loading Principle: Pilot Operated
• A pressure relief valve in which the main valve is combined with and controlled by an
auxiliary pressure relief valve (pilot-controlled).
Loading Principle: Controlled PRV
• A system consisting of a main valve in combination with control units. The closing
force is applied by a control device which will typically control an actuator on a direct
load pressure relief valve.
Pressure Relief Valve / Rupture Disk Combination
• A system consisting of a pressure relief valve in combination with a rupture disk.
 Set Pressure
• The inlet gauge pressure at which the Pressure Relief Valve is set to open.

Lift (%)

Set to popping point

0 Pressure (%)
94 96 98 100 102 104 106 108 110 121
 Simmer
• The audible or visible escape of compressible fluid between the seat and disc of the
Pressure Relief Valve prior to set pressure

Lift (%)
100

80

60

40

Simmer
20

0 Pressure (%)
94 96 98 100 102 104 106 108 110 121
 Operating Pressure Ratio
• The ratio of operating pressure to set pressure. 90% should not be exceeded for spring
loaded valves.
Maximum Allowable
Lift (%) Working Pressure
100

80
Operating
Pressure

60
Operating
Pressure
40
Ratio
20

0 Vessel
Pressure (%)
0

0
8

1
82

84

86

88

90

92

94

96

98
10

10

10

10

10

11

12
 Blowdown
• The difference between the set pressure and the closing pressure of a Pressure Relief
Valve (expressed as a percentage of set pressure).

Lift (%)
100

80

60

40 Blow-
down
20

0 Vessel Pressure (%)

76 78 80 82 84 86 88 90 92 94 98 100
 Overpressure
• The pressure increase over the set pressure of the pressure relief valve allowed to
achieve rated flow.

Lift (%)
100

80

60 Overpressure 10 %
40

20

0 Pressure (%)
94 96 98 100 102 104 106 108 110 121
 Terminology
 Maximum Allowable Working Pressure (MAWP). The maximum gauge pressure allowed at the
top of a completed vessel. Design pressure may be used instead of MAWP in all cases where the
MAWP has not been established. Design pressure is equal to or less than MAWP.
 Accumulation. The pressure increase over the MAWP of the vessel allowed during discharge
through the Pressure Relief Valve (governed by applicable codes).
 Maximum Allowable Accumulated Pressure: The sum of the MAWP and the accumulation.
Maximum Allowable Maximum Allowable Accumulation
Lift (%) Operating Pressure Working Pressure Pressure Single Valve
100

80

60

40

20
Vessel
0 Pressure (%)
0

1
82

84

86

88

90

92

94

96

98
10

10

10

10

10

11

12
 Back Pressure
 Back pressure is the pressure that exists at the outlet of a
safety valve.
Back Pressure

Built-up Superimposed
Back Pressure Back Pressure Back Pressure

variable constant variable

Exists only at
the outlet while the Exists only
valve is open in the blowdown
(flowing and blowing system when the
down). valve is closed.

Back Pressure = Built-up + Superimposed

= constant + variable
 Cold Differential Test Pressure (CDTP)
• The pressure at which a Pressure Relief Valve is adjusted to open on the test stand. It includes
corrections for constant back pressure or elevated temperature or both.
Lift (%)
100
Set pressure CDTP
80

60

40

20

0 Pressure (%)
94 96 98 100 102 104 106 108 110 112
 Abnormal Valve Function
 Flutter - The abnormal, rapid reciprocating motion of the movable parts of a
pressure relief valve in which the disc does not contact the nozzle
 Chatter - The abnormal, rapid reciprocating motion of the movable parts of a
pressure relief valve in which the disc contacts the nozzle
 Possible causes for the above include:
• Inlet pressure drop too high
• Excessive back pressure
• Oversized valve Lift (%)
Flutter
Lift (%)
Chatter
100 100

80 80

60 60

40 40

20 20

0 0
94 96 98 100 102 104 106 108 110 121 94 96 98 100 102 104 106 108 110 121

Vessel Pressure (%) Vessel Pressure (%)

Pressure Retaining Components
 Body
 Bonnet
 Nozzle
 Disc
 Cap
Valve Seat
 The area of contact between the valve nozzle and disc.
 Actual (ASME) Discharge Area
 The minimum net area that determines the flow through the valve.

A = πD2
4
Nozzle
 Conventional Valve Construction
 A spring loaded pressure relief valve whose
operational characteristics are directly
affected by changes in the back pressure on
the valve.
 Can be net-set to account for constant back
pressure only.
 Balanced Bellows Valve Construction

 A spring loaded pressure relief valve that

incorporates a bellows or other means to minimize
the effect of back pressure on the operational
characteristics of the valve.
 Should be used when:
– The built-up back pressure to set pressure ratio
exceeds the allowable accumulation (or 10% as an
industry rule).
– For isolating the bonnet chamber of the valve in
corrosive/hazardous service.
Back Pressure Terminology
Terminology
 Back pressure is the pressure that exists
at the outlet of a safety valve.
Back Pressure
Back Pressure

Built-up Superimposed
Back Pressure Back Pressure

variable constant variable

Exists only at
the outlet while the Exists only
valve is open in the blowdown
(flowing and system when the
blowing down). valve is closed.
Back Pressure = Built-up + Superimposed
= constant + variable
Back Pressure
L
 Superimposed BP
adds itself to the
spring force:
Fd = K / L + BPxA

 Set : Fd = Fu A
(Fu = P x A)

 Actual Opening:
Spring set + BP
P
Superimposed Constant Back Pressure

• When PRV Outlet is • Example:

connected to a Static • Actual set = 10 Barg
pressure source • Constant BP = 2 Barg
• No change under any • Test bench:
conditions of operation • CDTP = 8 = 10 - 2
• Conventional PRV can be
used if Spring Setting is
reduced by Constant Back
Pressure (CDTP)
Superimposed Variable Back Pressure

• Exists Before PSV opening

• Usually result of one or
more PSV discharging into
common piping
• Set pressure will increase Closed
by amount of Back
Pressure
• Bellows valve Required
Opened &
• Or reduce set
Flowing
pressure of
conventional valve
Balanced Bellows Safety Valve
• The Balanced Bellows
• isolates top side of disc for Back-
P
• isolates spring and guide from
outlet environment
• Typically, this type of valve can
be used:
• Any backpressure up to 50% of
set
• I absolute value of BP
• I Reduced capacity
• Check with manufacturer
Balanced Bellows Safety Valve

•Balanced valves:
•Bonnet must be vented
to atmosphere
•No back pressure
inside the bonnet,
inside the bellows
Built up Back Pressure

• Developed AFTER SV
opens Discharge
• Due to flow, pressure drop
in discharge piping
• Can be up to 10% of set
on Conventional SV’s BPBU
• Will cause reduced
capacity or SV instability if
over 10%….Balanced
Bellows Valve should be
specified
In
Pilot Operated Valve and Back
Pressure
• Pressure settings
independent from flow
control
• Not sensitive to Back
Pressure
• Forces created by back-
pressure on piston:
opposite, then
balanced
Back Pressure
Balanced Pilot
Back Pressure Conventional
Bellows Operated
CDTP =
Constant 50% No effect
Set – BP
50%
Super Imposed NO (loss of
No effect
Variable (or reduce Set) capacity
from 30%)

10% No effect No effect No effect

Built-Up
>10% NO 50% No effect

‘No effect’ = except for thermodynamic subsonic, or ‘unchoked’, flow

Sizing and Selection
API Sizing (Effective/Theoretical)
 Uses the sizing equations from API 520 Part 1
 Used for initial sizing to determine a preliminary safety valve size
 Utilizes an effective Kd and effective areas, which are independent of specific
valve design or manufacturer (theoretical)
Fluid Effective Kd
Vapor/Gas/Steam 0.975
Liquid 0.65
Two-Phase 0.8

 Uses API Standard 526 to select a valve

 ASME Sizing (Actual)
 Uses the sizing equations from API 520 Part 1
 Utilizes a de-rated Kd (K) and actual areas for a specific valve design and
manufacturer

Series Vapor Vapor De-rated Liquid Liquid De-rated

2600 0.953 0.858 0.724 0.652

2700 0.975 0.878 0.751 0.676

3800 0.954 0.859 0.869 0.782

 Must be used to verify the rated capacity of a selected valve

 Uses vendor catalogs to select a valve
Orifice Area Comparison: ASME vs API
Orifice API W X Y Z

D 0.11 0.15 0.121 0.1279 0.1244

E 0.196 0.225 0.239 0.2279 0.2214
F 0.307 0.371 0.394 0.3568 0.347
G 0.503 0.559 0.616 0.5849 0.5674
H 0.785 0.873 0.975 0.9127 0.887
J 1.287 1.43 1.58 1.496 1.453
K 1.838 2.042 2.25 2.138 2.076
L 2.853 3.17 3.48 3.317 3.221
M 3.6 4 4.43 4.186 4.065
N 4.34 4.822 5.3 5.047 4.9
P 6.38 7.087 7.79 7.417 7.206
Q 11.05 12.27 13.55 12.85 12.472
R 16 17.78 19.48 18.6 18.065
T 26 28.94 31.75 30.21 29.359
ASME vs API Sizing
 The following is excerpted from API 520 Part 1 – Sizing and Selection...
5.2.6 In summary, the effective orifice size and effective coefficient of discharge
specified in API standards are assumed values used for initial selection of a PRV size
from configurations specified in API 526, independent of an individual valve
manufacturer’s design. In most cases, the actual area and the rated coefficient of
discharge for an API letter orifice valve are designed so that the actual certified
capacity meets or exceeds the capacity calculated using the methods presented in
API 520. There are, however, a number of valve designs where this is not so. When
the PRV is selected, therefore, the actual area and rated coefficient of discharge for
that valve shall be used to verify the rated capacity of the selected valve and to
verify that the valve has sufficient capacity to satisfy the application.
ASME vs API Sizing: Capacity Comparison
Orifice API W X Y Z

Letter (K*A)vapor (K*A)liqiud (K*A)vapor (K*A)liqiud (K*A)vapor (K*A)liqiud (K*A)vapor (K*A)liqiud (K*A)vapor (K*A)liqiud

D 0.1073 0.0715 0.1287 0.0977 0.1076 0.0816 0.1094 0.0857 0.0969 0.0701

E 0.1911 0.1274 0.1930 0.1466 0.1915 0.1452 0.1949 0.1527 0.1914 0.1384

F 0.2993 0.1996 0.3182 0.2417 0.3002 0.2276 0.3051 0.2391 0.3156 0.2281

G 0.4904 0.3270 0.4795 0.3642 0.4908 0.3722 0.5001 0.3919 0.4934 0.3567

H 0.7654 0.5103 0.7488 0.5688 0.7673 0.5819 0.7804 0.6115 0.7810 0.5645

J 1.2548 0.8366 1.2265 0.9318 1.2568 0.9532 1.2791 1.0023 1.2656 0.9148

K 1.7921 1.1947 1.7514 1.3306 1.7957 1.3619 1.8280 1.4325 1.8023 1.3028

L 2.7817 1.8545 2.7189 2.0656 2.7862 2.1130 2.8360 2.2224 2.7875 2.0149

M 3.5100 2.3400 3.4308 2.6064 3.5162 2.6666 3.5790 2.8046 3.5484 2.5650

N 4.2315 2.8210 4.1358 3.1420 4.2385 3.2144 4.3152 3.3815 4.2453 3.0687

P 6.2205 4.1470 6.0785 4.6179 6.2332 4.7271 6.3415 4.9694 6.2398 4.5104

Q 10.7738 7.1825 10.5240 7.9951 10.7883 8.1816 10.9868 8.6095 10.8536 7.8455

R 15.6000 10.4000 15.2499 11.5854 15.6262 11.8506 15.9030 12.4620 15.6035 11.2789

T 25.3500 16.9000 24.8218 18.8573 25.3955 19.2595 25.8296 20.2407 25.4318 18.3833
ASME vs API Sizing: Example
Process Data
Fluid: Nitrogen
Required Capacity: 2100 lb/hr
Relieving Temp.: 250°F
Set Pressure: 200 psig
Back Pressure: 0 psig
Molecular Wt.: 28
Gas Flow Const.: 356
Compress. Factor: 1

W T Z
Sizing Equation A
C K d P  M K b
ASME vs API Sizing: Example
ASME Sizing API Sizing

A= A=
A = 0.147 in2 A = 0.130 in2

Valve must be selected based on Valve must be selected based on

“Actual” or “ASME” area!! “API” area!!
E orifice! E orifice!
 Sizing Scenarios
 Three types of sizing scenarios:
• Non-Fire
• Vapor/Gas
• Steam
• Liquid
• External Fire
• Vapor/Gas
• Steam
• Two-Phase
• Liquid/Vapor mixture
Pressure Level Relationships
Protected Equipment Pressure Relief Device
Pressure for ‘Sizing’ Pressure of certified capacity

Accumulation Overpressure
(10%, 16% or 21%) (usually 10%)

MAWP Set Pressure (opening)

Blowdown

Reseat Pressure

Operating Pressure
Non-Fire Sizing Applications

PRV

Pressure OUTLET BLOCK

Vessel
VALVE CLOSED
FULL INPUT FLOW
Non-Fire Single Valve Applications
Maximum Allowable
MAWP
Accumulation Pressure

100

80
Normal
Operating
60 Pressure
Lift [%]

Maximum set
40
Seat Tightness pressure
Test Pressure
20

0
82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 121

Vessel pressure [%] Typical blowdown Overpressure

10% or 3 psi
Non-Fire Multiple Valve Applications
Maximum Allowable
MAWP
Accumulation Pressure

100

80
Operating
Pressure
60 Range
Lift [%]

Maximum set Maximum set

40
pressure for at least pressure for
Seat Tightness Test one valve additional valves
20 Pressure

0
82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 116

Vessel pressure [%] Typical blowdown Overpressure

16% or 4 psi
Fire Sizing Applications

PRV

STORAGE OR
PROCESS VESSEL
 Fire Sizing Applications
There are two types of external fire sizing scenarios:
 Fire Gas Expansion (un-wetted surface area):
• Assumes the protected vessel is filled with gas
 Fire Vapor Generation (wetted surface area):
• Assumes the protected vessel is filled (partially) with liquid
• Already know the capacity
• Know the wetted surface area or vessel dimensions to calculate capacity
Fire Single Valve Applications
Maximum Allowable
MAWP
Accumulation Pressure

100

80
Normal
Operating
60 Pressure
Lift [%]

Maximum set
40
Seat Tightness pressure
Test Pressure
20
121
0
82 84 86 88 90 92 94 96 98 100 102 104 106 108 110

Vessel pressure [%] Typical blowdown Overpressure

21%
Set Pressure & Accumulation Limits
 ASME VIII, Blocked Discharge

ONE VALVE ONLY

110

10%
ALLOWED ONE
OR 3 PSIG,
ACCUMULATION: PSV
[0.20 BARG]
WHICHEVER
IS
GREATER

100 MAWP
(MAX. SET)
ASME VIII, Blocked Discharge
MULTIPLE VALVES
Allowed Accumulation: 116

2ND VALVE
MAX. SET: 105% MAWP 2ND, 3RD, ...
Overpressure: 10% 1ST

105
1ST VALVE
MAX. SET: MAWP
Overpressure: 16% 100 MAWP
ASME VIII, Fire

121

1 VALVE

21%
Allowed Accumulation :
21%

100 MAWP
 ASME VIII, Fire
2 VALVES
Allowed Accumulation: 121

MAX SET:
1ST VALVE: MAWP 2ND , 3RD, ...
2ND VALVE: 110% OF MAWP

110

Overpressures: 1ST VALVE

1ST VALVE: 21%
2ND VALVE: 10%

100 MAWP
 Required Process Data
The required process data needed to do a sizing calculation depends on:
• The Sizing Scenario
• Non-Fire
• Fire
• Two-Phase
• Fluid Type
• Vapor/Gas
• Steam
• Liquid
• Capacity Units
• Mass
• Volumetric
Required Process Data: Gas/Vapor
All sizing equations require the following process parameters…
Pset set pressure at valve inlet
Pconst constant portion of back pressure
Pvar variable portion of back pressure

Vapor/Gas Sizing Calculations

Wvapor required vapor capacity

Vgas required gas capacity

Trelief relieving temperature

Mvapor molecular weight of vapor

Ggas specific gravity of gas

k ratio of specific heats (cp/cv)

Z compressibility factor
Required Process Data: Steam
All sizing equations require the following process parameters…

Pset set pressure at valve inlet

Pconst constant portion of back pressure
Pvar variable portion of back pressure

Steam Sizing Calculations

Wsteam required steam capacity

Trelief relieving temperature

Required Process Data: Liquid
All sizing equations require the following process
parameters…
Pset set pressure at valve inlet
Pconst constant portion of back pressure
Pvar variable portion of back pressure

Liquid Sizing Calculations

Vliquid or Wliquid required liquid capacity
Gliquid specific gravity of liquid

m absolute viscosity of liquid

Required Process Data: Fire
All sizing equations require the following process
parameters…
Pset set pressure at valve inlet
Pconst constant portion of back pressure
Pvar variable portion of back pressure

Fire Vapor Generation Sizing Calculations

Awet wetted surface area
latent heat of vaporization at the PRV
hv
inlet
LxWxH & level vessel dimensions

Fire Gas Expansion Sizing Calculations

Toperating normal operating temperature
Aexposed exposed surface area
 Required Process Data: Two-Phase
All sizing equations require the following process parameters…
Pset set pressure at valve inlet
Pconst constant portion of back pressure
Pvar variable portion of back pressure

Required data for the Omega 9 Method, equation D3 sizing calculations:

 x0 vapor mass fraction
 W2-phase required 2-phase capacity
 n0 specific volume of the 2-phase system at SV inlet
 n9 specific volume of the 2-phase system at 90% of Pset
Required data for the Direct Integration sizing calculations:
 G maximum mass flux
 W2-phase required 2-phase capacity
Sizing Equations: Gas/Vapor
Vapor Mass Equation Gas Volume Equation

W T Z V T Z G
A  A
C  Kd P1Kb Kc M 1.175  C  K d  P 1  K b  K c

Where: Where:
P1 P set  P over  P atm
M
G
M air
(k 1)
(k 1 )
 2 
C 520  k 
k1
Sizing Equations: Gas/Vapor
• A = Required effective discharge area of the valve (in2)
• W = required flow through the valve (lb/hr)
• C = coefficient determined from an expression of the ratio of specific heat of the gas or vapor at
standard conditions
• P1 = relieving pressure = P1 + Pover + Patm (psia)
• Kd = effective coefficient of discharge (API = 0.975)
• Kb = capacity correction factor due to back pressure.
• Kc= Rupture disc correction factor. Kc =1 if no rupture disc in inlet.
• T = relieving temperature of the inlet gas or vapor (degree R = degree F + 460)
• Z = compressibility factor
• M = molecular weight of the gas or vapor
• V = required flow through the valve (SCFM)
• G = specific gravity or gas referred to air
Gas/Vapor Back Pressure Correction Factor (Conv. & PORV)
Gas/Vapor Back Pressure Correction Factor (Bellows)
Gas/Vapor Gasflow Constant (C)
 PRV With Rupture Disc At Inlet

Do PRV Calculation, then

Apply “Combination Factor” for that
Model PRV & Model/Material of RD*
As Established by the NB Testing.

OR
De-rate PRV Capacity by 10% (Kc=0.9)

*Listed in back of NB “Red Book”

PRV With Rupture Disc At Outlet

No PRV De-Rating Necessary (Kc =1)

Gas/Vapor Example
Fluid: Hydrocarbon Gas
Set pressure: 195 psig
Const. BP: 134 psig
Var. BP: 0 psig Gas Volume Equation

Mol. Wt.: 54 V T Z G
A
1.175  C  K d  P 1  K b  K c
Relief Temp: 200 ºF
Ratio Specific Heat (Cp/Cv) : 1.22
Compressibility factor: 0.8
Required Flow : 4500 SCFM
Gas/Vapor Example
V T ZG
A
1.175  C  K d  P 1  K b  K c

Where : P set = 195

V = 4500 P over = P set x 0.1
C = 339 (?) P atm = 14.7
Z = 0.8 P1 = P set +Pover + P atm
54 P = 229.2
G= = 1.864
28.97
Kc = 1 (why?)
Kd = 0.975 Kb = 0.99 (why?) BP%ABS =
.
. 100% = 64.878%
. .
T = 200 + 460 T = 660
V T Z G
A
1.175  C  K d  P 1  K b  K c

A= 1.602 in2 Calculated Area

Gas/Vapor Gasflow Constant (C)
Gas/Vapor Example
Fluid: Hydrocarbon Gas
Set pressure: 250 psig
Const. BP: 0 psig
Var. BP: 0 psig Gas Mass Equation

Mol. Wt.: 30
W T Z
A 
Relief Temp: 140 ºF C  Kd  P1 Kb  Kc M
Ratio Specific Heat (Cp/Cv) : 1.22
Compressibility factor: 0.8
Required Flow : 50,000 lb/hr
Gas/Vapor Example (2)
W T Z
A 
C  Kd  P1 Kb  Kc M

Where : P set = 250

W = 50,000 P over = P set x 0.1 = 25
C = 339 P1 atm = 14.7
Z =0.8 P = P set +Pover + P atm
M = 30 P = 289.7
Kd = 0.975 Kc = 1 (why?)
T = 140 + 460 T = 600 Kb = 1 (why?)

W T Z
A 
C Kd P1Kb Kc M

A = 2.088 in2 Calculated Area

Sizing Equations: Steam
Steam Equation
Ws
A
51.5  K d  P  K b  K sh  K n

Where:
P P set  P over  P atm

K sh superheat_correction_factor

Kn Napier_correction_factor
Sizing Equations: Steam
• A = Required effective discharge area of the valve (in2)
• Ws = required flow rate (lb/hr)
• P1 = upstream relieving pressure = P1 + Pover + Patm (psia)
• Kd = effective coefficient of discharge (API = 0.975)
• KN = correction factor for Napier equation
• KSH = superheat steam correction factor. For saturated steam at any
pressure, KSH = 1.0
Superheat Steam Correction Factor (Ksh)
Steam Example
Fluid: Steam
Set pressure: 200 psig
Steam Equation
Const. BP: 0 psig
Ws
Var. BP: 0 psig A
51.5  K d  P  K b  K sh  K n
Mol. Wt.: 18.02
Relief Temp: 500 ºF
Required Flow: 15000 lb/hr
Steam Example (2)
Where:
Ws Ws  15000
A
51.5  K d  P  K b  K sh  K n Kd  0.801

Kb  1

Pset  200
Pover  Pset  0.1
Patm  14.7
P  Pset  Pover  Patm

P  234.7

Ksh  0.95

Kn  1

Ws
A 
51.5  Kd  P  Kb  Ksh  Kn
A  1.631 Calculated Area
Sizing Equations
Non-fire Liquid

Liquid Volume Equation Liquid Mass

VL G Q
VL 0.002 
A G
38.0  K d   P K u
Q Liquid_Mass_flowrate
Where:

P P set  P over  P back

 liquid
G
 water
Kd = Coefficient of discharge
Ku = Correction factor due to viscosity
Sizing Equations
Liquid Example

Fluid: Hydrocarbon Liquid

Set pressure: 300 psig
Liquid Volume Equation
Const. BP: 50 psig
Var. BP: 0 psig VL G
A
Sp. Gravity: 0.92 38.0  K d   P K u

Viscosity: 0.8 cP
Required Flow: 5000 GPM
Sizing Equations
Liquid Solution

Solution…
P set  300
5000  0.92 P over  30
A
38.0  0.652  280  1 P back  50
 P  P set  P over  P back  P  280
Where
V L  5000 K u  1

G  0.92
A  11.568
K d  0.652
Sizing Equations
Fire Gas Expansion

F As
A GAS
P
F = 0.042 (Conservative; Relates To Bare
Vessel Metal Temperature At Relief)
As
= Total Exposed Unwetted Surface Area Of Vessel
P
= (Set Pressure-Inlet Pressure Loss +
Allowable Overpressure (21%) + 14.7, psia)
A
= Calculated PRV Orifice Area, in2
Sizing Equations
Fire Vapor Generation

0.82
Q = 21,000 FA LIQUID

Q = Total Heat Input To Wetted Surface Of Vessel, btu/hr

F = 1.0 (Assumes No Vessel Insulation)

Bare Vessel 1.0
Insulated 0.3
Earth Covered, Above Grade 0.03
Bare With Water Spray 1.0
Underground 0

A = Total Vessel Wetted Surface, ft2 (up to 25 ft. above ground level
Or, in the case of a sphere, to the elevation of largest diameter -
whichever is greatest)
 Sizing Equations
Fire Vapor Generation

W= Q
V
W = Required Valve Capacity, lbs/hr
Q = Total Heat Input to Wetted Surface of Vessel, btu/hr
V = Latent Heat Of Vaporization, btu/lb
EXAMPLES: AMMONIA 589
BENZENE 169
BUTANE 166
CO2 150
ETHANE 210
METHANE 219
PROPANE 183
WATER 900
109 /
Sizing & Selection | Farris Engineering | 10.21.2013 | Rev. 00
50
 2-Phase Sizing
2-Phase sizing scenarios are more difficult to perform than single-
phase sizing calculations.
Here is a summary of 2-Phase sizing methods:
 The old API method added vapor and liquid areas together
 New 2-Phase methods:
− Direct Integration of the Isentropic Nozzle Flow Calculation
− Omega two-point Method
− Omega one point method
− No procedure for certifying capacity.
2-Phase Sizing
 Many 2-phase liquid/vapor relief scenarios are possible
− 2-phase mixture enters the PRV
− 2-phase mixture is produced as the fluid moves through the valve
− Condensing 2-phase flow
2-Phase Sizing
 Direct Integration of the isentropic nozzle flow calculation.
 Based on the Homogeneous Equilibrium Method (HEM).
 Assumes:
• Fluid behaves as a “pseudo-single phase” fluid
• Mixture at thermal and mechanical equilibrium

 Requires a physical property database to perform flash

calculations.
• Equations in SizeMaster
• Need maximum mass flux G lb/s∙ft2
2-Phase Sizing

 Used for sizing 2-phase flashing or non-flashing flow through a

PRV using the Omega Method.
 Omega method calculates  parameter (which indicates the
expansion of the two-phase mixture).
 Assumes:
• Both phases have the same velocity (no slip)
• Mixture at equilibrium
 Two-point method (Omega 9)
• Specific volume data at the PRV inlet pressure.
• Specific volume data at the 90% of the PRV inlet pressure.
2-Phase Sizing

•=0
• No Expansion
•<1
• Non-Flashing Flow
• 1
• Flashing Flow
QUESTIONS ???