7.
16 Relief ValvesSizing, Specification,
and Installation
E. JENETT (1969, 1982) R. V. BOYD AND B. P. GUPTA
B. G. LIPTK (2003)*
Types of Designs:
Design Pressure Ranges:
Design Temperature:
Inlet Connection Sizes:
Orifice Areas:
Materials of Construction:
Seat and Seal Materials:
Accessories:
Cost:
Inaccuracy:
* B. P. Gupta and W. Y. Wong should also be credited for some work on this section.
2003 by Bla Liptk
PRV
Flow Sheet Symbol
(1995)
Spring-loaded
Weight-loaded
Balanced by bellows seals
Pilot-operated
Screwed designs from 5 PSIG [34 kPag to 10,000 PSIG (69 MPa)], higher as special
Flanged steel designs, ANSI CL 150#, 300#, 600#, 900#, 1500# and 2500# ASA
Flanged cast iron units in 125# and 250#
Ranges of Pilot-Operated Designs
Vacuum: 1.7 in. H2O to 14 PSIG (43.2 mm H2O to 96.5 kPag)
Low pressure: 3 in. H2O to 150 PSIG (76.2 mm H2O to 1034 kPag)
Medium to high pressure: 50 to 6,200 PSIG (0.345 to 42.75 MPag)
450 to 1000F (268 to 538C) with suitable material selections for pressure parts,
trim, and springs; breaks occur in the temperature ratings at 450F (232C) and 800F
(427C)
0.5 to 6 in. (12.5 to 150 mm); some suppliers up to 12 in. (300 mm) for special services
Pilot-operated PRVs available from 1 to 10 in. (25 to 250 mm) with double outlets
starting at 2 in. (50 mm)
API designated orifices: D, E, F, G, H, J, K, L, M, N, P, Q, R, and T (for orifice
areas, see Figure 7.16g)
2
Non-API orifices and full-bore orifices are available in areas up to 84 in.
Pressure parts: cast iron, bronze, cast steel, 300 and 400 series stainless, nickel steel,
Monel, Hastelloy, high-temperature carbon steel alloys, materials in compliance with
NACE MR0175; trim: basically any machinable alloy, can be cryogenic, NACE, or
high-temperature trim
Metal to metal or soft seats
Soft seat material options include Aflas, Buna-N, ethylene propylene, Kalrez, Peek,
Teflon , Urathene, Viton , etc.
Backflow preventer, dual pilots, field test connection with indicator, filter, pilot lift
lever, pressure spike snubber, remote blowdown, remote pressure sensor, remote valve
lift indicator, valve monitor, valve position indicator
See Figure 7.16o
2 PSI for pressures up to and including 70 psig (483 kPag)
3% for pressures above 70 to 300 PSIG (483 to 2068 kPag)
991
992 Safety and Miscellaneous Sensors

2% for pressures from 300 to 1450 PSIG (2068 to 9997 kPag)

1.5% for pressures above 1450 PSIG (9997 kPag)

Partial List of Suppliers: Anderson-Greenwood Tyco Flow Control (www.andersongreenwood.com)

Circle Seal Controls (www.circle-seal.com)
Conbarco Industries (www.conbarco.com)
Crosby Valve of Tyco Flow Control (www.tycovalves.com)
Farris Engineering, Division of Curtiss-Wright Flow Control Corp. (www.cwfc.com)
Fisher Controls International Inc. (www.emersonprocess.com)
Groth Corp. (www.grothcorp.com)
Hydroseal Valve Co. (www.hydroseal.com)
IMI Bailey Birkett Ltd. (www.imibb.co.uk)
Kerr Valve (www.kerrvalve.co.za)
Kunkle Valve Co. (www.kunklevalves.com)
J. E. Lonergan Co. (www.kunklevalves.com)
Mercer Valve Company (www.mercervalvecompanyinc.com)
Rego (www.regoproducts.com)
Varec Vapor Control Inc. (www.varecbiogas.com)
Walworth Valves (www.walworthvalve.com)

INTRODUCTION The relative simplicity and the self-contained and self-

In Section 7.15, the various overpressure protection codes
and standards were discussed along with the terminology and
nomenclature that is used in connection with pressure relief
valve (PRV) design. Some of these terms are also defined
and visually illustrated in Figure 7.16a. The main purpose of
Section 7.15 was to explain the methods by which the
required relief capacities are determined. The purpose of this
section is to assume that the required capacity is known and,
based on that, to determine the size, design features, and
installation details of the required PRV.
One might note that, during recent decades, the language
used in connection with overpressure protection valves went
through some changes. In the past, all overpressure protection
valves were referred to as pressure safety valves (PSVs). Then,
with the passage of time, first the liquid relieving valves and
then all nonfire protection valves came to be called pressure
relief valves (PRVs). By now, in most plants, these distinctions
have disappeared, and all overpressure protection valves are
referred to as PRVs. This practice is also used in this handbook.
The Nature of PRVs
Pressure relief valves are the last line of defense in the pro-
tection of personnel and equipment from the consequences
of the accumulation of energy or mass that is greater than
allowed by design limits. One of the prime responsibilities
of process plant management is to operate in a safe manner,
and one of the most important safety considerations is to
protect all equipment against overpressure.
Normally, plant operating instructions and controls keep
the operating pressures within design limits. In the event of
control malfunction, emergency shutdown systems should
serve to bring the system down in a safe and orderly manner.
However, if the emergency shutdown systems malfunction, the
plant design must incorporate pressure relief devices to dis-
pose of the accumulated energy and thereby avoid damage.
actuating nature of the PRV valve make it the most reliable
device short of the rupture disc (which does not, however,
reclose). It is important to remember that a pressure relief
valve is installed only to limit the pressure; it will not regu-
late, reduce, or depressurize the system unless special provi-
sions are incorporated.
The Purpose of PRVs
Pressure relief valves are commonly installed for one or more
of the following reasons:
1. To guarantee the safety of operating personnel
2. To prevent the destruction of capital investment as a
result of overpressure
3. To conserve process material from loss during and
after an overpressure-related accident
4. To minimize unit downtime caused by overpressure
5. To comply with local, state, national, and other court-
enforceable regulations
6. To avoid civil suits resulting from property or personal
damage external to the plant caused by overpressure
By designing and installing reliable overpressure protec-
tion systems, the plant will not only obtain favorable insur-
ance treatment, it will minimize pollution (primarily air pol-
lution) by preventing the discharge of overpressure vapors.
System Integrity and Noise
Because one of the reasons for installing a pressure relief
valve is compliance with local codes and regulations, the
designer must take into consideration the system integrity, in
particular the noise produced by the valve when it opens. The

2003 by Bla Liptk

 7.16 Relief ValvesSizing, Specification, and Installation 993

Vessel Typical Characteristics of

Pressure Vessel Requirements
Pressure Pressure Relief Valves
Maximum allowable Maximum relieving pressure
accumulated pressure 121
for fire sizing
(fire exposure only) 120

Maximum allowable Multiple valves

accumulated pressure for Maximum relieving pressure
116
multiple-valve installation for process sizing
(other than fire exposure) 115
Single-valve
Maximum relieving pressure
for process sizing
Maximum allowable

Percent of maximum allowable working pressure (gauge)

Maximum allowable set pressure
accumulated pressure for
110 for supplemental valves
single-valve installation
(fire exposure)
(other than fire exposure)
Overpressure (maximum)

105 Maximum allowable set pressure

for additional valves (process)

Maximum allowable
working pressure or Maximum allowable set
100
design pressure (see Simmer pressure for single valve
Note 4) (typical)
Blowdown (typical)
(see Note 6)

95

Closing pressure for

a single valve
Maximum expected
operating pressure 90 Leak test pressure (typical)
(see Notes 5 and 6)

85

FIG. 7.16a
Definitions of terms used in connection with overpressure relief systems. (Reproduced courtesy of the American Petroleum Institute from
API Recommended Practice 520, Sizing, Selection, and Installation of Pressure-relieving Devices in Refineries, Part ISizing and Selection,
7th ed., January 2000.)

valve may relieve the required amount of process fluid, but Special care must be taken to review the actual maximum
the vibrations caused by the sound power noise of the valve flows that can exist in the discharge piping. Velocities must
may be beyond the maximum allowable for which the dis- be calculated and noise calculations made to guard against
charge piping was designed. fatigue failures caused by excessive vibration induced by a
Failures in relief valve discharge piping have been high SPL. When making these calculations, it is necessary to
reported that can be linked to high sound power levels (SPLs) use the actual installed capacity of the valve. This is because,
inside the piping downstream of the relief valve and at the in most cases, the selected valve has greater capacity than the
point where the discharge piping joins the relief system calculated required capacity. Under certain relieving condi-
header. There have been cases reported in which excessive tions, at least for some time period, the actual flow corre-
velocities in the piping immediately downstream of the relief sponds to the size of the actual valve orifice rather than to the
valve have resulted in a standing sonic wave at the juncture calculated required capacity. This consideration is especially
of the valve discharge piping and the header piping, i.e., important for valves greater than 3 in. (75 mm) and, unfortu-
where the first increase in pipe size occurs. nately, there is no known technique for assessing this problem.

2003 by Bla Liptk

994 Safety and Miscellaneous Sensors
Reliability, Testing, and Redundancy
The designer may also have to consider the requirements
imposed by the insurance underwriting groups. Because the
purpose of overpressure protection is to prevent the destruction
of capital investment and to provide personnel safety, such
considerations as toxicity, polymerization, corrosion, and dam-
age to other equipment in the plant must also be considered
when deciding on the discharge destinations of PRVs.
Because unit downtime and loss of material are both to
be minimized, it is also important that the PRVs provide tight
shutoff against maximum operating pressure while it is below
the set point for actuation. Personnel safety and the minimi-
zation of property damage lead to requirements for high
reliability, both in terms of accuracy and repeatability.
A pressure-relieving valve in a chemical plant is rather
unique in that it, hopefully, will never need to operate. Fur-
thermore, it is also rare that any such system would ever be
operated for test purposes, although certain of its components
might be tested periodically. The capability for system testing
is usually not provided because of the cost of the added valves
and bypasses that would be needed. Even when such capa-
bility is provided, the system test is performed only at rather
long intervals.
A pressure relief valve is not tested weekly for its condition
as one might test an emergency generator or a fire pump. We
expect the PRV valve to work when called upon in spite of the
extended periods of stagnation while exposed to process fluids,
operating temperatures, and operating pressures, plus to the full
range of ambient conditions. This requirement that the valve
work when called upon, coupled with the requirement to protect
the safety of personnel and equipment, drives the designers to
consider redundancy. Such designs are exemplified by duplicate
or multiple relief valves, rupture discs plus safety valves, flare
valves backed up by pressure relief valves, etc.
Safety Checklist
Section 7.15 listed and discussed the code requirements and
practices recommended by standards that have been gener-
ated by regulating. In addition, the following considerations
and options should be kept in mind:
1. The use of extra safety factors in sizing or rating over
and above those established in codes, regulations, and
recommended practices
2. The provision of other protective facilities that may
result in credits under the codes or regulations
3. The provision of credit for redundancy or other pro-
tective facilities, even though such credit may not be
clearly established in codes or regulations
4. Preferences, particularly in installation practices,
based on operating or maintenance practices
5. The establishment of minimum design pressures for
various types of equipment in various services (This
would affect the pressure-relieving systems in that oper-
ating pressure may not always bear the same relationship
2003 by Bla Liptk
to design pressure and smaller relieving valves set at
the minimum design pressure may be suitable.)
6. The relationship between operating pressure and
relief valve set pressure as affected by the upsets to
operating conditions that are acceptable before pres-
sure relief occurs
7. The standardization of relieving device sizes and
types and the standardization of relieving device
mounting nozzle sizes and locations for various types
of equipment in different services
8. The inspection and test procedures established by the
company for its pressure-relieving systems or the
components of those systems
9. The accounting needs and practices of the company
as they might affect flow detection and metering in
the pressure-relieving system or at the valve
10. Noise produced and maximum level of noise allowed
in the discharge piping and header, depending on its
diameter
THE SIZING OF PRVS
Before sizing the pressure relief valve, one must determine
if the process material released will be vapor or gas, liquid,
or a mixture of liquid and vapor (two-phase). Each of these
cases is separately discussed below.
The design engineer should also remember that PRV
1
sizing programs are available on CDs from the manufacturers.
While these programs do save time, it is advisable to fully
understand the sizing steps and considerations. For these
reasons, both graphical methods of approximate PRV sizing and
accurate calculations will be described in the following pages.
Backpressure
Backpressure can adversely affect the set pressure, relieving
capacity, stability, and life span of all types of pressure relief
valves. Figure 7.16b represents the correction curve for the
effects of constant backpressure in reducing the flow across the
nozzle of conventional, nonbalanced valves when the spring
setting has been compensated for the constant backpressure.
The effect of backpressure on bellows sealed valves,
whether it is fixed or variable, is a function of the specific
valve size and design. There is general acceptance of the fact
that a backpressure up to 30% of inlet pressure will not need
correction. Above that value, the backpressure effect should
be evaluated by considering whether it is superimposed back-
pressure or built-up backpressure.
Superimposed Backpressure The superimposed backpres-
sure is the pressure that is present at the PRV outlet in the
relief header when the valve opens. This pressure is a gauge
2
pressure and is expressed in units such as PSIG, kg/cm (g)
or kPag. Generally, the superimposed backpressure is
assumed to be constant, which is an incorrect assumption if
more than one PRV is discharging into the same relief header.
 7.16 Relief ValvesSizing, Specification, and Installation 995

1.1

RATED CAPACITY WITHOUT BACK PRESSURE

1.0

CAPACITY WITH BACK PRESSURE

.9
.8
.7
EXAMPLE:
.6
SET PRESSURE = 100 PSIG
.5 CONSTANT BACK PRESSURE = 80 PSIG
80 + 14.7
.4 % ABSOLUTE B.P. = 100 + 10 + 14.7 100 = 76%
FOLLOW DOTTED LINE, K b = 0.89 (FROM CURVE)
.3
CAPACITY WITH B.P. = 0.89 RATED CAPACITY WITHOUT B.P.

EXAMPLE
.2
.1
0
10 20 30 40 50 60 70 80 90 100
Kb =

BACK PRESSURE, PSIA OR kPa

% ABSOLUTE BACK PRESSURE = 100
SET PRESSURE + OVRPRESSURE, PSIA OR kPa

FIG. 7.16b
Constant backpressure sizing factor, applicable when sizing conventional pressure relief valves for gas and vapor services.

In reality, this pressure is variable and is changing as a func- VENTED BONNET NON-VENTED BONNET
tion of the number of PRVs relieving into the header at any
one time.
As was discussed in Section 7.15, a fire zone has an area
2 VENTED SPRING
of 2500 to 5000 ft , and a local fire might cause discharges BONNET BONNET
from only one PRV in that area. Similarly, if the cause of the SPRING FS SPRING FS

overpressure condition is a blocked outlet, it too might affect

only one or two PRVs. On the other hand, if the supply of P2 P2
DISC
electric power, cooling water, instrument air, or steam fails, P2 GUIDE P2
the failure of such utilities can cause many PRVs to be reliev-
P2 P2 P2 P2
ing at the same time, and this, in turn, can cause the superim-
posed backpressure in the relief header to rise substantially. P1 P1
AD > AN
PI AN = FS P2 (AD AN) PIAN = FS + P2 AN
Built-Up Backpressure The built-up backpressure is the DECREASES SET PRESSURE INCREASES SET PRESSURE
pressure drop between the PRV outlet and the end of the
BALANCED DISK
discharge piping. Therefore, it is the sum of the pressure AND VENTED PISTON TYPE BELLOWS TYPE
losses in the pipe fittings, valves, and the pipe itself. Its units
2
can be given in PSI, kg/cm , and kPa. When choke flow
occurs, the built-up pressure can be very high.
VENTED VENTED
The built-up backpressure is a function of the discharge SPRING FS BONNET FS BONNET
flow rate, the sizes of the outlet fittings and pipe, the number VENT
of valves and other restrictions, and also by the compress-
ibility of the discharging vapors and by temperature. The P2 P2 P2 P2
VENTED
built-up backpressure will therefore be lower if the PRV is P2 BELLOWS
connected to a short tail pipe that vents to atmosphere.
P2 P2

P1 P1
Backpressure Effects The backpressure can affect the set AP = AN AB = AN
pressure of the pressure relief valve. This is illustrated in PI AN = FS PS SPRING FORCE
SET PRESS. P = =
Figure 7.16c, which considers several valve designs and AN NOZZLE SEAT AREA
means for remedying this effect. It is shown in this figure HAS VERY LITTLE EFFECT ON
SET PRESSURE
that venting or not venting the bonnet can change the direc-
tion of the backpressure effect. FIG. 7.16c
If the backpressure builds up as the valve opens, the valve Effect of backpressure on set pressure. (AN = nozzle area; AD = disc
may chatter and reclose. If the backpressure is constant and is area; AP = piston area; AB = bellows area.)

2003 by Bla Liptk

996 Safety and Miscellaneous Sensors

VALVE SIZES LYING BELOW HORIZONTAL POP LOWER THAN The basic sizing equation results from capacity conversions
ATMOSPHERIC SET POINT WHEN BACK PRESSURE IS APPLIED.
for relief valves described in Appendix 11 of that code. This
15
8T10
states that the test media capacity is converted to any other
10 vapor or gas by Equation 7.16(1),
3L4

5 M
W = K b CKAP 7.16(1)
4N6 6Q8 TZ
100

0
4P6 6S8
where
VARIATION OF RELIEVING POINT
SET PRESSURE TO ATMOSPHERE

5
10
15
20
25
30
11/2H2
IF11/2 2H3
35 11/2F2
ID11/2
40
0 5 10 15 20 25
BACK PRESSURE
SET PRESSURE TO ATMOSPHERE
FIG. 7.16d
Manufacturers tests on effect of backpressure on standard safety
relief valves. (Data courtesy of Farris Engineering Corp.)
already present when the valve starts to open, it should be pos-
sible (if all code and insurance requirements are fully satisfied)
to compensate for it by raising or lowering the spring setting.
In conventional pressure relief valves, constant backpres-
sures up to the critical pressure ratio can be compensated by
spring setting without affecting the capacity. Above that setting,
compensation can be used, but (as will be discussed later) an
appropriate capacity reduction factor must be employed in
sizing. All manufacturers provide this reduction factor, and
there is virtually unanimous agreement on the factor at any
given ratio of constant backpressure to actual relieving pres-
sure for both vapors and liquids.
Figure 7.16d shows that the dimensions and design of
the particular valve will establish the change needed in the
spring setting and that this change is a function of the back-
pressure. Therefore, it is not suggested that one compensate
for backpressure with the spring setting without consulting
the manufacturer of the particular valve. In fact, it is sug-
gested that spring setting adjustment be limited to the non-
critical applications and that pilot or bellows seal designs be
used to guarantee that the PRV will open on set pressure on
all critical applications.
Sizing for Vapor and Gas Relief
The basis for almost all pressure relief valve sizing for process
industry service is found in the ASME Unfired Pressure Vessel
Code Section VIII, Division 1, described in Section 7.15.
3L4
W = the relieving flow of gas or vapor, lbm/hr
Kb = a correction factor for constant backpressure, which
can be obtained from Figure 7.16b
21/2K4
3K4
C = a constant for gas or vapor, which is a function of
the ratio of specific heats k; it can be obtained from
Figure 7.15b or from Equation 7.16(2), below,
4L6
k +1/ k 1
2
2J3 C = 520 k 7.16(2)
21/2J4 k + 1
k = the specific heat ratio of the particular gas or vapor,
which can be obtained from Figure 7.15a
30 35 40 45 50 K = the coefficient of discharge, which is determined
from tests
100
A = the required nozzle area of the valve, in square inches
P = 1.1 (set pressure) plus atmospheric pressure in PSIA
M = the molecular weight of the gas or vapor
T = the absolute relieving temperature, Rankine
(F + 460)
Z = vapor compressibility at inlet conditions
The basic equation can be manipulated almost any number
of ways, and each manufacturer and designer has its own
favorite sizing procedure.
Graphical Method A commonly accepted and easily used
graphical approach is shown in Figures 7.16e and 7.16f. Here,
the orifice designations of the nozzle areas are those listed
in Table 7.16g, which represent the most common API area
designations. However, if manufacturers formulas are used,
care must be exercised to use the orifice area with the corre-
sponding recommended formulas. Table 7.16g shows the tab-
ulated nozzle orifice areas and corresponding orifice desig-
nations for the API and ASME formulas provided. Using the
ASME formula and selecting an orifice based the API area
may result in improper valve sizing.
Sizing by Calculation Those who prefer calculations to
using the graphical method first have to determine if the flow
is critical or subcritical. Critical flow occurs when the gas,
as a result of the lower pressure, expands downstream of the
PRVs orifice and reaches sonic velocity, which it cannot
exceed. The flow rate that corresponds to flow at sonic veloc-
ity is called critical flow. One can calculate the downstream
pressure that, if reached, will result in critical flow (Pcf) by
Equation 7.16(3).
k/(k1)
Pcf = P1[2/(k+1)] 7.16(3)

2003 by Bla Liptk

 7.16 Relief ValvesSizing, Specification, and Installation 997

Specific
heat ratio
VAPOR OR GAS CAPACITY (in units of 1,000 Ibm/hr)
K = Cp/Cv
2.0 1.6 1.4 1.2 1.0 0.1 0.2 0.3 0.4 0.5 0.7 1.0 2.0 3.0 4.0 5.0 7.0 10 20 30 40 50 70 100 200

.03

SE
T
PR
ES
S
.05

U
RE

PS
.07

IG
REQUIRED ORIFICE DESIGNATION AND AREA (in units of in2)

0.1
D

0.2 E

0.3

15
F

30
60

10 00 7
00
0.5 G

20

8
12 0
EXAMPLE 1

40

90 0
60 0 40 0
20 0

0
0 5 0
0.7

45 0 30 50
25
80

0
35 0

35 5 2 00
H

14 0 3
20 00

50

00
27
0
10 0
5 0

25

22 75 1
1.0

0
10

5
16

1
0

70
30 0

2
12
00
J
0
80

5 1
O

50
LE

80
CU

00
K

50
LA
2.0

60
R
W

25
EI

35
15
G
L

H
3.0

20
T
M EXAMPLE 2

10
TE
N

M
5.0
PE
RA
TU
P

RE
7.0

10 F
Q

R
20
T
30
Note: in2 = 645 mm2; PSIG = 0.07 barg; F = 32 + 1.8C

FIG. 7.16e
Graphical method of sizing pressure relief valves for vapor or gas services.

where C = a coefficient that is a function of the specific heat

Pcf = the downstream pressure, which results in critical ratio of the gas or vapor at inlet relieving conditions
flow in PSIA from Figure 7.15b. If C cannot be so determined,
P1 = the upstream relieving pressure in PSIA it is suggested that one use C = 315
k = the ratio of specific heats for any ideal gas Kd = the effective coefficient of discharge; for prelim-
inary sizing, a value of 0.975 can be used
Critical Flow Sizing Table 7.15a lists the critical flow pres- Kb = the capacity correction factor for backpressure,
sure ratio values at standard conditions for a number of gases. which can be obtained from manufacturers liter-
When the downstream pressure P2 is less than or equal to the ature or estimated from the API RP 520 based
critical flow pressure Pcf, the relieving flow will be in the critical Figure 7.16h for the preliminary sizing of bal-
region. Under these conditions, Equations 7.16(4) and 7.16(5) ances bellows PRVs
can be used to determine the required PRV discharge area (A). Kc = a factor reflecting the affect of a rupture disc being
installed upstream of the PRV (Its value is 1.0 if
there is no rupture disc. When a rupture is
A = [W/CKdP1KbKc] (TZ / M) (in US units) 7.16(4) installed and there is no published value available
for the combination, use the value of 0.9.)
A = 13,136[W/CKdP1KbKc] (TZ / M) (in SI units)
T = the inlet temperature of the gas or vapor being
7.16(5) relieved in R (K)
Z = the compressibility factor, reflecting the deviation
where of the process vapors from an ideal gas under
A = the required effective discharge area of the PRV relieving conditions at the PRV inlet
2 2
in in. (mm ) M = the molecular weight of the process gas or vapor
W = the required flow rate to be relieved in lb/hr (kg/hr) being relieved

2003 by Bla Liptk

998 Safety and Miscellaneous Sensors

Specific
heat ratio
GAS CAPACITY (in units of 1,000 SCFM)
K = Cp/Cv
2.0 1.6 1.4 1.2 1.0 0.1 0.2 0.3 0.4 0.5 0.7 1.0 2.0 3.0 4.0 5.0 7.0 10 20

.03

10 00
00
8
60 0
.05

90 00
45

0
7
35 5
0
27 25

50 0
.07 SE

0
2 5

40 0
T

17 5
PR

30 50
ES

2
.01

12
SU

20 0
D

2. 60
RE

0
50

15
80

1. 00
PS

1. 60

10
50
IG

0
REQUIRED ORIFICE DESIGNATION AND AREA (in units of in2)

2. 20
00

60
E

25
.4
.02

1. 80

15
20 0

35
.
0
50

.5

20
10

0
.03 F
00

70

10
30 0
0
80

.05 G

.07
H

1.0 EXAMPLE 1
J

SP
2.0

EC
IF
IC
G
L

RA
3.0

V
EXAMPLE 2

IT
M

Y

TE
N

A
M

IR
PE
5.0

=
RA

1
TU
P

RE
7.0

F
10
Q

R
20
T
30
Note: in2 = 645 mm2; PSIG = 0.07 barg: F = 32 + 1.8C

FIG. 7.16f
Graphical method of sizing pressure relief valves for gas services.
RATED CAPACITY WITHOUT BACK PRESSURE

1.00
20% OV
E RPRE
CAPACITY WITH BACK PRESSURE

SSU
0.90 R E
TABLE 7.16g 10
%
PRV Nozzle Orifice Areas in Square Inches (in. = 645 mm )
2 2 OV
ER
0.80 PR
ES
Orifice Designation API Area Actual (ASME) Area SU
RE
D .110 .1279 0.70

E .196 .2279
0.60
F .307 .3568
G .503 .5849 0.50
0 5 10 15 20 25 30 35 40 45 50
H .785 .9127
% GAUGE BACK PRESSURE = BACK PRESSURE, PSIG OR kPa 100
Kb =

SET PRESSURE, PSIG OR kPa

J 1.287 1.496
K 1.838 2.138
FIG. 7.16h
L 2.853 3.317 Variable or constant backpressure sizing factor, Kb , for balanced bel-
M 3.60 4.186 lows pressure relief valves on vapor or gas service. The curves rep-
resent a compromise of the values recommended by a number of relief
N 4.34 5.047
valve manufacturers and may be used when the make of a valve or
P 6.38 7.417 the actual critical flow pressure point for the vapor or gas is unknown.
Q 11.05 12.85 When the make is known, the manufacturer should be consulted for
R 16.0 18.60 the correction factor. These curves are for set pressures of 50 PSIG
(345 kPa) and above. For set pressures lower than 50 PSIG (345 kPa),
T 26.0 28.62
the manufacturer should be consulted for the values of Kb .

2003 by Bla Liptk

 7.16 Relief ValvesSizing, Specification, and Installation 999

P1 = (for conventional PRVs) the set pressure (1 + 100

accumulation allowed by code having jurisdic-
tion) + atmospheric pressure in PSIA (kPaa); (for
pilot-operated PRV valves) = the set pressure plus

CAPACITY AT ZERO BACK PRESSURE

90
accumulation minus Pinlet in PSIA (kPaa)

CAPACITY AT BACK PRESSURE

Pinlet = the inlet pipe loss upstream to the PRV in PSI (kPa)
80
Subcritical Flow Sizing If the PRV is provided with bel-
lows seals, the sizing for subcritical flow can be based on
Equation 7.16(4) or 7.16(5), but the backpressure correction SUPERIMPOSED B.P.
70
factor Kb should consider the subcritical flow and the tendency 10% ACCUMULATION
20% ACCUMULATION
of the disc of the PRV to drop to below full lift. For these reasons,
the Kb factor should be obtained from the manufacturer. BUILT-UP B.P.
60
When sizing conventional or pilot-operated PRVs for 10% ACCUMULATION
20% ACCUMULATION
subcritical conditions (P2 > Pcf), Equation 7.16(6) or 7.16(7)
should be used.
50
0 10 20 30 40 50
A = [W/735F2KdKc] {TZ/[MP1 ( P1 P2 )]} (in US units) BACK PRESSURE PSIG
SET PRESSURE + ACCUMULATION PSIG
7.16(6)

A = 17.9[W/F2KdKc] [TZ/MP1 ( P1 P2 )] (in SI units)

7.16(7)
where
F2 = the subcritical flow coefficient
Backpressure Effect on Capacity Backpressure affects the
capacity and thus the sizing of relieving devices. In a sense,
the PRV is similar to an open control valve, because its
upstream pressure is the process pressure, and its downstream
pressure is that which exists in the relieving header. However,
instead of being a controlling element, it is controlled by the
pressure conditions at its inlet and outlet.
Most safety valves will handle flow very similar to a
theoretical nozzle as long as they are fully open (at full lift)
so that the controlling flow area is established by the nozzle.
The capacity of a theoretical nozzle is not affected by the
downstream pressure as long as it does not rise to the point
where the P drops below the critical pressure drop needed
to maintain sonic flow. At higher backpressures, the flow
becomes subsonic.
The effect of backpressure on the capacity of a conventional
safety valve with an unvented bonnet is shown in Figure 7.16i.
Note that the two sources of backpressure (superimposed and
built-up) produce different effects. Because of this capacity
reduction due to lift action, conventional valves should never
be used where backpressure variation can exceed 10% of the
set pressure.
Sizing for Steam Relief
FIG. 7.16i
Effect of backpressure on capacity of conventional safety relief valves.
is used in sizing steam PRVs for fired boilers whereas, for
nonfired vessels, ASME Code Section VIII is applicable. The
basic steam sizing equation is a modification of Napiers.
A = Ws/(51.5P1KdKbKcKNKSH) (in US units) 7.16(8)
A = (190.4Ws)/(P1KdKbKcKNKSH) (in SI units) 7.16(9)
where
A, P1, Kd, Kb, Kc = as defined in connection with Equation
7.16(4)
Ws = the required relieving steam capacity,
lbm/hr (kg/hr)
KN = the Napier correction factor, which is 1.0
if P1 < 1500 PSIA (10,339 kPaa) [For
pressures between 1500 PSIA (10,339
kPaa) and 3,200 PSIA (22,057 kPaa),
use Equations 7.16(10) and 7.16(11) to
calculate the value of KN.]
KN = (0.1906P1 1000)/(0.2292P1 1061) (in US units)
7.16(10)
KN = (0.02764P1 1000)/(0.03324P1 1061) (in SI units)
7.16(11)

The need for steam relief sizing is more often encountered KSH = the superheat correction factor, which is
in the design of power plants than chemical plants. The sizing 1.0 for saturated steam (For steam
method itself is straightforward once the required load and tables, refer to Appendix 5 or see man-
the relieving conditions are established. ASME Code Section I ufacturers tables.)

2003 by Bla Liptk

1000 Safety and Miscellaneous Sensors

Sizing for Liquid Relief Calculating the Discharge Area For more accurate sizing
for liquid service PRVs, refer to Equations 7.16(12) and
The 1986 edition of ASME UG-131 requires that, for pres- 7.16(13) below:
sure relief valves on incompressible fluid service, a capacity
certification test using water at a temperature between 40 and A = [Q/(38KdKwKcKv)] SpG/( P1 P2 (in US units)
125F be conducted. For any other fluid, the manufacturers 7.16(12)
tables generally can be used as long as the equivalent water
A = [(11.78Q)/(KdKwKcKv)] SpG/( P1 P2 (in SI units)
volumetric rate in gpm is used to enter these tables.
Division I of the ASME Code Section VIII, since 1980, 7.16(13)
has required that liquid service PRVs be provided with capac- where
ity certification. This certification requires that the rated coef- A, Kc P1, P2 = as defined in connection with Equation
ficient of discharge be based on 10% overpressure. Existing 7.16(4)
PRVs that were manufactured before 1980, were not provided Q = the relieving flow of liquid in GPM (l/min)
with certification, but were sized with 25% overpressure Kd = the effective coefficient of dicharge, which
allowance need not be replaced, but new PRVs must be should be obtained from the manufacturer
designed for 10% overpressure operation. (For preliminary sizing use Kd = 0.65.)
For preliminary sizing purposes, disregarding viscosity Kw = the variable or constant backpressure capac-
and backpressure effects, the graph in Figure 7.16j can be used. ity correction factor, which is required only

2000

1500

1000
800
700
600
500
400 40

300 30
T
200 20

150 R

Q
100 10

REQUIRED ORIFICE DESIGNATION AND AREA (in units of in2)

80 8
LIQUID CAPACITY (in units of GPM)

70
IG

60 P 6
PS

50 5
RE

00

N
SU

20

40 4
ES

00

M
00 R

10

=
40 0
25 E P

60

ER

L 3
0

30
G

AT
U

W
A

00

25
G

15

0
15

Y
50 0

00
80

IT

2
75

20
0

1.
V

K
RA

0
0

.5
35
30

G
0

20

15
IC
20

20

1.
40 CIF
0

J
10

.6
10

E
SP
50

10 10
1.

0
25

.8

8
15

8
0

H
.4

7
6 6
5 G 5
4 4

3 F 3

2 E 2

1 D
.10
.08

.06
.05
.04
.03
GPM = 3.78 Ipm; PSIG = 0.07 barg: in2 = 647 mm2

FIG. 7.16j
Approximate relief valve sizing chart for liquids.

2003 by Bla Liptk


1.00
0.95
0.90
0.85
0.80
Kw
0.75
0.70
0.65
0.60
0.55
0.50
0 10 20 30 40
Percent of Gauge Backpressure = (PB /PS) 100
FIG. 7.16k
Curve for the determination of Kw as a function of the ratio of PB/PS..
Kw is the capacity factor, which is to be used on liquid service
pressure relief valves with balanced bellows for correcting the effect
of backpressure. PB/PS is the percentage ratio of backpressure
divided by set pressure (both in PSIG). This curve represents the
values recommended by various manufacturers and should only be
used if the supplier is not known. Otherwise, the applicable Kw
factor should be obtained from the supplier. (Reproduced courtesy
of the American Petroleum Institute from API Recommended Prac-
tice 520, Sizing, Selection, and Installation of Pressure-relieving
Devices in Refineries, Part I Sizing and Selection, 7th ed., January
2000.)
for bellows sealed PRV valves (Figure 7.16k)
(For conventional or pilot-operated valves,
or when the backpressure is atmospheric,
use Kw = 1.0.)
Kv = the capacity correction factor for viscosity,
which can be obtained from Figure 7.16l
or from Equation 7.16(14), in which R is
the Reynolds number
0.5 1.5 1.0
Kv = [0.9935 + (2.878/R ) + (342.75/R )]
7.16(14)
SpG = specify gravity of liquid at flowing condi-
tions relative to water at 60F
Viscosity Correction The factor Kv accounts for the fact that
the resistance to flow encountered when handling viscous
liquids above 50 to 100 SSU may reduce the velocity and
thus capacity enough to require a larger orifice size than the
usual liquid capacity formula would indicate. Because the
correction factor is a function of the flow conditions, and
these in turn depend on the orifice diameter, a trial orifice is
2003 by Bla Liptk
7.16 Relief ValvesSizing, Specification, and Installation 1001
1.0
0.9
KV Viscosity Correction Factor
0.8
0.7
0.6
0.5
0.4
0.3
101 10 2 10 3 10 4 105
R = Reynold s Number
FIG. 7.16l
Curve for the determination of the viscosity correction factor KV ,
50 which is given as a function of the Reynolds number of the process
fluid being relieved. (Reproduced courtesy of the American Petro-
leum Institute from API Recommended Practice 520, Sizing, Selec-
tion, and Installation of Pressure-relieving Devices in Refineries,
Part I Sizing and Selection, 7th ed., January 2000.)
usually calculated based on no viscosity correction at all,
based on Figure 7.16j.
Having determined this nonviscous orifice size, the
next larger standard orifice is selected and used on the graph
shown in Figure 7.16m to find the correction factor. This
procedure is then repeated, using the corrected value as a
trial value, until the corrected required orifice area is less
than that of the standard orifice that was used to establish the
Kv factor.
Sizing for Flashing Liquid Relief
API RP 520 Appendix D (7th ed., 2000) describes a method
for PRV sizing on two-phase service, but it is still a somewhat
controversial subject. No sizing method has been validated
by tests, nor is there any recognized procedure for certifying
two-phase relief capacity. Problems associated with flashing
include the possibility of autorefrigeration and ice formation,
which might require the use of heat tracing or specially
selected PRV materials.
While the actual sizing is discussed below, certain fea-
tures of the valve discharge system can affect both valve
sizing and the cost of the installation. Because the amount
of flash is influenced by the discharge line size through the
actual backpressure developed, the ability of discharge line
sizing to suppress vapor generation should be considered.
Based on limited experience and some calculation, it appears
that the most economical valve size results at about 30%
backpressure. Balanced safety valves are usually used in flash-
ing flow to minimize the effects of the flashed vapors and of
the resultant backpressure on valve operation and capacity.
In the absence of experience in a particular service, some
manufacturers use an enthalpy balance (isenthalpic flash)
1002 Safety and Miscellaneous Sensors

0.2 0.5 1.0 2.0 5.0 10 20 50 100 200 500 1,000 2,000 5,000

O
RI
EXAMPLE

FI
V

C
IS

E
CO

D
ES
SI

IG
T
Y

N
AT

AT
I
O

O
PE

N
A
R

N
AT

D
I N

A
R
G

RE
T
TE

A
P
M

Q
P.

in
2
M

SA

N
Y

L
BO 6

H
LT 0

J
SE

F
80 0

CO

G
10

N
15 0

D
15

S
00

E
20 500

U
0
20 50
15 000

N
0
2 00

IV
0
00

2 0
20

30 00

.(
0

30 0

SS
40 00
30 000

U
40 0
50 00

)
00

50
40 00 0

60 000
0

60 0
50 00

8 000

0
60 000 0

80 0
10

11
1.

3.
0

26
10

16 5
0. 0.
80 000

6. 4. 3
8

.0
78 50

.0
0

.0
38 1.2

0 2.
10

38 34
5 3
0.

0.
0.
11

85
19
30

87
0

6
7
0.74 0.78 0.82 0.86 0.88 0.90 0.92 0.94 0.96 0.97 0.98 0.99
0.72 0.76 0.80 0.84 0.87 0.89 0.91 0.93 0.95 1.0
VISCOSITY CORRECTION FACTOR Ku
GPM = 3.78 Ipm: in2 = 645 mm2

FIG. 7.16m
Viscosity correction chart.

across the valve to calculate the expected volumetric rates
of liquid and vapor downstream of the valve. The required
discharge areas are then established independently for these
two rates, which are treated as all liquid and all vapor,
respectively. Both sizing calculations must be made at the
same overpressure with the appropriate capacity correction
factors applied as needed. The discharge area of the PRV is
selected to be at least equal to the sum of these two calcu-
lated areas.
While this method is not theoretically refined, there have
been no reported incidents in which this procedure led to an
undersized valve. The method could conceivably lead to an
oversized valve, which in turn can possibly result in valve
chatter. However, it is probable that the valve plus its dis-
charge piping will come to a stable condition of balance
between the effects of flashing and the downstream pressure
drop.
Special Cases
There are a number of special cases (such as relieving polymeri-
zing materials, handling high-temperature water, Dowtherm
systems, super pressure steam system, cryogenic fluids, toxic
materials relief, etc.) for which manufacturers have devel-
oped special designs of valves and sizing experience or spe-
cial sizing methods. It is recommended that the reader avail
himself of all available advice and assistance. Frequently, the
recommendations of two manufacturers will not agree. The
reader is thus alerted that he has a problem case and that
further study may be warranted.
SPECIFICATION AND SELECTION
Pressure relief valves serve to provide relief from overpres-
sure by opening a path for the excess process fluids flow to
a safer location. After the excess pressure is relieved, they
reclose, thereby not only preventing the further loss of pro-
cess fluids but also returning the process to normal operation.
A properly designed and installed PRV will perform these
tasks automatically, reliably, economically, and efficiently.
The most commonly accepted means of providing this is
to sense the rising pressure by some sort of force-balance
mechanism that, when its set point is reached, opens the
required relieving area for fluid flow. Usually, this force bal-
ance has the process pressure acting upon a given area on
one side; on the other side, that force is compared against
the force of springs or weights.
The magnitude of the forces that are being balanced can
be reduced, and thus their control improved, through the use
of secondary devices such as pilot valves, solenoids, etc. Of
the above-mentioned design options, the weight-loaded
valves have largely disappeared from process plant services
except in extremely low-pressure applications where their
high accuracy and the absence of the spring constant effect
caused by valve travel makes them advantageous.
Figure 7.16n shows a specification form that can be used
to list the required features of pressure relief valves before
they are sent out for bids by PRV manufacturers. Figure 7.16o
provides some cost estimating information on a list price
basis, which plant engineers can use if, based on their pre-
vious projects, they know their probable discount schedules.

2003 by Bla Liptk

 7.16 Relief ValvesSizing, Specification, and Installation 1003

SHEET OF
PRESSURE RELIEF VALVES
SPEC. NO. REV.
NO BY DATE REVISION
CONTRACT DATE

REQ. P.O.

BY CHKD APPR.

1. Tag Number
2. Service

3. Line No./Vessel No.

GENERAL
4. Full Nozzle/Semi Nozzle
5. Safety or Relief
6. Conv., Bellows, Pilot Op.
7. Bonnet Type
8. Size: Inlet Outlet
CONN. 9. Flange Rating or Screwed
10. Type of Facing
11. Body and Bonnett
12. Seat and Disc
13. Resilient Seat Seal
MATERIALS 14. Guide and Rings
15. Spring
16. Bellows
17.
18. Cap: Screwed or Bolted
19. Lever: Plain or Packed
20. Test Gag
OPTIONS
21.
22.
23.
24. Code
25. Fire
BASIS
26.
27.
28. Fluid and State
29. Required Capacity
30. Mol. Wt. Oper. sp. gr.
31. Oper. Press. Set Press.
32. Oper. Temp. Rel. Temp.
33. Constant
34. Back Pressure Variable
35. Total
FLUID DATA 36. % Allowable Overpressure
37. Overpressure Factor
38. Compressibility Factor
39. Latent Heat of Vaporization
40. Ratio of Specific Heats
41. Operating Viscosity
42. Barometric Pressure
43.
44.
45. Calc. Area sq. in.
46. Selected Area
47. Orifice Designation
48. Manufacturer
49. Model No.
Notes:

FIG. 7.16n
Pressure relief valve specification form.

2003 by Bla Liptk

1004 Safety and Miscellaneous Sensors

COST IN $1.000 Conventional PRVs

28
27
As it is shown in Figure 7.16p, the conventional PRV is a
26 force balance device that is held closed by a spring when the
25
inlet pressure is below its set pressure. When the set pressure
24
23 is reached, the upward force overcomes that of the spring,
22 and the valve opens. When the inlet pressure drops below the
21
set pressure by some percentage (this difference is called
20
19
ALLOY STEEL BODY blowdown), the valve recloses. The housing of the spring is
AND SPRING WITH
18 BELLOWS ALLOY STEEL BODY AND vented to the outlet of the PRV, and therefore the operation
SPRING
17 of the valve is directly affected by the backpressure.
16
15 The main difference in the operation of a PRV on liquid
CS BODY AND SPRING
14
WITH BELLOWS
relief service from that of a vapor relief valve is that it does
13
not have pop action. This is because, on liquid service, the
12
11 CS BODY AND SPRING force that lifts the disc is generated by the reactive forces
10 (the impact of the flowing liquid stream on the disc holder)
9
8 IRON BODY, SS TRIM,
to achieve full lift. These reactive forces build slowly during
7 CS SPRING the initial 2 to 4% of overpressure, and only after that will
6 the valve suddenly surge to full lift. The blowdown (the
5
4 percentage by which the inlet pressure has to drop below the
3 set pressure for the valve to close) on liquid service is much
2
1
larger than on gas servicearound 20%.
0 SIZE
D E F G H J K L M N P Q R T PRV Bodies and Bonnets The basic requisite for a direct
RELIEF VALVE ORIFICE AREA DESIGNATIONS
spring-loaded pressure-relieving valve is a suitable valve body,
FIG. 7.16o which is usually an angle-type device, having an inlet connec-
The list prices of flanged relief valves for preliminary estimating tion that is suitable for the inlet pressure/temperature require-
purposes. ments under both normal and relieving conditions. The body,

SECONDARY
DISC ANNULAR ORIFICE
HOLDER

DISC

ADJ RING

NOZZLE

BASE

SECONDARY SECONDARY
ANNULAR ORIFICE ANNULAR ORIFICE

ONE ADJUSTING RING

VALVE CLOSED VALVE PARTIALLY OPEN VALVE FULLY OPEN

FIG. 7.16p
All the main components of a conventional pressure relief valve are shown on the left. On the lower right, the closed, partially open, and
fully open positions of the valve are illustrated. On the top right, the critical working components (nozzle, adjusting ring, disc, and disc
holder) are identified.

2003 by Bla Liptk

 7.16 Relief ValvesSizing, Specification, and Installation
the outlet, and the bonnet are usually designed for a lower
pressure than the process pipeline or the inlet connection of
the PRV. Body connections can be flanged, screwed, or welded.
The bonnet is sized to accommodate the spring for the
maximum pressure rating of the valve. The bonnet is used
when the discharging medium must be confined within the
valve body and discharge piping. All bonnet-type valves have
either caps over the adjusting bolt or lifting levers, either
plain or packed.
Flanged valves for steam boilers usually have an open
spring with a yoke in place of a closed bonnet. The spring
is exposed on the steam valve, whereas the spring is totally
enclosed on the bonnet type valve. Marine boiler valves are
of the yoke type except that additional cover plates must be
added and sealed to prevent tampering with the spring. The
covers are vented (not pressure tight).
Seat and Spring The PRV inlet incorporates a valve seat
with a disc for full closure of the inlet port. The disc is usually
spring loaded, and the spring force is applied directly on the
disc by means of a stem. The disc may be either disc guided
or top guided. A bottom (disc)-guided valve has vanes or
feathers for guiding in the valve bore (inlet port). Process
valve are usually top guided (Figure 7.16p). Boiler valves
and liquid relief valves are often disc guided.
The set pressure is determined by the selection of the
proper spring and by adjusting the bolt that compresses the
spring to the correct opening pressure. Springs are classed in
different ranges so that the spring is never overstressed and
so that proper clearance between the coils allows for full lift.
The spring force at open position must not exceed the lifting
force of the flowing medium when the valve is fully open.
The spring setting may be adjustable in a narrow range. This
adjustment can be 30% or more on low-range springs and
5% on higher-range springs. The manufacturer must be con-
sulted for the acceptable range for a particular spring.
Nozzles and Blowdown Rings The inlet of the PRV may be
described as a bushing, semi-nozzle, or full nozzle. The bush-
ing is used on bottom-guided valves. The semi-nozzle is
usually found in cast iron valves. Both are screwed into the
PRVs body. The full nozzle is utilized on steel valves and
is the part of the valve that is designed for the pressure rating
of the process line.
The seat, orifice, and flange facing is one piece. The
flange of the valve is used for bolting force, which is to ASA
standards. The nozzle flange construction is similar to a Van
Stone-type flange. The discharge area or orifice of a nozzle
type valve is smaller than the nominal inlet. The converging
of the nozzle results in a high velocity, which provides the
high kinetic energy required to obtain high lift.
Pop Action The capacity of PRVs must be accurately cal-
culated, and their action must be reliable and foolproof over
the long run. Reliability is achieved by the maximum use of
simple mechanisms such as springs and linkages, and so
2003 by Bla Liptk
1005
forth. Accuracy in relieving capacity is achieved by conser-
vatism, by treating the relief device as an orifice, and by
attempting to size and install it so that it can always release
the process fluid (and thus energy).
In Figure 7.16p, one should note that there is an adjust-
able ring around the nozzle. Furthermore, the disc has either
a fixed or adjustable deflecting lip. The purpose of this lip is
to form a huddling chamber, which provides the pop action
of these pressure relief valves. The inlet nozzle is used to
efficiently generate the required velocity head (and thus
capacity), while the lip and the ring on the nozzle form a
secondary orifice and a device for reconversion of this veloc-
ity energy into static pressure to provide the pop action when
sufficient vapor flow develops.
Valve Lift and Capacity Being spring-loaded, PRVs require
some increase in force, because the movement of the spring
occurs while the valve is opening. The amount of this force
increase is determined by the spring constant and by the
amount of valve lift required to achieve full capacity. Most
PRVs reach their full capacity opening at about 3% above
their set pressure. If the pressure rises further, the area of
opening does not increase, so the increase in PRV capacity
is the result only of increased valve pressure differential.
Therefore, at 3% overpressure, the valve has fully lifted.
At this point, the curtain or cylinder area (huddling chamber)
between nozzle and disc is greater than the cross-sectional
area of the nozzle. The so-called low-lift valves gain more
capacity at higher pressure, because they have not reached
their limiting dimensions for the curtain area at the low
overpressures. In such cases, it is not permitted under the
ASME Code to calculate down-ratings for valves at lower
pressure based on performance at a higher test pressure,
although up-rating above test pressure is permitted, because
it will always tend to be quite conservative.
In contrast to gas or vapor PRVs, liquid service relief
valves generally do not reach their full capacity dimensions
until their full nominal rating overpressure of 10% is reached.
In liquid PRVs designed prior to 1980, this overpressure was
25%. Down-rating to lower pressures is permitted and pro-
vided by all manufacturers. It is important to understand and
design for this up-rating and down-rating, especially when
considering actual flow during maximum relief. This can
affect pressure losses in inlet and outlet piping.
Balanced PRVs
Two of the most common means of eliminating the effect of
backpressure on the set pressures of a PRVs set pressure are
the use of bellows seals and of a balancing piston design.
Figure 7.16q describes both of these devices. The balanced
disc, which is operated by a vented piston, is shown on the
left, and the bellows sealed designs are on the right. Note
that these devices may or may not provide a true balance,
depending on how well they match the nozzle area.
1006 Safety and Miscellaneous Sensors

1.00

.90
A-100 PSIG (690 kPa)
.80 B-100 PSIG (690 kPa)
.70
C-100 PSIG A-100 PSIG (690 kPa)
.60 A-10 PSIG (69 kPa)

.50 B-11.19 PSIG (77.21 kPa)

A-10 PSIG (69 kPa)
.40 MANUFACTURER A 20 % OVERPRESSURE
BONNET .30 MANUFACTURER A 10 % OVERPRESSURE
MUST MANUFACTURER B 10 % OVERPRESSURE
BE .20
MANUFACTURER C 10 % OVERPRESSURE
VENTED
.10
0
10 20 30 40 50 60 70 80
BELLOWS DETAIL-
BALANCED SAFETY BACKPRESSURE
% BACKPRESSURE = 100
RELIEF VALVE SET PRESSURE

FIG. 7.16r
Backpressure capacity reduction factor (Kb) for balanced bellows
PRV valves.

When sizing the PRV for liquid service, it is common

SAFETY RELIEF VALVE BELLOWS DETAIL-
WITH BALANCED DISC UNBALANCED SAFETY
AND VENTED PISTON RELIEF VALVE
FIG. 7.16q
Balancing devices include balancing pistons (on the left) and bel-
lows seal (on the right), which can be placed on either balanced
(top) or unbalanced (bottom) relief valves.
The backpressure effect on the PRVs set pressure has
already been discussed in connection with Figure 7.16c. This
figure illustrated several valve designs and four different
means of remedying this effect. On the lower right,
Figure 7.16c illustrates a PRV that is provided with vented
bellows seals. In this design, if the bellows area (AB) is the
same as the nozzle area (AN) of the PRV, the valve will be
balanced, and the backpressure will have no effect on the
pressure set point at which the valve opens. Such a balanced
PRV is shown on the upper right of Figure 7.16q.
If the bellows area (AB) is not the same as the nozzle
area (AN), the valve will be unbalanced, and the backpressure
will affect the set point. Even among balanced bellows
designs, there are differences among the Kb correction factors
of different manufacturers (Figure 7.16r). These variations
are a function of the specific valve design.
Equations 7.16(4) and 7.16(5) should be used when siz-
ing balanced bellows PRVs for gas or vapor service. In these
equations, the backpressure correction factor Kb serves to
correct for the loss in capacity resulting from subcritical flow
and for the condition when the valve disc does not lift fully.
For preliminary sizing estimates, Figure 7.16b can be used to
obtain a Kb correction factor, but, because each manufacturers
PRV design is a little different, the actual value of Kb should
be eventually obtained from the selected manufacturer.
practice to use the minimum pressure drop in the standard
formula [Equation 7.16(12) or 7.16(13)], which includes the
Kw factor for backpressure correction. For liquid applications
as well, there is variation in this factor among vendors.
As was shown by Equation 7.16(14), viscous materials
adversely affect the capacity of relief valves. Because the
required correction depends on the Reynolds number, the
point at which a correction is required will be a function of
orifice size, flow rate, and flowing viscosity (Figure 7.16l).
There is reasonably good agreement among manufacturers as
to the viscosity correction, and there is also general agreement
that viscosities below 50 to 100 SSU do not require correction.
Pilot-Operated PRVs
The pilot-operated PRV shown in Figure 7.16s consists of an
unbalanced floating piston type main valve and an external
or integral pilot. During normal operation, because the area
of the piston is larger on the top than on the bottom, and
because both are exposed to the same process pressure, the
resulting net force holds the PRV tightly closed. As the pro-
cess pressure rises, the seating force increases with it. This
feature is an advantage in applications in which the maximum
operating pressure is close to the relief set pressure and it is
important to prevent leakage.
When the set point is reached, the pilot vents the pressure
from the top of the piston, and the piston lifts. When the
process pressure drops below the set point of the pilot, it
closes its vent, which, in turn, reseats the piston.
The pilot can be pop-action or modulating and can be
flowing or nonflowing. The modulating design can save
expensive process fluids and can shorten the system recovery
time by relieving only as much process fluid as needed to
lower the pressure below its set point. For most services
except for inert gases, the nonflowing designs are preferred.

2003 by Bla Liptk

 7.16 Relief ValvesSizing, Specification, and Installation 1007

VARIABLE
ORIFICE PILOT
NOZZLE
A
BLOW DOWN
ADJUSTMENT

PILOT
PILOT VALVE VALVE

VIEW A-A
BLOWDOWN
RING
A

VENTURI

MANUAL
BLOWDOWN
PORT

OUTLET

ALTERNATE
PILOT SUPPLY
FROM REMOTE
LOCATION INLET
EXTERNAL PILOT SUPPLY SELF ACTUATING
EXTERNAL BLOWDOWN ADJUSTMENT

FIG. 7.16s
Pilot-operated relief valve designs showing the external (left) and integral pilot versions (right).

Integral or External Pilot The PRV on the right of Figure
7.16s utilizes an integrally mounted conventional safety valve
that, based on the relationship between the process pressure and
its set point, sends the process pressure to the top of the main
piston or vents it. The external pilot design on the left permits
adjustment of blowdown without a need for entering the valve
proper and uses an external sensing line to the pilot.
There are also pilot-operated PRVs in which the blow-
down and relief settings are independently adjustable through
the pilot valves mounted on top of the main piston or disc
chamber. Most of these designs have not received wide accep-
tance because of the large number of static and moving seals
they require for proper functioning and because of the small
clearances and potentials for plugging in the pilot mechanisms.
Advantages Where operating pressures approach the set
pressure, and where the process fluids are toxic and thus
present hazardous leakage problems, pilot-operated valves
present special economic and safety advantages.
1. The probability of leakage is reduced when the oper-
ating pressure approaches the set pressure because, as
the process pressure increases, the forces that are hold-
ing the piston closed also increase. In contrast, in the
spring-operated valves, the differential pressure on the
seat decreases under these conditions, causing sim-
mering near the set pressure.
2. Flexibility is provided by the potential for remote
operation.
3. Because nozzles are not needed to generate the veloc-
ity for pop action, the capacity is larger. The potential
increase in capacity over the largest nozzle orifice for
a given body size ranges from 150% for smaller sizes
to about 120% for the larger sizes.
4. There is improved operability at up to 98% of set
pressure due to lower blowdown. Figure 7.16t shows
these advantages.
5. There is a reduction in the loss of product loss, down-
time, and maintenance.
Disadvantages
1. There is increased potential for failure due to the large
number of static and moving parts.

2003 by Bla Liptk

1008 Safety and Miscellaneous Sensors

SPRING PILOT SERVO PILOT SERVO

LOADED SAFETY SAFETY
VALVE VALVE VALVE
1.22 Po
SET AT THE SET AT A
USUAL LOWER
PRESSURE PRESSURE 10 MIN.
1.20 Po
VALVE SIZE
SET HERE
1.18 Po

OVER- 8 INCREASED
1.16 Po PRESS SAFETY WHEN
SIZED AT
1.02 Po

1.14 Po

1.12 Po
USUAL USUAL SET
SET AT M.A.W.P.
1.10 Po

2 8%
1.08 Po SAVINGS IN
SHELL THICKNESS
BLOW OF A PROPOSED
DOWN 4 9% PRESSURE VESSEL
1.06 Po
INCREASED OR
THROUGHPUT
3 8% DERATING
1.04 Po OF A CORRODED
PRESSURE VESSEL

1.02 Po SET AT M.A.W.P.

BLOW DOWN 1 98%

Po OF SET

PROCESS OPERATING PRESSURE

5 CUT PRODUCT LOSSES, 6 REDUCE DOWN-TIME, 7 CUT MAINTENANCE

FIG. 7.16t
Comparing the operating ranges of conventional spring-loaded PRVs to the ranges of pilot-operated ones.

2. Small clearances exist in pilot mechanisms that can
be plugged by dirty process fluids.
3. The lead lines between the process and the pilot valve
and between pilot and main valve are small in size and
therefore have a higher potential for plugging.
Modulating Pilot-Operated Valves The modulating pilot-
operated relief valve is especially useful where some degree
of oversizing is necessary or desirable, because this valve
design helps to eliminate chattering. The main feature of the
modulating pilot-operated relief valve is that it has a zero
blowdown, which allows the main valve to modulate while
being approximately at the set pressure.
On gas or vapor service, this valve is at full lift when the
overpressure is about 3%, and when it is about 10% on liquid
service. Due to the variable orifice feature, the modulating
PRV valve opens only to relieve the overpressure and hence
reduces both the noise and the upset to the downstream
process. Figure 7.16u shows the lift of the valve piston as
a function of the process pressure during modulation. It can
be seen that this PRV valve changes its lift (opening) as the
rate of discharge is surging, thus avoiding chatter.
When to Consider Pilot-Operated PRVs When the follow-
ing conditions exist, it is justified to consider the use of pilot-
operated PRVs (POPRVs):
1. The expected PRV inlet losses are significant.
2. The margin between the operating pressure and the set
pressure is less than 10%.
3. The operating pressure is less than 15 PSIG.
4. The lighter weight of the POPRV is a consideration.

2003 by Bla Liptk


100
% FULL LIFT OF PISTON
75
50
25
3%
OVERPRESSURE
99 100 101 102 103
% SET PRESSURE
0 100%
VALVE CAPACITY
FIG. 7.16u
The operation of modulating pilot-operated pressure relief valves on gas or vapor (left) and on liquid service (right).
5. If the required orifice size is larger than P, both cost
and operating performance favor the consideration of
using POPRVs.
6. A depressuring system is needed.
In connection with depressuring, it should be noted that
such units should be used only as backups in addition to
regular pressure-relieving systems. These backup systems
should be sized to lower the process pressure from the set
pressure to 50% of design pressure within 15 min. They are
considered when the response time of the regular PRVs is
insufficient on reactors with potential for runaway reactions,
on gas filled tanks exposed to fire, on high-pressure fluid
applications in the event of major leakage, and in the reduc-
tion of hydrogen partial pressure to minimize the potential
for exothermic reactions.
Specification and Selection Checklist
In addition to selecting a particular pressure relief valve for
a specific service, it is advisable to review the following
checklist of the most frequent PRV system problem areas:
1. Make sure that, from among ASME Section I and VIII,
API, NFPA, etc., the right codes have been followed.
2. Specify both maximum and minimum normal oper-
ating temperatures and design the PRV for those and
not for the temperatures that might be reached during
fire relief conditions. Evaluate the high-temperature
effects on the seat and seal of the PRV, check for
temperature causing disc warpage or spring set-point
change.
2003 by Bla Liptk
7.16 Relief ValvesSizing, Specification, and Installation 1009
100
% FULL LIFT OF PISTON
75
LE
IB
S
ES
PR
50
OM
C
N-
NO
25
10% OVERPRESSURE
108 99 100 101 102 103 104 105 110
% SET PRESSURE
0 100%
VALVE CAPACITY
3. Make sure that the set pressure of the PRV is equal
to or less than the tank design pressure. If the PRV
protects several vessels, make sure that the hydrostatic
head of liquids is considered in selecting its set point
so that the design pressure, even at the lowest point,
will not be exceeded.
4. Make sure that the inlet and outlet line losses are
consistent with the code limits, and consider the use
of POPRVs with remote pressure detection when high
inlet loss is unavoidable.
5. Select a safe discharge point for the PRV if the process
fluid is toxic, corrosive, or flammable to protect both
the operators and the environment.
6. Consider the possible process upsets as well as start-
up and shut-down conditions when selecting the oper-
ating margin (difference between set pressure and oper-
ating pressure) for the PRV; if the process fluid is toxic,
corrosive, or very valuable, make that margin large.
7. Consider galling or seizing problems in guiding or
other close clearance areas, which can be caused by
bad materials selection, foreign matter entry, or deposit
buildup.
8. Check for atmospheric corrosion effects on the dis-
charge portion of the valve bonnet and other portions
of the discharge header system. Check, in particular,
the effect on high-stressed elements such as springs.
Consider the use of diaphragm seals and bellows seals.
9. Consider the possibility of polymer or other material
buildup in throats of valve or operating mechanism
after or during relief, which could impair valve action.
Consider the use of various seals.
10. Consider the resistance of the PRV valve assembly to
vibration.
1010 Safety and Miscellaneous Sensors
11. Provide the valve designs that will minimize chatter
on pulsating services.
12. Consider the probable condition of the valve and its
seating after exposure to external fire.
13. Evaluate whether the inlet, outlet, and/or the PRV
itself requires thermal tracing, because winter tem-
peratures can cause freezing of the process fluid. Eval-
uate the need for steam jacketing to prevent
tendencies of solidification or crystallization within
the valve. Check, in particular, the degree of steam
jacketing required.
14. Make sure the features are provided to accurately
guide the disc.
15. Check the need for valve position indicating devices.
16. Check the availability and desirability of augmenting
normal disc seating forces or keeping them constant
until the valve set point is reached so as to minimize
leakage.
17. Select seat and seal materials that are compatible with,
and are not dissolved by, the process fluids. On H2S
service, make sure that the valve materials are selected
in compliance with NACE MR0175. Also, make sure
that the seat will reseat tightly after relieving on spe-
cific service.
18. Make sure that the proper design features are selected
for countering the effects of all types of backpressures
and the resulting variations in set point and blowdown.
19. Evaluate the consequences of, and provide the ability
to detect, bellows rupture.
20. Consider open-spring vs. bonneted-spring designs.
21. Evaluate the degree of blowdown needed and answer
questions such as: Does blowdown have to be adjust-
able? Can pop action be destroyed in adjusting blow-
down?
22. Evaluate the need for special service valves such as
chlorine service, toxic material, LPG storage tank,
ICC approved, Coast Guard approved, etc.
23. Evaluate the need for various auxiliary features such
as test gags, lifting levers open or packed, screwed
vs. bolted adjusting nut caps, etc.
24. Evaluate the level of noise produced and its effect on
discharge piping.
PRV OPERATION AND PERFORMANCE
The topics of blowdown, PRV chatter, valve tightness or
leakage, and discharge system considerations are discussed
in the following paragraphs.
Blowdown
The phenomenon of blowdown is caused by the use of springs
in PRVs. The relieving system, when in operation, is a kinetic
system in which the PRV is at a point of high kinetic energy
in contrast to the equipment that it is protecting. The valve
2003 by Bla Liptk
spring balances against a pressure that equals the pressure in
the protected tank minus the kinetic effects.
When the PRV is closed, the system is a static one, with
no kinetic effects. Therefore, the pressure at the point of
spring balance is equal to that in the protected tank. When
the PRV is open, its inlet pressure is less than the pressure
in the protected vessel because of the inlet pressure drop.
This discrepancy between relieving and static conditions
requires the allowance for blowdown.
Blowdown is the amount by which the protected tanks
pressure has to drop below the PRVs set pressure for the valve
to reseat. This pressure difference is needed to ensure that
the valve satisfies its force balance once it closes. The normal
blowdown of a PRV is between 2 and 7% of set pressure.
Pilot-operated PRVs can reduce the blowdown to about 2%,
and engineers should always consult the supplier of a partic-
ular PRV design for the actual percentage of their design.
Section I of the ASME code for fired boilers requires that
the PRVs reach their full lift at a pressure not greater than 3%
over their set point and reclose within the maximum blowdown
values given in Table 7.16v. Section VIII of the ASME code
for unfired vessels does not provide a blowdown requirement,
and the industrial practice is about 7%, which means that the
normal operating pressure must be under 93% of set pressure.
Setting the Blowdown The position of the adjustable ring
on the PRV nozzle (Figure 7.16p) controls the blowdown.
This position establishes a secondary orifice area as the valve
opens and closes. Blowdown is set by first bringing this ring
all the way up to the disc (this corresponds to the maximum
blowdown position) and then lowering it a number of turns
as recommended by the vendor. This is necessary because
most test facilities have limited supplies of gas, and the set
pressure is usually tested at zero blowdown.
For process PRVs, the percent blowdown per turn is
usually based on methane. A 5% blowdown setting estab-
lished by using methane can represent about 11% when the
valve is handling butane. Very few manufacturers can provide
or have published data on this.
If blowdown is an important consideration, field tests
usually must be made after the PRV is installed. Even then,
it is nearly impossible to simulate actual, desired, or design
relieving conditions. Pilot-operated valves are much less sub-
ject to these considerations, because they can usually be set
for smaller blowdowns. Three percent is fairly standard for
a POPRV, and as little as 1% can be achieved in some cases.
TABLE 7.16v
Blowdown Recommendations by ASME for Fired Boilers
and Associated Tanks Operating at up to 375 PSIG
Pressure Relief Valve Set Maximum Blowdown
Pressure in PSIG Recommended
<67 4 PSI
<67 to <250 6% (of set pressure)
>250 to <375 15 PSI
 7.16 Relief ValvesSizing, Specification, and Installation
PRV Chatter
Energy losses in the inlet piping to the PRV and the protected
tank (as well as an oversized valve) can lead to a condition
known as chatter. Under these conditions, the PRV valve
repeatedly cycles between its open and closed positions. Vari-
ations in backpressure exceeding about 10% while a conven-
tional PRV is relieving will also produce an unstable force
balance condition and chatter.
Section II of API RP-520 endorses the widely used limit
of 3% of set pressure as the maximum limit for the pressure
loss in the inlet piping of a PRV. If, during relief, there are
losses much higher than 3%, they can drop the pressure at
the PRV seat to the reseating value. When this happens, the
valve closes, but as soon as it does, it is immediately sub-
jected to a pressure rise, because closure has eliminated the
kinetic effects. This rise in pressure can be enough to cause
the PRV to reopen, and the cycle repeats.
Oversized valves can also cause this same condition,
because a spring-loaded valve needs to have about 20 to 30%
of its maximum flow to establish a stable force relationship
to maintain a stable disc position. Chatter has at least two
detrimental effects. One is that the valves seating condition
will cause leakage. The other detrimental effect is that bel-
lows failure can be expected if the disc chatters or flutters.
Chatter and Inlet Line Loss in POPRVs Pilot-operated valves
are not subject to chatter to the same extent, because they are
open or closed and cannot throttle down to flows in the 20
to 30% range. Thus, if they are oversized, repeated openings
and closings may be needed to hold the system pressure, and
the net result is an action approaching chatter. Modulating pilot-
operated relief valves overcome the basic problem of over-
sizing and inlet pressure losses that are the causes of chatter.
As far as their set pressure is concerned, POPRVs can
have more than 3% pressure drop in their inlet line if they
are using a remote sensor (Figure 7.16s shows a local pres-
sure pilot line). In such situations, the inlet line loss will still
limit the relieving capacity of the valve. Therefore, the inlet
line loss should always be considered before the POPRV is
sized. If this is not done, when the inlet loss is calculated, it
might be found that a larger valve needs to be used. Naturally,
in all high line loss cases, one should consider the relocation
TABLE 7.16w
ASME Section VIII Provides the Following Recommendations for Maximum Set Pressures and Maximum Accu-
mulated Pressures for Both Single and Multiple PRV Installations for Both Fire and Non-Fire Cases
PRV Installation Single
Maximum Pressure Set%
st
Non-Fire Case, 1 PRV 100%
Non-Fire Case, Additional PRV N/A
st
Fire Case, 1 PRV 100%
Fire Case, Additional PRV N/A
Fire Case, Supplemental PRV N/A
2003 by Bla Liptk
1011
of the POPRV to the point where the remote pilot line detects
the process pressure.
Chatter on Liquid Service The subject of chatter is of spe-
cial interest when relief valves are mounted on vessels that
are full of liquid. In the past, conventional valves designed
for vapor service were also used in liquid service, and this
had catastrophic results. This is because, in a liquid system,
the pressure profile immediately upstream of the PRV valve
can change rapidly when the valve pops open, especially
if there is a significant length of inlet piping between the valve
and the vessel being protected. In that case, when the valve
opens rapidly, an immediate reduction in pressure (at the inlet
to the valve) can make the PRV valve close prematurely. The
pressure then builds back up again quickly, the valve must
open again, and the cycle repeats; thus, chatter ensues.
Most manufacturers offer a liquid-service trim designed
specifically to overcome this problem. The piping between
the inlet to the valve and the process being protected should
be kept to a minimum. Direct connection of the valve to the
process vessels is preferred, if practical. Another potential
solution is to use a pilot-operated or modulating pilot-operated
PRV valve that is provided with a remote sense line, depend-
ing on the process conditions and type of process liquid.
PRV Tightness and Leakage
If fire is the only potential cause of overpressure, the valve
tightness in spring-loaded valves can be markedly improved
by taking advantage of the 20% accumulated pressure that
the ASME Code allows for this condition (Table 7.16w).
If one valve is set for 109% of maximum allowable
working pressure (MAWP), and 10% accumulation is
allowed, this results in the same size valve as one set at 100%
allowing 20% accumulation. However, if the operating pres-
sure is at or near 90% of the maximum allowable, the first
valve will have about twice the force keeping the seat tight
at the operating pressure as that available in the case of the
second valve (Figure 7.16x).
Using Two PRVs Another way to reduce leakage in some
installations is to use two PRVs. This is a possibility if, in a
particular application, there is a large fire load but relatively
Single Multiple Multiple
Accumulated% Set% Accumulated%
110% 100% 116%
N/A 105% 116%
121% 100% 121%
N/A 105% 121%
N/A 110% 121%
1012 Safety and Miscellaneous Sensors

VESSEL TYPICAL SAFETY RELIEF VALVE CHARACTERISTICS

PRESSURE VESSEL REQUIREMENTS
PRESSURE SET AT M.A.W.P., SIZED FOR 10% O.P.

MAX. ALLOWABLE ACCUMULATED 120

PRESSURE ALTERNATE UPSTREAM
(FIRE EXPOSURE) PRESSURE

OF ORIFICE (VARIES)
MARGIN OF SAFETY
DUE TO SELECTION
(FLOWING PRESSURE)
UNDER FIRE CONDITIONS

ALTERNATE OVERPRESSURE (AVG. SET)

115
ACCUMULATION

MAX. ALLOWABLE ACCUMULATED 110

VESSEL PRESSURE, % OF M.A.W.P. (GAUGE)

PRESSURE UPSTREAM PRESSURE
(OTHER THAN FIRE EXPOSURE) (FLOWING PRESSURE)

OVERPRESSURE
ACCUMULATION

OVERPRESSURE
MAX. ALLOWABLE SET PRESSURE 105
(SUPPLEMENTAL VALVES ONLY,
OTHER THAN FIRE EXPOSURE)
MAX. SET PRESS. (POP)

TOLERANCE
UG-133(f)
MAX. ALLOWABLE WORKING PRESS. 100 SET PRESSURE (POP)
MAX. ALLOWABLE SET PRESS. SIMMER (AVG. SET)
(OTHER THAN FIRE EXPOSURE)
(10% BUT NOT LESS THAN
RECOMMENDED MARGIN

STD. TIGHTNESS TEST

START TO OPEN PRESSURE

BLOW DOWN
25 PSI OR 172.5 kPa)

MIN. SET PRESS. (POP)

SIMMER (MIN. SET)
95 START TO OPEN PRESSURE
BLOW DOWN

SEAT LOADING AVAILABLE

RESEAT PRESS. (AVG. SET)

NORMAL OPERATING PRESS. 90

RESEAT PRESS. (MIN. SET)

NOTE: ABOVE VALVE WOULD MEET THE

REQUIREMENTS OF UG-125 (c),
UG-125(d) AND UG-133(a), ASME
UNFIRED PRESSURE VESSEL
CODE.
85

FIG. 7.16x
Characteristics of a single safety relief valve used to protect a pressure vessel having the listed requirements.

small operating load. In such a case, the small valve is set at Seat Designs, O-Rings, and Temperature Greatly influenc-
100% and sized for 10% accumulation at the operating load, ing valve tightness are the factors of seating design, cleanli-
but it will accumulate to 20% under fire conditions. The large ness of the process fluid handled, and installation practices.
PRV is set at 109% and is sized to handle the fire load 10% In the area of seating closure design, some of the mechanical
overpressure. Such a combination of two PRVs will generally containment designs of the nozzle, disc, and guiding moving
reduce leakage quantities (Figure 7.16y). parts have been claimed to pay off handsomely in terms of
The use of a pair of PRVs becomes even more attractive trouble-free service.
if company policy requires the use of two PRVs. Similarly, The so-called soft seat designs and the O-ring seats do
on low-pressure tall towers, if the API recommendation is much to prevent leakage as long as the PRV does not relieve.
followed and therefore the PRV inlet loss is limited to 3% However, it is good practice to check the design and question
of set pressure, the use of two valves becomes attractive. the vendor about what the leakage will be after the PRV

2003 by Bla Liptk

 7.16 Relief ValvesSizing, Specification, and Installation 1013

TYPICAL SAFETY-RELIEF VALVE CHARACTERISTICS

VESSEL
PRESSURE VESSEL REQUIREMENTS WHEN USED FOR FIRE EXPOSURE ONLY
PRESSURE
SET AT 1.1 M.A.W.P., SIZED FOR 9.1% O.P.

MAX. ALLOWABLE ACCUMULATED 120

PRESSURE UPSTREAM PRESSURE
(FIRE EXPOSURE ONLY) (FLOWING PRESSURE)

OVERPRESSURE
OF ORIFICE (VARIES)
MARGIN OF SAFETY
DUE TO SELECTION

OVERPRESSURE
115

MAX. SET PRESSURE (POP)

ACCUMULATION

TOLERANCE
UG-133(f)
MAX. ALLOWABLE SET PRESS. 110 SET PRESSURE (POP)

VESSEL PRESSURE, % OF M.A.W.P. (GAUGE)

(FIRE EXPOSURE ONLY) SIMMER
(AVG. SET)
START TO OPEN PRESSURE

STD. TIGHTNESS TEST

BLOW DOWN
MIN. SET PRESSURE (POP)
SIMMER (MIN. SET)
105
START TO OPEN PRESSURE

BLOW DOWN
RESEAT PRESSURE (AVG. SET)

MAX. ALLOWABLE WORKING 100

PRESSURE
RESEAT PRESSURE (MIN. SET)

SEAT LOADING AVAILABLE

95

NORMAL OPERATING PRESSURE 90

NOTE: ABOVE VALVE WOULD MEET THE
REQUIREMENTS OF UG-125(d)
AND UG-133(b), ASME UNFIRED
PRESSURE VESSEL CODE. THIS
IS A SUPPLEMENTAL VALVE.

85

FIG. 7.16y
Illustrating the various pressures in a case where a supplemental valve has been installed to handle the fire load.

reseats. In some designs, the O-ring is actually expected to
be shredded or destroyed during relief. Therefore, until the
ring is replaced, the PRV will only provide a metal-to-metal
secondary seat after the first relief.
Temperature probably provides the most serious limita-
tion on soft seal or O-ring materials. In addition to soft seat
sealing, the flexible seat has been well received in some
services outside the temperature limits of synthetic seating
materials. The knife-edge seat is perhaps the most desirable
for services where icing or similar deposits can form on the
seat during relief. The knife-edge seat has also been used on
liquid services containing fine solids in suspension.
Flatness and Cleanliness Most process service valves as
tested and shipped by the manufacturer have a seat finish of
less than 5 in. with a flatness deviation of less than 5 to
15 in. (0.13 to 0.38 m). For this reason, even nozzle defor-
mation caused by bolting stresses is a concern.
The method of holding the nozzle in the pressure-
containing body to minimize the effects of bolting forces is
one of the distinguishing features of some PRV designs.
Other design goals include minimizing piping reactions that
would tend to deform the nozzle, applying the spring load to
the disc, and various disc designs that act to compensate for
differential expansion effects. These are refinements that

2003 by Bla Liptk

1014 Safety and Miscellaneous Sensors
manufacturers have developed as users demanded tighter,
longer-lasting valves while the PRV service conditions grew
progressively more severe.
The influence of fluid cleanliness on PRV performance
is illustrated by contrasting the refinery or chemical industry
practices to those of missile service. In a number of refinery
and chemical plant applications, experience has shown that
the valve will leak once it has opened and reseated. In many
plants, it is accepted that you may just as well take it down,
clean and lap it, reset it, and reinstall it.
Contrast this with the shop inspection requirements on
some missile service PRVs where 200 successive cyclings
on clean, high-pressure nitrogen must still leave the valve
virtually bubble tight. This requirement is regularly met on
a production basis.
PRV INSTALLATION
The inlet and outlet line losses of the individual PRVs are
calculated on the basis of their rated capacity, not on their
required relieving capacity. This approach should also be
used as the basis for sizing PRV manifolds so as to minimize
built-up backpressure and PRV chattering.
PRV Location
Pressure relief valves should be placed close to the tank or
equipment they are protecting to minimize their inlet pressure
losses. Their location should also be selected with the goal
of avoiding unstable flow patterns and minimizing inlet tur-
bulence. Therefore, a minimum distance of ten pipe diameters
should be provided between such fittings as orifices, elbows,
valves, and flow nozzles and the PRV.
Relief valves should be located with full consideration
given to the need for convenient maintenance access. Easy
and safe access is a very important element in making sure
that inspection and testing is regularly performed. If there is
no convenient natural access to the valve, the installation of
a platform should be considered. PRVs should not be located
at the end of long and stagnant horizontal pipes.
PRV Mounting
Vapor relief valves should be mounted on the top of the
protected tank and should be connected to its vapor space
above the liquid level or to piping that is connected to the
vapor space. Liquid service PRVs should be connected below
the normal liquid level in the tank. All PRVs should always
be mounted vertically, not only because horizontal mounting
can adversely affect their operation but also because horizon-
tal mounting violates the ASME code and the API recom-
mended practice.
Pressure relief valves should not be mounted close to
vibration or turbulence sources such as orifice plates or positive
2003 by Bla Liptk
displacement pumps/compressors. This is because the pres-
sure spikes can cause premature relieving, and the pulsation
can alter the PRVs set pressure.
PRVs should not be mounted at the end of horizontal
pipes, either. This is because, when the PRV opens, debris
such as welding slag, pipe scale, and foreign objects that are
present in the horizontal pipe will be transported into the
valve and will either cause leaking after the PRV recloses or
require immediate maintenance to be performed on the valve.
PRV Inlet Piping
The inlet pipe to all PRVs should be as short and direct as
possible and should be the same size or larger than the inlet
connection of the valve. The inlet pipe should not connect to
locations in the process where unstable or turbulent flow
patterns exist. When the PRV is relieving vapors, it should
be sloped upward to the PRV so that liquid entrainment would
be minimal. If the line has a low point, it should be drained.
If the process is such that the inlet pipe can be plugged,
it is recommended to provide a clean, nonreactive liquid
purge to keep the inlet line clean. If plugging of the inlet line
can be caused by low temperatures, such as generated by the
cooling of high-viscosity polymers or by ice formation at
ambient temperatures, the PRV inlet line should be heat
traced.
PRV Outlet Piping
The outlet pipe size should be the same as or larger than the
PRV outlet connection. The outlet pipe should be sized to
limit the backpressure when the PRV is relieving so that this
backpressure will neither shift the set pressure nor prevent
the PRV from operating at its full rated capacity. In case of
conventional spring-loaded PRVs, the maximum limit for
built-up backpressure is 10% of the set pressure. For PRVs
with balanced bellows, it is between 30 and 50%. For pilot-
operated PRVs, it is 50% of the set pressure.
The outlet pipe should always be properly drained. The
preferred choice is to provide self-draining. When that is not
possible, a low-point drain with shut-off valve should be
provided, and the drain should be piped to a closed system.
In selecting the materials of construction for the outlet
pipe, design engineers should evaluate the possibility of
autorefrigeration occurring during PRV relieving. If that is
the case, the expected low temperatures should be calculated,
and suitable pipe materials should be selected to protect
against fracturing the brittle metal.
When the PRV discharges to the atmosphere, long-radius
elbows should be used, and both the weight of the outlet pipe
and the reaction forces should both be considered in design-
ing the pipe supports. The tail pipes should be angle-cut to
reduce both the relieving noise level and the reaction force.
Local bylaws should be consulted in setting the allowable
noise level, which should be calculated on the basis of API
RP 521, Section 5.4.4.3.4, in the 1997 edition.
 7.16 Relief ValvesSizing, Specification, and Installation
The discharge location should be selected so that, if
steam, hot water, or nitrogen is being discharged, it will not
injure the operators. The tip of the atmospheric outlet pipe
should be provided with both a screen and a weather cap.
Calculating the Reaction Force Large reaction forces gen-
erated by the large volumes and high velocities of discharged
fluids as the discharging stream makes a 90 turn at the PRV
can overload supports, distort manifolds, and cause leakage
related accidents even fire. When the PRV discharges
directly to the atmosphere, the outlet piping should be brace
supported and, in case of very large valves, even dual outlets
should be considered to balance the reaction forces. The
reaction force of an open PRV discharge can be calculated
using Equation 7.16(15).
F = (W/366)[kT/(k + 1)Mw] + AoP2 7.16(15)
where
F = the reaction force in lb
W = the required relief capacity of the PRV in lb/hr
k = the ratio of specific heats of the relieved gases
(Table 7.15a)
Ao = the area of the outlet of the discharge pipe at the
2
point of discharge, in.
T = the flowing temperature of the relieved vapors at
the inlet of the PRV in R
Mw = the relieved gas or vapor
P2 = the pressure inside the discharge pipe at the point
of discharge in PSIG
When the PRV discharge is sent into a closed system,
only at points of sudden expansion is it likely that significant
reaction forces will exist. The manifold supports in such cases
should be designed on the basis of detailed calculations.
PRV Block Valves
Section I of the ASME Boiler and Pressure Vessel Code does
not allow the use of block valves at all. In contrast, PRVs
protecting nonfired pressure vessels are permitted to be isolated
on both their inlets and outlets if on-line maintenance is impos-
sible. In that case, block valves are permitted if they are provided
with a spare PRV and if the service they are in has a history of
leakage, plugging, or other causes of frequent maintenance.
When isolating valves are used around PRVs, they must
be distinguished by special tagging, and the plant operations
should be such that only authorized personnel can operate
them. It is also important that the open and closed positions
be visible and clearly identified. The plants operating manual
should clearly state the required position of these block
valves and should also state the reasons why they are locked
open or closed. The operating manual should require not only
the periodic checking of PRV isolation valve positions but
also the checking of their condition.
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1015
Multiple PRVs
One situation in which the use of a small and a large PRV
is justified on the same tank or equipment is when the
process can have two vastly different relieving capacities.
In such a case, the smaller valve is needed, because a single
large one would chatter when relieving small flows. The
other case, when multiple valves of identical size can be
used, is when the total relieving area required is more than
that of a P orifice (Figure 7.16g). Whenever multiple
valves are installed, one PRV should be set at the set pres-
sure and the other(s) at 105% of that pressure, as listed in
Table 7.16w.
The use of multiple PRVs can extend their life spans and
make it easier to keep their inlet line losses below 3% of set
pressure. Another advantage can be the reduction of the PRV
inventory of the plant, if the use of multiple valves reduces
their variety in the plant.
Among the multiple valves, each should have its own
nozzle or other direct connection to the protected vessel or
equipment. No tree branching of several PRVs from the same
main inlet line should be used.
Spare PRVs
PRVs on critical equipment or processes that cannot be shut
down should be provided with spares so that the processing
operation can continue even when the PRV fails. The instal-
lation of a spare PRV is also recommended if the maintenance
history of a particular valve is such that it needs maintenance
more often than at regular service intervals.
Spare PRVs are also needed on applications in which the
valve needs immediate servicing after each time it relieves
because the process fluid is corrosive, fouling, or contains
solids. Spares are also recommended if the PRVs operate near
their extreme design limits, such as at very low or very high
temperatures.
Whenever a PRV is spared, the spare valve must be
provided with full-bored isolation valves on both its inlets
and outlets. Car seal open (CSO) valve designs are required
for these applications, because these block valves must be
locked open when the spare PRV is in service.
TEST, INSPECTION, AND AUDIT
There are three levels of continuous status maintenance and
reviews of pressure safety systems. Periodic testing serves to
make sure that the performance of each PRV is within spec-
ifications. The purpose of inspections is to check on the
quality and reliability of the testing program, whereas the
main purpose of the audits is to make sure that the design of
the safety systems has been adopted to the various changes
that are always occurring in operating plants.
1016 Safety and Miscellaneous Sensors
PRV Testing
All PRVs should be tested before their installation, after each
fire event or case of relieving dirty process fluids, and at the
frequency of the service intervals set by the plant. Certified
technicians are required to perform the PRV tests. Testing is
performed either in a test workshop or, if the PRVs are
provided with field test connections, in situ.
During the test, technicians should look for signs of tam-
pering, process-related damage, leakage, wear, and corrosion.
They should also test the set pressure, blowdown, overpres-
sure, and seat tightness of each PRV and make the required
adjustment, if any. To test the tightness of the seat, they
should follow API Standard 527.
After the testing is done, the staff should prepare a test
report for each PRV and mark the PRV tag with the date and
test pressure that was checked.
PRV Inspection
The purpose of the inspection is to ensure that the testing
was properly performed and that no foreign objects, welding
beads, or rust was left inside the PRVs. The inspector will
also check for signs of tampering, leakage, erosion, wear,
and corrosion and verify that the PRV flanges are clean and
in good condition.
The inspectors will also make sure that the PRVs tag is
the same one that appears on the P&ID flow sheet and that
it is securely tied to the valve. Finally, the inspectors should
also make sure that the performance data obtained during
testing and reported in the test report are acceptable for the
particular PRV application.
PRV Audit
The audit evaluates the pressure safety of a complete pro-
2
cessing unit. The main goal of the audit is to confirm that
the tasks in the action list of the previous audit have been
performed, and the maintenance strategy of the plant has been
properly followed. Any process changes that have occurred
since the last audit are carefully evaluates in terms of their
effects on the pressure safety systems.
If, because of the process changes, PRVs can be removed,
or previously acceptable ones have become oversized or
undersized, the audit should reveal that. The final product of
an audit is a prioritized new action list that will serve to
further improve the operating safety of the plant.
References
TM
1. Farris Engineering, SizeMaster Mark IV, Pressure Relief Valve Engi-
neering Software, Version 4.2 (http://www.avrasoft.com/sizemaster).
2. Wong, W. Y., Improve PRV audit, Hydrocarbon Process., November
1998.
2003 by Bla Liptk
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