Sizing and Selecting Pressure Relief Valves

Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.

Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Instrumentations For additional information on this subject, contact
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Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Sizing And Selecting Pressure Relief Valves
Engineering Encyclopedia Instrumentations
Content Page
INTRODUCTION................................................................................................................ 1
SPECIFICATIONS REQUIRED FOR SIZING PRESSURE RELIEF VALVES.................. 2
Process Flow Diagrams ............................................................................................. 4
Piping & Instrument Diagrams................................................................................... 6
Instrument Specification Sheets ................................................................................. 6
Basis of Selection.....................................................................................................11
Conditions Requiring Overpressure Protection..............................................11
Contingencies That Cause Overpressure........................................................13
Operational Requirements for Overpressure Protection .................................14
Effective-Area Concept.................................................................................14
Methods for Determining Relieving Pressure ............................................................14
Operating Contingencies ...............................................................................15
Fire Contingencies ........................................................................................17
Steam Service...............................................................................................18
CALCULATING THE SIZE OF A PRESSURE RELIEF VALVE - HAND
CALCULATOR METHOD.................................................................................................19
Basis for Calculating Valve Size ...............................................................................19
Service Conditions........................................................................................20
Flow Rate.....................................................................................................20
Effective Discharge Area ..............................................................................21
Sizing Equations For Specific Applications...............................................................22
Sizing for Gas and Vapor Relief....................................................................22
Sizing for Steam Relief .................................................................................24
Sizing for Liquid Relief .................................................................................25
Sizing for Two-Phase Liquid-Vapor Relief....................................................26
SELECTING A PRESSURE RELIEF VALVE - MANUFACTURERS CATALOG
METHOD ...........................................................................................................................28
Sources of Required Data.........................................................................................28
Instrument Specification Sheets.....................................................................28
Manufacturers Catalogs...............................................................................28
Administrative Requirements....................................................................................31
SIZING AND SELECTING A PRESSURE RELIEF VALVE - COMPUTERIZED
SIZING METHOD..............................................................................................................32
Program Applications...............................................................................................32
RELIEF VALVE AUTHORIZATION PROCESS...............................................................37
Relief Valve Authorization, Form 3099A..................................................................40
Form 8020-611 ........................................................................................................40
Relief Valve Test Report, Form 3750 .......................................................................42
WORK AID 1: RESOURCES FOR DETERMINING RELIEF VALVE
SPECIFICATIONS .............................................................................................................44
Work Aid 1A: Procedure for Determining Applicable Contingencies for PZV
Sizing and Selection .................................................................................................44
Work Aid 1B: Procedure for Determining Relieving Pressure of PZVs .....................45
WORK AID 2: RESOURCES USED TO CALCULATE THE SIZE OF A RELIEF
VALVE-HAND CALCULATOR METHOD.......................................................................47
Work Aid 2A: Formulas and Procedures to Size PZVs for Gas and Vapor................47
Work Aid 2B: Formulas and Procedure to Size PZVs for Steam Relief.....................51
Work Aid 2C: Formulas and Procedure to Size PZVs for Liquid Relief.....................52
Work Aid 2D: Procedure to Size PZVs for Two-Phase Liquid/Vapor Relief.............54
WORK AID 3: RESOURCES USED TO SELECT A RELIEF VALVE -
MANUFACTURERS CATALOG......................................................................................56
WORK AID 4: RESOURCES USED TO SIZE AND SELECT A PRESSURE RELIEF
VALVE - COMPUTERIZED SIZING METHOD...............................................................57
GLOSSARY........................................................................................................................61
ADDENDUM......................................................................................................................62
Addendum 1: Crosby Engineering Handbook ...........................................................63
Addendum 2: Properties of Gases.............................................................................64
Addendum 3: SAES-J-600, Pressure Relief Devices, ................................................65
ADDENDUM 4: Crosby Catalogs............................................................................66
Table of Figures Page
Figure 1. Information Sources for PZV Sizing and Selection..................................... 3
Figure 2. Process Flow Diagram of HPPT ................................................................ 5
Figure 3.Typical P & ID............................................................................................ 6
Figure 4. ISS Form No. 8020-611-ENG, Sheet 1...................................................... 8
Figure 5. ISS Form No. 8020-611-ENG, Sheet 2...................................................... 9
Figure 6. ISS Form No. 8020-611-ENG, Sheet 3.....................................................10
Figure 7. Basis of Relief Capacities Under Selected Conditions
1
..............................12
Figure 8. Example Determination of Relieving Pressure for a Single Valve
Installation (Operating Contingencies)1 ....................................................15
Figure 9. Example Determination of Relieving Pressure for a Multiple Valve
Installation (Operating Contingencies)
1
....................................................16
Figure 10. Example Determination of Relieving Pressure for a Single Valve
Installation (Fire Contingencies)
1
..............................................................17
Figure 11. Example Determination of Relieving Pressure for a Multiple Valve
Installation (Fire Contingencies)
1
.............................................................17
Figure 12. Inputs and Considerations for PZV Size Calculation ...............................19
Figure 13. PZV-100 Thermal Relief Valve...............................................................29
Figure 14. CROSBY-SIZE Report Sheet for PZV-200............................................36
Figure 15. Chart I - Projects Authorization Procedure for RV Installation and
Changes....................................................................................................37
Figure 16. Chart II - Operations Facilities Authorization Procedure for Relief
Valve Installation and Changes .................................................................39
Figure 17. Relief Valve Authorization, Form 3099A................................................41
Figure 18. Relief Valve Test Report, Form 3750......................................................43
Figure 19. Set Pressure and Accumulation Limits for Pressure Relief Valves
2
..........46
Figure 20. Company Database Administration Menu................................................58
Saudi Aramco DeskTop Standards 1
INTRODUCTION
The process of specifying a pressure relief valve involves three main phases:
1. Determining the specifications for the PZV
2. Calculating the flow area of the PZV orifice (effective area)
3. Selecting and verifying the size of the PZV
The first phase involves both the collection of data from existing sources and the determination of
the design basis of the PZV. The data that must be collected to size and select pressure relief
valves are specified in API RP-520. The collected data is then recorded on Saudi Aramcos
Instrument Specification Sheet (ISS) Form 8020-611 ENG. The design basis includes the
evaluation of all potential causes of overpressure and the calculation of the PZVs relieving
pressure.
In the second phase, a preliminary valve size is calculated based on the particular valve
specifications that were determined in the first phase. For the required relieving conditions, the
area of the PZV orifice is calculated so that it provides the required flow rate and volume of
discharge. This calculated area is called "effective area" because it is based on values that are
assumed, or conceptually assigned from design requirements, rather than values that are actually
measured. This module will demonstrate two methods to calculate the effective areausing a
hand calculator and using a manufacturers computer program.
In the third phase, the calculated "effective area" and the service conditions that are specified on
the ISS are used to select a valve from either a manufacturer's catalog or a manufacturers
computer program.
This module also describes the relief valve authorization process. As code certified valves, the
events in the service history of each PZV require authorization by responsible engineers.
Signatures are recorded for the approvals required for the origination, installation, maintenance
and removal of each PZV.
SPECIFICATIONS REQUIRED FOR SIZING PRESSURE RELIEF VALVES
Figure 1 shows the relationship between the information sources for the data that must be
specified on the Instrument Specification Sheet and the proces of sizing a PZV.
The first step in establishing the size of a PZV is to determine the conditions for which
overpressure protection may be required. In order to determine the overpressure conditions, one
must obtain process and equipment information about the physical system that requires
overpressure protection. Then, each of the potential causes of overpressure must be evaluated
both in terms of the pressures that may be generated and the rates at which fluids must be
relieved. API RP-520, Part I, Section 4.1, "Determination of Relief Requirements," lists the
following information that is needed for calculating relieving rates:
Process flow diagram (PFD)
Piping & Instrument Diagram (P & ID)
Design Basis (or Basis of Selection)
All of these items are described in more detail on the following pages. API RP-520 also states
that the material balance is needed; however, it will be described later. In addition to the
information above, the following items should be obtained.
Equipment Specifications - Originating engineers involved in the sizing and selection
of PZVs must review specifications of the equipment to be protected in order to
confirm MAWP, and establish the set pressure for its PZV.
Construction Layout Drawings - The location of each major piece of process
equipment is shown on construction layout drawings. Often layout drawings are
used as background drawings for pipe routing drawing. In turn pipe routing
drawings often include vent relief header routing information. These and other
engineering drawing are used to evaluate the physical relationship between the
protected equipment and associated equipment and piping.
Fluid Properties Data - Fluid properties data are taken from standard engineering
references. 'Flow of Fluids Through Valves, Fittings, and Pipe', Technical Paper No.
410 (Crane) is an excellent standard engineering reference.
Obtain Required
Infomation
PFD

P&ID

Equipment
Specification
Sheets

Layout
Drawings

Material
Balance

Design
Basis

Vendor
Data

Fluid
Properties
Data

Record data
on appropriate
ISS Form
Determine Basis
for Relief
Calculate
Effective Area
Use ISS Form for
Bid Solicitation
Figure 1. Information Sources for PZV Sizing and Selection
Process Flow Diagrams
Process conceptual designs are depicted on PFDs (Figure 2). PFDs also include the material and
heat balance information that is related to each step in the process. After a PFD is completed, the
minimum pressure and temperature design ratings for equipment and piping are determined.
Engineering designers use these design ratings for the detail design of equipment and pipe. After
engineering and design approval, final design pressure and temperature (P&T) ratings are
assigned. Design P&T ratings are classified as "Maximum Authorized Working Pressure"
(MAWP) and "Maximum Authorized Working Temperature" (MAWT) for equipment and pipe.
These ratings are used when equipment is purchased.
Data obtained from the PFD (and P & ID) drawings should not be used blindly. Pressure and
temperature gauge readings may be reported on the wrong process line. They can be located on
the right line, but in a different place than the drawing shows. This does not mean that acquiring
accurate data is a hopeless task, but a certain degree of caution is required in using data for
calculations. The data should stand the test of reasonableness. Are the temperature, pressure,
and flow in the expected range? Is the pressure higher at the pump and continuously decreasing
as the stream progresses through the plant? Does the temperature rise as expected after passing
through a heat exchanger?
Figure 2. Process Flow Diagram of HPPT
Piping & Instrument Diagrams
Piping and Instrument Diagrams (P & IDs) contain some of the data that are required for sizing
and selecting PZVs. Figure 3 shows a typical P & ID for a High Pressure Production Trap. Note
that the PZV instrument tag number (PZV 132) is printed on the P & ID. The PZV set pressures,
and sometimes the maximum operating pressure (MAWP), are also shown on P & IDs.
Figure 3.Typical P & ID
The data from P & IDs are not sufficient for final PZV sizing and purchase specification because
P & ID revisions lag behind equipment specification changes. Final PZV set pressure and sizing
determinations must come from MAWPs that are included in either As-Built or Approved for
Construction equipment specifications. Data that are taken from P & IDs for PZV sizing should
only be used for estimating sizes in Rev.A of the ISS.
After a PZV is sized and selected the Set Pressure and size of the PZV are printed next to the
Instrument Society of America (ISA) symbol (balloon), which identifies the PZV on the P & ID.
Instrument Specification Sheets
Instrument Specification Sheets (ISSs) are used to record detailed engineering information onto a
standard form, which is suitable for the sizing and selection of PZVs. Saudi Aramco Engineering
Standard J-007, Instrumentation Forms, lists three ISS forms for PZV specification. ISS form
number 8020-611-ENG is used for specifying spring loaded, screwed or flanged, PZVs in English
units. ISS 8020-611M-ENG is used to specify PZVs in metric units, and ISS 8020-612-ENG is
used to specify pilot operated PZVs. Only ISS 8020-611-ENG will be described in this module.
ISS form 8020-611-ENG (Figures 4 - 6) consists of three sheets that have a total of 98 lines for
recording data. There is a sidebar space on each sheet for recording revisions, authorization
signatures, and for identifying the data lines on each sheet. Each sheet contains an item
identification area along the bottom. Sheet 2 (Figure 5) contains data and a space for a simplified
relief valve sketch or other information that is not identified by a line number. Sheet 3 (Figure 6)
contains data and space for calculating the orifice area.
Four PZVs can be specified on one ISS form. Each PZV has a data entry column on the form;
however, multiple PZVs that are specified on one ISS should be related by model and/or process
application. For example, a spare PZV can share an ISS with the main PZV, or with PZVs on
duplicate process equipment (e.g., two identical heat exchangers), or with several PZVs in a
multiple relief valve application.
Initially, the ISS form contains generic information that is presented for competitive bid
solicitation. At this point, the form is referred to as Revision A (Rev.A). ISS Rev.A is completed
after the basis for relief has been selected and after an effective sizing area has been calculated.
Rev. A is based on API sizing estimates unless a PZV vendor is specified at the time of initial area
sizing. All ISS revisions after vendor selection must be based on the manufacturer's data for the
selected PZV.
Figure 4. ISS Form No. 8020-611-ENG, Sheet 1
Basis of Selection
Conditions Requiring Overpressure Protection
All causes of overpressure, or contingencies, must be evaluated for each PZV installation in terms
of the pressures generated and the rates at which fluids must be relieved. Causes of overpressure
in process equipment can range from a single event to a complex combination of events. Figure 7
below is a table that summarizes some, but not all, operating conditions that lead to the indicated
relief capacities.
Item No. Condition Pressure Relief Device
(Liquid Relief)
Pressure Relief Device
(Vapor Relief)*
1 Closed outlets on vessels Maximum liquid
pump-in rate
Total incoming steam and vapor plus that
generated therein at relieving conditions
2 Cooling water failure to
condenser
Total vapor to condenser at relieving
conditions
3 Top-tower reflux failure Total incoming steam and vapor plus that
generated therein at relieving conditions less
vapor condensed by sidestream reflux
4 Sidestream reflux failure Difference between vapor entering and
leaving section at relieving conditions
5 Lean oil failure to absorber None, normally
6 Accumulation of
noncondensables
Same effect in towers as found for Item 2; in
other vessels, same effect as found for Item 1
7 Entrance of highly volatile
material
Water in hot oil
Light hydrocarbons in
hot oil
For towers , usually not predictable
8 Overfilling storage or surge
vessel
Maximum liquid
Pump--in rate
9 Failure of automatic
controls
Must be analyzed on a case-by-case basis
10 Abnormal heat or vapor
input
Estimated maximum vapor generation
including noncondensables from overheating
11 Split exchanger tube Steam or vapor entering from twice the cross-
sectional area of one tube; also same effects
found in Item 7 for exchangers
12 Internal Explosions Not controlled by conventional relief devices
but by avoidance of circumstances
13 Chemical reaction Estimated vapor generation from both normal
and uncontrolled conditions
14 Hydraulic expansion
Cold fluid shut in
Line outside process
area
shut in
See C.2
See C.2
15 Exterior fire Estimate by the method given in D.5

16 Power failure (steam,
electric, or other)
Fractionators
Reactors
Air-cooled exchangers
Surge vessels
Maximum liquid
inlet rate
Study the installation to determine the effect
of power failure; size relief valve for the worst
condition that can occur
All pumps could be down, with the result that
reflux and cooling water would fail
Consider failure of agitation or stirring,
quench or retarding steam; size valves for
vapor generation from a runaway reaction
Fans would fail; size valves for the difference
between normal and emergency duty
* Considerations may be given to the suppression of vapor production as the result of the devices relieving
pressure being above operating pressure, assuming constant heat input. (Procedures for sizing pressure relief
devices are presented in Section 4 of API-RP-520.)
Figure 7. Basis of Relief Capacities Under Selected Conditions
1
Contingencies That Cause Overpressure
Fire Contingency - Any pressure vessel in a plant that processes flammable liquids may be
exposed to fire at some point in its life, even if the vessel does not contain flammable liquid. If an
open, free-burning fire occurs, vessels and other equipment that are exposed to the flame will
absorb heat by radiation or by direct contact with the flame or hot gases. Escaping flammable
liquids may be carried away For this reason, a PZV should be provided for pressure vessels to
relieve overpressure that is caused by fire. (API RP-2001 describes ways to limit heat input from
a fire using surface drainage and firewater application.)
Fire contingency applies to any liquid-filled process equipment (within a fire zone) that has a
wetted surface. A wetted surface is any surface that is both in contact with the process liquid and
can be exposed to fire. An uninsulated, wetted surface of a vessel will absorb radiation as sensible
heat. As the temperatures of the vessel and the liquid rise, the temperatures will essentially
become equal. At the boiling point of the liquid, the radiation will be absorbed as latent heat and
the resulting vapor generation will cause the pressure to rise to the set pressure of the PZV. As
long as the vapor that is generated is less than the flow capacity of the PZV, the valve will
intermittently open and close to protect the vessel. If the rate of vapor generation is greater than
the rated capacity of the PZV, the pressure will increase beyond the permissible accumulation and
create an unsafe situation.
A PZV may not protect a pressure vessel that contains only vapor because the vessels wall
temperature can rise very rapidly and lead to vessel failure. For this reason, a vessel that contains
only vapor should be protected by reducing its pressure to atmospheric and by limiting the heat
input from a fire.
Equipment that does not have a reasonable quantity of wetted surface cannot be protected by a
PZV against a fire contingency. Prime movers (pumps, compressors, etc.) and low-volume
equipment (pipes, tubes, etc.) are typical examples of equipment that cannot be protected against
a fire contingency by a PZV. In addition, jacketed vessels are also exempt from fire contingencies
unless the jacket contains a liquid, or the unjacketed area exposed to fire has sufficient wetted
surface to protect the vessel from heat damage. SADP-Section XII, Section 5.3.1 lists exceptions
to fire risk contingencies in paragraphs (a), (b), and (d). Paragraph (d). This reference should be
reviewed when determining fire contingencies.
Blocked Discharge Contingency (BD) results from overpressure caused by cessation of fluid
transport out of process equipment. Some possible causes of BD can be determined from P &
IDs. For example, when maintenance, process control, and check valves are present, BD must be
considered. Other conditions that can cause BD can only be determined from equipment
specification data, and/or chemical properties. If a valid BD contingency is discovered, 10%
overpressure is allowed. Relieving pressure is 1.1 times set pressure converted to appropriate
pressure units.
Finally, BD alone does not cause overpressure. Evaluation of the energy source (mechanical,
thermal, chemical, etc.) under BD conditions determines if overpressure is possible. This
information is only available from engineering specification data and/or chemical properties.
Once the energy source is known (e.g., maximum discharge pressure of a prime-mover), the MOP
at the equipment must be determined. If the MOP is higher than MAWP, a valid BD contingency
exists, and PZV area calculations must be completed.
Other Contingencies, which are not related to fire or BD, can cause overpressure of process
equipment. Thermal relief and run-away chemical reactions are the most common examples.
Thermal relief is a special case of BD where a liquid that is trapped in a piece of equipment
expands as a result heat transfer from an external source (except fire). The thermal relief
contingency must be considered as a basis of selection if the hydraulic pressure due to
expansion of the liquid exceeds the MAWP of the equipment. Thus, the surface area and heat
transfer rate are required to solve thermal relief contingencies.
No API sizing procedure can protect against some run-away chemical reactions. The design
engineer must recognize these cases and review engineering literature for possible solutions for
protecting against these contingencies.
Operational Requirements for Overpressure Protection
To meet the requirements of the ASME Code, accumulated pressure must be limited to 110
percent of MAWP for a single-valve installation sized for operating (non-fire) contingencies.
For multiple PZV applications, ASME code requirements limit accumulated pressure to 116
percent of MAWP in vessels that are protected by for a multiple-valves sized for operating (non-
fire) contingencies.
Effective-Area Concept
If protection against more than one contingent event can be provided by a PZV, an effective
area calculation must be made for each particular contingency. The largest effective area
calculation from all of the contingencies is selected as the Basis for Relief, which is used to
specify the PZV. The effective-area concept allows area sizing by calculation, which is
independent of the manufacturer.
Methods for Determining Relieving Pressure
Relieving pressure for PZVs in liquid service is defined in Section 4.2.1 of API RP-520 as the set
pressure plus the allowable overpressure. The allowable overpressure can vary depending on
the contingency and on whether the installation involves a single PZV or multiple PZVs (not
spare PZVs). The units of measurement for relieving pressures depend on process fluid
properties as reflected in the area sizing equation. Because liquids are generally considered to be
non-compressible, gauge pressures (psig) are generally used. For compressible fluids,
atmospheric pressures (psia, psia = psig + 14.7) are generally used.
The three methods for determining the relieving pressure of PZVs are categorized as follows:
Operating contingencies
Fire contingencies
Steam service
Operating Contingencies
Single-Valve Installation - For operating (nonfire) contingencies, Section XIII of the ASME Code
requires that the accumulated pressure shall be limited to 110 percent of the MAWP. The set
pressure of the valve shall not exceed the MAWP. Figure 8 shows an example of the
determination of relieving pressure for a single valve.
Characteristic Value
Valve Set Pressure Less Than MAWP
Protected Vessel MAWP, psig 100
Maximum accumulated pressure 110
Valve set pressure, psig 90
Allowable overpressure, psi 20
Relieving Pressure, psia 124.7
Valve Set Pressure Equal to MAWP
Figure 8. Example Determination of Relieving Pressure
for a Single Valve Installation (Operating Contingencies)
1
Multiple-Valve Installation - For operating (nonfire) contingencies, Section VIII of the ASME
Code requires that the accumulated pressure shall be limited to 116 percent of the MAWP. The
set pressure of the first valve shall not exceed the MAWP. The set pressure of the additional
valves shall not exceed 105 of the MAWP. Figure 9 shows an example of the determination of
relieving pressure for a multiple valve installation.
The staging of the valves, helps to preventing chattering, since not all relieving cases are at
maximum flow. (Only one valve is required). ASME Section VIII allows these 105% valves to
have 116% accumulation. The reason for this is that these same valves only reach full lift at 10%
overpressure. Thus 10% of 105% set pressure = 1.1 * 105 = 115.5 or round up to 116.
First Valve
(Valve Set Pressure Equal to MAWP)
Additional Valve
(Valve Set Pressure Equal to 105 Percent of MAWP)
for a Multiple Valve Installation (Operating Contingencies)
1
Supplemental-Valve Installations provide protection against additional hazards from fire or
other sources of heat. They are used only in addition to valves that are sized for operating
(nonfire) contingencies. The set pressure for a supplemental valve for fire is limited to 110
percent of the MAWP.
Such supplemental pressure relieving devices shall be capable of preventing the pressure form
rising more than 21% above the maximum allowable working pressure.
Again we see that the supplemental valves like any other Section VIII valve, reaches full lift at
10% overpressure. Hence, with a setpressure allowable of 110% we have 110% * 1.1 = 121%
accumulation.
Fire Contingencies
For fire contingencies, Section VIII of the ASME Code requires that the accumulated pressure
shall be limited to 121 percent of the MAWP. This requirement applies to single-, multiple-, and
supplemental-valve installationFigure 10 shows an example of the determination of relieving
pressure for a single valve installation.
Valve Set Pressure Less Than MAWP
Valve Set Pressure Equal to MAWP
for a Single Valve Installation (Fire Contingencies)
1
Figure 11 shows an example of the determination of relieving pressure for a multiple valve
installation.
First Valve
Additional Valve
for a Multiple Valve Installation (Fire Contingencies)
1
Steam Service
Protection against overpressure by steam is treated as any other ASME Section VIII material for
API PZV sizing except that area sizing equations contain a superheat correction factor K
SH
, and a
Napier K
N
correction factor. Generally contingencies regarding steam relief outside of boiler
houses are caused by pressure regulator failures in tropical climates.
API/ASME area sizing equations use saturated steam as a basis for the flow coefficients used in
the equations. If process fluid steam is saturated the value of K
SH
is one (K
SH
= 1) otherwise the
value is taken from the API RP-520 Table 10-Superheat Correction Factors K
SH
.
The Napier factor K
N
corrects for changes in steam properties at high pressures above 1515 psia
where K
N
= (0.1906P
1
- 1000)/(0.2292P
1
- 1061) and P
1
= psia Relieving Pressure (Set Pressure
+ Overpressure + Atmospheric Pressure).
CALCULATING THE SIZE OF A PRESSURE RELIEF VALVE - HAND
CALCULATOR METHOD
After the specifications are determined and recorded on the ISS, the next activity is to calculate a
preliminary valve size. This preliminary valve size is called the effective discharge area. Figure
12 shows the inputs that are used to determine the basis for calculating the size of a PZV.
Blocked Flow
Contingency
Fire
Contingency
Thermal
Contingency
Worst Case
Area Calculations
Other
Contingency
ASME SEC VII
Standards
API RP-520
Standards
SAES-J-600
Standards
SADP 600
Standards
Figure 12. Inputs and Considerations for PZV Size Calculation
Basis for Calculating Valve Size
The basis for calculating a valve size follows calculations of valid contingencies. The contingency
that requires the largest effective area dictates the size of the PZV. The basis for calculating valve
size can be divided into three areas:
Service conditions
Flow rate
Effective nozzle area
Service Conditions
The ISS Service Conditions Section includes details about the process fluid and the process itself.
Fluid properties such as molecular weight, compressibility, and specific heat, and process
requirements such as temperature and pressure are used to determine the basis for relief and to
calculate the effective area of the valve. As discussed below, data listed in the Service
Conditions section of the ISS is used to select the appropriate sizing equation. Also, correction
factors are used when the ideal or assumed conditions associated with each of the sizing equations
are different from the actual service conditions. Backpressure is an example of a service
condition variable that requires the use of correction factors.
Flow Rate
The effective area sizing equations included in Work Aid 2 show that the required effective
discharge area, variable A, equals a flow rate (variable W, V, or Q), which is modified by other
coefficients in the equation. The modifiers and coefficients are derived from published chemical
properties.
BD Contingencies - In BD (Blocked Discharge) contingencies, the flow rate is determined by the
prime-mover, which has a capacity to generate a flow rate in the protected device at some MOP.
The flow rate is taken from process information in the equipment specifications and it is
substituted into the appropriate API area sizing equation.
Thermal Relief Contingencies - In thermal relief contingencies, the flow rate is derived from
chemical properties data that relate temperature to liquid expansion. The design engineer must
determine the surface area of the blocked pipe and calculate the liquid expansion using the Saudi
Aramco solar heat rate of 950 W/sq m (300 BTU/hr-ft
2
).
The thermal expansion of trapped fluids can be approximated by using the following formula:
gpm
BH
500GC
Where:
gpm = flow rate at the flowing temperature, in U.S. gallons per minute
B = cubical expansion coefficient per F for the liquid at the expected temperature
H = total heat transfer rate in BTU per hour (see formula below)
G = specific gravity referred to water (1.0 at 60F. Liquid compressibility is usually
ignored.)
The following formula can be used to calculate the total heat transfer rate for Saudi Aramco
applications.
H = H
s
A
s
Where:
H = total heat transfer rate in BTU/hr-ft
2
H
s
= solar heat rate in BTU/hr (300 BTU/hr from SAES L-043, Section 4.2.2)
A
s
= heat transfer surface area in ft
2
Fire Contingencies - Flow rate in fire contingencies is the vapor generated by the energy
released into the process liquid by the fire. Flow rates are likewise derived from heat transfer
rates and chemical properties as shown in the following equations.
W = Q/H
vap
Where:
W = mass flow in pounds per hour
Q = total heat absorption in BTU per hour
H
vap
= latent heat of vaporization in BTU per pound
The total heat absorption, Q, depends on the vessel insulation and whether prompt fire fighting
efforts and adequate drainage exist. When prompt firefighting efforts and adequate drainage
exist,
Q = 21,000F (A
wet
)
0.82
When prompt firefighting efforts and adequate drainage do not exist,
Q = 34,500F (A
wet
)
0.82
Where:
Q = total heat absorption to the wetted surface in BTU per hour
F = environmental factor (page 7-18 of Addendum 1)
A
wet
= total wetted surface in square feet (page 7-19 of Addendum 1)
Because this module is an introductory review of relief valve sizing, the flow that is generated in a
container by an external fire is considered to be a stable saturated vapor.
Effective Discharge Area
API RP-520 defines the effective discharge area, or equivalent flow area, as a nominal or
computed area of a pressure relief valve used in recognized flow formulas to determine the size of
the valve. The effective discharge area is generally less than the actual discharge area. An
effective discharge area is calculated in order to specify the actual orifice area that is required for
a PZV.
The effective discharge area for a PZV is calculated in using the API critical flow equation. The
first area solution is often a trial estimation for sizing. The back pressure factor, K
b
, is assumed
to be 1 unless reliable engineering data indicates that back pressure will exist in the system. For
example, if a vent header is known to have a constant pressure of 15 psig, then a superimposed
back pressure of 15 psig would be used to determine K
b
.
Sizing Equations For Specific Applications
The terms that are used in engineering equations are not standardized throughout the industry.
API uses P
1
to designate gage pressure (psig) in liquid equations and absolute pressure (psia) in
gas and vapor equations. P
1
is always the upstream relieving pressure into the PZV in API
equations. Different variable designations often share the same letter symbol in API equations.
For example, A is the effective discharge area in the area sizing equation and it is the total wetted
surface in the heat transfer rate equation.
ISS 8020-611 ENG defines terms and units on each printed line. In some cases two options are
printed (e.g., Item 37, MW or SP GR @ FLOWING TEMP). In these cases the design engineer
should circle the option that applies to the value that is entered in the data block.
Sizing for Gas and Vapor Relief
The sizing equations for gas and vapor are divided into two main categories depending on
whether the flow is critical or subcritical. Critical and subcritical flow are best described using an
example of the expansion of a compressible gas across a nozzle. If the downstream pressure
decreases, the velocity and specific volume of the gas will increase until the mass flow rate of the
gas reaches a limiting velocity. This limiting velocity is equal to the velocity of sound in the
flowing gas in the throat of the nozzle. The mass flow rate that corresponds to the limiting
velocity is called the critical flow rate.
The pressure in the throat at sonic velocity is called the critical flow pressure, P
cf
. Under critical
flow conditions, the pressure in the throat cannot fall below the critical flow pressure even if the
downstream pressure is much lower. At critical flow, the expansion that occurs as the pressure
decreases from the throat pressure to the downstream pressure is irreversible. The energy is
dissipated in turbulence into the surrounding fluid.
The ratio of P
cf
to the inlet pressure, P
1
, is called the critical pressure ratio. The critical flow
pressure ratio may be estimated using the following equation.
P
P
2
k 1
cf
1
k/(k 1)
1
]
1
+
Where:
P
cf
= critical flow throat pressure in psia
P
1
= upstream relieving pressure in psia
k = ratio of specific heats for any ideal gas
If the downstream pressure is less than or equal to P
cf
, critical flow will occur. If the downstream
pressure is greater than P
cf
, subcritical flow will occur. The sizing equations for these two
instances are described below.
Sizing for Critical Flow - When sizing gas or vapor PZVs, one must calculate the critical back
pressure to determine whether the flow is critical or subcritical. The critical back pressure is
calculated by multiplying the relieving pressure by the critical flow pressure ratio for the
particular gas, which can be found on page 27 of Addendum 2. If pressure downstream of the
throat (use total back pressure until a PZV is selected) is less than the critical back pressure, the
equation below may be used to calculate the effective discharge area, A, for the PZV. The
manufacturers PZV with an effective discharge area equal to or greater than the calculated value
of A is chosen for the application.
A
W
CKPK
TZ
M
1 b
Where:
A = effective discharge area of the PZV expressed in sq. in.
W = required flow rate through the valve expressed in lb/hr (mass flow units)
K = effective coefficient of discharge = 0.975, or certified manufacturers value.
K
b
= capacity correction factor due to back pressure, Bellows PZVs only. Use
Addendum 1 or manufacturers values.
M = molecular weight of hydrocarbon gas or vapor
P
1
= upstream relieving pressure in psia, (Set Pressure psig x % Overpressure) +
14.7 = P
1

psia)
C = specific heats ratio coefficient. Use page 7-9 of Addendum 1 to derive C
based on the ratio of the specific heats, k.
T = relieving temperature R (Rankine = F + 460)
Z = compressibility factor at inlet conditions. Use P
r
and T
r
to derive Z from
Addendum 4. Z = 1 is a conservative value.
For an example of relief valve sizing for critical flow, refer to pages 7-22 and 7-23 of the Crosby
Engineering Handbook in Addendum 1.
Sizing for Subcritical Flow - If the back pressure is greater than the critical back pressure, either
of the equations below may be used to calculate the effective discharge area, A, for the PZV.
A
W
735F K
ZT
MP (P P )
2 1 1 2
A
V
4645.2F K
ZTM
P (P P )
2 1 1 2
A
V
863.63F K
ZTG
P (P P )
2 1 1 2

Where:
F
2
= coefficient of subcritical flow =
( )
k
k 1
r
1 r
1 r
2/k
(k 1)/ k
_
,
1
]
1
k = specific heat ratio k = C

p
/ C
v
.
r = ratio of back pressure to upstream relieving pressure, P
2
/P
1
.
V = required flow rate through the valve expressed in scfm (standard cubic feet per
minute at 14.7 psia and 60F)
G = specific gravity relative to Air @ STP, (G = M / 28.97)
P
1
= upstream relieving pressure in psia, ((Set Pressure psig x % Overpressure) +
14.7 = P
1

psia)
P
2
= back pressure in psia
Z = compressibility factor at relieving inlet conditions. Use P
r
and T
r
to derive Z
from Addendum 4. Z = 1 is a conservative value.
Bellows PZVs operating in the subcritical flow regime are sized using the critical flow equation
except that the manufacturers K factor must be used.
Saudi Aramco design engineers shall not size spring loaded PZVs under API subcritical flow
conditions outlined in API RP-520, Section 4.3.3. SAES-J-600 section 5.2.1, expressly forbids
the use of conventional PZVs when total back pressure on the valve exceeds 10% of set pressure.
Sizing for Steam Relief
PZVs in steam service may be sized using the following equation:
A
W
51.5PKK K
1 N SH

Where:
A = effective discharge area expressed in sq. in.
W = required flow rate through the valve expressed in lbs/hr (mass flow units)
P
1
= upstream relieving pressure in psia, ((Set Pressure psig x %Overpressure) +
14.7 = P
1
psia)
K
SH
= superheat correction factor. K
SH
= 1 for saturated steam. Otherwise use
Addendum 7.
K
N
= correction factor for Napier equation. K
N
= 1 where P
1
1515 psia. Where P
1
> 1515 psia and 3215 psia, use Page 7-6 of Addendum 1 or K
N
= (0.1906P
1
-
1000) / (0.2292P
1
- 1061)
Section 4.4, 'Sizing for Steam Relief', in API RP-520 outlines requirements, and includes
examples for sizing PZV's in steam service under ASME Section VIII. Reliable steam tables can
be found in Crane TP-410. There are two steam tables in Crane, 'Properties of Saturated Steam
and Saturated Water' and 'Properties of Superheated Steam.' Superheated steam has different
volume/mass, temperature, and pressure properties than saturated steam; therefore, ASME/API
relief valves for steam service require a superheat correction factor K
SH
in the effective area
sizing equation. Likewise, steam at pressures above 1515 psia require a correction factor K
N
.
Sizing for Liquid Relief
PZVs for liquid relief may be sized by using the following equation:
A
Q
38K K K
G
P P d
W V 1 2
Where:
A - Effective discharge area expressed in sq. in.
Q - Required flow rate through the valve expressed in gpm, (volumetric flow units)
K
d
- Effective coefficient of discharge = 0.650, or certified manufacturers value.
K
W
- Capacity correction factor due to back pressure, Bellows PZVs only. (Pages 7-
3 to 7-5 of Addendum 1 or manufacturers value.)
K
v
- Capacity correction factor due to viscosity. (Page 7-7 of Addendum 1 or
manufacturers value.)
G = Specific gravity (water = 1 @ 60F)
P
1
= Upstream relieving pressure in psig. This is the set pressure plus allowable
overpressure. (Note this Value is in gauge units not absolute).
P
2
= Total back pressure in psig.
The PZV should first be sized for nonviscous-type application to obtain a preliminary discharge
area, A. From the manufacturers standard orifice sizes, the next orifice size that is larger than A
is used to determine the Reynolds number using the following equation.
R
Q(2800G)
m A
Where:
R
=
Reynolds number
Q = flow rate at the flowing temperature, in U.S. gallons per minute
G = specific gravity (water = 1 @ 60F)
m = absolute viscosity at the flowing temperature, in centipoises
A = effective discharge area in square inches
After the Reynolds number is determined, the factor viscosity correction factor, K
V
, is used to
correct the preliminary discharge area as shown in the following equation.
A
A
K
R
V
Where:
A = area corrected for viscosity
A
R
= required area without viscosity correction
K
v
= viscosity correction factor
K
v
can be obtained from the graph on page 7-7 of Addendum 1. If the size of the corrected area
exceeds the chosen standard orifice area, the calculations above are repeated using the next larger
standard orifice area.
Sizing for Two-Phase Liquid-Vapor Relief
API RP-520, section 4.7, page 37, 'Sizing for Two-Phase Liquid/Vapor Relief', presents
methodology for sizing PZVs which relieve process fluids that are partially liquid and partially
gas. API methodology recommends the following:
1. Determine the quantity of liquid and calculate an effective area based on that
determination.
2. Determine the quantity of vapor and calculate an effective area based on that
determination.
3. Add the two areas together and choose a PZV with an orifice greater than the sum
of liquid and vapor areas.
4. Use the same pressure values, relieving pressure and back pressure in both
calculations.
5. Select either liquid or gas trim. Rule of Thumb. If more thane 50% of the flow (on a
mass basis) is liquid, then use liquid trim.
Relief valve problems involving two phase flow conditions beyond a 3/4D1 size PZV used for
thermal relief should only be resolved by senior engineers specializing in relief valve technology. It
is further recommended that a test stand or bench scale test apparatus be used to test the selected
valve. Oversized PZVs tend to chatter, and often leak after a release. And most calculations of
PZVs for two phase flow conditions will be oversize effective relief areas.
The test apparatus must have close temperature control as well as pressure control. Furthermore
under flashing conditions both wet-bulb and dry temperatures must be measured. Data on the
valve performance should be measured and recorded over a wide 'true temperature' range at
constant relieving pressure. Finally back pressure should be varied over a reasonable range based
on installed valve conditions.
Information about and from the test apparatus must have the approval of the valve manufacture.
Capacity certification testing for ASME stamps does not involve two phase fluids except steam.
In the cases where the process fluid is a mass produced refrigerant, the manufacturer of the
refrigerant will usually be able to recommend a suitable relief device for their product. They can
also direct Saudi Aramco design engineers to client engineers who have process experience with
the product. Complex relief valve sizing and selection problems must be reviewed by senior
engineers who have experience with the process involving protection.
SELECTING A PRESSURE RELIEF VALVE - MANUFACTURERS CATALOG
METHOD
There are two parts to the selection of relief valves. The first part is an engineering decision
regarding the PZV type and features. The second part is the selection of a manufactured relief
valve that meets the requirements determined. Both parts are interdependent because design
engineers must specify features that are available in manufactured relief valves.
This section will describe the sources of required data on which the design engineer will base his
decisions, and the administrative (documentation) requirements for relief valve selection.
Sources of Required Data
Instrument Specification Sheets
The ISS 8020-611 ENG specifies relief valves that meet the requirements of Saudi Aramco.
These requirements include specifications from ASME and API standards and recommended
practices. Rev.A also includes specifications based on engineering judgment. For example,
although balanced bellows and soft seats are not required by Saudi Aramco standards, they may
be specified on the ISS because they are considered to be cost effective by the design engineer
and the engineering manager.
After approval, ISS 8020-611 ENG will specify a PZV that is suitable for a vendor quotation.
Saudi Aramco engineers may allow vendors to recommend products that conform to the ISS.
The design engineer must then review and approve the vendors selection. Final revision of the
ISS represents agreement between Saudi Aramco engineering and the relief valve manufacturer
that the valve delivered to Saudi Aramco will meet the requirements of the ISS and the
ASME/API certification.
Manufacturers Catalogs
After a vendor selects and quotes a PZV, catalogs and other publications published by the
manufacturer are required to verify that the quoted PZV meets the requirements of the ISS. In
some cases, where non-standard options are required, factory correspondence is required to verify
the quotation.
Manufacturers' catalogs contain both certified and non-certified valve capacities. Catalogs also list
materials of construction for each class of relief valve, and they include instructions for relating a
model, or style, number to the features that are available in a particular class, or series, of relief
valve.
Valve capacity tables are always included for Air, Water, and Steam in catalogs for ASME
Section I or VIII certified relief valves. Capacity tables relate certified capacities to set pressure
values at a fixed allowable overpressure (usually 10%). Capacity units are usually gpm for water,
lb/hr for steam, and scfh for air. Some catalogs include effective discharge coefficients, K values.
Addendum 4 contains two Crosby relief valve catalogs. Crosby Style JOS, JBS and JLT and
Crosby Series 800 Adjustable Blowdown and Series 900 OMNI-TRIM Pressure Relief Valves,
Catalog No. 902 (Cat. 902) contains information and certified capacities for Crosby's small size,
conventional, and thermal relief PZVs that conform to the requirements of the PZV.
As an example, assume a simple case of a single contingency thermal relief valve, PZV-100,
which is located on a length of pipe between two block valves (see P & ID in Figure 13).
Figure 13. PZV-100 Thermal Relief Valve
Assume that the specifications from the ISS are as follows:
calculated flow rate, Q = 0.0254 gpm
effective discharge are, A = 9.29 x 10
-5
sq. in.
conventional relief valve
bronze or brass construction materials required (6.2.2, SAES-J-600)
blowdown adjustment is not required
non-sour service
special accessories are not required
lifting lever is not required
test gag is not required
Assume that one of the approved vendors (found in SAES-J-002) quotes a Crosby relief valve
with a style number of 951501MA; however, the valve is not bronze or brass because
manufacturers no longer use these materials.
The engineer should revise the ISS and obtain approval for a carbon steel valve with stainless
steel trim because only the stainless steel will be in contact with the process fluid during
discharge.
Page 3 of Cat. 902 (Addendum 4) compares the Series 800 pressure relief valves with the Series
900. Observe that Series 900 is designed for Thermal Relief and it does not have adjustable
blowdown. The PZV does not require a blowdown adjustment reseating rate after discharge, so
Series 900 is selected.
The procedure for selecting a style number for Crosby Series 900 PZVs is illustrated on page 7 of
the catalog. From the style designation information on page 7, number 951501MA is chosen.
The meaning of the style designation is as follows:
1st digit - 9 for Series 900
2nd digit - 5 for 0.074 sq. in. Effective Orifice Area
3rd digit - 1 for 1500 psig Maximum set Pressure
4th digit - 5 Kalrez Seat Material (Inert Fluorocarbon) soft seat (p. 11)
5th digit - 0 Standard Materials (p. 9)
6th digit - 1 Connection Size 3/4 in. x 1 in. NPS (p. 16, P&T ratings)
7th digit - M Connection Type Male NPT inlet and Female NPT discharge
8th digit - A Standard Screwed Cap (p. 10)
Materials of construction for Series 900 relief valves are listed on page 9 of Cat. 902. Crosby
Series 900 relief valves have carbon steel cylinders (Fluid Cavity & Bonnet) and 316 stainless
steel (316 SS) Base (Body). Disk and seat assemblies are stainless steel, and a Kalrez
fluorocarbon soft seat is specified. Soft seat details are shown on page 11 of Cat. 902.
Connections are 3/4" MNPT (0.75 SC-NPTM, SAEP-1131) inlet and 1" FNPT (1 SC-NPTF,
SAEP-1131) outlet. A type 'A' carbon steel cap completes the selected style.
Cap details are shown on page 10 of Cat. 902.
Note also that the data for the PZV, records that certified bronze/brass relief valve production by
Saudi Aramco approved vendors has been discontinued. The Crosby Series 900 Style 951501MA
has all inert materials, stainless steel and Kalrez, in contact with the process fluid (process water)
under normal conditions.
Certified water capacities for Crosby Series 900 relief valves are listed on page 22 of Cat. 902. At
120 psig set pressure the selected valve (0.074 sq. in effective area) will discharge 23 gpm. The
same valve is certified for 543 lb/hr steam capacity. Both capacities exceed the required flow
rated calculated for the PZV.
The P & ID can be revised to show: 3/4 x 1 Set @ 120 psig next to PZV-100. Rev. C of the ISS
can be prepared to show Crosby on line 4, and 951501MA on line 5. Lines 10, 13, 15, 49, 60,
61, 76, and 82 should also be changed to include vendor data.
Administrative Requirements
Saudi Aramco standard 34-SAMSS-611, 'Safety Relief Valves Flanged Conventional And
Balanced Types', Issue Date 1 DEC 96, section 1.2, requires ISS form 8020-611 ENG to be
included with "Buyer's Quotation Request or Purchase Order." Official Saudi Aramco
administrative requirements related to quotations and purchasing beyond this statement and the
acceptable vendor list in SAES-J002 are beyond the scope of this module.
The ISS should be revised after the selection of the Crosby 3/4" x 1" 951501MA relief valve. ISS
form 8020-611 ENG is a generic specification designed to solicit competitive bids from
acceptable manufacturers. After bid selection the ISS form is revised with the manufacturers
model number and other special information related to the selected manufacturers valve. The
revised (Rev.B or higher) ISS form 8020-611-1-ENG then becomes part of the purchase order.
After purchasing the PZV, Saudi Aramco form 3099A 'Relief Valve Authorization' must be
completed. Form 3099A is central to the disposition of a PZV throughout its useful life, even if
the valve is 'Mothballed'. Saudi Aramco standards SAEP-318 and SAEP-1131 are devoted
exclusively to instructions and procedures related to form 3099A and relief valve authorization.
Saudi Aramco form 3750 'Pressure Relieving Device Maintenance Report' is the on-site version of
8020-611 ENG. It contains all information related to the testing, and inspection of a PZV in
much the same way as 8020-611 ENG contains all of the information related to sizing, and
selection of a PZV. Instructions and procedures routine testing and inspection of relief valves is
contained in SAEP-319. Instructions for filling out form 3750 are outlined in Saudi Aramco
standard SAEP-1133.
Both Forms 3099A and 3750 as well as 8020-611 ENG are part of the Saudi Aramco company
wide computer system.
SIZING AND SELECTING A PRESSURE RELIEF VALVE - COMPUTERIZED SIZING
METHOD
Crosby-Size is the relief valve sizing computer software provided by Crosby Valve and Gage
Company. The computer applications features include:
accurate calculations
user-selected units
selection of valve size and style
valve data storage
printed reports
specification sheets
Crosby-Size is a menu-driven application. Prior to using this application, the user must have a
basic understanding of the relief valve sizing calculations that were described in Work
Aid 2. The main menu of Version 2.1 of the software contains the following options:
1. Section I Steam Valve Sizing
2. Section I Steam Valve Flow Calculation
3. Section VIII Gas/Steam/Liquid Sizing
4. Section VIII Valve Flow Calculation
5. API RP-520 Fire Sizing
6. Miscellaneous Reports and Utilities Menu
7. CROSBY-SIZE Program Configuration Menu
The first five options are used to size and select PZVs, and they relate to ASME Section I and
VIII, and API RP-520. The sixth option, Miscellaneous Reports/Utilities Menu, is used to save
sizing and selection data and to print reports of the selected PZV. The last option, CROSBY-
SIZE Program Configuration Menu, is for program administration, which is used to organize
files, select a printer, select program variables, and 'toggle' certain program features. Each Option
in the main menu is described in a section of the software manual, which is indexed by
identification tabs bearing each option name. Work Aid 3 contains the procedures for using the
application.
Program Applications
The 'Valve Sizing Options:' screen provides nine sizing options based on a combination of the
state of the process fluid and the type of PZV that will be used. In some cases, Crosby PZV
classes are part of the sizing and selection.
For sizing and selection of PZVs for liquids, the available option selection presupposes that the
user is familiar with Crosby relief valves. If a wrong class of valve is chosen during the initial
entry from the selection screen, the user can return to the selection screen and try a different
choice. Most of the data entered into the program is retained until the user returns to the 'Main
Menu'.
The discussion of CROSBY-SIZE will now follow program selections that verify the sizing and
selection example on pages 7-22 and 7-23 of the Crosby Engineering Handbook in Addendum 1.
The fluid and vessel data are as follows:
Fluid Data
Fluid: Benzene
Required Capacity: 5000 lb/hr
Set Pressure: 200 psig
Back Pressure: Atmospheric
Inlet Relieving Temperature: 100F
Molecular Weight: 78.11
Latent Heat: 172 BTU/lb
Specific Heat Ratio (k): 1.12 (p. 7-26 of Addendum 1)
Vessel Data
Diameter (D): 15 ft.
Length (L): 30 ft.
Elevation (H): 15 ft.
Max. Fluid Level (F): 147 inches (12.25 ft.)
Type: Cylindrical with spherical ends
Prompt fire-fighting efforts and adequate drainage exist.
Placement: Horizontal
Insulation: None
Assume the ISS states the following:
Tag No.: PZV-200
Valve conn.: 300 lb. x 150 lb.
At the Main Menu of the CROSBY-SIZE program, the API RP520 Fire Sizing option is selected
and the following data are enter at the prompts.
Prompt Enter
Select Tank Type: Sphere or Cylinder
(S/C)?
C
Cylinder Type: Horizontal or Vertical
(H/V)?
H
Type of Ends: Flat or Spherical (F/S)? S
Enter wetted area manually? N
[D] Diameter, in Ft 15
[L] End-to-End Length. in Ft 30
[H] Height off Ground, in Ft 15
[F] Fluid Level, in Ft 12.25
[T] Latent Heat, in Btu/lb 172
Adequate Drainage & Fire Fighting
Equipment Provided (Y/N)?
Y
Insulation Types: Options: Bare Vessel
Accept These Options (Y/N/Quit) ? Y
Req. Cap. Other Than Fire Exp.: 0
Set Pressure: 200
Types Of Back pressure: Superimpos
ed Constant
Back Pressure: Superimposed Constant: 0
Overpressure: 21
Specific Heat Ratio: 1.12
Molecular Weight: 78.11
Temperature: 100
Compressibility Factor: 1.0
Valve Types: Options: JOS
Do you require all Stainless Steel Valve
(Y/N) ?
N
Selected Valves Include: JOS-25,
300 x 150
Cap Type Selections: Options: Screwed
Cap
[C]onditions, [S]ave, [R]eport. [V]alve
Type, or [Q]uit?
R
CROSBY-SIZE Sizing Reports: Report
Options:
Crosby
Report
Sheet w/
Formulas
Print to Screen/Printer (S/P) P
Customer Name: SAUDI
ARAMCO
Customer Reference: EXAMPLE
Comments [ENTER]
[C]onditions, [S]ave, [R]eport. [V]alve
Type, or [Q]uit?
Q
[ESC] to Quit ESC
The program generates the report shown in Figure 14.
CROSBY-SIZE ASME Section VIII Date: Sept. 21, 96
Pressure Relief Valve Report Sheet (Note 1)
Customer: SAUDI ARAMCO Prepared By:
Reference: EXAMPLE Saudi Aramco
Quote/Tag: EXAMPLE/
Gas & Vapor Mass Flow Spring Loaded Pressure Relief Valve Sizing
Service Conditions
Required Capacity32330.8 lb/hr
Set Pressure200.0 psig
Overpressure 21 %
Temperature100 F
Backpressure - Constant 0.0 psig
Specific Heat Ratio 1.12
Calculated Values
Required Orifice Area 1.052 sq in
Effective Orifice Area1.287 sq in
Calculated Flow 39568.1 lb/hr
Calculation Formula (USCS) (Note 1)
A = --------------------------------------
Pi * C * K * h-bm
Required Orifice Area (A) 1.052 sq in
Required Capacity (W) 32330.8 lb /hr
Set Pressure (P) 200.0 psig
Temperature (T)100 F
Relieving Pressure (P1) 256.7 psia
Molecular Weight (M) 78.11
Back Pressure Correction (Kb) 1.000
Effective Coefficient Of Discharge (K) 0.975
Specific Heat Coefficient (C) 329
Compressibility Factor (Z) 1.000
Valve StyleJOS-25-A
Valve Size (Inlet-Orifice-Outlet) 2 J 3
Valve Connection (inlet-Outlet) 300 x 150
(Note 1)
API effective orifice area and effective coefficient of discharge area used in the flow and sizing
calculation shown on this report.
CROSBY-SIZE Section VIII Report Sheet, Page #2 Date: Sept. 21, 96
Customer: SAUDI ARAMCO Prepared By:
Reference: EXAMPLE Saudi Aramco
1-508-384-3i2i
Fire Sizing Vessel Dimensions
Tank TypeCylinder
OrientationHoriz.
Type of EndsSpherical
Diameter15.00 ft.
End-To-End Length30.00 ft.
Evaluation15.00 ft..
Fluid Level 12.25. ft.
Latent Heat of Vaporization 172.00 BTU/lb
Adequate Fire Fighting & DrainageYes
Insulation Type Bare Vessel
Insulation Conduction Factor 1.0000
Wetted Area 901.13 sq ft.
Required Flow Due To Fire Capacity 32330.8 lb/hr
Figure 14. CROSBY-SIZE Report Sheet for PZV-200
RELIEF VALVE AUTHORIZATION PROCESS
The authorization process is the final phase in the sizing and selection of a PZV. The
authorization process that is followed depends on the responsible organization, Projects or
Operations. The authorization process for Projects is shown graphically in Chart I of SAEP-318,
(Figure 15). Chart I has an authorization, administration path diagram for new PZVs provided
with projects. These procedures are governed by Saudi Aramco standards SAEP-318 SAEP-319.
Figure 15. Chart I - Projects Authorization Procedure for
RV Installation and Changes
The authorization process for Projects is further explained below.
1. The Originating Engineer, or Originator, completes lines 1-4 of Form 3099A in
accordance with the requirements of Saudi Aramco specification SAEP-1131,
Section 2. ISS Form 8020-611-ENG is attached to form 3099A until the original
3099A/ISS 8020-611ENG is filed by the Relief Valve Administrator.
Form 3099A, is forwarded to the Senior Project Engineer, or Superintendent
Operations Engineering for approval and authorization signature.
2. A signed copy of Form 3099A is returned to the Originating Engineer.
3. The Originating Engineer submits 3099A to the Projects Inspection Supervisor or
Operations Foreman for disposition.
4. The Project Inspection Supervisor reviews and signs off Form 3099A using ISS
8020-611ENG to verify the data on Form 3099A for newly constructed facilities.
5. The Originator, or someone under his supervision, enters the data into the relief
valve database. The original 3099A is distributed to the Relief Valve Administrator
for approval signature.
6. The Relief Valve Administrator assigns a relief valve number to the PZV, then
approves, and signs 3099A. The original 3099A and a copy of 3750 is returned to
the Originating Engineer. The original 3750 and a copy of 3099A is distributed to
the Computer Operations Department. The Computer Operations Department
enters data from Forms 3099A and 3750 into the Saudi Aramco computer, signs the
forms, and returns 3099A
7. After receipt of an approved copy of 3099A, the Originating Engineer completes
work order Form 981-1, and distributes a copy to the Maintenance Relief Valve
Test Unit, or Contractor Shops Division.
8. The Maintenance Relief Valve Test Unit, or the Contractor Shops Division, will
record the test data on form 3750, and mark the PZV in accordance with SAEP-
1131. Form 3750 for the PZV is distributed to the Relief Valve Administrator.
9. The Projects Inspection Supervisor, or Operations Foreman checks and approves
final installation of the PZV. He then signs Form 3099A, and distributes the form to
the Supervisor of the Commissioning Unit.
10. The Supervisor of the Commissioning Unit also inspects the installation of the PZV
to insure the relief valve is ready for commissioning of the process equipment. The
Supervisor of the Commissioning Unit then signs Form 3099A, and submits it to the
Relief Valve Administrator.
11. The Relief Valve Coordinator checks and files original Form 3099A. He then
distributes copies of Forms 3099A and 3750 to the Computer Operations
Department, and a copy of 3099A to the Supervisor of Operations Engineering
Inspection.
The authorization process for Operations is shown in Chart II of (Figure 16).
Figure 16. Chart II - Operations Facilities Authorization Procedure
for Relief Valve Installation and Changes
Relief Valve Authorization, Form 3099A
The Relief Valve Authorization Form 3099A consists of two major sections and an area for
remarks (Figure 17). The top section is divided into data areas and letter/number blocks. The
areas are identified by line numbers and column numbers. Specific details for the entry of
information in each area are outlined in SAEP-1131, Section 2.
Authorization regulations, distribution requirements, and disposition rules regarding Form 3099A
are outlined in SAEP-318.
Form 8020-611
The Form 8020-611 (ISS) is used to record detailed engineering information, which is suitable for
the sizing and selection of PZVs. Saudi Aramco Engineering Standard J-007, Instrumentation
Forms, lists three ISS forms for PZV specification. ISS form number 8020-611-ENG is used for
specifying spring loaded, screwed or flanged, PZVs in English units. ISS 8020-611M-ENG is
used to specify PZVs in metric units, and ISS 8020-612-ENG is used to specify pilot operated
PZVs.
Unlike 3099A and 3750, an ISS for a PZV is not a perpetual document. The final revision of an
ISS for a PZV is attached to the initial 3099A. The distribution and disposition of 3099A/8020-
611-ENG was presented above.
Requirements regarding ISS 8020-611-ENG are contained in Saudi Aramco standards SAES-J-
600, and 34-SAMSS-611.
Figure 17. Relief Valve Authorization, Form 3099A
Relief Valve Test Report, Form 3750
Form 3750, Relief Valve Test Report is part of the PZV authorization process. Each time a work
order Form 981-1 is issued for a PZV, a Form 3750 must be completed.
The Form 3750 is organized by areas, which are identified by line numbers and column numbers.
Specific details for information entry in each area are outlined in SAEP-1133, Section 3. A
sample Form 3750 is shown in Figure 18. Data entry into the form is associated with the trouble-
shooting discussions in Module 5. SAEP-1133 should be referenced in conjunction with various
PZV T&I operations. Note that the inspection period required in 3099A line 2, columns 74-75
should originate from Form 3750 after initial testing of the PZV.
Figure 18. Relief Valve Test Report, Form 3750
WORK AID 1: RESOURCES FOR DETERMINING RELIEF VALVE
SPECIFICATIONS
This Work Aid provides the procedures for determining the Basis of Selection and the relieving
pressure of PZVs in accordance with SAES-J-600. These procedures are taken from API RP-520
and Section VIII of the ASME code.
Work Aid 1A: Procedure for Determining Applicable Contingencies for PZV Sizing
and Selection
This procedure can be used to determine all applicable contingency events. This procedure
cannot be used to calculate the effective area for each applicable contingency.
1. Determine whether blocked discharge contingency is applicable.
A. On the P & ID, follow each process feed line connected to the protected device
(whose PZV is to be sized) back to a likely pressure source upstream. The
pressure source will usually be a prime mover (i.e., turbine, compressor, pump,
etc.), but could be any process equipment which can generate pressure in the line
under study.
B. Follow each process discharge line that is connected to the protected device
downstream as far as the first device that is protected by a PZV. Note all devices
that can block the discharge in that line. The last blocking device (usually a valve)
in the line upstream of the device protected by the PZV will be the final device on
that discharge line that can block the flow out of the protected device under study.
2. Determine whether fire contingency is applicable.
A. If the information is not provided, determine whether the equipment is in a fire
zone (wholly or partly below 25 ft. above a fire-bearing surface) using a plot plan.
Yes, the equipment is in a fire zone. Go to step 2B.
No, the equipment is not in a fire zone. Fire contingency is not applicable in this
case.*
B. Does the equipment contain liquid and does it have a sufficient amount of wetted
surface?
Yes. Go to step 2C.
No. Fire contingency is not applicable in this case.*
C. Is the equipment jacketed?
Yes. Fire contingency is not applicable in this case.*
No. Fire contingency is applicable in this case.*
* If in doubt, select fire as a contingency or compare the fire contingency area to
other contingencies. Seek the guidance of a senior engineer or engineering
manager.
3. Determine whether thermal relief contingency is applicable.
A. Can the liquid-filled equipment be sealed closed?
Yes. Go to step 3B.
No. Thermal relief contingency is not applicable in this case.
B. Can continued heat input be avoided?
Yes. Thermal relief contingency is not applicable in this case.
No. Thermal relief contingency is applicable in this case.
Work Aid 1B: Procedure for Determining Relieving Pressure of PZVs
The following procedure and the table in Figure 23 can be used to determine the maximum
accumulation and set pressures of PZVs for single- and multiple-valve installations in
accordance with Section VIII of the ASME Code.
Procedure
1. Obtain the maximum allowable working pressure (MAWP) of the equipment or vessel
from As Built or Approved for Construction equipment specifications.
2. Calculate the maximum accumulated pressure by multiplying the MAWP by the percent
Maximum Accumulated Pressure from Figure 23.
3. Calculate the relief valve set pressure by multiplying the MAWP by the percent Set
Pressure from Figure 23.
4. Calculate the relieving pressure by adding the set pressure and the percent overpressure
plus 14.7.
Single-Valve Installations Multiple-Valve Installations
Maximum Maximum
Set Accumulated Set Accumulated
Pressure Pressure Pressure Pressure
Contingency (percent) (percent) (percent) (percent)
Nonfire only
First Valve 100 110 100 116
Additional valve(s) 105 116
Fire only
First valve 100 121 100 121
Additional valve(s) 105 121
Supplemental valve 110 121
Note: All values are percentages of the maximum allowable working pressure.
Figure 19. Set Pressure and Accumulation Limits for Pressure Relief Valves
2
WORK AID 2: RESOURCES USED TO CALCULATE THE SIZE OF A RELIEF
VALVE-HAND CALCULATOR METHOD
This Work Aid provides the formulas and procedures to calculate the size of a pressure relief
valve. These procedures assume that the basis of relief has been selected.
Work Aid 2A: Formulas and Procedures to Size PZVs for Gas and Vapor
Formulas
Equation 1: Flow Rate for Thermal Contingencies
gpm
BH
500GC
Where:
gpm = flow rate at the flowing temperature, in U.S. gallons per minute
B = cubical expansion coefficient per F for the liquid at the expected
temperature
H = total heat transfer rate in BTU per hour (see formula below)
G = specific gravity referred to water (1.0 at 60F. Liquid compressibility is
usually ignored.)
Equation 2: Total Heat Absorption for Fire Contingencies
When prompt firefighting efforts and adequate drainage exist,
Q = 21,000F (A
wet
)
0.82
When prompt firefighting efforts and adequate drainage do not exist,
Q = 34,500F (A
wet
)
0.82
Where:
F = environmental factor (page 7-18 of Addendum 1) or (Table D-3 API
520 PT1) or (Table D-3 API 520 PT1)
A
wet
= total wetted surface in square feet (Page 7-19 of Addendum 1)
Equation 3: Flow Rate for Fire Contingencies
W = Q/H
vap
Where:
W = mass flow in pounds per hour
H
vap
= latent heat of vaporization in BTU per pound
Equation 4: Effective Discharge Area for Critical Flow
A
W
CKP K
TZ
M
1 b
Where:
W = required flow rate through the valve expressed in lb/hr (mass flow
units)
C = specific heats ratio coefficient. Table 8 and Table 9 of API 520 PT1
(Addendum 1)
K = effective coefficient of discharge = 0.975, or certified manufacturers
value.
P
1
= upstream relieving pressure in psia, ((Set Pressure psig x
%Overpressure) + 14.7 = P
1

psia)
K
b
= capacity correction factor due to back pressure, Bellows PZVs only.
Use Addendum 1 or manufacturers value.
Z = compressibility factor at inlet conditions. Use Addendum 4.
Equation 5: Effective Discharge Area for Subcritical Flow
A
W
735F K
ZT
MP (P P )
2 d 1 1 2
A
V
4645.2F K
ZTM
P (P P )
2 d 1 1 2
A
V
863.63F K
ZTG
P (P P )
2 d 1 1 2
Where:
F
2
= coefficient of subcritical flow ( )
_
,
1
]
1
k
k 1
r
1 r
1 r
2/k
(k 1)/k
k = specific heat ratio k = C
p
/ C
v
.
r = ratio of back pressure to upstream relieving pressure, P
2
/P
1
.
V = required flow rate through the valve expressed in scfm (standard cubic feet
per minute at 14.7 psia and 60F)
K
d
= effective coefficient of discharge = 0.975, or certified manufacturers value.
G = specific gravity relative to Air @ STP, (G = M / 28.97)
P
1
= upstream relieving pressure in psia, (Set Pressure psig + Overpressure psig
+ 14.7 = P
1

psia)
P
2
= back pressure in psia
Z = compressibility factor at relieving inlet conditions. Use P
r
and T
r
to derive
Z from Addendum 4. Z = 1 is a conservative value.
Equation 6: Critical Pressure Ratio
P
P
2
k 1
cf
1
k/(k 1)
1
]
1
Where:
P
cf
= critical flow throat pressure in psia
P
1
k = ratio of specific heats for any ideal gas
Procedure for Determining Effective Discharge Area for Vaporizing Liquids
1.0 Obtain the following information:
molecular weight of hydrocarbon vapor, M, from the ISS
relieving temperature, T, from the ISS
relieving pressure, P
1
(the set pressure and the percent overpressure plus 14.7)
2.0 Determine the total wetted surface area.
2.1 Calculate, A
wet
, the total wetted surface area using Page 7-19 of Addendum 1. If
the vessel dimensions are not known, obtain them from the vessel design sheet.
To calculate the end-to-end length of an elliptical vessel, add the tangent-to-
tangent length to 2 times the tangent-to-end length.
3.0 Determine the rate of vapor or gas vaporized from the liquid.
3.1 Calculate, Q, the total heat absorption to the wetted surface in BTU per hour
using Equation 2.
3.2 Calculate, W, the mass flow rate in pounds per hour using Equation 3.
4.0 Calculate the effective discharge area.
4.1 If the specific heats ratio coefficient is not known, find the value of k on page 7-9
of Addendum 1. Then find the value of C based on k by using the equation on
page 7-9 of Addendum 1.
4.2 If the effective coefficient of discharge, K
d
, is not known, use 0.975.
4.3 Determine the back pressure correction factor, K
b
, using Addendum 1, or use the
manufacturers value.
4.4 If the compressibility factor, Z, is not known, use Addendum 4 to determine Z.
4.5 Substitute the values for W, M, C, K, P
1
, K
b
, T, and Z into Equation 4 and solve
for A.
Procedure for Determining Effective Discharge Area for Subcritical Flow
required hydrocarbon flow, W, in pounds per hour
molecular weight of hydrocarbon vapor, M
relieving temperature, T
relieving pressure, P
1
, the set pressure and the percent overpressure plus 14.7.
2.0 If the compressibility factor, Z, is not known, use Addendum 4 to determine Z.
3.0 Determine whether flow is subcritical by calculating the critical back pressure.
3.1 Find the Critical Flow Pressure Ratio for the gas in Table 8, page 27 of Addendum
2.
3.2 Multiply the relieving pressure, P
1
, by the Critical Flow Pressure Ratio in 3.1 to
calculate the critical back pressure.
3.3 If the back pressure is greater than the critical back pressure, the PZV can be sized
using Equation 5 (subcritical flow).
4.0 Calculate the total back pressure.
4.1 Total Back Pressure - Superimposed Back Pressure + Built-up Backpressure.
5.0 Determine the coefficient of subcritical flow, F
2
.
5.1 Find the value of k on page 7-26 (Table T7-7) of Addendum 1, the Crosby
Engineering Handbook or other handbook.
5.2 Calculate, r, the ratio of the back pressure to the upstream pressure by dividing P
2
(from 4.1) by the relieving pressure P
1
(from 2.0).
5.3 Use the F2 equation under Equation 5 with the values for r and k to determine F
2
.
6.0 Substitute the values for W, F
2
, K, Z, T, M, P
1
, P
2
, V, and G into the Effective Discharge
Area for Subcritical Flow Equation and solve for A. (Equation 5)
7.0 Select the manufacturers standard orifice size that is equal to or greater than the orifice
size calculated for A.
Work Aid 2B: Formulas and Procedure to Size PZVs for Steam Relief
This Work Aid contains the formulas and procedure to size PZVs for steam service.
Formulas
Equation 7. Effective Discharge Area for Steam Relief
A
W
51. 5P K K K
1 d N SH
Where:
A = effective discharge area expressed in sq. in.
W = required flow rate through the valve expressed in lbs/hr
K
d
= effective coefficient of discharge = 0.975, or certified manufacturers value.
P
1
K
SH
= superheat correction factor.
K
N
= correction factor for Napier equation.
Procedure
flow rate in lbs/hr
set pressure in psig
percent accumulation
superheat correction factor, K
SH
(K
SH
= 1 for saturated steam. Otherwise use
Addendum 7.)
2.0 Calculate the upstream relieving pressure, P
1
, in psia.
2.1 Multiply the set press by the percent accumulation to obtain the allowable
overpressure.
2.2 Add the allowable overpressure from 2.1 to the set pressure plus 14.7 to obtain the
upstream relieving pressure.
3.0 Determine the correction factor for Napier equation, K
N
.
3.1 If P
1
1515 psia, K
N
= 1. If P
1
> 1515 psia and 3215 psia, use Page
7-6 of Addendum 1 or substitute P
1
into the equation below and solve for K
N
.
K
N
= (0.1906P
1
- 1000) / (0.2292P
1
- 1061)
4.0 Substitute W, K (0.975), P
1
, K
SH
, and K
N
into the effective area discharge equation and
solve for A.
5.0 Select the manufacturers standard orifice size that is equal to or greater than the orifice
size calculated for A.
Work Aid 2C: Formulas and Procedure to Size PZVs for Liquid Relief
This Work Aid contains the formulas and procedure to size PZVs that require capacity
certification in accordance with Section VIII, Division I, of the ASME Code. The procedure
includes determining the coefficient of discharge at 10% overpressure.
Formulas
Equation 8. Total Heat Transfer Rate
H = H
s
A
s
Where:
H = total heat transfer rate in BTU/hr-ft
2
H
s
= solar heat rate in BTU/hr (300 BTU/hr from SAES L-043, Section 4.2.2)
A
s
= heat transfer surface area in ft
2
Equation 9. Liquid Expansion Rate
gpm
BH
500GC
Where:
gpm = flow rate in gallons per minute
B = cubical expansion coefficient per F
H = total heat transfer rate in BTU/hr
G = specific gravity
C = specific heat of trapped fluid in BTU/lb. F
Equation 10. API Liquid PZV Sizing Equation
A
Q
38K K K
G
P P
d W V 1 2
Where:
A = effective discharge area in in
2
Q = flow rate in gpm
K
d
= effective discharge coefficient (Use K
d
= .650 if unknown)
K
v
= viscosity correction factor
K
w
= back pressure correction factor
G = specific gravity (water = 1 @ 60 F)
P
1
= upstream relieving pressure in psig
P
2
= total back pressure in psig
Equation 11. Reynolds Number
R
Q(2800G)
A
Where:
R
=
Reynolds number
Q = flow rate at the flowing temperature, in U.S. gallons per minute
G = specific gravity (water = 1 @ 60 F)
m = absolute viscosity at the flowing temperature, in centipoise
A = effective discharge area in square inches
Procedure
1.0 Calculate the total heat transfer rate, H.
1.1 Obtain the following information
surface area of the equipment in ft
2
, A
s
.
Saudi Aramco solar heat rate (300 BTU/hr-ft
2
), H
s
.
1.2 Multiply the heat transfer surface area of the equipment by the Saudi Aramco solar
heat rate to calculate the total heat transfer rate.
2.0 Calculate the expansion rate of the trapped fluid, gpm.
cubical expansion coefficient per F, B.
total heat transfer rate in BTU/hr (H from 1.0 above)
specific gravity, G (water = 1 @ 60F & 1 atm)
specific heat of the trapped fluid in BTU/lb. F, C.
2.2 Substitute the values obtained in 2.1 into the Liquid Expansion Rate equation to
calculate the expansion rate of the trapped fluid.
3.0 Determine the Reynolds number and the capacity correction factor for viscosity, K
v
.
discharge temperature (F) and pressure (psig)
flow rate of the fluid in gallons per minute (gpm from 2.0 above)
specific gravity, G, of the liquid at the flowing temperature
absolute viscosity, m, (Figure ?? at discharge temperature)
area, A, from manufacturers standard orifice sizes
3.2 Substitute the values obtained in 3.1 into the Reynolds Number equation and
calculate the Reynolds number.
3.3 Use the Reynolds number that was calculated in 3.2 to determine the viscosity
correction factor, K
v
, in Figure ?.
3.4 Divide the area of the manufacturers standard orifice sizes, A, by the viscosity
correction factor, K
v
, from 3.3 to obtain the orifice area corrected for viscosity.
3.5 If the corrected area from 3.4 exceeds the manufacturers standard orifice size,
repeat the steps starting with 3.0 and substitute the manufacturers next largest
standard orifice size for A. If the corrected area from 3.4 is less than or equal to
the manufacturers standard orifice size, select that standard orifice size.
Work Aid 2D: Procedure to Size PZVs for Two-Phase Liquid/Vapor Relief
This Work Aid contains the formulas and procedure to size PZVs for two-phase liquid/vapor
relief. This procedure was taken directly from API RP-520, Section 4.7.
Procedure
1.0 Determine the amount of liquid that flashes by an isenthalpic (adiabatic) expansion from
the relieving condition either to the critical downstream pressure for the flashed vapor or
to the back pressure, whichever is greater.
2.0 Calculate individually the orifice area required to pass the flashed vapor component, using
the critical or subcritical equation in Work Aid 2A as appropriate, according to service,
type of valve, and whether the back pressure is greater or less than the critical
downstream pressure.
3.0 Calculate individually the orifice area required to pass the unflashed liquid component
using the effective discharge equation in Work Aid 2C. The pressure drop (P
1
- P
2
) is the
inlet relieving pressure minus the back pressure.
4.0 Add the individual areas calculated for the vapor and liquid components to obtain the total
orifice area, A, that is required.
5.0 Select a pressure relief valve that has an effective discharge area equal to or greater than
the total calculated orifice area. The designer should recheck the back pressure that will
exist for the specific relief valve selected, with its particular discharge installation, by
examining the vapor generation downstream of the pressure relief valve nozzle. Where
appropriate, corrections can be applied to the individual orifice areas previously
calculated. Furthermore, selecting a balanced pressure relief valve is often desirable to
minimize the effect of flashed vapor on the valve capacity.
WORK AID 3: RESOURCES USED TO SELECT A RELIEF VALVE -
MANUFACTURERS CATALOG
This Work Aid contains a procedure for selecting a PZV from a relief valve manufacturers
catalog. A completed ISS and the manufacturers quotation and catalog are needed for this
procedure.
Procedure
1.0 Obtain the style designation for the PZV from the manufacturers quotation.
2.0 Using the PZV style designation and the manufacturers catalog, determine the following:
Valve size
Style
Pressure and temperature ratings for the connections
Materials of construction
Type of cap and lever
3.0 Compare the PZV specifications on the ISS with the valve characteristics from the
manufacturers catalog. If the answer to any of the questions below is no and the option
offered by the manufacturer is not acceptable, select a different PZV that meets the
specifications on the ISS.
3.1 Do the inlet and outlet sizes match the sizes specified in the BODY section of the
ISS?
3.2 Do the materials of construction in the catalog meet the requirements in the
BODY and TRIM MATERIALS sections of the ISS?
3.3 Is the PZV orifice area equal to, or greater than, the size requirement in the
ORIFICE AREA section of the ISS?
3.4 Does the valve include other specifications from the ISS such as a lifting lever,
balanced bellows, etc.
WORK AID 4: RESOURCES USED TO SIZE AND SELECT A PRESSURE
RELIEF VALVE - COMPUTERIZED SIZING METHOD
This Work Aid contains the procedure for using the CROSBY-SIZE application (Version 2.1).
This procedure assumes that the user has a basic knowledge of personal computers and that the
proper printer was selected during the software installation process. A completed ISS is
required to perform this procedure.
Procedure
1.0 To access Crosby-Size enter the csize subdirectory and type "crosby" then press the
[ENTER] key. After the start-up screen appears, press the any key to make the Main
Menu appear.
2.0 If you are instructed that your computer has been configured and that you can begin the
sizing procedure, go to Step 8.0. Otherwise, at the Main Menu, select the last option,
CROSBY-SIZE Program Configuration Menu, and press [ENTER]. The CROSBY-SIZE
Configuration menu will replace the Main Menu.
Option one, 'Company Database Administration,' is used to create report headers
which will identify the author of the reports generated by the software.
Option two, 'Printer Maintenance Menu,' is used to identify the printer that will be
used with the software.
Options three through five, 'Program Options Settings,' 'Computation Unit
Settings,' and 'Atmospheric Pressure Settings' are important for PZV sizing and
selection.
The last option, 'Reindex Files,' is used to save the selected configurations for
database presentations.
3.0 Select the 'Company Database Administration' option and press [ENTER]. Read the
'Company Administration Menu' section in the manual pages 12-14 for instructions on
editing the information on this menu. Make changes to the data entry areas so that the
menu appears as shown in Figure 24.
Figure 20. Company Database Administration Menu
3.1 When you have finished editing the data entry areas, review the information on the
screen, and correct any errors. Press [ESCAPE] to return to the Main Menu. Any
changes will be saved by the program.
4.0 At the Main Menu, select the 'Program Options Settings' option and press [ENTER].
Read the 'Program Options Settings' section of the manual on pages 15 & 16.
4.1 Select 'Reactive Force' and toggle the block from "OFF" to "ON" by pressing
[ENTER]. With Reactive Force "ON", the program will calculate the reactive
force at PZV discharge.
4.2 Toggle 'Noise' and 'Weights Printing' from "OFF" to "ON". With Noise' "ON",
the program will calculate PZV discharge dB
a
(Sound pressure level in decibels on
the 'a' scale) at a distance requested by the design engineer. With 'Weights
Printing' "ON", the program will list the weight of the selected PZV.
4.3 Leave 'CxK Manual Factor' "OFF". The program will require the data entry of k
(Specific Heats Ratio C
p
/C
v
) and will calculate C (Specific Heats Ratio
Coefficient).
4.4 Leave 'Rupture Disk' "OFF" because no rupture disk is used with PZVs.
4.5 Press [ESCAPE] to save the entries and return to the 'Program Configuration
Menu'. Entries that have been changed in the 'Program Option Settings' screen are
not saved permanently by the program. When the user 'quits' CROSBY-SIZE
these values return to the default "OFF", positions.
5.0 Highlight 'Computation Unit Settings' and press [ENTER]. Read the 'Computation Unit
Settings' section of the manual pages 17-19.
5.1 Select 'Date Format' and press [ENTER]. The program provides a selection option
screen 'Date Format'. Select 'USA' and press [ENTER].
5.2 Review the other settings in the menu; however, do not change any setting. Press
[ESCAPE] to return to the 'Program Configuration Menu'.
6.0 Highlight the 'Atmospheric Pressure Settings' option and review this section of the manual
pages 20 & 21. Observe the selection option screen, and then press [ESCAPE] to return
to the 'Program Configuration Menu'. (Any accidental change will be ignored by the
program.)
7.0 Crosby-Size program configuration is complete press [ESCAPE] and an inquiry screen
will prompt with a question "Save Settings Permanently". Note that the default "Y", press
[ENTER] to save changes. (Note: Typing "N" will return all selected options and data to
the Crosby-Size default values.)
8.0 Record the data from Exercise 1 into the table below. Other data have been provided in
the table for you. At the 'Main Menu' screen, select the 'API RP520 Fire Sizing' option.
Enter the appropriate data when you receive the following prompts.
Prompt Enter
Select Tank Type: Sphere or Cylinder (S/C)? C
Cylinder Type: Horizontal or Vertical (H/V)? H
Type of Ends: Flat or Spherical (F/S)? S
Enter wetted area manually? N
[D] Diameter, in Ft
[L] End-to-End Length. in Ft
[H] Height off Ground, in Ft
[F] Fluid Level, in Ft
[T] Latent Heat, in Btu/lb
Adequate Drainage & Fire Fighting Equipment Provided (Y/N)? Y
Insulation Types: Options: Bare Vessel
Req. Cap. Other Than Fire Exp.: 0
Set Pressure:
Types Of Back Pressure: Superimposed
Constant
Back Pressure: Superimposed Constant:
Overpressure:
Specific Heat Ratio:
Molecular Weight:
Temperature:
Compressibility Factor:
Valve Types: Options: JOS
Do you require all Stainless Steel Valve (Y/N) ? N
Selected Valves Include:
Cap Type Selections: Options: Screwed Cap
[C]onditions, [S]ave, [R]eport. [V]alve Type, or [Q]uit? R
CROSBY-SIZE Sizing Reports: Report Options: Crosby Report Sheet
w/ Formulas
Print to Screen/Printer (S/P) P
Customer Name: SAUDI ARAMCO
Customer Reference: PZV-131
Comments [ENTER]
[C]onditions, [S]ave, [R]eport. [V]alve Type, or [Q]uit? Q
[ESC] to Quit ESC
GLOSSARY
allowable overpressure The pressure increase over the set pressure of the relieving
device, expressed in pressure units or as a percent. It is the
same as accumulation when the relieving device is set at the
maximum allowable working pressure of the vessel.
critical flow rate The flow rate that corresponds to the limiting velocity.
critical flow pressure ratio The absolute pressure ratio of the pressure in the throat of
a PZV at sonic velocity (P
cf
) to the inlet pressure (P
1
).
critical flow rate The flow rate that corresponds to the limiting velocity.
effective discharge area A nominal or computed area of a pressure relief valve used
in recognized flow formulas to determine the size of the
valve. It will b less than the actual discharge area.
limiting velocity The maximum mass flow rate through the PZV nozzle,
which is equal to the velocity of sound in the flowing media
at that location.
originator An engineer who initiates a RV installation or change that
requires authorization approvals by providing the design
and specification information. He can be an engineer for
any discipline (i.e.; Operations Engineering, Maintenance
Engineer, Inspection Engineer, Projects Engineer, Plant
Engineer, etc.)
relieving pressure The total of the set pressure plus overpressure plus
atmospheric pressure. For gases and vapors, the relieving
pressure is expressed in absolute units (psia). For liquids,
the relieving pressure is expressed in gauge units (psig).
set pressure The Inlet gauge pressure at which the pressure relief valve
is set to open under service conditions.
wetted surface Any surface that is both in contact with the process liquid
and can be exposed to fire.
ADDENDUM
1. Crosby Engineering Handbook, Technical Publication No. TP-V300
2. API RP-520
3. SAES-J-600, Pressure Relief Devices, Chapter 7.0
4. Crosby Catalogs
Addendum 1: Crosby Engineering Handbook
Addendum 2: Properties of Gases
Addendum 3: SAES-J-600, Pressure Relief Devices,
ADDENDUM 4: Crosby Catalogs

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Sizing and Selecting Pressure Relief Valves

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Note: The source of the technical material in this volume is the Professional

Engineering Development Program (PEDP) of Engineering Services.

15 Exterior fire Estimate by the method given in D.5

Engineering Encyclopedia Instrumentations

k = specific heat ratio k = C

Engineering Encyclopedia Instrumentations

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