Global A Potential Hub To Deliver Dynamic Professionals. Certified Process Design Professional Lesson # 07 PSV Selection & Sizing Part 02 Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Steps for Pressure Safety Valve (PSV) Sizing Calculation 1. Develop Process Safety Diagram (PSD) – Establish a diagram showing safety controls, interlocks, and protection systems. 2. Develop relief scenarios – Identify credible overpressure scenarios based on causes (e.g., blocked outlet, fire, thermal expansion). 3. Determine required relief area – Calculate relief area for each scenario considering the phase (Gas, Liquid, or Twophase) and thermodynamic conditions. 4. Choose worst-case scenario – Identify the scenario with the highest relief requirement to design the PSV. 5. Select proper orifice and valve body – Use standards (API 520/521/526) to select orifice and body size matching required flow and set pressure. 6. Calculate inlet line size – Ensure pressure drop (ΔP) in the inlet line is <3% of the PSV set pressure. 7. Preliminary tail pipe sizing – Estimate discharge piping to check pressure drop and backpressure implications. 8. Perform flare system modeling – Simulate discharge into flare header to verify backpressure and optimize tail pipe size. 9. Select PSV type – Choose between: Conventional Balanced Bellows (for high backpressure) Pilot Operated (for precise performance or high set pressures) Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Develop Process Safety Diagram (PSD): A Process Safety Diagram (PSD) illustrates the placement of all process safety equipment (e.g., PSHH, TSHH, PSVs, BDVs, rupture discs). It serves as the foundation for identifying and evaluating all potential relief scenarios. The PSD must be created prior to performing any PSV sizing calculations. Develop Relief Scenarios: Identify potential overpressure situations by analyzing general causes (e.g., blocked outlets, utility failures, fire) using the Process Safety Diagram (PSD) as a reference to ensure all safety devices and conditions are considered. Possible Scenarios Vessel / Column HEX Pump Compressor Line ● ● ● Blocked Outlet ● ● Thermal Expansion ● Tube Rupture ● Gas Blow-by ● ● Inlet Control Valve Failure ● ● ● ● ● Exterior Fire Note: Exterior Fire is not applicable for PHEX! Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Blocked Outlet / Blocked Discharge This scenario occurs due to the unintentional closure of a block valve or failure of a control valve in the closed position on an outlet line. It commonly affects production separators, compressor discharge piping, and pump discharge piping. In such cases, safety relief valves must be sized to handle 100% of the expected upstream flow. For multi-phase streams, the relief rate must account for the total inlet flow — both gas and liquid phases. Thermal Expansion/ Thermal Relief Thermal Expansion Relief Valves (TERVs) are needed in liquid-full systems that can be blocked in and exposed to heat from the atmosphere or process. This heat input can cause fluid expansion and lead to overpressure if not properly relieved. Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Tube Rupture A tube rupture in a heat exchanger can cause vapor to rapidly enter the tube or shell side, resulting in a sudden pressure surge that propagates at sonic velocity. Since PSVs may not respond quickly enough, rupture discs are typically used for protection in such cases. Gas Blow-by Gas blow-by happens when a vessel’s liquid level drops too low—often due to level control failure—allowing gas to escape through the liquid outlet. This leads to high-pressure gas entering downstream low-pressure systems, posing a risk of overpressure. Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Inlet Control Valve Failure In this case, overpressure occurs due to excess inlet flow when an inlet control valve fails. The relief rate is calculated as the difference between the maximum possible inlet flow and the outlet flow at relief conditions, assuming no corrective response from outlet valves (i.e., they remain at their normal operating positions). External Fire Production and processing facilities are typically divided into fire zones using barriers like plated decks, firewalls, or platform edges. In the event of a fire, all equipment within the affected zone is considered fully exposed. During the fire, it is assumed that no feed or product flows through the affected system, and all normal heat sources are halted. Additionally, no credit is given for water spray systems or thermal insulation on vessels. Fire Type Pool Fire: Systems containing significant liquid hydrocarbon inventory are evaluated for potential pool fire scenarios. The heat flux for such fires will be calculated according to API RP 521. A 40% reduction in heat flux may be considered if there is effective drainage and prompt firefighting efforts, as outlined in API RP 521. Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Jet Fire: In cases where a jet fire is a potential risk, the relief load will be calculated based on the higher heat flux generated by the fire. Jet fires produce heat flux ranging from 50 kW/m² to 300 kW/m². However, the actual net heat flux to the fluid depends on several factors, including the fuel type, vessel temperature, surface emissivity, fire environment, and the radiative and convective components of the fire. Vessel Type & Fluid Relief Type Vessel types can be classified as: Dry or empty vessel Vessels containing liquid, where the effect of the wetted area of the vessel needs to be considered. Fluid relief types can be categorized as: Sub-critical fluid: Pressure (P) is less than 0.9 times the critical pressure (Pc), i.e., P < 0.9 * Pc. Near-critical fluid: Pressure is between 0.9 * Pc and 1.1 * Pc, i.e., 0.9 * Pc < P < 1.1 * Pc. Super-critical (dense phase) fluid: Pressure is greater than 1.1 times the critical pressure, i.e., P > 1.1 * Pc. Where: Pc = Critical Pressure P = Relieving Pressure Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Totally = 2x2x3 = 12 cases possible Hence 12 methods of calculation for Fire case. Determine the required relief area for each case (gas, liquid, or two-phase). Target of sizing relief valve 1. Determine the relief rate. 2. Determine the required relief area. 3. Select the standard relief area. Applicable Standards API RP 520: Guidelines for sizing, selection, and installation of pressure relief devices. API RP 521: Guidance on pressure relief system design and depressuring analysis. Relief fluid category Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Determining the relief rate is the first and most critical step in relief valve sizing. Certain scenarios—such as gas blow-by, tube rupture, and especially fire cases—involve complex calculations and multiple steps due to varying thermodynamic and process conditions. While API RP 520 and 521 provide simplified methods for estimating relief rates, these methods may not cover all possible scenarios or complexities. As a result, many companies have developed internal procedures and tools to more accurately determine relief rates tailored to their specific processes and equipment. Relief Valve Sizing for Single-Phase Vapor Flow Relief valves handling single-phase vapor flow are sized following the methodology outlined in API RP 520, Section 3. The sizing equations are divided into two categories based on the nature of the flow: o o Critical flow Subcritical flow To determine which equation to apply, the critical pressure condition must first be checked using the following formula: If flow is critical (Pcf > downstream pressure P2), the critical sizing equation is used: Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. If flow is subcritical, the following equation will be used (API 520) Subcritical Flow Coefficient (F₂) Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Relief valves in steam service will be sized as follows: Relief Valve Sizing for Single-Phase Liquid Flow For single-phase liquid flow, the sizing is performed using the method specified for certified relief valves as outlined in API RP 520. The following equation is applicable only to non-flashing (incompressible) liquids: Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Two-Phase Relief Valve Sizing For two-phase (liquid/vapor) relief, the sizing must follow the method outlined in API 520 Part 1, Appendix D: "Sizing for Two-Phase Liquid/Vapour Relief". This updated methodology replaces older API approaches due to findings that previous methods could significantly underestimate the required relief area in certain scenarios. The method is based on the Leung Omega Method, which is rooted in the Homogeneous Equilibrium Model (HEM)—assuming both thermal and mechanical equilibrium between liquid and vapor phases. Determine required relief area for each case (Gas, Liquid, 2-Phases) Required relief area is calculated from relief rate. Hence relief rate calculation is very important step Choose the worst case scenario to be a governing case The case which giving the maximum relief area will be a governing case. Select proper orifice and valve body size based on STD The standard orifice sizes for pressure relief valves are selected based on: API RP 526 Or GPSA Data Book, Chapter 5, Figure 5-7 The valve body size—defined by inlet × outlet flange diameter—must comply with: API Standard 526: “Flanged Steel Pressure Relief Valves,” 4th Edition, June 1995 To calculate the inlet line size for a pressure relief valve, the pressure drop (ΔP) across the inlet line should be less than 3% of the set relieving pressure (RP), as per API RP 520 Part II guidelines. This is to avoid excessive pressure loss that could affect valve performance. Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Inlet Line Design Considerations for Relief Valves The inlet pipe diameter must be at least equal to the PSV inlet flange size. The inlet piping should slope upward continuously from the source vessel to the valve to prevent liquid accumulation or traps. Heat tracing is recommended if there's a risk of freezing or solidification, especially for viscous or congealable liquids. A continuous clean purge should be installed if there is potential for coke, polymer buildup, or solids deposition in the relief path. Car Seal Open (CSO) valves should be installed with the stem in a horizontal or vertically downward orientation to prevent accumulation of debris or fluid at the stem. Perform Preliminary Estimate Of Tail Pipe Discharge line must be sized so that the Mach number remains below 0.75 to ensure non-choked flow. Tail Pipe Design Considerations The discharge line diameter must be equal to or greater than the PSV outlet flange size. Closed discharge piping must slope continuously downward to the header to prevent liquid accumulation. No check valves, orifice plates, or other flow restrictions are allowed in relief valve discharge lines. Design must account for thermal expansion from hot or cold relief streams. Consider the effects of auto-refrigeration, which may require brittle fracture-resistant materials. Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Risers must discharge at least 10 ft above any platform located within 50 ft horizontally. Must include a drain hole to avoid accumulation of liquids. Radiant heat from potential ignition of discharge must be evaluated in the design. CSO (Car Seal Open) valves should be installed with the stem oriented horizontally or vertically downward. Perform Flare system modeling to indicate total back pressure and most suitable tail pipe size. Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Select PSV type (Conventional, Balanced Bellow, Pilot Operated) Back Pressure Type Effects on Valves: Gas Applications Value (% of set pressure) < 30% 30–50% Constant Conventional Balanced Bellow No effect Set point increased by back pressure > 50% Set point increased by back pressure; Flow becomes sonic < 10% Set point varies with back pressure Lift/Capacity reduced No effect Lift/Capacity reduced Unstable — Do not use < 10% No effect No effect Lift/Capacity reduced 10–30% Unstable — Do not use > 50% Back Pressure 20–50% Constant Variable Superimposed No effect Generally unstable — Do not use Flow becomes subsonic Effects on Valves: Liquid Applications Value (% of set pressure) < 20% Flow becomes subsonic Generally unstable — Do not use > 50% Type Flow becomes subsonic No effect 30–50% Variable Built-up No effect Generally unstable Do not use 10–30% Variable Superimposed Pilot Operated Conventional Set point increased by back pressure Balanced Bellow No effect Lift/Capacity reduced > 50% Set point increased by back Generally unstable pressure; Flow becomes — Do not use sonic < 10% Set point varies with back pressure 10–20% Unstable — Do not use Email: admin@omesolglobal.com Pilot Operated No effect No effect No effect Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Back Pressure Type Effects on Valves: Liquid Applications Value (% of set pressure) Conventional 20–50% Lift/Capacity reduced > 50% Generally unstable — Do not use < 10% Variable Built-up Balanced Bellow No effect No effect 10–20% Unstable — Do not use > 50% Email: admin@omesolglobal.com Pilot Operated Lift/Capacity reduced No effect Generally unstable — Do not use Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Assess Relief Scenarios Judgement Scenario to be considered separately An external fire could cause the pressure in V-6010 to rise to the relief valve setting through vaporization of liquids. Equipment layout shows no potential that “jet fire” will happen on located area thus “pool fire” will be determined as a basis for calculation. Yes Source of Scenario Overpressure 1 Fire Case 2 Tube Rupture This case is not applicable. No 3 Inlet control valve failure CVs are fail to close type therefore this case is not applicable for sizing PSV. No 4 Gas Blow-by Gas blow-by can occur by: • Liquid in a V-1 drop so low that gas exits via the liquid outlet nozzle due to level control failure. Loss of liquid level will result in gas from V-1 passing into V-2 via F-1 and/or F-2. Gas blow-by is based on following assumptions: • Control valve upstream fails 100% open • The upstream pressure is at the high pressure alarm • The downstream pressure is 110% of the set point of the relief valve on the downstream vessel • No possibility that the bypass valve around the control valve is opened. Yes 5 1. Water Blocked Discharge: This scenario will relate to two trips; first LIAHH and secondly LAHH. Credit can be taken that either of these two will actuate. It is unreasonable to assume both will fail to respond. Hence, this scenario cuts off the feed to Blocked Outlet vessel and no relief is needed. Yes 2. Oil Blocked Discharge: This scenario relates to only oil trip, while interface level is already healthy. No credit can be taken that this trip will work. Hence PSV needs oil relief. 6 Thermal Relief This case is not applicable. No Possible Relief Scenarios There are three different possible relief scenarios: o o o Fire Case. Gas Blow-by Case. Blocked Outlet Case. Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Fire Case Scenario: An external fire could cause the pressure in V-2 to rise to the relief valve setting through vaporization of liquids. Equipment layout shown no potential that “jet fire” will happen on located area thus “pool fire” will be determined as a basis for calculation. Relief Condition PSV-2 set pressure = 250 psig Allowable Accumulation = 21% Maximum allowable accumulated pressure = 250x1.21 = 302.5 psig. Relieving temperature =? Although relief may occur 61 minutes after a fire starts, API RP 520 assumes the fire is managed within 15 minutes, making this scenario unlikely in actual operation. By input all required parameters (eg. Vessel dimensions, fluid relieving properties), in to calculation sheet. Required relief area = 0.183 in2 Relief Load = 4,066 lb/hr Therefore Select 1xEx2 orifice with discharge area of 0.196 in2 Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Gas Blow-by Scenario: Liquid in a V-1 drop so low that gas exits via the liquid outlet nozzle due to level control failure. Loss of liquid level will result in gas from V-1 passing into V-2 via F-1 and/or F-2. Gas Blow-by Assumptions and Relief Conditions: Gas blow-by is evaluated under the following assumptions: The upstream control valve fails fully open (100%). Upstream pressure reaches the high-pressure alarm level. Downstream pressure is assumed to reach 110% of the PSV set point. No possibility that the bypass valve around the control valve is opened as locked close. Relief Conditions: PSV-2 Set Pressure: 250 psig Allowable Accumulation: 10% Maximum Allowable Accumulated Pressure: 250 × 1.1 = 275 psig Assume F-1 and F-2 are same maximum Cv of 433. C1 assumed 26.5 (C1 is normally obtained from valve vendor) Assume only one control valve is fail. Therefore Cg = C1 x Cv = 433 x 26.5 = 11,474.5 V-1 hold pressure at PAH = 350 psig V-2 operating pressure = 275 psig (250 psig x 1.1 = 275 psig) Differential pressure = 350-275 = 75 psi Reliving temperature = 80 deg F How to find the maximum relief rate via F-1 and/or F-2? Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. The maximum relief rate can be determined using control valve sizing software (e.g., Fisher, Masoneilan, HYSYS) or standard sizing equations such as those found in the GPSA Engineering Data Book. By entering all necessary parameters (e.g., fluid relieving properties) into the calculation sheet for vapor relief scenarios: Required Relief Area: 11.57 in² Relief Load: 245,703.5 lb/hr Based on this, a 6xR x 8 orifice with a discharge area of 16 in² is selected. Blocked Outlet 1. Water Blocked Discharge This scenario involves two independent trips: a high-high interface level (LIAHH) and a high-high liquid level (LAHH). Since it is highly unlikely both would fail, it's assumed that at least one will stop the feed to the vessel, eliminating the need for pressure relief. 2. Oil Blocked Discharge In this case, only the oil trip is considered active, with the interface level remaining normal. No reliability credit is given to the oil trip, so a pressure safety valve (PSV) is required for protection. Relief Conditions: PSV-2 Set pressure: 250 psig Allowable accumulation: 10% Maximum relieving pressure: 250 x 1.1 = 275 psig Relieving temperature: 130 °F Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. From simulation data: Oil flow rate: 508,100 lb/hr (equivalent to 25,000 BPD) Oil density: 55.21 lb/ft³ Using the provided fluid properties and inputting them into the relief valve calculation sheet for a typical liquid relief scenario: Required relief area: 2.76 in² Selected orifice size: 3" x L x 4" Actual discharge area: 2.853 in² This selected orifice provides slightly more area than required, ensuring safe relief capacity. Selection of Governing Relief Scenarios Relief Case Design Orifice Size Relief Phase Fire Case 1×Ex2 Vapor Gas Blow-by 6×Rx8 Vapor Blocked Outlet 3×Lx4 Liquid Selected Governing Case: Gas Blow-by Calculated Relief Rate: 287,530 lb/hr Required Orifice Area: 11.57 in² Chosen Orifice Area: 16 in² Resulting Rated Flow Calculation: Rated flow = (16 / 11.57) × 287,530 lb/hr = 397,621 lb/hr Inlet line sizing calculation Inlet line sizing calculation is based on pressure drop less than 3 % of set pressure PSV Set Pressure: 250 psig Allowable Pressure Drop (3%): 0.03 × 250 = 7.5 psi Rated Mass Flow: 397,621 lb/hr Based on the maximum rated flow and associated relief conditions, the pressure drop for an 8" inlet line is calculated as 5.3 psi, which is within the allowable limit. Conclusion: The 8" line meets the inlet pressure drop criteria and is suitable for use. Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Outlet line sizing calculation Outlet line sizing calculation is based on the maximum Mach No. of 0.75 Preliminary Estimate: o 12” Line → Mach number = 0.71 → Acceptable Aspen Flare System Analyzer Modeling Result: o 10” Line → Mach number = 0.45 → Also acceptable Conclusion: Both 12” and 10” outlet lines satisfy the Mach number requirement, with 10” being more conservative and efficient. Selection of Relief Valve Type Result from Aspen Flare System Analyzer simulation give total back pressure of 70 psig PSV set pressure = 250 psig PSV Type % of Maximum Back Pressure Allowable Maximum Back Pressure Allowable (psig) Conventional 10% of SP 25 psig Balanced Bellow 30% of SP 75 psig Pilot Operated N/A N/A Summary: Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. If you want to learn new skills online. Join or expert LED training courses. Registration Process Kindly follow the mentioned below steps to proceed further. Step #01: Please follow the mentioned below link for registration application submission: https://omesolglobal.com/student_registration.php Step #02: Please follow the mentioned below link for fee submission: https://omesolglobal.com/submit-fee-online.php 2CheckOut.com Inc. (Ohio, USA) is a payment facilitator for goods and services provided by Octagon Management & Engineering Solutions (Omesol). Available Payment Methods: VISA, MASTER CARD, Paypal, Discover, American Express, Diners Club International, JCB, Skrill, Wise. Inquire Now E-mail: admin@omesolglobal.com Web: www.omesolglobal.com WhatsApp / Call: +1 -251-285-4593 Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Testimonials Here's what some of our previous clients have said about the impact of our training programs. I took the Process Design Engineering (ENG 101) after finishing the Aspen Hysys Basic class. 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It was a very useful and interesting course, and the instructors were very flexible to adapt the topics and schedules according to our needs. - Facundo Sala Process Engineer (Buenos Aires) Argentina Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Great course. My instructor did his best to make sure, I understood everything. - Echezona I.Nwankwo Houston, USA I consider OMESOL a great on-line institute for anybody who wants to improve his / her knowledge about Process Engineering and a lots of other trainings. Please, go ahead and book any training you want, you will really enjoy the courses and the way the teachers teach their lessons. Thanks a lot OMESOL Team and I would like to say a special thanks to my teachers for the great job they have done during my courses. Again, if you want to learn online, I recommend OMESOL. - Estêvão Adriano Tibúrcio Angola LNG (OPCO) The digital information and supporting documents provided by the instructor were valuable for better understanding of the course. The instructor always cordially answered all the question that I came in with during the course. - Ana Maria Ortiz Process Engineer Calgary, Canada It was really good experience of online learning of HYSYS. Classes were fully interactive with enough time for clarifications. It is a good opportunity for working professionals as essay to manage classes, learning at the same time to practice on real cases. - Iqbal Cheema Manager Operations, Sohar Refinery (ORPIC), Oman More Email: admin@omesolglobal.com Website: www.omesolglobal.com Global A Potential Hub To Deliver Dynamic Professionals. Our Clients Email: admin@omesolglobal.com Website: www.omesolglobal.com
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