US Chevron Spec. PSV - Sizing and Selection of Pressure Relief Valves

Integrity Critical
FRS-DU-5056-E
Sizing and Selection of Pressure Relief Valves
Operating Environment: LNG, Onshore, Pipelines, Topsides
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Rev. Date Description Author Technology Leader

C 7/08 Revision O. Torrey M. Porter (Sponsor)
D 2/11 Revision D. Paul M. Porter (Sponsor)
E 02/17 General revision M. Marashi M. Porter
February 2017 © 2006–2017 Chevron U.S.A. Inc. All rights reserved. Confidential – Restricted Access 1 of 20
Integrity Critical
Sizing and Selection of Pressure Relief Valves FRS-DU-5056-E
Summary of Changes
Revised technical content may be marked with change bars in the right margin as directed by Author.
The Author denotes the following technical changes to this revision as detailed below:
Author notations regarding this revision
Moved information from “Materials for Pressure Relief Valves” section to FRS-DU-5032.
Safety Critical Changes (if applicable) are noted below
n/a
Integrity Critical
Contents
1.0 Scope............................................................................................................................................... 4
2.0 References ...................................................................................................................................... 4
2.1 Owner Documents .............................................................................................................. 4
2.2 Industry Codes and Standards ........................................................................................... 5
2.3 Conflict Resolution .............................................................................................................. 5
3.0 Acronyms ........................................................................................................................................ 5
4.0 General ............................................................................................................................................ 5
5.0 Determination of Cold Differential Test Pressure ....................................................................... 6
5.1 General ............................................................................................................................... 6
5.2 Formula ............................................................................................................................... 7
5.3 Back Pressure Correction ................................................................................................... 7
5.4 Temperature Correction ...................................................................................................... 7
6.0 Pressure Relief Valve Capacity Formulas ................................................................................... 8
6.1 Pressure Relief Valve Nozzle Effective Orifice Areas (Typical) .......................................... 8
6.2 Sizing of Pressure Relief Valves ......................................................................................... 9
6.3 Pressure Relief Valve Liquid Formula................................................................................. 9
6.4 Pressure Relief Valve Gas or Vapor Formula ................................................................... 11
6.5 Pressure Relief Valve Steam Formula .............................................................................. 13
6.6 Pressure Relief Valve Fire Expansion Gas Formula ........................................................ 14
6.7 Rupture Disk Sizing........................................................................................................... 15
6.8 Temperature Relief Device Liquid Formula ...................................................................... 15
6.9 Vacuum Safety Valve Gas Formula .................................................................................. 16
6.10 Liquid-Vapor Mixture ......................................................................................................... 16
7.0 Selection of Pressure Relief Device ........................................................................................... 17
8.0 Selection of Valve Construction ................................................................................................. 17
8.1 Open Spring Type Valves ................................................................................................. 17
8.2 Closed Spring Type Valve (Preferred Type) ..................................................................... 17
8.3 Pressure Relief Valves with Lifting Levers ........................................................................ 18
8.4 Temperature Relief Devices ............................................................................................. 18
8.5 Pressure Relief Valve Caps .............................................................................................. 18
8.6 Test Gags .......................................................................................................................... 19
9.0 Ratings for Pressure Relief Valves ............................................................................................ 19
9.1 Inlet Flange and Inlet Body Rating .................................................................................... 19
9.2 Outlet Flange and Outlet Body Ratings ............................................................................ 19
10.0 Connections for Pressure Relief Valves .................................................................................... 19
11.0 Pressure Relief Valve Handling Before Installation and Test.................................................. 20
12.0 Inspection and Testing ................................................................................................................ 20
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1.0 Scope
1. This specification defines the following:
a. Technical requirements for sizing overpressure protection devices.
b. Design requirements for type, construction, and materials for overpressure protection
devices.
2. Application of overpressure protection devices and disposal systems are defined in
FRS-DU-5057.
3. Overpressure protection for atmospheric storage is defined in FRS-DU-971 and
FRS-SU-5038.
2.0 References
1. The following documents are referenced herein and are considered part of this specification.
2. Unless otherwise specified in Section 2.1 or 2.2, use the latest edition of the referenced
documents.
2.1 Owner Documents

FRS-DU-971 Venting Equipment for Atmospheric Aboveground Storage Tanks with
Cone Roofs
FRS-SU-5032 Relief Valves
FRS-SU-5033 Rupture Discs
FRS-SU-5038 Tank Pressure–Vacuum Vent Valves
FRS-DU-5057 Overpressure Protection
[FRS] GB-J1442 Instrumentation for Vacuum Breaker on Fractionator Towers
NCM-DU-2301 Design for Offshore Noise Control
NCM-DU-5096 Design for Onshore Noise Control
PIM-SU-5112 Piping Material Line Classes
PIM-DU-5138 Piping Design
PIM-SU-5300 Piping Service Classes and Materials Requirements
PIM-SU-6198 Design and Layout of Offshore Piping Systems
PPL-SU-6185 Piping Material Line Classes for Pipeline Applications
PVM-SU-4750 Carbon Steel Pressure Vessels
SID-SU-5106 Safety in Designs
Integrity Critical
2.2 Industry Codes and Standards

American Petroleum Institute (API)
Std 520 Sizing, Selection, and Installation of Pressure-Relieving Devices,
Part I – Sizing and Selection
Std 521 Pressure-Relieving and Depressuring Systems
Std 526 Flanged Steel Pressure-Relief Valves
RP 576 Inspection of Pressure-Relieving Devices
American Society of Mechanical Engineers (ASME)

B1.20.1 Pipe Threads, General Purpose (Inch)
B16.5 Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS 24
Metric/Inch Standard
B31.1 Power Piping, ASME Code for Pressure Piping, B31
B31.3 Process Piping, ASME Code for Pressure Piping, B31
B31.4 Pipeline Transportation Systems for Liquids and Slurries,
ASME Code for Pressure Piping, B31
B31.8 Gas Transmission and Distribution Piping Systems,
ASME Code for Pressure Piping, B31
Boiler and Pressure Vessel Code (BPVC)
Section I, Rules for Construction of Power Boilers
Section VIII, Rules for Construction of Pressure Vessels
2.3 Conflict Resolution

Supplier shall submit any conflicts among the inquiry documents in writing to Owner for
resolution.
3.0 Acronyms
NPS Nominal Pipe Size
PRD Pressure Relief Device
PRV Pressure Relief Valve
SS Stainless Steel
4.0 General
1. Pressure relief valves (PRV) shall be sized using calculation techniques (capacity formulas)
that simulate the condition during each relief situation being considered.
2. PRV data sheets, with sizing basis and orifice area calculated by Supplier, shall be submitted
to Purchaser for future reference.
Integrity Critical
3. Relief load, fluid properties, relieving pressure, and back pressure shall be determined in
accordance with FRS-DU-5057.
4. A copy of PRV summary sheets indicating operating set pressure, cold differential set
pressure, valve size and type, fluid specifications, and complete material specifications shall
be submitted to Purchaser for review.
5. Sizing of all valves for service conditions, including back pressure given, shall be checked by
Supplier. Sizing calculations for each valve shall be submitted to Purchaser.
6. Items defined in this specification shall comply with noise level requirements specified in
NCM-DU-5096 (onshore) and NCM-DU-2301 (offshore).
7. Deviations from this specification shall be subject to Purchaser review and written
acceptance.
8. Relief valves shall comply with FRS-SU-5032.
9. Rupture discs shall comply with FRS-SU-5033.
10. PRVs for ASME code-stamped boilers or ASME code-stamped pressure vessels shall be
marked with the following:
a. ASME code stamp.
b. Certified capacity.
c. Other data required by ASME code.
11. For pressure vessel protection, pressure relief devices (PRDs) provided without ASME
stamp shall be subject to Purchaser’s written authorization.
12. PRVs protecting pipeline shall comply with the applicable ASME piping code: B31.1,
B31.3, B31.4, or B31.8.
Note: For materials requirements, refer to the section in FRS-DU-5032 entitled “Materials for
Pressure Relief Valves.”
5.0 Determination of Cold Differential Test Pressure

5.1 General
1. Cold differential test pressure shall be such that the PRV meets the constraints of this
specification and FRS-DU-5057.
2. Cold differential test pressure shall achieve the following:
a. Not exceed maximum allowable accumulated pressure of PRV being tested.
b. Provide a suitable margin to exist between PRVs’ set pressure and operating pressure
(to minimize unnecessary operation and/or leakage of relief device).
Note: Refer to FRS-DU-5057 for additional information.

3. Constraints shall be met throughout minimum to maximum range of variable superimposed
back pressure.
Integrity Critical
5.2 Formula
To calculate cold differential test pressure (psig), the back pressure correction (psi) shall be
subtracted from the set pressure (psig), and then the result shall be multiplied by the temperature
correction factor.
5.3 Back Pressure Correction

1. Back pressure corrections referenced in this section shall only be used to determine cold
differential test pressure. They shall not be used to determine relief valve capacity.
2. Conventional PRVs with closed disposal system discharges shall have back pressure
correction equal to the minimum superimposed back pressure.
3. Conventional pressure relief valves with atmospheric discharges shall have back pressure
correction of 0 psi.
4. Balanced PRV with closed disposal system discharges shall have back pressure correction of
0 psi.
5. For the purpose of this specification, closed disposal system minimum superimposed back
pressures between +1 and –1 psig shall be considered to be 0 psig in determining cold
differential test pressure.
5.4 Temperature Correction
Note: PRVs, whether they will experience high or low temperatures in service or not, are
usually adjusted and tested at atmospheric temperature. An increase in temperature
causes a reduction of valve set pressure. This reduction is due to thermal expansion of
valve body and bonnet and to higher spring temperature, both of which reduce spring
loading.
An adjustment shall be made in cold differential test pressure to compensate for the effect of
higher PRV service temperatures. This adjustment may be important in reducing chronic PRV
leakage. As an example, typical correction factors are shown in Table 1.
Note: Service temperature correction for each particular type of PRV design and spring
material is listed in manufacturer’s bulletin.
Table 1: Sample Factors for Temperature Corrections

Service Temperature (°F) Correction Factor
–100 to 200 None
201 to 400 1.02
401 to 900 1.03
901 to 1100 1.04
1101 to 1400 1.05
Note:
This table is to be used as an example only; see manufacturer’s bulletin for actual values.
Integrity Critical
6.0 Pressure Relief Valve Capacity Formulas

6.1 Pressure Relief Valve Nozzle Effective Orifice Areas (Typical)
Note: Table 2 shows the effective orifice areas of standard API PRVs.
Table 2: Typical Pressure Relief Valve Nozzle Effective Orifice Areas

Nozzle Orifice Effective Orifice Area (2)
(1) (1) Normal Size Designations
Letter Sq. Inches
D 0.110 1D2, 1-1/2D2 or 1-1/2D3
E 0.196 1E2, 1-1/2E2 or 1-1/2E3
F 0.307 1-1/2F2 or 1-1/2F3
G 0.503 1-1/2G3or 2G3
H 0.785 1-1/2H3 or 2H3
J 1.287 2J3 or 3J4
K 1.838 3K4 or 3K6
L 2.853 3L4 or 4L6
M 3.600 4M6
N 4.340 4N6
P 6.380 4P6
Q 11.050 6Q8
R 16.000 6R8 or 6R10
T 26.000 8T10
Notes:
(1) The first two columns of this table are reproduced courtesy of American Petroleum Institute.
(2) Manufacturer’s standard designations. First number is nominal inlet size. Last number is
nominal outlet size.
1. For specific ASME flange class, manufacturer’s catalog or API 526 shall be consulted for
actual size available.
Note: The calculations of PRV area are based on the use of an API effective discharge
coefficient to calculate an API effective orifice area. These procedures allow the
direct selection of a standard valve orifice size designated “D” to “T” in API 526.
Section VIII of BPVC requires the use of a 0.9 de-rating factor for certifying the
discharge coefficient of PRVs protecting equipment designed to this code. For PRVs
specified to protect Section VIII of BPVC equipment, the manufacturer will quote a
combination of orifice area and discharge coefficient which represent the de-rated
performance of the PRV. When using manufacturers’ data to estimate “actual”
capacity (e.g., pop-open flow for vapor service) of the PRV, it is this de-rated data
that should always be used.
Integrity Critical
2. For an existing or proposed valve, the manufacturer’s ASME certified coefficient may be
used in the PRV sizing equations presented in the sections below. In this case, it shall be
confirmed that the discharge coefficient and the orifice area used are consistent.
Note: Manufacturers sometimes quote ASME certified discharge coefficient based on

actual orifice area rather than API effective area.
6.2 Sizing of Pressure Relief Valves

1. Pressure relief valves shall be sized in accordance with latest edition of API 520. For new
valves, sizing shall be confirmed by valve manufacturer.
2. The PRV manufacturer shall be aware of all potential relief fluids that could influence the
PRV trim selection.
3. The sizing case for each shall be included on the specification if a PRV has cases with more
than one of the following:
a. Gas flow.
b. Liquid flow.
c. Two phase/flashing liquid flow.
6.3 Pressure Relief Valve Liquid Formula

1. PRVs subject to liquid relief shall be sized in accordance with API 520 Part I.
2. Temperature relief valves designed for liquid thermal expansion shall comply with
Section 6.8.
3. Valves that are ASME code stamped and have trim fully open at 10 percent overpressure in
liquid service shall be sized with the following formula:
𝐺𝑃𝑀 𝐺
𝐴= √
38 (𝐾𝐷 )(𝐾𝑊 )(𝐾𝐶 )(𝐾𝑉 ) (𝑃𝑅 − 𝑃𝐵 )
Equation 1
Where:
A = API effective discharge area, in square inches.
GPM = Flow rate at flowing temperature and selected overpressure; in U.S. gallons per
minute.
KD = Coefficient of discharge, to calculate the API effective area; use a value of 0.65.
KW = Capacity correction factor due to back pressure. If back pressure is atmospheric,
factor can be disregarded, or KW = 1.00. For conventional valves with back
pressure that require no special correction, KW = 1.00. Balanced bellows valves
with back pressure shall require correction factor as determined from API 520
Part I, Figure 31, or manufacturer. For pilot valves, confirm with the
manufacturer if any back pressure correction is required.
Integrity Critical
KC = Combination correction factor for installations with rupture disk upstream of

PRV. This value equals 1.0 if rupture disk is not installed and 0.9 if rupture disk
is installed.
KV = Capacity correction factor due to viscosity. This may not be significant, in which
case KV = 1.00. If a relief valve is sized for viscous liquid service, KV is obtained
from API 520 Part I, Figure 37 or Equation (30).
G = Specific gravity of liquid at flowing temperature referred to water = 1.00 at 60°F.
Note: Refer to API 520 Part I for formulas in SI units.
PR = Relieving pressure, in psig. This equals set pressure plus overpressure and shall
not exceed maximum allowable accumulated pressure.
PB = Total back pressure, in psig.
4. PRVs that do not require capacity certification (on non-ASME application or older-style
liquid trim PRVs that are built to be fully open at 25 percent overpressure) shall be sized in
accordance with the following formula:
𝐺𝑃𝑀 𝐺
𝐴= √
38 (𝐾𝐷 )(𝐾𝑊 )(𝐾𝐶 )(𝐾𝑉 )(𝐾𝑃 ) (1.25𝑃 − 𝑃𝐵 )
Equation 2
Where:
A = API effective discharge area; in square inches.
GPM = Flow rate at flowing temperature and selected overpressure; in U.S. gallons per
minute.
KD = Coefficient of discharge. To calculate the API effective area, use a conservative
value of 0.62.
KW = Capacity correction factor due to back pressure. If back pressure is atmospheric,
factor can be disregarded, or KW = 1.00. For conventional valves with back
pressure that require no special correction, KW = 1.00. Balanced bellows valves
with back pressure shall require correction factor as determined from API 520
Part I, Figure 31, or manufacturer. For pilot valves, confirm with the
manufacturer if any back pressure correction is required.
PRV. This value equals 1.0 if rupture disk is not installed and 0.9 if rupture disk
is installed.
KV = Capacity correction factor due to viscosity. For most applications, viscosity may
not be significant, in which case KV = 1.00. If a relief valve is sized for viscous
liquid service, KV is obtained from API 520 Part I, Figure 37 or Equation (30).
KP = Capacity correction factor due to overpressure. Many, if not most, relief valves
in liquid service on non-ASME stamped equipment are sized on basis of
25 percent overpressure. This factor for overpressure can be obtained from
API 520 Part I, Figure 38. If other than nozzle valve, manufacturer’s curve or
capacity tables shall be consulted for particular valve.
For 25% overpressure = 1.00.
Integrity Critical

G = Specific gravity of liquid at flowing temperature referred to water = 1.00 at 60°F.
P = Set pressure at which relief valve is to begin opening, in psig.
PB = Total back pressure, in psig.
6.4 Pressure Relief Valve Gas or Vapor Formula

1. PRVs subject to gas or vapor flow shall be sized for relief in accordance with API 520 Part I.
2. PRVs subject to gas or vapor flow shall be checked to determine if the flow is critical or
sub-critical to ensure the appropriate sizing equation is used.
3. The critical flow pressure ratio may be estimated using the following ideal gas relationship:
𝑃𝑐𝑓 2 (𝑘⁄(𝑘−1))
= ( )
𝑃𝑅 𝑘+1
Equation 3
Where:
Pcf = Critical flow nozzle pressure, in psia.
PR = Upstream relieving pressure, in psia.
k = Ratio of ideal gas specific heats at relieving temperature.
4. When the ratio of back pressure to inlet pressure is greater than the critical flow pressure ratio
Pcf / PR, the flow through the PRV is subcritical.
5. Gas or vapor relief valves in critical flow conditions shall be sized in accordance with the
following formula:
𝑊 𝑇𝑍
𝐴= √
𝐶(𝐾𝐷 )(𝑃𝑅 )(𝐾𝐵 )(𝐾𝐶 ) 𝑀
Equation 4
Where:
A = API effective discharge area of valve, in square inches.
W = Flow through valve, in lb/hr.
C = Coefficient determined by ratio of ideal gas specific heats at inlet relieving
temperature. This can be obtained from API 520 Part I, Figure 32 or Table 8.
If specific heat ratio cannot be determined, it is suggested to let C = 315
(which corresponds to a specific heat ratio coefficient of 1.0).
KD = Coefficient of discharge. A value of 0.975 shall be used when calculating the
API effective area.
Integrity Critical
PR = Relieving pressure in psia. This equals set pressure plus overpressure plus
atmospheric pressure. Largest value of PR would be maximum allowable
accumulated pressure given in psia.
KB = Capacity correction factor due to back pressure. This can be obtained from
API 520 Part I.
For balanced bellows valves, KB is 1.0 when the back pressure is less than
30 percent of set pressure. When back pressure is between 30 percent and
50 percent of set pressure, KB should be obtained from the valve manufacturer
but an approximate value may be found in API 520 Part I Figure 30. When back
pressure is above 50 percent, KB shall be obtained from the manufacturer. For set
pressures lower than 50 psig, the valve manufacturer shall always be consulted
for the proper value of correction factor KB.
For conventional valves in critical flow, KB is 1.0.
For pilot valves, confirm with the manufacturer if any back pressure correction
is required.
PRV. Value of 1.0 shall be used if no rupture disk is installed. Value of 0.9 shall
be used if rupture disk is installed in combination with PRV. If available,
Supplier data shall be used.
T = Absolute temperature of inlet vapor, in °F + 460.
Z = Compressibility factor for deviation of actual gas from a perfect gas, a ratio
evaluated at inlet conditions. For calculation where coefficient C is derived
using the ideal gas ratio of specific heats, a value of Z less than 0.8 or greater
than 1.1 shall not be used.
M = Molecular weight of gas or vapor.
6. Conventional or pilot PRVs subject to gas and vapor in subcritical flow conditions shall be
sized in accordance with the following formula:
𝑊 𝑇𝑍
𝐴= √
735(𝐹2 )(𝐾𝐷 )(𝐾𝐶 ) 𝑀𝑃𝑅 (𝑃𝑅 − 𝑃𝐵 )
Equation 5
Where:
A = API effective discharge area of valve, in square inches.
W = Flow through valve, in lb/hr.
F2 = Coefficient of subcritical flow.
𝑘 1 − 𝑟 (𝑘−1)⁄𝑘
𝐹2 = √( ) (𝑟)2⁄𝑘 [ ]
𝑘−1 1−𝑟
Equation 6
Integrity Critical
k = Ratio of ideal gas-specific heats evaluated at inlet temperature.

r = Ratio of backpressure to upstream relieving pressure PB/PR.
API effective area.
pressure relief valve. KC = 1.0 if no rupture disk is installed and 0.9 if rupture
disk is installed.
T = Absolute temperature of inlet vapor, in °F + 460.
Z = Compressibility factor for deviation of actual gas from a perfect gas, a ratio
evaluated at inlet conditions. For calculation where coefficient C is derived
using the ideal gas ratio of specific heats, a value of Z less than 0.8 or greater
than 1.1 shall not be used.
M = Molecular weight of gas or vapor.
PR = Relieving pressure in psia. This equals set pressure plus overpressure plus
atmospheric pressure. Largest value of PR would be maximum allowable
accumulated pressure given in psia.
PB = Total back pressure, in psia.
7. An alternative sizing method for gas or vapor relief valves is the derivation of the coefficient
C using the isentropic coefficient together with the real compressibility in the equations
presented above.
Note: This method is discussed further in API 520 Part I Annex B. A thorough
understanding of this method is required before implementation.
6.5 Pressure Relief Valve Steam Formula

1. Valve shall be sized for steam relief in accordance with API 520 Part I.
2. The following formula shall apply for critical flow steam relief valves where the inlet
temperature is below 1200°F. For temperatures above 1200°F use Equation 4.
𝑊
𝐴=
51.5(𝑃𝑅 )(𝐾𝐷 )(𝐾𝐵 )(𝐾𝐶 )(𝐾𝑁 )(𝐾𝑆𝐻 )
Equation 7
Where:
A = API effective discharge area, in square inches.
W = Flow rate, in lb/hr.
PR = Relieving pressure, in psia. This equals set pressure plus overpressure plus
atmospheric pressure. Section I of BPVC applications are permitted only
6 percent accumulation. Other applications may need to comply with
Section VIII of BPVC, wherein 10 percent accumulation is permitted.
Integrity Critical

API effective area.
KB = Capacity correction factor due to back pressure. (1) For balanced bellows valves
KB is 1.0 when the back pressure is less than 30 percent of set pressure. When
back pressure is between 30 percent and 50 percent of set pressure, KB should be
obtained from the valve manufacturer, but an approximate value may be found
in API 520 Part I, Figure 30. When back pressure is above 50 percent, KB shall
be obtained from the manufacturer. For set pressures lower than 50psig, the
valve manufacturer shall always be consulted for the proper value of correction
factor KB. (2) For conventional valves in critical flow, KB is 1.0.
pressure relief valve. KC = 1.0 if no rupture disk is installed and 0.9 if rupture
disk is installed.
KN = Correction factor for Napier equation. KN = 1 if PR ≤ 1500 psia. If PR is greater
than 1500 psia but less than 3200 psia, the following equation shall be used:
0.1906𝑃𝑅 − 1000
𝐾𝑁 =
0.2292𝑃𝑅 − 1061
Equation 8
KSH = Correction factor due to amount of superheat in steam. This can be obtained
from manufacturers’ tables and/or API 520 Part I, Table 9. For saturated steam at
any pressure factor KSH = 1.0.
6.6 Pressure Relief Valve Fire Expansion Gas Formula

1. Valves for gas expansion due to external fire shall be sized in accordance with API 521.
2. The following calculation method shall be used only as a last resort. Purchaser shall be
consulted for alternate calculation methods and/or equipment selection, prior to using the
following formula:
𝐹𝑆
𝐴=
(𝑃𝑅 )0.5
Equation 9
Where:
A = Safety valve API effective orifice area, in square inches.
F = Safety valve factor. Recommended minimum value is F = 0.01. If actual value is
unknown, F = 0.045 shall be used.
S = Surface of vessel exposed to fire, square feet.
PR = Relieving pressure, psia.
0.1406(𝐷𝑇)1.25
𝐹=
𝐶𝐾𝐷 (𝑇1 )0.6506
Equation 10
Integrity Critical
Where:
F = Safety valve factor.
DT = TW − T1
C = Coefficient determined by the ideal gas-specific heat ratios at inlet temperature.
This can be obtained from API 520 Part I, Figure 32 or Table 8. If specific heat
ratio cannot be determined, it is suggested that C = 315 for hydrocarbons and C =
356 for diatomic gases (this corresponds to specific heat ratios of 1.0 and 1.4,
respectively).
API effective area.
TW = Temperature of vessel wall °R. This is obtained from API 521, Figure 1 for
10 minute fire exposure. Figure 2 (or equivalent data) should be used to confirm
that the additional time to vessel failure at relieving conditions is greater than
one minute.
T1 = Temperature of gas at relieving pressure, °R. This T1 corresponds to relieving
pressure obtained on basis of constant volume pressure increase.
(𝑃𝑅 )(𝑇𝑁 )
𝑇1 =
𝑃𝑁
Equation 11
Where:
T1 = Temperature of gas at relieving pressure, °R.
PR = Relieving pressure, psia.
TN = Initial or normal operating temperature, °R.
PN = Initial or normal operating pressure, psia.
6.7 Rupture Disk Sizing

1. Rupture disks shall be sized in accordance with API 520 Part I, Section 5.11.
2. When a rupture disk is installed at the inlet of a PRV, the overall coefficient of discharge
shall be in accordance with API 520 Part I, Section 5.11.2.
6.8 Temperature Relief Device Liquid Formula
Note: Temperature relief device designs generally correspond to spring-loaded relief valves.
1. Capacities shall be obtained from appropriate formulas or manufacturer’s tables.
2. To protect for thermal relief on water side of heat exchangers, relief valve size shall be
nominal pipe size (NPS) 3/4 as a minimum.
3. If expansion relief is required around check valves, block valves, or pumps, sizes NPS 3/4
and larger shall be acceptable. Provided the line material specification permits, screwed
connections are acceptable for small sizes.
Integrity Critical
6.9 Vacuum Safety Valve Gas Formula
6.9.1 General
Section VIII, Division 1 and Division 2 of BPVC does not provide safety valve guidance (set
pressure, accumulation, and capacity calculation) for vessels in vacuum service.
6.9.2 Vacuum Breaker System

1. If necessary, vacuum breaker system shall be installed to protect vessels against excessive
external pressure.
2. System shall consist of instrument control loop that actuates a single seated, quick opening,
control valve through which a high pressure source of inert gas or emergency air enters
vessel that requires vacuum relief.
3. Control valve shall normally be held closed by instrument air, with an automatic nitrogen or
emergency air backup supply to keep valve closed in case of air failure.
4. System shall be installed in accordance with GB-J1442.
6.9.3 Vacuum Safety Valve

For rare situations that require a vacuum safety valve, valve capacity shall be obtained from
specific manufacturer’s curves, formulas, or tables.
Note: Refer to FRS-DU-5057 for additional information.
6.10 Liquid-Vapor Mixture

1. Total orifice area required for pressure relief of liquid-vapor mixture shall be determined by
using the Direct Integration of the Isentropic Nozzle Flow methodology detailed in API 520,
Part I, Annex C. The following is the preferred form of the mass flux equation:
𝑃
((−9266.1) ∫𝑃 𝑣𝑑𝑃)
2 1
𝐺𝑛 = [ ]
𝑣𝑡2
Equation 12
Where:
Gn = Nozzle mass-flux in lb/s-ft2.
v = Specific volume of the fluid in ft3/lb.
P = Pressure in psia.
Subscript 1 represents conditions at the relief valve inlet.
Subscript t represents conditions at the nozzle throat. The pressure step size used
for the numerical integration should be small enough to accurately calculate the
mass-flux and shall not be larger than the greater of (1) 5 percent of absolute
inlet pressure or (2) 10 psi. Typically, step sizes of 2 psi are required to
accurately determine the maximum mass flux required for sizing the PRD.
Integrity Critical
a. A thorough understanding of this method is required before implementation.

b. The maximum mass flux calculated shall be included on the data sheet supplied to the
PRD manufacturer.
2. The calculation shall be required for relief of the following:
a. Two phase streams.
b. Liquid streams that flash in the PRD.
Note: The mass flux equation may be used for all homogenous fluid regimes. As such, it is a
generic calculation technique that is a suitable alternative sizing method for all
common sizing equations, whether gas, vapor, supercritical, liquid, or two-phase.
3. For PRD’s relieving saturated water and protecting equipment of Section VIII of BPVC, the
mass-flux shall be obtained from Section VIII of BPVC, Appendix 11.
7.0 Selection of Pressure Relief Device

PRD (conventional PRV, balanced bellows PRV, pilot-operated PRV, or rupture disk) shall be
selected in accordance with FRS-DU- 5057.
8.0 Selection of Valve Construction

8.1 Open Spring Type Valves
1. Open spring-type valves shall only be permitted in the following:
a. Steam service, such as boilers and waste heat boiler, if required by
Section I of BPVC.
b. Steam service, such as turbine cases, located inside shelters or buildings.
2. Open spring-type pressure valves located outdoors on an operating unit shall have a metal
hood over safety valve spring to prevent water seepage into valve interior or accumulation of
foreign material such as catalyst dust.
3. Drawings of hood shall be submitted by manufacturer to Purchaser for review and
acceptance, since spring covers shown in manufacturers’ catalogs are not typically
considered satisfactory.
8.2 Closed Spring Type Valve (Preferred Type)

1. Closed spring type valves shall be required in the following service:
a. Steam service, such as turbine cases exposed to weather, if Section I of BPVC does not
apply.
b. Hydrocarbon service.
c. Chemical service.
d. Air service.
2. Closed bonnet of pressure valves shall have vent connections. Vent connections shall be
NPS 1/2 inch, as a minimum.
Integrity Critical
3. Conventional PRV bonnet vent shall be closed by installing a threaded plug in vent
connection.
4. Balance bellows PRV bonnet vent shall be vented to closed flange system or to atmosphere.
a. If vented to atmosphere, vent shall have a bug-proof screen.
b. If the valve is in toxic, flammable, or sour service, the vent shall be piped to a safe
location.
8.3 Pressure Relief Valves with Lifting Levers

1. Lifting levers shall be provided only if required by ASME Code.
2. Applications for which lifting levers are required in accordance with ASME Code shall
include the following:
a. Steam safety valves to which Section I of BPVC applies.
b. PRVs on air, steam, and water over 140°F (60°C) service, to which Section VIII of
BPVC applies.
c. Safety valves for air receivers.
3. Lifting levers, if required, shall be standard type.
4. Safety valves with closed bonnets, where no leakage of vapor at lifting lever can be tolerated,
shall have packed lifting levers.
8.4 Temperature Relief Devices

The use of Swagelok and other similar non-code valves shall be discouraged. Use of such valves
shall be subject to Purchaser review and written acceptance.
8.4.1 Water Service

If high pressure hydrogen or other hazardous materials would discharge to atmosphere in event
of a tube leak in a condenser or cooler, temperature relief valves shall be top guided.
8.4.2 Hydrocarbon or Chemical Service

1. Valves that discharge to drain or sewer shall be top guided standard relief valves with size
and type connection as required by the line material specification.
2. Poppet-type spring-loaded check valves, equal to Parker1Series 440 or 450 high pressure
check valves, shall be acceptable alternates if expansion relief is required around check
valves, block valves, or pumps for services limited to maximum pressure of ANSI Class 300
flange ratings and maximum temperature of 500°F (260°C).
8.5 Pressure Relief Valve Caps

Closed bonnet PRVs shall have threaded or bolted caps over spring adjusting screw.
1
Parker is a registered trademark of Parker Hannifin Corp
Integrity Critical
8.6 Test Gags

Unless accepted in writing by Purchaser, test gags shall not be included.
9.0 Ratings for Pressure Relief Valves

9.1 Inlet Flange and Inlet Body Rating
1. Rating of PRV inlet body (upstream of PRV seat) shall be the same as PRV inlet flange
rating, if possible.
2. If large relief devices are required and inlet body rating is not the same as inlet flange rating,
an inlet body rating suitable for relieving conditions shall be used.
3. PRV inlet flange and inlet body ratings shall be suitable for design and relief conditions of
line, vessel, or equipment upon which they are installed.
4. Inlet flange and inlet body of steel PRVs shall be as a minimum ANSI Class 150.
5. Minimum pressure rating of valves with screwed connections shall match the rating
corresponding to ANSI 600. Pipe threads shall comply with ASME B1.20.1.
9.2 Outlet Flange and Outlet Body Ratings

1. Rating class for the outlet body and outlet flange of the PRV shall be equivalent to the flange
rating of the line into which the valve discharges.
2. Outlet flange rating specified shall be checked against manufacturer’s pressure temperature
limitations on PRV outlet for orifice area required.
3. Minimum outlet flange and body ratings shall be ANSI Class 150.
10.0 Connections for Pressure Relief Valves

1. PRVs with threaded inlet and outlet connections may be used, provided calculated relieving
capacity can be met, as follows:
a. On vessels in services and sizes in which threaded nozzle connections are permitted by
PVM-SU-4750.
b. On piping services and sizes in which threaded valves and fittings are permitted by
PIM-DU-5138 (onshore) or PIM-SU-6198 (offshore) and PIM-SU-5112 (onshore) or
PIM-SU-5300 (offshore) or PPL-SU-6185, as applicable.
2. PRVs with flanged inlet and outlet connections shall be used on vessels and piping for all
sizes and services other than those for which threaded connections are permissible.
a. Flange facing shall comply with PIM-SU-5112 (onshore) or PIM-SU-5300 (offshore) or
PPL-SU-6185, as applicable.
b. Flanged connections shall comply with ASME B16.5.
3. PRV inlet or outlet connections shall not be NPS 3/8, 1-1/4, 2-1/2, 3-1/2, or 5.
Integrity Critical
11.0 Pressure Relief Valve Handling Before Installation and Test

1. Inlet and outlet flanges of PRVs shall be protected and openings shall be covered to prevent
entrance of foreign matter or moisture.
2. Valves shall be transported and stored vertically to keep out all foreign materials in
accordance with API 520.
3. Valves shall be treated in the following manner:
a. Valves shall be handled carefully to avoid damage.
b. Valves shall not be subjected to heavy shocks.
c. Valves shall be stored in an orderly manner.
4. Caution shall be taken before testing or installing PRVs to ensure that any extraneous
material inside body or nozzle is completely removed.
5. Valve set pressures shall be checked before valve is installed.
6. PRV connections shall be cleaned before installing valve.
7. PRV inlet or block valve ahead of relief device shall be blinded off while pressure testing
piping systems, equipment, or vessels.
8. Additional guidance on the proper handling and shipment preparation of PRVs can be found
in API 576 and FRS-SU-5032.
12.0 Inspection and Testing

Note: Refer to SID-SU-5106 for information related to PRV accessibility for inspection,
testing, and maintenance.
Inspection and testing shall comply with API 576 and Purchaser’s general instructions.

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Integrity Critical

Operating Environment: LNG, Onshore, Pipelines, Topsides

Rev. Date Description Author Technology Leader

Author notations regarding this revision

Safety Critical Changes (if applicable) are noted below

2.1 Owner Documents

2.2 Industry Codes and Standards

American Society of Mechanical Engineers (ASME)

2.3 Conflict Resolution

5.0 Determination of Cold Differential Test Pressure

Note: Refer to FRS-DU-5057 for additional information.

5.3 Back Pressure Correction

5.4 Temperature Correction

Table 1: Sample Factors for Temperature Corrections

6.0 Pressure Relief Valve Capacity Formulas

Table 2: Typical Pressure Relief Valve Nozzle Effective Orifice Areas

Note: Manufacturers sometimes quote ASME certified discharge coefficient based on

6.2 Sizing of Pressure Relief Valves

6.3 Pressure Relief Valve Liquid Formula

KC = Combination correction factor for installations with rupture disk upstream of

For 10% overpressure = 0.60.

6.4 Pressure Relief Valve Gas or Vapor Formula

k = Ratio of ideal gas-specific heats evaluated at inlet temperature.

6.5 Pressure Relief Valve Steam Formula

Note: Refer to API 520 Part I for formulas in SI units.

KD = Coefficient of discharge. A value of 0.975 shall be used when calculating the

6.6 Pressure Relief Valve Fire Expansion Gas Formula

6.7 Rupture Disk Sizing

6.8 Temperature Relief Device Liquid Formula

6.9 Vacuum Safety Valve Gas Formula

6.9.2 Vacuum Breaker System

6.9.3 Vacuum Safety Valve

Note: Refer to FRS-DU-5057 for additional information.

6.10 Liquid-Vapor Mixture

a. A thorough understanding of this method is required before implementation.

7.0 Selection of Pressure Relief Device

8.0 Selection of Valve Construction

8.2 Closed Spring Type Valve (Preferred Type)

8.3 Pressure Relief Valves with Lifting Levers

8.4 Temperature Relief Devices

8.4.1 Water Service

8.4.2 Hydrocarbon or Chemical Service

8.5 Pressure Relief Valve Caps

8.6 Test Gags

9.0 Ratings for Pressure Relief Valves

9.2 Outlet Flange and Outlet Body Ratings

10.0 Connections for Pressure Relief Valves

11.0 Pressure Relief Valve Handling Before Installation and Test

12.0 Inspection and Testing

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