Design of Safety Valves

Design standard: ASME VIII / API 520

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01
Objective
Objective Objective of the presentation
Design of Safety Valves – ASME VIII / API 520
Codes and standards

Design
The objective of the presentation is to show the
design of safety valves in compliance with ASME VIII / API 520
Inlet pressure loss

Back pressure
 Standard specifications for the design of safety valves
 Formulas for the design of safety valves
 Factors Influencing the stability
in operation

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 2 / 26
Objective National and international standards
for the calculation specifications of safety valves
Codes andstandards
Codes and standards

Design
Calculation levels for safety valves

Inlet pressure loss

AD 2000 –
Back pressure ISO 4126-1 API 520 ASME VIII
Merkblatt A2

Calculation levels of inlet pressure loss and back pressure

AD 2000 –
ISO 4126-9
Merkblatt A2
Chapter 7 + 9
Chapter 6

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 3 / 26
Objective What impact does this have on the user?
Codes andstandards
Codes and standards

Design  ISO 4126-1 must be applied in the European region

for size determination of safety valves
Inlet pressure loss Size
determination  TRBS is not yet available for specification of the safety
Back pressure valve

 There is no effect on the capacity and function up to a

pressure loss of 3%
Inlet  Pressure losses >3% must be taken into account in the
pressure loss capacity calculation. The operation may be affected.

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 4 / 26
Objective What impact does this have on the user?
Codes andstandards
Codes and standards

Design  Effect on the capacity taking the pao/po curve into

consideration
Inlet pressure loss
Back pressure  This ratio is observed for absolute pressures.
Back pressure

 Capacity minimisation must also be

taken into consideration for low set
pressures.
 p = 03 bar g (set pressure)

Correction factor for back pressure Kb

rated coefficient of discharge Kdr /αw

 pao = 1.013 bar a (ambient pressure)

 po = (0.3 barg + 0.1 barg + 1.013 bar
a) (pressure in the system to be
secured)
 pao / p0 = 1.013 bar a / (0.3 barg +
0.1 bar g + 1.013 bar a) = 0.72
 >> Kb = 0.81
Ratio back pressure / set pressure pao/ po

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 5 / 26
Objective What parameters are important for the
Codes and standards
design and how are they related?
Design
Design High Performance
Inlet pressure loss
 Coefficient of discharge αw:
the rated coefficient of discharge from
Back pressure component testing (often also referred
to as αd)
 Orifice area A0:
actual orifice area
 Substance information
medium-dependent substance data
 Operating data:
state parameters like pressure and
temperature

d0

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 6 / 26
Objective Coefficient of discharge and rated coefficient
Codes and standards
of discharge
Design
Design
German Code American Code
Inlet pressure loss

Back pressure
VdTÜV Merkblatt ASME-Code Sec.VIII,
SV 100, § 3.3.1 Div. 1, UG-131 (e)

Coefficient of qmeasured qmeasured

discharge = Kd =
qtheoretical qtheoretical

Rated coefficient w = 0.9 x  K = 0.9 x Kd

of discharge

qmeasured = actual measured qm

qtheoretical = calculated qm

 or Kd = coefficient of discharge
d or K = rated coefficient of discharge
0.9 = correction factor

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 7 / 26
Objective Differentiation of media
Codes and standards

Design
Design Subcritical
Steams/
Inlet pressure loss gasses
Supercritical
Back pressure

Low viscosity
Liquids
High viscosity
Medium
Saturated steam
Steam

Superheated steam

Two- Liquid phase

phase
flow Gaseous phase

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 8 / 26
Objective Required data on materials
Codes and standards

Design
Design Gasses/ Saturated Superheated
Liquids
steams steam steam
Inlet pressure loss
Set pressure pset psig x x x x

Back pressure Back pressure pa psig x x x

x

Temperature T [°C] x x

Mass flow* qm [kg/h] x x x x

Volumetric flow rate* qv [m³/h] x x x x

(while operating)
Volumetric flow rate* qv [Nm³/h] x

Overpressure c [%] x x x x

Real gas factor Z [-] x

Molar mass M [kg/kmol] x

Isentropic exponent k [-] x

Density  [kg/m³] x

Kinematic viscosity  [m2/s] x

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 9 / 26
Objective Design for gasses/steam as per ASME VIII
Codes and standards

Design
Design

W Z•T
•
Inlet pressure loss
Code A=
C•K•P M
Back pressure

Z•T
• Medium data – components
M C

W
Process data – components
P

1
Flow coefficient – components
K

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 10 / 26
Objective Design for gasses/steam as per API 520 vs.
Codes and standards
ASME VIII
Design
Design

W T•Z
Inlet pressure loss
API A= •
C • Kd • P1 • Kb • Kc M
Back pressure

W T•Z
ASME A= •
C • K • P1 M

ASME/API AASME x K ≥ AAPI x Kd

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 11 / 26
Objective Design for gasses/steam as per API 520 vs.
Codes and standards
ASME VIII
Design
Design

W T•Z
Inlet pressure loss
ASME VIII A= •
C • K • P1 M
Back pressure

ASME VIII

 Actual orifice area A [inch²]

 Mass flow W [lb/h]
 Functional isentropic exponent C [-]
 Rated coefficient of discharge K
 Relieving pressure P1 [psi g]
 Temperature T [°F]
 Molar mass M [kg/kmol]
 Real gas factor Z [-]

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 12 / 26
Objective Orifices as per API RP 526 and ASME VIII
(Steams and Gasses)
Codes and standards

(Type 526, orifice and discharge coefficient K individual for LESER types)
Design
Design

API Effective API coefficient of ASME Actual ASME coefficient of

Designation
Inlet pressure loss Orifice Area [sq in] discharge Kd Orifice Area [sq in] discharge K

Back pressure
D 0.110 0.239
E 0.196 0.239
F 0.307 0.394
G 0.503 0.616
H 0.785 0.975
J 1.287 1.58
K 1.838 2.25
0.975 x 0.801
L 2.853 3.48
M 3.60 4.43
N 4.34 5.30
P 6.38 7.79
Q 11.05 13.55
R 16.00 19.48
T 26.00 31.75

Example for E-Orifice:

ASME VIII API 520
0.239 in² x 0.801 ≥ 0.196 in² x 0.975
0.194 in² ≥ 0.1911 in²

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 13 / 26
Objective Design for steam as per API 520 vs. ASME VIII
Codes and standards

Design
Design

W
Inlet pressure loss
API A=
51.5 • P1 • Kd • Kb • Kc• KN • KSH
Back pressure

W
ASME A=
51.5 • K • p0 • KN • KSH

ASME/API AASME x K ≥ AAPI x Kd

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 14 / 26
Objective Design for saturated steam as per ASME VIII
Codes and standards

Design
Design
W
Inlet pressure loss
ASME VIII
A=
51.5 • K • p0 • KN • KSH
Back pressure

ASME VIII

 Actual orifice area A [in²]

 Pressure in pressure chamber p0 [bar abs]
 Mass flow W [lb/h]

 Rated coefficient of discharge K

 Napier correction factor KN
 Superheated steam correction KSH
factor

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 15 / 26
Objective Orifices as per API RP 526 and ASME VIII
(Saturated Steam)
Codes and standards

(Type 526, orifice and discharge coefficient K individual for LESER types)
Design
Design

API Effective API coefficient of ASME Actual ASME coefficient of

Designation
Inlet pressure loss Orifice Area [sq in] discharge Kd Orifice Area [sq in] discharge K

Back pressure
D 0.110 0.239
E 0.196 0.239
F 0.307 0.394
G 0.503 0.616
H 0.785 0.975
J 1.287 1.58
K 1.838 2.25
0.975 x 0.801
L 2.853 3.48
M 3.60 4.43
N 4.34 5.30
P 6.38 7.79
Q 11.05 13.55
R 16.00 19.48
T 26.00 31.75

Example for E-Orifice:

ASME VIII API 520
0.239 in² x 0.801 ≥ 0.196 in² x 0.975
0.194 in² ≥ 0.1911 in²

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 16 / 26
Objective API sizing vs. ASME VIII sizing
Codes and standards
(Liquids)

Design
Design

W G
Inlet pressure loss
API A= •
38 • Kd • KW • Kc • KV p1 – p2
Back pressure

W
ASME A=
2407 • K • (p0 – pa0 ) • w

ASME/API AASME x K ≥ AAPI x Kd

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 17 / 26
Objective Design equation for liquids as per API 520
Codes and standards

Design
Design

W G
Inlet pressure loss
API A= •
38 • Kd • KW • Kc • KV p1 – p2
Back pressure

API

 Actual orifice area A [in²]

 Pressure in pressure chamber p1 [psi a]
 Back pressure p2 [psi g]
 Mass flow Q [US gpm]
 Specific density G
 Rated coefficient of discharge Kd
 Correction factor for bellows Kw
 Correction factor for bursting disc Kc
 Correction factor for viscosity Kv

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 18 / 26
Objective Orifices as per API RP 526 and ASME VIII
(Liquids)
Codes and standards

(Type 526, orifice and discharge coefficient K individual for LESER types)
Design
Design

API Effective API coefficient of ASME Actual ASME coefficient of

Designation
Inlet pressure loss Orifice Area [sq in] discharge Kd Orifice Area [sq in] discharge K

Back pressure
D 0.110 0.239
E 0.196 0.239
F 0.307 0.394
G 0.503 0.616
H 0.785 0.975
J 1.287 1.58
K 1.838 2.25
0.65 x 0.579
L 2.853 3.48
M 3.60 4.43
N 4.34 5.30
P 6.38 7.79
Q 11.05 13.55
R 16.00 19.48
T 26.00 31.75

Example for E-Orifice:

ASME VIII API 520
0.239 in² x 0.579 ≥ 0.196 in² x 065
0.138 in² ≥ 0.127 in²

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 19 / 26
Objective Inlet pressure loss
Influencing factors
Codes and standards

Design
p2 = p1 p2 = p1 - p
Inlet pressureloss
Inlet pressure loss p = 0 p > 0

Back pressure
Valve is Valve is
closed open

p2 p2

p p

p1 p1

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 20 / 26
Objective Inlet pressure loss
Standards and bodes
Codes and standards

Design
 A maximum pressure loss of 3% between the vessel and the safety
valve is permissible for the most common international standards and
Inlet pressureloss
Inlet pressure loss
codes.
Back pressure  API 520 Part II (08.2003), 4.2.2
“When a pressure relief valve is installed an a line directly connected to
a vessel, the total non-recoverable pressure loss between the protected
equipment and the pressure relief valve should not exceed 3 percent
except as permitted in 4.2.3 for pilot-operated pressure relief valve.”

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 21 / 26
Objective Calculation
(Only calculated as per AD and ISO)
Codes and standards

Design p = (  l/d +  )  /2  w2

Inlet pressureloss
Inlet pressure loss
Flow Flow
Back pressure
resistance rate

 = Pipe friction coefficient (pipeline)

l/d = Length and diameter of a pipe
 = Friction coefficient (components)
 = Density
w = Speed

I d
p

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 22 / 26
Objective Inlet pressure loss
Codes and standards

Design
The following measures prevent malfunctions that are caused by an
inadmissible inlet pressure loss:
Inlet pressureloss
Inlet pressure loss

Back pressure  Reduction of the flow rate through

– increasing the pipe diameter
– reducing the mass flow through a smaller valve
– reducing the mass flow through a lift stopper
– reducing the mass flow through an O-ring-damper

 Reduction of the flow rate through

– shorter inlet pipeline
– low-resistance connection Incorrect Correct
to the vessel

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 23 / 26
Objective Inlet pressure loss
(Only calculated as per AD and ISO)
Codes and standards

Design
Reduction of the flow rate is more effective
than reduction of the flow resistance
Inlet pressureloss
Inlet pressure loss

Back pressure
Reduction (%) Reduction of pressure loss
110

100
90 p = (  l/d +  )  /2  w2
80

70
Reduction of flow resistance
60
50
40

30
20
Reduction of the flow rate (w)
10

0
10,0 20,0 30,0 40,0 50,0 60,0 70,0 80,0 90,0 100,0
Reduction of the pressure loss (%)

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 24 / 26
Objective Back pressure
Definition
Codes and standards

Design
Back pressure
Inlet pressure loss

Back pressure
Back pressure
Built-up External back
back pressure pressure

Constant Variable Back pressure

Exists
Exists only in the permanently in the
outlet while the outlet system The
safety valve external back
blows off. It is pressure is
dependent on the dependent on the
flow loss in the blow-off of the
discharge line. safety valve Back pressure = built-up back pressure –
external pressure

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 25 / 26
Objective Back pressure – stability
Setting
Codes and standards

Design
The following measures prevent malfunctions
resulting from the back pressure:
Inlet pressure loss
 Constant back pressure
Back pressure
Back pressure
– settings to differential set pressure (CDTP)
– use of stainless steel bellows
 Variable back pressure
– use of stainless steel bellows

Design of safety valves – ASME VIII / API 520 | LESER GmbH & Co. KG | 01.03.2011 | Rev. 01 26 / 26