Relief Valve Sizing for Pump Discharge

Jayanthi Vijay Sarathy, M.E, CEng, MIChemE, Chartered Chemical Engineer, IChemE, UK
Oversizing relief valves is not uncommon. In differential head is 52.5 m. The fluid is water
the case of pumping systems which is derated, operating at a density of 1,000 kg/m3. The
relief valves are installed on the pump back pressure acting on the RV discharge is 1
discharge. These are sized based on the barg.
maximum shut-off head developed by the
pump and if higher than the design pressure of
the piping and equipment.
During the design phase, the pump vendor
curves would not be available. Therefore, a
common practice is to choose a shut-off head
between 15% to 25% more from the rated Figure 1. Pump Schematic
point and the relief valve [RV] is sized for the
Therefore, estimating the maximum discharge
normal capacity of the pump. But sizing based
pressure of the pump,
on a shut-off margin can cause the RV and the
"#."×&'''×(.)&
associated piping to be oversized and lead to 𝑃! = 14 + & ' = 19.1 𝑏𝑎𝑟𝑎 (1)
&'!
higher procurement costs.
The shut-off pressure is estimated as,
However when the pump performance curves ".$%×(%$.%×"(((×).*")
𝑃! = 14 + & ' = 20.4 𝑏𝑎𝑟a (2)
are available from the vendor, it can so happen "(!

that the shut-off head margin would be lower Considering the case of blocked outlet, the RV
than the assumed shut-off head. Say a value of can be sized based on API 520/521 and the RV
25% is chosen during design phase, but the designation chosen from API 526 as,
pump vendor curves can indicate lower at &&.+)×, ./
around 15% to 20%. Instead with pump 𝐴* = &- ' × 010 2 (3)
" ×-# ×-$ ×-% & 10'

vendor curves, a lower head and lower flow

Where,
rate at which the RV discharges can help
Q = flow rate [lit/min]
reduce the RV size, which can help reduce
costs and avoid any valve chattering. Ar = Required effective discharge area [mm2]

Case Study Kd = Coefficient of Discharge [0.65]

To explain with a case study, a suction vessel Kw = Back pressure correction factor [1.0]
operates at a design pressure of 19.6 bara. The Kv = Correction factor due to viscosity [1.0]
liquid outlet is connected to a pump and its Kc = Combination correction factor for
associated piping at 150 class rating of 19.6 installations with rupture disc upstream of
bara design pressure at 380C. A relief valve is pressure relief device [1.0]
installed on the pump discharge with a set SG – Liquid specific gravity [-]
pressure of 19.6 bara.
P1 = Upstream relieving pressure [kPag] [Set
In the design stage where pump curves are not pressure + allowable over pressure]
available, a shut-off margin of 25% is assumed
P2 = back pressure [kPag]
to size the relief valve. The pump operates at a
rated flow of 31 m3/h at a maximum suction Acorr = Orifice area based on corrected
flange pressure of 14 bara. The required viscosity [Ar / Kv]
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 "/$
Substituting the values with the requisite unit 𝐴12,, = = 142 𝑚𝑚$ 𝑜𝑟 0.22 𝑖𝑛$ (10)
"
conversions, where 10% accumulation is
From API 526, the selected standard orifice
added to 19.6 bara, i.e., 2045 kPag,
size is ‘F’ with an effective discharge area of
"".-*×%"- "
𝐴, = &(..%×"×"×"' × 12$(/%0"((3 = 212 𝑚𝑚$ (4) 0.307 in2.

$"$
Comparing both results, it is seen that when
𝐴12,, = = 212 𝑚𝑚$ 𝑜𝑟 0.33 𝑖𝑛$ (5)
" the pump shut-off head margin is lower, the
From API 526, the selected standard orifice size of the relief valve also decreases.
size is ‘G’ with an effective discharge area of Therefore, once the pump curves are available
0.503 in2. from the vendor, it is important to revisit the
RV Sizing based on Pump Curves RV sizes and see, if they can be made smaller
along with the associated piping sizes. This
When the pump performance curves are
also adds to costs savings & avoids mechanical
available from the vendor as shown below, the
damage due to valve chattering.
RV size can be re-estimated.
References & Further Reading
1. “Sizing Selection and Installation of
Pressure Relieving Devices in Refineries”,
API Recommended Practice 520, 7th
Edition, January 2000, Part -1
2. “Pressure Relieving and Depressuring
Systems”, API Standard 521, 6th Edition, Jan
2014
3. “Control Valve Handbook”, Fisher’s
Handbook, 5th Edition
Figure 2. Pump Vendor Curves

The shut-off head margin [Ps] is estimated as,

3&.)
𝑃2 = &"#." − 1' × 100 = 17.87% (6)

Taking RV accumulation of 10%, the relieving

pressure of the RV [Pr] becomes,
𝑃* = 19.6 × 1.1 = 21.56 𝑏𝑎𝑟𝑎 (7)
The corrected differential head becomes,
(&(.31&5)×&'!
𝐻! = & &'''×(.)&
' = 57.1 𝑚 (8)

From the pump curves shown, the

corresponding flow rate for a differential head
of 57.1 m is 20.7 m3/h.
Performing a RV sizing for the blocked outlet
case with the new RV set pressure of 19.6 bara
and a flow rate of 20.7 m3/h for 1 barg back
pressure, the RV size becomes,
"".-*×3/% "
𝐴, = & ' × 12 3 = 142 𝑚𝑚$ (9)
(..%×"×"×" $(/%0"((

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