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HOW TO DESIGN THE DISCHARGE PIPING OF A STEAM SAFETY VALVE

Technical Report · October 2016

DOI: 10.13140/RG.2.2.31349.58085

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 GUIDE Nº 7a

HOW TO DESIGN THE DISCHARGE PIPING OF A STEAM SAFETY VALVE

Emilio Casado
POWER CONSULTING ENGINEER

October 2016. Revision 3

 CONTENT

1. INTRODUCTION

2. THE EXPANSION OF STEAM THROUGH THE VALVE AND THE

DISCHARGE PIPING. DESIGN CRITERIA

3. DISCHARGE OF THE SAFETY VALVE WITHOUT THE DISCHARGE

PIPING. FREE DISCHARGE OF THE VALVE

4. DISCHARGE OF THE SAFETY VALVE THROUGH A DIRECT CONNECTED

PIPING (VENT STACK)

5. DISCHARGE OF THE SAFETY VALVE THROUGH AN UNBRELLA PIPING

(VENT STACK)

6. CONCLUSIONS

7. REFERENCES

8. NOMENCLATURE
1. INTRODUCTION

The industrial and the power plants have steam flowing through pipes,
components and equipments and also have safety valves that usually
release the steam through a discharge piping to the atmosphere when
there are pressure accessions, in order to protect the integrity of the
systems.

The design and calculation of the valves and the discharge piping may be
done applying the References [3], [4], [5] or [6] that are very similar.

To simplify the design and optimize the size of the discharge piping, the
author exposes in this document an alternative method that is based on
the References [1] and [3]. It applies to steam that is dry and saturated or
reheated at the valve inlet and also to other gases with the relation
between the specific heat at constant pressure to the specific heat at the
constant volume closes to 1.3 as CO2, SO2, NH3, Cl2, CH4 and C2H4.

The method exposed in the Reference [3] is used by many engineers

because it has been a great improvement in the design of the discharge
piping, but it has some aspects that should be clarified, as are the
following:

- The Figure 2 of this Reference [3] shows that the pressure is

decreasing from the valve inlet to the end of the discharge piping,
but in the Example Calculations B and C, the pressure at the
discharge piping inlet is greater than at the elbow outlet.
- The Reference [3] doesn’t take into account the resistance
coefficient of the discharge piping to calculate the critical pressure
at the end of the piping.
- The resistance coefficient of the discharge piping doesn’t take into
account its inlet and outlet.

The new method developed in this guide, has taken into account these
points.
2. THE EXPANSION OF STEAM THROUGH THE VALVE AND THE
DISCHARGE PIPING. DESIGN CRITERIA

The method is based in the following design criteria.

 The expansion of the steam through the nozzle valve is isentropic. The
pressure at the nozzle throat, Po, is related with the pressure at the
valve inlet, P1, by this equation:

Po = P1[2/(1 + a)]a/(a – 1) (1)

The coefficient a, is the expansion coefficient, equal to the ratio of

the specific heat of the steam at constant pressure to the specific
steam at constant volume.
For saturated steam consider a = 1.13 and for reheated steam take
a = 1.3
The equation (1) will be:
For saturated steam: Po = 0.578P1 (1a)
For reheated steam: Po = 0.546P1 (1b)

 The global expansion of the steam through the valve (the nozzle
plus the outlet connection) and the discharge piping is an
intermediate expansion between isentropic and isenthalpic. The
relation between the valve inlet pressure P1 and its specific volume
ve1 with the pressure P and its specific volume ve in whichever point
downstream the nozzle valve, is given by the following equation:

P1ve1a = Pvea (2)

The value of a, is given in the graph of the Figure 2 for saturated

steam with DP = P1 – P.
For reheated steam take a = 1.17 for whichever pressure.
 NOTE: The Figure 2 has been obtained by the author from the
Steam Tables, calculating for different pressures the isentropic and
isenthalpic expansions and selecting the intermediate value.
The coefficient a obtained by the author for the isentropic
expansion is reflected in the Figure 2a. Note that it is less 1.13 for PS
equal or greater than 1000 psia. In any case if we use these values,
the difference with the results given by the equations (1a) and (8b)
is equal or less than 10 %.
For the reheated steam the value of a obtained by the author is
very close to the above value of 1.3.

 The pressure at the valve outlet, PA, is similar to the pressure at the
elbow outlet PB (see Figures 1a and 1b) because the pressure drop
in the elbow is negligible compared with the pressure drop in the
valve, so take PA = PB.
The values of PA and PB may be calculated with these equations:

Saturated steam: PA = PB = 0.682x10-3(Wo/d2) [P1ve1]0.5 (3a)

Reheated steam: PA = PB = 0.612x10-3(Wo/d2) [P1ve1]0.5 (3b)

Also we can use the following equation (4) for both types of steam:

PA = PB = Po (do/d)2 (4)

This equation has been obtained assuming that the equations (3a)
and (3b) are applicable to the nozzle of the valve, changing d by do.

 The size D and the length L of the discharge piping must be selected
in order to allow the valve discharge the same flow rate, Wo that
the valve discharges without the piping in a free discharge.
In order to achieve this, the back pressure created by the discharge
piping at its entrance (section B of the Figures 1a and 1b) must be
equal or less than PB.
 The relation between the flow rate of steam through the discharge
piping, the pressure drop and the piping characteristics is given by
this equation obtained from the Reference [1]:

W = 1891YD2[(PB – PF)/veBKD]0.5 (5)

Y is the expansion factor from the graph of the Figure 3 for DP/P
equal to (PB – PF)/PB and K = KD
KD is the resistance coefficient of the discharge piping calculated for
the direct connected type and the umbrella type respectively with
the following equations (6a) and (6b)

KD = [(D/d)2 – 1]2 + 0.022L/D1.207 + 1 (6a)

KD = 1 + 0.022L/D1.207 + 1 (6b)

The resistance coefficient of the discharge piping KD is composed by

3 parts. One part is the connection of the elbow to the discharge
piping, named as KBC that is [(D/d)2 – 1]2 for the Figure 1a and 1 for
the Figure 1b. Other part named as KCF is 0.022L/D1.207 that
corresponds to fL/D with the friction factor f approached in the
turbulent region of the Moody’s Diagram to the expression
0.022/D0.207. Finally the third part corresponds to the end of the
discharge piping with KF = 1.

 From the Critical Conditions Line of the Figure 3 it is possible to

deduce the graph of the Figure 4 that for pipes, relates the steam
inlet pressure P, the flow resistance coefficient K and the critical
pressure PCR at the end of the piping.
In this Figure for P = PB and K = KD we obtain PCR = PF and applying
the equation (5) we calculate the flow rate capacity W of the
discharge piping.
If W is equal or greater than Wo, the diameter D and the length L of
the discharge piping are valid and allow to the safety valve
discharge the required flow rate Wo.
Alternatively to the Figure 4 we may use the following approach
equations:

For K < 15 use PCR = (0.493/K0.312)P (7a)

For K equal or greater than 15 use PCR = [12.2/(52 + K)]P (7b)

 Figure 2: Intermediate expansion between isenthalpic and isentropic of the
saturated steam. Expansion coefficient a
1,1
Ps = 100 psia
Ps = 200 psia
Ps = 500 psia

1,05 Ps = 1000 psia

Ps = 1500 psia

1
Ps = 2000 psia

Ps = 2500 psia
Expansión 0,95
Coefficient
a

0,9

0,85

0,8
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1
DP/Ps
 Figure 2a: Isentropic expansion of the saturated steam
Expansion coefficient a
1,15
a = 1,12 para PS < 1000 psia

1,1
PS = 1000 psia

1,05 PS = 1500 psia

1
PS = 2000 psia
a

0,95 PS = 2500 psia

0,9

0,85

0,8
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1
DP/PS
 Figure 3: Expansion factor Y for saturated or reheated steam flow through piping

0,95

0,9

0,85

0,8

Y
0,75
K = 1000
15 20 40 100
0,7 8 10
6
4
3
0,65
2 CRITICAL CONDITIONS LINE
1,5
1,2
0,6 0,596 0,72

0,55
0,454
0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1
DP/P
 Figure 4: Relation among P, PCR and K in the critical conditions for the flow of
steam (saturated or reheated) through piping
800

700 K = 1,5

600

500 4

PCR (psia) 400

10

300 15
20

200 40
80
100
100
300
1000
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600
P (psia)
3. DISCHARGE OF THE SAFETY VALVE WITHOUT THE PIPING. FREE
DISCHARGE OF THE VALVE

The relation between Wo the flow discharged by the valve, the inlet
pressure P1 and the nozzle diameter may be calculated using the
following equations.
Saturated steam:

Wo = 40.45do2P1kn (8a)

The parameter kn is a correction factor given in the Reference [7]

that is kn = 1 for P1 equal or less than 1500 psia and
kn = (0.1906P1 – 1000)/(0.2292P1 – 1061) for P1 > 1500 psia.
The equation (8a) is also known as the Napier’s equation in the
References [5], [6] and [7].
Alternatively and based in the equations (1a) and (3a) it’s possible
to use the equation (8b) that is:

Wo = 848do2(P1/ve1)0.5 (8b)

The difference between the results obtained with the equations

(8a) and (8b) is less than 5 % until P1 = 2000 psia and may be a little
more than 10 % when P1 = 3000 psia.
Reheated steam:
From the equations (1b) and (3b) we obtain:

Wo = 893do2(P1/ve1)0.5 (8c)

Usually the valve supplier gives the data of Wo and do but in any
case the equations (8a), (8b) and (8c) may be used to calculate the
flow rate discharged and the nozzle diameter of the valve required
for the inlet pressure P1
4. DISCHARGE OF THE SAFETY VALVE THROUGH A DIRECT
CONNECTED DISCHARGE PIPING

When the discharge piping is attached to the elbow outlet, as

shows the Figure 1a, the optimum design will maintain the pressure
PB calculated with the equations (3a), (3b) or (4) to discharge a flow
rate W equal or greater than Wo.
The process to calculate the optimum values of D and L of the
discharge piping has the following steps:
1) If we know the nozzle diameter do of the valve, apply the
equations (3a), (3b) or (4) to calculate PB.
If we don’t know do, first apply the equations (8a), (8b) or (8c) to
calculate it.
2) Apply the equation (2) to calculate veB.
3) Select a value for D and with the foreseen layout calculate L.
Note that to maintain the valve discharge capacity Wo, we must
select D > d.
Apply the equations (6a) and (5) to obtain respectively KD and
W.
If W is equal or greater than Wo, the discharge piping is valid. If
not, increase D or decrease L until obtain W equal or greater
than Wo.
In the application of the equation (5), note that PF and Y are
unknown. We proceed in this manner:
Enter in the Figure 3 with K = KD and in the Critical Conditions
Line take the corresponding value of Y.
Enter in the Figure 4 with K = KD and P = PB and obtain PCR = PF.
Note that if PCR is equal or less than 14.7 psia, PF must be equal
to 14.7 psia.
Now we can apply the equation (5).

Though the selected values of D and L, let to pass a flow rate that
may be greater than Wo really the flow rate discharged will be Wo
and the pressure at the end of the piping will be P’F that is lower
than the value of PCR obtained before.
To calculate the value of P’F we may assume that there exists a
fictitious additional resistance coefficient KB at the elbow outlet
that fulfills the equation (5) in this form:

Wo = 1891YD2[(PB – P’F)/veB(KB + KD)]0.5

To calculate P’F and KB proceed in this manner:

Assume a value for P’F in the range 14.7 < P’F < PF and obtain K
in the Figure 4 for PB and PCR = P’F. It will be K = KB + KD.
Now obtain Y in the Figure 3 for K in the Critical Conditions Line.
If applying the equation (5) is W = Wo the values of K and P’F are
those we are looking for.
If it is W < Wo, select a lower value for P’F and repeat the process.
If W > Wo, select a greater value for P’F.
Take into account that minimum allowed value of P’F is 14.7 psia.
5. DISCHARGE OF THE SAFETY VALVE THROUGH UN UMBRELLA
DISCHARGE PIPING

This type of discharge piping is showed in the Figure 1b.

The design process is the same as that of the direct connected type but
there is an additional criterion to be taken into account in order to
prevent the steam exit at the bottom of the discharge piping, in the
section B.

This criterion comes from the Reference [3] and it is that P’b be equal or
less than 14.7 psia.

The pressure P’b is calculated with this equation:

P’b = PB[1.12e0.5(d/D)**2 – 1.133] (9)

If P’b > 14.7 psia, select a greater value of D to obtain in the equation a
value of P’b equal or less than 14.7 psia.
6. CONCLUSIONS

With this Guide we can calculate the required nozzle diameter of the valve
do, the free flow rate of the valve Wo, the length L and the diameter D of
the discharge piping that has a capacity greater than Wo

The results for the flow rate W obtained with this Guide are similar to
those of the Reference [3] but slightly lower, because the Reference [3]
doesn’t take into account the pressure loss in the section change from B
to C nor at the end of the discharge piping where K = 1
7. REFERENCES

[1] Crane Technical Paper No. 410. “Flow of Fluids Through Valves, Fittings
and Pipe”

[2] H. E. Brandmaier and M. E. Knebel. “Steam Flow Through Safety Valve

Vent Pipes”. ASME. Journal of Fluids Engineering. 98. PP. 199-206. June 01
1976.

[3] G. S. Liao. “Analysis of Power Plant Safety and Relief Valve Vent
Stacks”. Transactions of the ASME. Journal of Engineering for Power.
October 1975.

[4] Max W. Benjamin. “Sizing Vent Piping for Safety Valves”. Heating,
Piping and Air Conditioning”. October 1941.

[5] ANSI B 31.1 – 2007. Nonmandatory Appendix II. “Rules for the design
of safety valve installations”.

[6] Westinghouse Electric Corporation. “Criteria and Guidelines for the

Design of Safety and Relief Valve Installations”. Document 1.21 Revision 1.
August 1977.

[7] Crosby Pressure Relief Valve Engineering Handbook. Technical

Document No. TP – V300. May 1997.

[8] M. Samimy and A. L. Addy. “The Fluid Dynamics of Safety Valve Vent
Stacks”. Journal of Fluids Engineering. Transactions of the ASME.
September 1985, Vol. 107/397.

[9] Alias Mohd Noor, Srithar Rajoo, Shussain Salleh and Muhammad
Hanafi Md Sah. “Flow Study and Design Analysis of a Safety Valve Vent
Pipe. Research Gate, December 2014.

[10] Daniel A. Crowl and Scott A. Tripler. ”Sizing Pressure-Relief Devices” .

[Link]/cep. October 2013 CE
8. NOMENCLATURE

a …………. Polytrophic coefficient of the steam expansion (Cp/Cv)

Cp, Cv …….Specific heats of the steam at constant pressure and volume

(BTU/lb-ºF)

d …………. Internal diameter of the elbow (in)

do ……….. Nozzle throat diameter of the valve (in)

D ………… Internal diameter of the discharge piping (in)

f ………….Friction factor

K ………… Resistance coefficient

KD ………. Resistance coefficient of the discharge piping

KB ………. Fictitious resistance coefficient at the valve outlet

L ………… Equivalent length of the discharge piping (ft)

P1 ………. Steam pressure at valve inlet (psia)

PS ………. Saturated inlet pressure at valve inlet (psia)

PCR …….. Critical steam pressure at the end of the pipe (psia)

Po ………. Critical steam pressure at the nozzle valve throat (psia)

Pb ………. Valve back pressure (psia)

P’b ……… Minimum attainable back pressure (psia)

PB ………. Pressure at the 90º elbow outlet (psia)

PF ………. Pressure at the end of the discharge piping (psia)

DP …….. Pressure drop (psi)

ve ………. Specific volume of the steam (ft3/lb)

 Wo …….. Flow rate capacity of the valve (lb/h)

W ……….Maximum flow rate capacity of the valve plus the discharge piping
(lb/h)

Y ……….. Expansion factor for the steam

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