Jump Start: Fire Overpressure Analysis in Aspen HYSYS and Aspen Plus

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A Brief Tutorial (and supplement to training and online documentation)
Anum Qassam, Product Management, Aspen Technology, Inc.
Jennifer Dyment, Product Marketing, Aspen Technology, Inc.

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Contents
Introduction .................................................................................................................................................. 1
Initial Setup ................................................................................................................................................... 2
Unwetted (API) Calculation........................................................................................................................... 3
Supercritical Calculation ............................................................................................................................... 8
Wetted (API) Calculation.............................................................................................................................12
Semi-Dynamic Flash Calculation .................................................................................................................19
References ..................................................................................................................................................24
Additional Resources .................................................................................................................................. 24

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Introduction
API Standard 521 recommends that all pressure vessels under 25 feet in elevation be protected against
overpressure resulting from an external pool fire. A plant fire is a dangerous situation where flammable
fluid is trapped inside a high pressure vessel, with heat continually added to the system. For two-phase
separators, the trapped liquid inventory’s composition, temperature, and pressure are constantly in flux.
For a vessel with no liquid inventory, ideal gas expansion can ease the difficulty of the calculation, but
the complexity of the relief load calculation increases substantially at non-ideal conditions. The Safety
Environment in Aspen HYSYS and Aspen Plus offers a variety of calculation methodologies to quickly
calculate the orifice area required to protect a vessel against overpressure due to the fire contingency.

This is not meant to be used as a stand-alone reference document. AspenTech recommends that a
range of other resources be referenced to give the new user a comprehensive view of how to use Aspen
HYSYS and Aspen Plus. These may include:

 Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS and Aspen Plus v8.6
 AspenTech support website (support.aspentech.com)
 AspenTech courseware available in on-line and in-person versions
 AspenTech business consultants
 Additional Jump Start Guides—available on a variety of related topics

This document provides a detailed overview of the steps required to calculate the required relief load
for the fire overpressure contingency within the Safety Environment of Aspen Plus and Aspen HYSYS,
with a detailed overview of calculation assumptions and nuances for both the new and experienced
safety engineer.

This document will assume the user is familiar with all the basic functionality of the Safety Environment
including, but not limited to:

(1) Adding a relief device

(2) Designing and Sizing a Pressure Safety Valve
(3) Multi-valve sizing
(4) Line Sizing
(5) Reports

Please refer to the previously published Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS and
Aspen Plus v8.6 for additional details on any of the aforementioned topics.

Either Aspen Plus or Aspen HYSYS can be used to follow this jump start guide. Following the jump start
guide with the example file “PRESSURE RELIEF STARTER.hsc” in Aspen HYSYS or the example file “Safety
Analysis without PRD.bkp” in Aspen Plus is strongly recommended. Both files are available on aspenONE
Exchange.

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Initial Setup
All examples and screenshots in this guide are based on the example file “PRESSURE RELIEF
STARTER.hsc” in Aspen HYSYS. If more familiar with Aspen Plus, users can use the “Safety Analysis
without PRD.bkp” file instead. Make sure that the correct units are selected when specifying
parameters when prompted.

To begin, the user should:

(1) Open the file “PRESSURE RELIEF STARTER.hsc” or “Safety Analysis without PRD.bkp”
(2) Enter the Safety Analysis environment,
(3) Add a PSV to stream vapOut,
(4) Open the PSV system tab by double clicking the icon on the flowsheet
(5) Set the Design Temperature to Reference
(6) Set the Design Pressure to 35 psig

Figure 1: Initial Setup of Flowsheet and PSV System Tab

For detailed explanations on any of the aforementioned steps, please refer to the Jump Start: Pressure
Safety Valve Sizing in Aspen HYSYS and Aspen Plus v8.6.

 Tip - Are you ready to enter the safety environment?

Before the user enters the safety environment, the user must confirm that the simulation flow-sheet
contains a stream that best reflects the contents of the vessel (e.g. the feed stream to the protected
unit operation). For help with Aspen Plus or Aspen HYSYS simulation environment, refer to the
respective simulation Manuals available at http://support.aspentech.com.

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Unwetted (API) Calculation

This section describes how the user can calculate the required relief load for a vessel with all-vapor in
accordance with API 521 Section 5.15.2.2.2. The Unwetted (API) method is generally applicable for ideal-
like systems with vapor compressibility between 0.8 and 1.1.

Getting Started
Select the Scenarios tab and click the Create Scenario button.

Figure 2: Scenario Tab

Double click on the newly-created scenario to open up the Scenario Setup screen. The user can also
highlight the scenario and click the Open Scenario button.

Figure 3: Scenario Setup

Next, select Fire from the Scenario Type dropdown menu.

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Figure 4: Scenario Selector

The user can confirm the fluid properties by selecting the Fluid Properties tab. The property specifically
of interest in the fire calculation is the Operating Phase of the Reference Stream (vapOut @ Main).

Figure 5: Operating Phase on Fluid Properties Tab

Since the Reference stream is all-vapor at the operating conditions specified on the Equipment Tab, only
the Unwetted (API) and Supercritical Calculation Methods are available in the dropdown list on the
Scenario Setup tab.

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Figure 6: Calculation Method Dropdown

The user should confirm that the Unwetted (API) method is selected.

Calculation Parameters
The Max Wall Temp is the only calculation-specific input for the Unwetted (API) calculation, and it is
defaulted to the API-recommended 593.3 °C (1100 °F) for carbon-steel. The user can change this value
for the specific equipment metallurgy.

Figure 7: Unwetted (API) Calculation Parameter

Vessel Parameters
This section will detail how the user can specify or calculate the exposed area value for up to three
vessels in the same system.

Specify Exposed Area

If the user has a value for the exposed area, the user must select “No” for the “Calculate Exposed Area?”
Input. The Exposed Area box will turn blue, and the user can type in the exposed area.

Figure 8: Unwetted (API) Specify Exposed Area

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Calculate Exposed Area

If the user would like to calculate the exposed area, the user must select “Yes” for the “Calculate
Exposed Area?” Input. The user can then enter the Diameter, Vessel Tan/Tan, Elevation, Maximum
Flame Height, and Additional Area % in order to calculate the exposed fire area per API 521.

Figure 9: Unwetted (API) Calculate Exposed Area

Note that the calculation assumes that the vessels have 2:1 Ellipsoidal heads.

Number of Vessels Selection

The user can also calculate the exposed area as the sum of up to three vessels. From the number of
vessels dropdown, select 3.

Figure 10: Number of Vessels Dropdown

The user can enter any of the equipment specific parameters for three vessels.

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Figure 11: Unwetted (API) Exposed Area Calculation for Three Vessels

Results
The Unwetted (API) calculation methodology determines the Required Relieving Flow based on Equation
(12) in API 521 5e.

Figure 12: Unwetted (API) Required Relieving Flow

The Relieving Temperature is calculated based on an ideal gas expansion from the operating conditions
to the relief temperature, per Equation (11) in API 521 5e.

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Figure 13: Unwetted (API) Relieving Temperature

Supercritical Calculation
This section of the document will detail the steps required to calculate the required relief load for a
vessel that contains a supercritical fluid at relieving conditions. Note that the methodology is also
applicable for non-ideal vapor systems.

The implementation is based on the algorithm developed by Ouderkirk in the article “Rigorously Size
Relief Valves for Supercritical Fluids.”

Getting Started
In order to use the supercritical calculation method, the user must ensure that the Reference Stream
Operating Phase is Vapor (verify on Fluid Properties tab) and that the Number of Vessels is 1. Confirm
that the Reference Stream is still vapOut @ Main.

Figure 14: Preconditions to Use Supercritical Calculation

Select Supercritical from the Calculation Method dropdown.

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Figure 15: Supercritical Calculation Method Selector

Calculation Parameters
The user should select whether adequate drainage or firefighting is present near the vessel. The
selection will affect the constant in the fire heat flux equation (see API Section 5.15.2.2.1).

Figure 16: Supercritical Calculation Parameters

The user must next specify the vessel dimensions.

Vessel Parameters
This section will detail how the user can specify the equipment dimensions and F factor for the
Supercritical calculation methodology.

Equipment Dimensions
The user must specify the Vessel Orientation, Diameter, Vessel Tan/Tan, Elevation, Maximum Flame
Height, and Additional Area % for the Supercritical calculation methodology.

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Figure 17: Supercritical Vessel Parameters

Environmental F Factor
The user can also calculate or specify the environmental factor for each vessel based on the insulation
conductivity and insulation thickness on each vessel. An F factor of 1 means there is no insulation or
heat input reduction. Traditional values for insulation thickness and conductivity are available in the F1
help.

Specify F Factor
If the user would like to specify the exposed area, select “No” for “Calculate F Factor?” Input. The
Environment Factor F input will turn blue, and the user can enter the value in the box.

Figure 18: Specify F Factor

Calculate F Factor
If the user would like to calculate the exposed area, select “Yes” for “Calculate F Factor? “Input. The
Insulation k and Insulation Thickness values will become blue. The user can enter the numbers as
appropriate for the vessel, and the Environment Factor F will be calculated.

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Figure 19: Calculate F Factor

Edit Flash Table

The user can also view and edit the flash details by clicking the Edit Flash Table link.

Figure 20: Edit Flash Table

The experienced user can edit the # of Flashes and Max Iteration Temperature for better accuracy.

Figure 21: Supercritical Flash Data

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Results
The Required Relieving Flow is determined by the Mass Flow Rate that results in the greatest Required
Orifice Area from the iterative flash calculation (see Edit Flash Table dialog box).

Figure 22: Supercritical Required Relieving Flow

The relieving temperature is based on the Temperature that corresponds to the greatest Required
Orifice Area from the iterative flash calculation (see Edit Flash Table dialog box).

Figure 23: Supercritical Relieving Temp

Note that the supercritical calculation methodology uses the Direct Integration (HEM) methodology to
determine the Calculated Orifice. Therefore the user cannot select an alternative sizing method; the
dropdown is deactivated.

Wetted (API) Calculation

This section of the document will detail the steps required to calculate the required relief load for a
vessel that contains liquid at relieving conditions.

The implementation is based on Section 5.15.2.2.1 from API 521 5e.

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Getting Started
Confirm that the Scenario Setup tab for Scenario100 of 100 PSV 001 is open (see Figure 3). To select a 2-
phase stream for this example, the user should check the “Override” checkbox to select an alternate
stream for the scenario analysis.

Figure 24: Override Stream

The Select Reference Stream dialog box should open. Select stream FeedStream.

Figure 25: Reference Stream Selector

The user can confirm that the reference stream operating phase is two phase by checking the fluid
properties tab.

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Figure 26: Verify Operating Phase (Wetted Vessel)

The user should also confirm that Fire is the selected Scenario Type (see Figure 4). The Calculation
Method drop down for fire is based on the operating phase of the Reference Stream fluid. For a two-
phase Reference Stream, Wetted (API) and Semi-Dynamic Flash should be available in the drop down.

Figure 27: Wetted (API) Calculation Method Drop-down

Select Wetted (API) calculation method.

Calculation Parameters
This section details the selection of the calculation parameters specific to the Wetted (API) calculation
methodology.

The user should select whether adequate drainage or firefighting is present near the vessel. The
selection will affect the constant in the fire heat flux equation (see API Section 5.15.2.2.1).

Figure 28: Wetted (API) Drainage Parameter

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Next, the user can specify the latent heat of vaporization, or use the simulation engine to estimate the
latent heat of vaporization for a wide-boiling point mixture. The Required Relieving Flow is indirectly
proportional to the value of the latent heat of vaporization, so the user should take great care to use a
reasonably conservative value in the calculation.

Specify the Latent Heat of Vaporization

To specify the latent heat of vaporization, select “No” for the “Estimate Latent Heat?” dropdown; the
Latent Heat input box will turn blue, and the user can enter the desired value.

Figure 29: Specify Latent Heat of Vaporization

Estimate the Latent Heat of Vaporization

To estimate the latent heat of vaporization, select “Yes” for the “Estimate Latent Heat?” dropdown; the
Initial % Vaporized and Final % Vaporized input boxes will turn blue, and the user can enter those values.

Figure 30: Estimate Latent Heat of Vaporization

The latent heat of vaporization is based generally on the heat required to vaporize the specified portion
of the Reference Stream at relieving conditions (excluding sensible heat, per API 521).

Vessel Parameters
This section will detail how the user can determine the Exposed Area and Environmental Factor for the
Wetted (API) calculation methodology.

Exposed Area
The user can specify or calculate the exposed wetted surface area for up to 3 vessels by changing the
Number of Vessel drop down. The user can continue to either specify or calculate the exposed wetted
surface area for each vessel.

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Figure 31: Wetted (API) Multi-vessel Configuration

Specify Exposed Area
To specify the exposed area for the vessel, the user must select “No” for the “Calculate Exposed Area?”
Input. The Exposed Area box will turn blue, and the user can type in the exposed area.

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Figure 32: Wetted (API) Specify Exposed Area

Calculate Exposed Area

To calculate the exposed area, the user must select “Yes” for the “Calculate Exposed Area?” Input. The
user can then specify the Vessel Type, Diameter, Vessel Tan/Tan, Liquid Level, Elevation, Maximum
Flame Height, and Additional Area % in order to calculate the exposed fire area per API 521.

Figure 33: Wetted (API) Calculate Exposed Area

Note that the calculation assumes that the vessels have 2:1 Ellipsoidal heads.

Environmental Factor
The user can also calculate or specify the environmental factor for each vessel based on the insulation
conductivity and insulation thickness on each vessel. An F factor of 1 means there is no insulation.
Traditional values for insulation thickness and conductivity are available in the F1 help.

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Specify F Factor
Select “No” for “Calculate F Factor?” Input. The Environment Factor F input will turn blue, and the user
can enter the value in the box.

Figure 34: Wetted (API) Specify F Factor

Calculate F Factor
Select “Yes” for “Calculate F Factor?” Input. The Insulation k and Insulation Thickness values will become
blue. The user can enter the numbers as appropriate for the vessel, and the Environment Factor F will be
calculated.

Figure 35: Wetted (API) Calculate F Factor

Results
The Required Relieving Flow is calculated using the Wetted (API) calculation methodology.

Figure 36: Wetted (API) Required Relieving Flow

The Relieving Temperature is determined by a bubble-point flash of the Reference Stream liquid.

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Figure 37: Wetted (API) Relieving Temperature

Semi-Dynamic Flash Calculation

This section of the document will detail the steps required to calculate the required relief load for a
vessel that contains liquid at relieving conditions.

The Center for Chemical Process Safety in “Guidelines for Pressure Relief and Effluent Handling Systems”
recommends using a batch vaporization methodology to more accurately assess the Required Relieving
Flow for a vessel that contains liquid inventory. This is the methodology implemented in the Semi
Dynamic Flash calculation.

Getting Started
In order to use the Semi-Dynamic Flash calculation method, the user must ensure that the Reference
Stream Operating Phase is Liquid or Two-Phase (see the Getting Started section for the Wetted (API)
Calculation for more details). Furthermore, the user must confirm that the Number of Vessels is 1. For
users following along with the example file, confirm that FeedStream @ Main is the selected Reference
Stream.

Figure 38: Semi-Dynamic Flash, Confirm Operating Phase

Select Semi-Dynamic Flash from the Calculation Method dropdown.

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Figure 39: Semi Dynamic Flash Calculation Method Drop-down

Calculation Parameters
The user should select whether adequate drainage or firefighting is present near the vessel. The
selection will affect the constant in the fire heat flux equation (see API Section 5.15.2.2.1).

Figure 40: Semi-Dynamic Flash Drainage Drop-down

The user must next specify the vessel dimensions.

Vessel Parameters
For the Semi-Dynamic Flash Calculation Method, the user must specify the Vessel Type, Diameter,
Vessel Tan/Tan, Liquid Level, Elevation, Maximum Flame Height, and Additional Area % in order to
calculate the exposed fire area per API 521.

Note that since the calculation method is based on a series of batch vaporizations of the liquid
inventory, the liquid level will change over the course of the flashes. The user needs to provide only the
initial liquid level at the onset of the fire.

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Figure 41: Semi-Dynamic Flash Vessel Inputs

Note that the calculation assumes that the vessels have 2:1 Ellipsoidal heads.

Environmental Factor
The user can also calculate or specify the environmental factor for each vessel based on the insulation
conductivity and insulation thickness on each vessel. An F factor of 1 means there is no insulation.
Traditional values for insulation thickness and conductivity are available in the F1 help.

Specify F Factor
Select “No” for “Calculate F Factor?” Input. The Environment Factor F input will turn blue, and the user
can enter the value in the box.

Figure 42: Semi Dynamic Flash Specify F Factor

Calculate F Factor
Select “Yes” for “Calculate F Factor?” Input. The Insulation k and Insulation Thickness values will become
blue. The user can enter the numbers as appropriate for the vessel, and the Environment Factor F will be
calculated.

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Figure 43: Semi Dynamic Flash Calculate F Factor

Edit Flash Table

The user can also view and edit the flash details by clicking the Edit Flash Table link.

Figure 44: Edit Flash Table Link

If the liquid inventory vaporizes fully before the Max Iteration Temperature is reached, then we
recommend that the user attempt to change the # of Flashes and Max Iteration Temperature for more
accurate results. We recommend selecting a Max Iteration Temperature and # of Flashes so that the
liquid inventory doesn’t fully vaporize, and such that the % Vaporized is 5-10% per flash step.

Figure 45: Semi Dynamic Flash Edit Flash Table

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 Jump Start: Fire Overpressure Analysis in Aspen HYSYS
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••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••

Results
The Required Relieving Flow is determined by the maximum Vapor Volumetric Flow generated during
the step-wise batch vaporization.

Figure 46: Semi Dynamic Flash Required Relieving Flow

The relieving temperature is based on the temperature that resulted in the maximum generated Vapor
Volumetric Flow.

Figure 47: Semi-Dynamic Flash Relieving Temperature

Conclusions
API 521 recommends that all vessels under 25 ft. in elevation be protected for the fire overpressure
scenario. Depending on the protected system, varying levels of rigor may be required in determining
the required relieving load. The Safety Environment in Aspen HYSYS and Aspen Plus now provides
rigorous determination of the required fire relief load. Users can quickly and easily size relief devices for
the fire overpressure scenario.

© 2014 Aspen Technology, Inc. AspenTech , aspenONE , the aspenONE logo, and the Aspen leaf logo are trademarks of Aspen Technology, Inc. All rights reserved.
® ® ®

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 Jump Start: Fire Overpressure Analysis in Aspen HYSYS
and Aspen Plus
••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••

References
1. American Petroleum Inst., “Sizing Selection, and Installation of Pressure-Relieving Devices in
Refineries,” ANSI/API RP 520, 8th Ed., Part 1: Sizing and Selection, Washington D.C., Dec. 2008.

2. American Petroleum Inst., “Pressure-relieving and Depressuring Systems,” ANSI/API Standard 521,
Fifth Ed., Jan. 2007.

3. Center for Chemical Process Safety, “Guidelines for Engineering Design for Process Safety,” 2nd Ed.,
April 2012.

4. Ouderkirk, Ryan. “Rigorously Size Relief Valves for Supercritical Fluids,” in Chemical Engineering
Process, August 2002.

Additional Resources

Public Website:
http://www.aspentech.com/products/aspen-HYSYS.aspx

Online Training:
http://www.aspentech.com/products/aspen-online-training

AspenTech YouTube Channel:

http://www.youtube.com/user/aspentechnologyinc

© 2014 Aspen Technology, Inc. AspenTech , aspenONE , the aspenONE logo, and the Aspen leaf logo are trademarks of Aspen Technology, Inc. All rights reserved.
® ® ®

24
© 2014 Aspen Technology, Inc. AspenTech , aspenONE , the aspenONE logo, and the Aspen leaf logo are trademarks of Aspen Technology, Inc. All rights reserved.
® ® ®