Educational Institute for Equipment and Process Design

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 Educational Institute for Equipment and Process Design

Suppose we have the following conditions:

1.The mixture enters the separators and the separator simply separate the liquid from the gas
stream. The liquid by means of a pump is sent to another unit to be reused in the plant. The gas
stream passes through a PV and its pressure is controlled or regulated, which now becomes
suitable for downstream unit. Now imagine that for any reasons, which is not important, the control
valve fails and closes. What will happen? Let’s check the consequence! The pressure before the
valve increases, which means the pipe connecting separator to control valve is pressurized, which
means the separator pressure increases. Now you know the meaning of design pressure which
was explained in second offline video, right? In a simple way, the pressure inside the vessel
increases until it becomes equal to the design pressure of the vessel. What do you expect now?
The explosion and damage to the vessel.

How to prevent it? Using a PSV in our design. The PSV should be mechanically designed in a
way that when the pressure in the vessel reaches design pressure, it should open and relieve
the pressure and excess flow.
Imagine the operating pressure of the vessel is 25 barg and its design pressure is 30 barg. The
PSV should open at 30 barg. In PSV terminology, we say the set pressure should be 30 barg.
Also, the amount of flow which is excess-accumulated- and discharged so that again the pressure
is less than the design pressure is called relief load.
2. Imagine the above scenario again. This time everything is in perfect condition and the valve
works properly. But this time, a fire breaks out near the vessel; the fire radiates the heat to the
vessel and as a result the water inside the vessel receives the heat via convection heat transfer
and expands. What does it mean? It means the pressure inside the vessel increases as a result
of expansion. Now you know the meaning of design pressure which was explained in second
offline video, right? In a simple way, the pressure inside the vessel increases until it becomes
equal to the design pressure of the vessel. What do you expect now? The explosion and damage
to the vessel.
How to prevent it? Using a PSV in our design.
 Educational Institute for Equipment and Process Design

In first condition, we have to design and size a PSV due to valve failure case. In second condition,
we have to design and size a PSV due to fire case.
In PSV terminology, we call each case, a scenario.
For a real process plant design, we have different scenarios based on API-521, which is shown
on next page.
Educational Institute for Equipment and Process Design
 Educational Institute for Equipment and Process Design

Let’s convert API-521 table into more practical approach toward PSV scenario detection in a
process plant.

1.Heat exchanger Whenever there is a cooled-water heater

exchanger, consider the case of hydraulic
expansion.

When the difference between design pressure of

High-pressure side and low-pressure side is
high, consider tube rupture scenario.

2.Valves When the difference between design pressure of

High-pressure side and low-pressure side is
high, consider inadvertent valve opening.

If a valve closes and causes high pressure, then

consider closed outlet.

3.Pumps We can install a PSV at the discharge of a pump

and whenever the discharge pressure in
abnormal conditions reaches shut-off pressure,
PSV can handle it and relieve the pressure.

In modern design, we simply increase the design

pressure of pipe connected to discharge of the
pump equal to shut-off pressure and as a result,
there is no need to consider any PSV at the outlet
of pumps.
 Educational Institute for Equipment and Process Design

4.Vessels Consider the fire-unwetted surface scenario for

reactor vessel which are filled with catalysts.

Consider the fire-wetted surface scenario for

drums containing water.

5.Towers When the reflux pump fails due to any reasons,

the reflux flow is cut off. Before the cut-off, the
reflux flow provides has a cooling effect on tower
and when it is cut-off, the hot stream pressure
increases in tower and causes over-pressure.

When the air cooler fails, again the overhead

stream cannot be cooled, which finally causes
the overpressure in tower.

To see the examples in a process plant, check the One Note File.
Now that we have founded possible scenarios, we need to determine some parameters for each
PSVs which are explained below:

• Accumulation = Overpressure

The pressure increases over the MAWP of the vessel, expressed in pressure units or as a
percentage of MAWP or design pressure. Maximum allowable accumulations are established by
applicable codes for emergency operating and fire contingencies.

• Backpressure

The pressure that exists at the outlet of a pressure-relief device as a result of the pressure in the
discharge system. Backpressure is the sum of the superimposed and built-up backpressures.

• Built-up backpressure

The increase in pressure at the outlet of a pressure-relief device that develops as a result of flow
after the pressure-relief device opens.

• Superimposed backpressure

The static pressure that exists at the outlet of a pressure-relief device at the time the device is
required to operate. Superimposed backpressure is the result of pressure in the discharge system
coming from other sources and may be constant or variable.

• Relieving conditions
 Educational Institute for Equipment and Process Design

Relieving pressure, shown as P1 in the various sizing equations, is the inlet pressure of the PRD
at relieving conditions. The relieving pressure is the total of set pressure plus overpressure.
Examples:
 Educational Institute for Equipment and Process Design

At this stage, after obtaining above information, we need to determine relief load and orifice area
sizing. To do so, we follow the following procedure:

1.Determine the scenario, using API-521

2.Calculate the relief load, using API-520 Part1
3.Calculate the orifice area, using API-520 Part1
4.Select proper PSV type by checking backpressure
5.Use API-526 to determine the designation and the inlet and outlet sizing
6.Use API-520 Part2 to detail its construction

To help you better understand how the procedure works, one example is provided in Appendix.

After doing for all PSVs, we get a table like below:

We are done with PSV sizing and datasheets.

 Educational Institute for Equipment and Process Design

Flare Package

Flare package components Header network or simply piping network

Knock-out drum

Stack

Let’s detail it:

1.Header Network All PSVs are discharged to a header which

is called flare header.

We use Aspen Flarenet to size flare header

Network. Here is the criteria:

1. For both header and tailpipes, the Mach

number of both 0.1 and 0.5 are taken
into account.
2. The maximum ρν2 for the whole piping
should be 150000 kg/m/s2
3. The sound/ noise level should not
exceed the recommended value of 100
DBA
 Educational Institute for Equipment and Process Design

2.Knock-out drum sizing K.O.D is used to separate the water droplet

from flare gas in order to avoid burning rain!

K.O.D is sized based on API-521

procedure. To verify API-521 excel sheet
results, Flaresim software is used.

3.Stack We use stack to not only combust flare

gases, but also reduce the thermal radiation
impact of the combusted gas.

Stacks are sized using Flaresim software.

Flaresim provides its users with
comprehensive report about thermal
radiation, noise and temperature status in
different radius.
 Educational Institute for Equipment and Process Design

Appendix