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Lesson # 09 Relief Valve Sizing

Part 02

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Special Relief System Considerations

The following equipment consideration should be followed for relief system

design.

Fired Heater

If there is a possibility that the process side of a heater may be blocked in,
then a relief valve should be provided to protect the heater.

Pumps

Relief valves are required on the discharge of each positive displacement

pump. Normally, these reliefs are piped back to the process upstream of the
pump rather than to the flare system.

Isolation valves around the relief valves may not be required if the pump
itself can be isolated for maintenance purpose.

Vessels And Tanks

Vessels or tanks which are subjected to atmospheric “breathing” due to

cooling of gas or liquid content are normally protected by “breather” valves
or vacuum relief valves. Vessels in higher pressure services are normally
designed for full vacuum if upset conditions can cause vacuum situation –
otherwise vacuum relief valves must be provided to meet the code
requirements.

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Compressors

Each positive displacement compressor must have relief valve on the

discharge of each stage upstream of the block and check valves in order to
protect compressor. These reliefs are normally piped to a closed system.

Low Temperature Flaring

When low temperature streams are relived, the flare system piping and
equipment exposed to cryogenic temperature may require stainless steel or
other acceptable alloys. The system should be designed for the coldest
process stream to be relived plus the lower temperature effect of the
expanding fluid (Joule Thomson Effect). Material selection should be made
according to applicable code and recommendations.

Shutdown Valve (SDV) and blowdown valve (BDV) Considerations

Actuated valve may refer to on-off valve which operates in fully open or
fully close or control valve which operates in throttling mode. However, term
actuated valve is mostly used for on-off services valve. Actuated valve may
also be named Shutdown Valve (SDV) and blowdown valve (BDV).

Shutdown valve is a valve installed for safety purpose during plant

shutdown; the valve is normally open during plant operating condition and
closed during plant shutdown.

Blow-down valve is a valve installed for safety purpose by depressurizing

the system during plant emergency condition, the valve is normally closed
during plant operating condition and open during depressurization.

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Actuated valve mainly consists of:

 Main Body
 Actuator
 Limit Switches
 Solenoid Valve or other pilot valve
 Air Filter Regulator

Other supporting equipment may be attached to the valve such as quick

exhaust valve to achieve desired opening or closing time, unidirectional flow
regulator, etc.

Actuated Valve Symbol In P&ID:

Below picture shows actuated valve complete with solenoid, and limit switch
symbol in P&ID

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Emergency Shut-off Valve (ESV) General Installation Standard For Major

Equipment:

(ESV) used for isolating the equipment from the units in an emergency. The
Installation standards of ESV are:

Vessels

It is not necessary to provide ESV always on the vessel outlet line. If liquid
volume and fluid condition in the vessel meet the following requirements,
ESV shall be provided on Vessel outlet lines.
(i) Vessel Volume
Limitation can be changed with respect to the project specification and
your company design standard
 Liquefied Petroleum Gas more than 100 tons or Toxic liquid more
than 30 tons
(ii) Fluid Condition
 If liquid flash point is below 22.8oC and boiling point is below 37.8oC
(NFPA NO. 321)
 LPG, Naphtha, liquid with temperature more than auto ignition
temperature (EXOR)

Furnaces

Fuel lines to process furnaces and steam boilers shall be provided with
remotely operated emergency valves.

A manually operated block valve shall be provided in each fuel line. This
includes the pilot gas supply line, if it is a separate line.
These valves shall be located at least 15 meters horizontally from the furnace
or boiler being protected.

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ESV on the snuffing steam (Used to "snuff" or put out an unwanted

fire, and it does this by excluding air from the area where the potential
fuel is located) line shall be located at least 15 meters horizontally from the
furnace.

Reboiler
ESV will be installed on the steam inlet line to Reboiler, especially in case
when control valve is installed on the Reboiler outlet condensate line.

Compressor

ESV shall be provided in the suction and discharge lines of centrifugal

compressors to prevent seal gas leakage. Other specifications for ESV
installation are as below.
i) In case when Control Valve closing time is too slow.
ii) Balance line with ESV between suction and discharge may be if
requested by client.

Pumps
 ESV will be provided in the suction line of Pumps. (Treated as Vessel
Outlet ESV)
 ESV may be installed on the discharge line of high head pumps to
prevent back flow.

Vacuum Pumps
 ESV will be installed on the suction line (process side) of Vacuum
Pumps to prevent seal liquid from backflow into process.

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Alarm and Trip

Alarm and trip signals should be indicated on DCS or CCR panel. When the
signal tells abnormal situation happened, it is expected that operator takes
appropriate countermeasure. As for compressor and other package units,
alarm and trip signal are indicated on the local panel. Only common alarm
and trip signals are indicated on DCS or CCR panel. It is expected that
operator explores cause of the failure at the local panel and takes appropriate
action. Each ESD (Emergency Shut Down) shall be independent of the
distributed control system (DCS) and may be activated either by plant
transducers (e.g. high pressure, low flow) or manually from CCR.

Typical set point for level alarm and level trip

- High / Low alarms at 80% and 20% of the range

- High / Low trips at 90% and 10% of the range

 Dedicated level switch is provided for level trip.

 Minimum 5 minutes will be available for the operator’s to react,
after high or low level alarm actuated and before gas break through
or liquid flooding takes place. Or an independent ESV is provided for
the operator to initiate manually to close the outgoing flow.
 Set point for temperature and pressure alarm and trip differ with
respect to the project nature.

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TRIP SEQUENCE:

Typical TRIP SEQUENCE is as follows

Note:
*1 S/D SEQUENCE may be originated from either Local or All (Total) Shut
Down.
*2 A solenoid reset button, which will not work until the ESD system has
been reset at the ESD control panel.
*3 Limit switch (ESV open)
*4 Limit switch (ESV shut)
*5 Manual Handle
*6 Position indicators feeding open or closed back to the ESD controller.
*7 A bypass to permit on line testing, with the bypass valve locked closed.

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Applicable Code & Standards

 API 520 (Parts I & II) Guidelines for PSV sizing, selection, and
installation.
 API 521 Recommendations for designing pressure-relieving and de-
pressuring systems.
 ASME BPVC Section VIII, Division 1 Requirements for pressure vessel
design and PSV inclusion.
 ISO 4126 Standards for pressure relief device requirements and
performance.
 NFPA 30 Guidelines for pressure relief in flammable and combustible
liquid handling.
 EN 4126 (European Standard): Requirements for designing and testing
pressure relief devices.

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Task: Use Aspen Hysys to design the safety PSV for a vessel to protect it
from fire events based on API standards.

Design the safety PSV for a vessel to protect it from fire events based
on API standards.

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Step: 01

Start a New Case

Step: 02
Add components

Nitrogen n-Pentane

CO2 n-Hexane

H2S n-Heptane

Methane n-Octane

Ethane n-Nonane

Propane E-Mercaptan

n-Butane

Step: 03

Select Peng Robinson as a property package

Step: 04
Enter in to the Simulation Environment and add the Material Stream and
input the following parameters:
Feed Composition Feed Conditions

Nitrogen 0.01 n-Pentane 0.03

Temperature [C] 66
CO2 0.07 n-Hexane 0.05
Pressure [kPa] 4238
H2S 0.08 n-Heptane 0.03 Molar Flow
[kgmole/h] 4218
Methane 0.47 n-Octane 0.04

Ethane 0.07 n-Nonane 0.05

Propane 0.05 E-Mercaptan 0.01

n-Butane 0.04

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Step: 05

Add a valve after the stream with a Delta P 0.0034 Kpa

Step: 06

Add a two phase separator after the valve

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Step: 07

Click on Pressure Relief option to switch to Safety Analysis environment.

Step: 08

Add a PSV on vapor outlet

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Step: 09
Select PSV in a navigation menu on the left and input the design
temperature and pressure.

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Step: 10

Select PRD Data option Select Relief Valve Type Conventional  Select
Body Material Stainless Steel.

Step: 11

Go to Scenario option Create Scenario  Select Type Fire Case And

Check Sizing Case.

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Step: 12

 Select Scenario in a navigation menu on the left.

 Select scenario reference stream: Click Select button  Select the
stream (Vap) for the case.
 Select Relieving Phase – Method : Direct Integration (HEM)
 Select Calculation Method: Unwetted (API)

Step: 13
 Select Vessel Type Vertical (Incl. Bottom Head)
 Select Head Type Hemispherical
 Insert Diameter 3.658 m, Vessel Tan/Tan 11.58 m, Elevation 1.524 m

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Step: 14
 Select the orifice size , Selected Orifice >= Calculated Orifice

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Step: 15

 Click Fluid Properties option to view fluid properties.

Step: 16
 Click Relief Composition option to view components fractions in the
relief.

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Step: 17

 Select PSV in a navigation menu on the left Rating to view scenario

details.

On Analysis: Recommended Orifice size is 5.064 cm2 (H)

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