1.

Define the System

TO FLARE

SDV

BDV

BDV
TO FLARE

TO FLARE

SDV SDV SDV

SDV

BDV

SDV

SDV SDV

SDV

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SDV

1. Calculate each system volume inventory ; both piping and equipment.

Example : Piping Inventory Calculation
Length From 3P-SDV-0013 5000-V-60 3"-300# Valve 5000-V-60 5000-V-60 Reducer 3" x 2" Reducer 3" x 2" 3"-GP-3P-022-BA1 2"-B1-BD-202 2"-B1-BD-202 5000-V-60 5000-V-60 To 5000-V-60 5000-PSV-V-60 4"-B1-PHL-100 5000-PSE-V-60 Reducer 3" x 2" 3P-BDV-0016 3P-PV-0023 VALVE 3P-PV-0022 VALVE 3P-SDV-0015 3P-SDV-0014 (ft) 161.7 3.3 16.4 32.1 5.2 10.2 3.7 5.2 Equival ent El. Ratio (ft) 1.2 0.0 1.3 0.0 1.3 0.0 1.3 0.0 1.3 0.0 1.3 0.0 1.3 0.0 1.3 0.0 0.0 0.0 0.0 0.0 NPS (inch) 4 2 3 2 3 2 3 3 2 2 2 2 Internal Equivale Pipe nt Diamete Schedul r Length e (inch) (ft) S40 4.026 199.17 S80 1.939 4.26 S80 2.901 21.32 S80 1.939 41.71 S40 3.069 6.82 S40 2.067 13.22 S80 2.901 4.81 S40 S40 S80 S80 S80 3.069 2.067 1.939 1.939 1.939 6.82 20.89 7.25 26.65 5.54 Piping Volume (ft3) 17.607 0.087 0.979 0.855 0.350 0.308 0.221 0.350 0.487 0.149 0.546 0.114 22.0543 Vapour fraction 0.8077 1.0000 1.0000 1.0000 1.0000 1.0000 1.0000 1.0000 1.0000 1.0000 0.0000 0.0000 Liquid Volume (ft3) 3.3859 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.5465 0.1137 4.0461

16.1 1.3 5.6 1.3 20.5 1.3 4.3 1.3 Total

Example : Equipment Inventory Calculation

ID Tag Number Equipment Name (ft) (ft) Length Orientation HLL NLL LLL Volume Total HLL NLL LLL (ft) (ft) (ft) (ft3) (ft3) (ft3) (ft3) 2.00 0.75 0.50 62.9 54.18 15.74 2.500 12.000 HORIZONTAL 8.812 0 0 0 95 3 6 63.0 54.18 15.74 Total 8.812 0 3 6 HLL Wetted Area (ft2) 71.849 71.849 NLL Wetted Area (ft2) 36.811 36.811 LLL Wetted Area (ft2) 29.174 29.174 Total Area (ft2) 104.065 104.065

5000-V-60

HP TEST SEPARATOR

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Tool

Utilities

1. Adjust massflow of related stream to achieve volume flow correspond to inventory calculation
2. Mix those stream, the result is as BASIS COMPOSITION 3. Balance it to initial pressure condition, the result is as BASIS SIMULATION

Initial condition as follow : # FIRE at design pressure or PAHH # ADIABATIC at operating pressure

4. Tool/ Utilities or CTRL+U *) The higher the initial pressure, the grater the flowrate load to flare.. Because the time is set 15 minutes No matter the initial pressure

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*) want to know more HYSYS short cut ? check in my blog : www.process-eng.blogspot.com Article : useful HYSYS shortcut

1. Depressuring Dynamic

2. Add Utility

3. View Utility

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re name to : FIRE CASE

Select stream BASIS SIMULATION : FIRE Select horizontal vessel Select horizontal vessel
HYSYS model the entirely system volume as a vertical cylinder with flat both bottom and top.

keep as it is

Automatically calculated by HYSYS But , You can manually fill to apply some margin of total inventory volume Fill volume of liquid Based on NLL or HLL
HHL result worst case. Still remember the heat input ? Example : Q = 21000FA^0.82 The wetted area based on HLL bigger than NLL. (The greater the wetted area the greater the heat input rate to vessel)

HYSYS will adjust vessel size both Diameter and Height so that both the total and liquid volume are correct correspond to the input value. Is it difficult to achieve that volume ? As a matter of fact, it is not. Actually, the real problem is, the wetted area based on HYSYSs vessel size is not equal with the actual wetted area.
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Now, at this stage we will skip this problem this will need long explanation I will include it in another tutorial

Select : Fire API 521

To be applied only if heat flux of 21.000 BTU/hr ft^1.64 or Q = : Q = 21000FA^0.82

For fire case : ForLoss fire case : Heat = None Heat Loss = None
no heat loss should be assumed in fire case simulation for worst case

other cases , such as *) 1. Jet fire , the heat flux is 95,500 BTU/ft2/hr. C1 = 95,500 2. For small system, the fraction area exposed by fire is 1.0 instead of 0.82 C2 = 1 3. For vessel with insulation, or covered by earth, the environment factor less than 1.0 ex = 0.3

Now, at this stage we will skip those other problem this will need long explanation I will include it in another tutorial

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*)check in my blog for detail explanation : www.process-eng.blogspot.com Article : fire case heat input rate

Fill Pb = 0
For initial value, Pb =0 If the vapor flow equation is SUBSONIC , the value should be updated based on flareNet study result. # Pb has no significant effect for other vapor flow equation. See table below !

Select : Musoneilan
See table below !, it shows the result of sensitivity test for each vapor flow equation method.

Fill Cf = 1
It is critical flow factor, generally the value close to 1.0 Ex : 0.90 , 0.94 Cf = 1 for worst case of peak flow
Parameter Pb Cv Peak flow Unit Musoneilan psig 0 25 50 USGPM ( 60f, 1psi) 4.044 4.052 4.126 lb/hr 4210 4217 4292 Fisher 25 8.406 4193 Supersonic, (Cv in inch2) 0 25 50 0.102 0.1019 0.102 4191 4204 4204 Subsonic, (Cv in inch2) 0 25 50 0.102 0.1038 0.109 4201 4264 4423

0 8.400 4190

50 8.406 4193

The method selection has no significant effect to the result (peak flow) Now, you can choose one of the method with no worry about the result, personally , I prefer using MUSONEILAN In my opinion, Musoneilan is the most simple and easy to be used. DONT use SUBSONIC if the system is not in sub-critical condition

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The back pressure has significant effect only for SUBSONIC method

This equation show ; the back pressure has effect to the depressuring result,,
Do you know,, Why the back pressure has effect only for subsonic method ? *) In sub critical condition, the flowrate through control valve , nozzle, orifice, etc., ,will depends on the differential pressure between inlet and outlet.

In critical condition, the flowrate through control valve , nozzle, orifice, etc., ,will only depends on the inlet pressure.

Cf Flow Cv

MUSONEILAN 0.9 0.95 1 4202.545 4205.035 4205.123 4.486085 4.252576 4.040034

SENSIVITY test result Fill Cf = 0.9 -1.0 There is no worry about the result ^_^

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*)check in my blog : www.process-eng.blogspot.com Article : critical - subcritical

Fill PV work : 50 % for FIRE CASE

PV Work Term Contribution refers to the isentropic efficiency of the process. A reversible process should have a value of 100% and an isenthalpic process should have a value of 0%

Recommended value
UN-CHECK will result in greater peak flow rate

For gas-filled systems 80% to 100% For liquid filled systems 50% to 70%

More liquid more interaction between liquid and vapor. decrease isentropic efficiency For small system inventory ( small vessel model) more friction between fluid and the vessel wall decrease isentropic efficiency A higher isentropic efficiency results in a lower final temperature. A lower isentropic efficiency results in a higher final peak flow rate

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Depressurized from design pressure*)

Set depressuring time = 15 minutes *)
Considering of the maximum reduction of the vessel stress, vessel with thickness less than 1 inch, generally requires faster depressuring rate. Consideration of limiting flare capacity, the depressuring time longer than 15 minutes may be applied

use Calculate Cv mode

RUN after READY TO CALCULATE

Fill initial value

HYSYS will adjust the Cv value to achieve final pressure (e.g.100psig) at depressuring time (e.g. 15 min)

The longer the depressuring time, the higher the depressuring load

Set final pressure = 100 psig Or 50 % design pressure *)

-100 psig for thickness less than 1 inch -and 50% DP for more

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*)check in my blog : www.process-eng.blogspot.com Article : basic depressuring - why 15 minutes?

MAX. Cv MIN. System Temperature (during depressuring) MIN. outlet RO Temperature (during depressuring) MAX. FLOW for fire case

PERFORMANCE

Result in peak flow to flare = 10740 lb/hr Max Cv = 16.63

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HYSYS Tool / Utilities or CTRL+U *)

Select stream BASIS SIMULATION ADIABATIC Rename : Adiabatic Case

1ST step

2nd step

Fill all of data similar with FIRE CASE except that volume of liquid based on LLL
LLL mean lower liquid increase isentropic efficiency will result in lower final temperature (see page 12) Lower liquid lower flashed vapor formed from liquid phase will result in shorter depressuring time

3rd

step

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Select : Adiabatic
No heat input

During a fire case the vessel is covered with flame. In this case, heat loss to the surrounding atmosphere determined by taking a normal atmospheric temperature is generally not correct as the vessel's surrounding temperature is very high. You should use no heat loss, select NONE for FIRE CASE
NONE for ADIABATIC Can be applied if the fluid temperature is lower than the environment temperature. SIMPLE for ADIABATIC

Select : None
HYSYS does not account for any heat loss

Heat Loss Parameter :

Use NONE for FIRE CASE Use SIMPLE for ADIABATIC except for system which is the fluid temperature lower than environment , NONE model should be applied (for lower final temperature)

I suggest you to use SIMPLE heat loss model for accurate calculations. Use default values except the AMB temperature.
I suggest you to use DETAILED model for accurate calculations IF ONLY you know what to do :- ) (I myself dont know how to use this option,,suusahhh cuuukkk).

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See page .10 about Pb Fill CV as FIRE CASE result Cv = 16.63 see page 14

Cf = Cf in accordance with FIRE CASE Cf 0.9 1.0

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Fill 100% for worst case

For gas-filled systems 80% to 100% For liquid filled systems 50% to 70%

For small system, or liquid filled system, engineering adjustment should be used. The lower efficiency shall be used for accurate calculation

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Depressurized from operating pressure*) TRIAL depressuring time to meet final pressure 0 psig HYSYS will calculate final pressure based on depressuring time

use Calculate Pressure mode

In some cases, the final pressure cant meet 0 psig, (slightly above 0 psig). The system cant be decrased to lower pressure. its OK

The fact, the fluid is released to flare. The pressure of the system is correspond to the back pressure . Therefore, the final pressure is slightly above atmospheric condition
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Required adiabatic depressuring time

Min Temperature outlet RO Min Temperature In the system

Adiabatic peak flow

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Select File

Select : # Temperature # Pressure # Mass Flow

VIEW strip chart Depressuring profile

VIEW result in Table Depressuring data

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also click PERFORMANCE/ STRIP CHARTS

An example : show table

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Aspen HYSYS does not take the volume of the vessel heads into account so the volume will be the liquid in the cylindrical portion only. Aspen HYSYS defaults the volume to be equal to the volumetric flow of the feed BASIS SIMULATION. This will be disproportionate to the total volume inventory calculation where the certain margin volume is applied. Aspen HYSYS defaults the height and diameter vessel in accordance with the volume. This may be disproportionate to the actual total wetted area calculation. At present, Aspen HYSYS does not have the option for jet fire case where the heat flux is more than 21.000 BTU/hr ft^1.64. The method of spreadsheet can be used to model jet fire case. API recommends depressuring to the lower of 50% of the initial pressure or 100 psig / 6.9 barg. PV work term gas-filled systems 80% to 100% liquid filled systems 40% to 70% A higher efficiency results in a lower final temperature If one is checking that the minimum temperature of the vessel will not fall below a certain value (for example, for validating the steel alloy grade), and then 100% will give the most conservative result.

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