11-3842 PSV Jump Start

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®
A Brief Tutorial (and supplement to training and online documentation)
Nicholas Brownrigg, Product Marketing, Aspen Technology, Inc. Wilfried Mofor, Product Management, Aspen Technology, Inc.

© 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved.11-3842-0813

Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Adding a Pressure Relieving Device to a HYSYS Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Designing and Sizing a Pressure Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valve Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Scenario Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sizing Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Multiple Valve Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Line Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Documentation Builder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Introduction
When designing a chemical process and its equipment, safety is of substantial concern. All possible strategies should be considered to eliminate the risk of accident and injury when implementing a process design. One safety concern that occurs frequently in a plant is the over-pressurization of equipment or piping. In order to prevent dangerous bursts, explosions, and fires, pressure relief valves are designed and installed to bleed out excess liquid or vapor causing pressure build-up. Process conditions vary vastly at each location of a pressure relief valve. Because of this, and the strict regulation of safety equipment, completing a design of a pressure relief valve by hand can be a time consuming and laborious exercise. To solve this problem, Aspen HYSYS V8.3 has a pressure safety valve sizing feature, which uses data from a process simulation to help automate PSV calculations. Aspen HYSYS uses common valve design standards, most notably API 520, 521, to determine pressure relief valve sizing information and values. 25 common overpressure scenarios are included in the program and can be analyzed and sized for. Aspen HYSYS also features a line sizing functionality, allowing the user to quickly choose the schedule and diameter according to pressure drop and fluid velocity constraints for piping entering and leaving the pressure safety valve. Line sizing is completed in Aspen HYSYS without having to perform any fluid flow computations. The documentation builder pulls valve sizing and process variable information directly from simulation to automatically complete required forms normally requiring manual incorporation. This Jump Start guide will walk the reader through the process of using pressure relief valve features in Aspen HYSYS towards designing a pressure relief valve. AspenTech recommends that a range of other resources be called upon in conjunction with this document to give the user a comprehensive view of how to use Aspen HYSYS. These may include: • AspenTech support website (support.aspentech.com) – contains information on the use of AspenTech products and provides answers to frequently asked questions. • AspenTech courseware available in on-line and in-person versions • AspenTech business consultants This document will show how to size pressure safety valves using Aspen HYSYS V8.3. It assumes that the user has Aspen HYSYS V8.3 or higher installed on her or his computer and a functional process design completed.

© 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved.11-3842-0813

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Adding a Pressure Relieving Device to a HYSYS Simulation
In order to add a pressure safety valve to a HYSYS process flowsheet, the user must enter the ‘Safety Analysis’ environment. This environment provides a setting for relief scenario setup and PSV sizing and documentation. After designing a process in Aspen HYSYS and converging the simulation, click on ‘Pressure Relief’ in the Home ribbon of the HYSYS Simulation environment to enter the Safety Analysis environment. Alternatively, the ‘Safety Analysis’ button, located on the bottom left of the Aspen HYSYS program, can be used. Both options are shown below in Figures 1 and 2.

Figure 1. Pressure Relief Button on Home Tab

Figure 2. Safety Analysis Option in Aspen HYSYS

After opening the Safety Analysis viewing window, select the ‘Unit Operations’ option in the navigation pane on the left of the screen. This will display all the unit operations and subflowsheets present in the simulation for which a pressure safety valve can be designed. Also, in the navigation pane is the “Unattached Streams” option, in which floating/dangling streams with no connections to process models are located (Figure 3).

Figure 3. Location of Unit Operations and Unattached Streams Menus in Safety Analysis Panel

To add a PSV to a simulation, click the ‘Add PSV’ option on the ribbon in the Safety Analysis environment. This switches the cursor into attach mode. Move the mouse to hover over the arrow of a stream on which a PSV is necessary. A blue box appears as the target for unit operation exit streams. Click on the blue box to attach a relief valve to that location.

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Figure 4. Add PSV Option in Safety Analysis Environment

A PSV can also be added using the navigation pane. Open the ‘Unit Operations’ or ‘Unattached Streams’ node and right click the desired block or stream. Scroll to highlight the ‘Create PSV’ option. When prompted, select which stream the valve should be located on. An example of this PSV addition method is shown in Figure 5.

Figure 5. Adding a Pressure Safety Valve and Selecting the Appropriate Stream

A PSV will be placed on the flowsheet in the Safety Analysis environment after following one of the methods described above. Figure 6 shows an example flowsheet with a PSV attached to a stream connected to a process unit, while Figure 7 shows a PSV attached to a single stream unaffiliated with any unit operations.

© 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved.11-3842-0813

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Figure 6. Process Stream with PSV

Figure 7. Unattached Stream with PSV

Designing and Sizing a Pressure Safety Valve
Adding a pressure safety valve to a unit operation in a simulation allows the user to open tabs in which the pressure safety valve can be designed and sized to meet relief specifications and requirements.

Valve Design
Double-clicking on a pressure safety valve on the flowsheet opens the ‘Valve Design’ tab, shown in Figure 8. In this tab, general valve design details are input.

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Figure 8. Valve Design Tab

First, choose the appropriate options from the dropdown menus to define the valve material of construction, valve type, and valve discharge. Next, the valve design temperature and the set pressure at which the valve opens should be specified. After doing so, set a value for the superimposed backpressure present in the valve, according to design calculations. If the valve will have a rupture disk, ensure that the ‘Rupture Disk Factor’ entry has a value of 0.9. If there will be no rupture disk, this value should be 1. Click the ‘Create Scenario’ button above the scenario list table to evaluate multiple relief scenarios for which a relief valve is necessary and obtain PSV sizing for each scenario. The ‘Create Scenario’ button and a populated scenario list table are shown in Figure 9.

Figure 9. Creating a Scenario in the Valve Design Tab

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

After clicking the ‘Create Scenario’ option, a new pressure relief scenario is created in the scenario list table. To open the ‘Scenario Setup’ tab and obtain a relief load and PSV size, simply click the emergency scenario name on the scenario list table. Another method of opening the ‘Scenario Setup’ tab is to return to the Unit Operations tree in the navigation pane (Figure 10). Click the PSV option under its corresponding unit block to open the scenario listing. Then, choose the applicable scenario to open the ‘Scenario Setup’ tab.

Figure 10. Opening Scenario Setup Tab from Unit Operations Tree

Scenario Setup
After clicking on a scenario or choosing a scenario from the navigation pane, the ‘Scenario Setup’ tab, shown in Figure 11, appears.

Figure 11. Scenario Setup Tab

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Included in Aspen HYSYS are four different design codes. The four codes are API 520 & 521, ASME VIII, PD 5500, and EN 13445. Select the pertinent design code from the dropdown menu before continuing. Enter the relieving temperature necessary for the given relief scenario being analyzed before proceeding to calculation of the relieving pressure. Click the ‘Calc…’ button next to the Relieving Pressure box to bring up the window shown in Figure 12.

Figure 12. Relieving Pressure Calculation Window

In the Relieving Pressure Calculation window, input the allowable overpressure percentage, which determines the amount of pressure that can build up beyond the set pressure before the valve opens. After finishing, verify that the relieving pressure is correct, and select ‘OK’ to continue. Similar to the Relieving Pressure Calculation window, clicking ‘Calc…’ next to the Total Backpressure box opens the window displayed in Figure 13. Set the parameters describing the backpressure and click ‘OK’ to continue.

Figure 13. Backpressure Calculation Window

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Enter the valve discharge coefficient if the value differs from the default value of 0.9750. Then, choose the failure scenario type under the Relief Load grouping. To obtain a relieving flow load, a manually calculated value can be entered or the reference flow value from the HYSYS process stream that the PSV is attached to can be used. Additionally, if a relief scenario that is highlighted in blue on the scenario list (Fire, Control Valve Failure, Exchanger Tube Rupture, Fan Failure, or Reflux Failure) is chosen, the relief load can be calculated in Aspen HYSYS by selecting the ‘Calculated’ radio button and by providing more parameters surrounding the scenario where prompted. Figure 14 shows the scenarios available in the Scenario Type list, while Figure 15 shows a sample relieving load calculation for a Fire relief scenario..

Figure 14. Relief Load Scenarios Available

Figure 15. Sample Calculation of Relieving Flow for Fire Relief Scenario

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

When all scenario input is complete, Aspen HYSYS will display valve sizing results in the table on the right-hand side of the tab, detailed in the next section of this guide.

Sizing Results
After finishing parameter input in the Valve Design and Scenario Setup tabs, the valve sizing results will be displayed in the Valve Results table (Figure 16), located within the Scenario Setup tab.

Figure 16. Valve Results Table inside ‘Scenario Setup’ Tab

The results table includes important information required to choose an appropriate safety valve for installation. The calculated orifice area and valve coefficient are given. Also provided is the level of noise, in decibels, that the valve will make at a given height when in use. Using the calculated orifice area, the user is prompted to select an actual standardized orifice size for the valve from a dropdown menu in the Valve Results table (Figure 17). It is recommended to pick the next largest orifice size from the calculated orifice size in order to ensure correct valve operation. For example, in Figure 17, because the calculated orifice is 8.442 cm2, the user should select the 11.858 cm2 option from the dropdown menu. After selecting an orifice size, the valve’s rated capacity and capacity used is displayed, along with orifice design information and in and out flange sizing.

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Figure 17. Selected Orifice Dropdown Box with Options

If the scenario being analyzed is the basis case for which the valve is sized, select the ‘Sizing Case’ box, next to the Scenario Name input box. Then, return to the Valve Design tab to proceed to line sizing for the relief valve.

Multiple Valve Sizing
If the computed relief load is too large to be relieved using just one pressure safety valve, it is necessary to pass the relieving flow through multiple pressure valves. Successful sizing of multiple valves for a stream in Aspen HYSYS requires returning to the Simulation environment and using a tee splitter block to divide the relief load stream into multiple streams equal to the number of relief valves necessary. Figure 18 shows an example flowsheet with a tee splitter for the ‘Vap Outlet’ stream in the process split into two separate relief load streams.

Figure 18. Tee Block to Size Multiple Valves for ‘Vap Outlet’ Stream

Double-click the stream entering the tee block, and define its conditions, properties, and composition by selecting the ‘Define from Other Stream…’ button that appears in the material stream window (Figure 19), and then select the appropriate stream to be relieved by multiple valves.

© 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved.11-3842-0813

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Figure 19. ‘Define from Other Stream…’ Option in Relief Load Material Stream Window

Return to the flowsheet, double-click the tee block, go to the parameters section, and input the appropriate flow ratio for each stream exiting the splitter to define how the flow of the relief load will be split amongst the valves (Figure 20).

Figure 20. Defining the Flow Ratio for the Relief Load Splitter

After setting up the tee block to split the relief load flow, return to the Safety Analysis environment. Add a PSV to each stream exiting the tee block, such that the streams exiting the tee block look similar to the ones shown in the flowsheet in Figure 21.

© 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved.11-3842-0813

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Figure 21. Safety Analysis Environment Flowsheet with PSVs Attached

Proceed to size the safety valves as previously described in this guide, except use a 16% allowable overpressure when determining the relieving pressure for the valve with the highest flow rate and an 11% allowable overpressure for all subsequent valves with lesser flowrates.

Line Sizing
Return to the Valve Design tab after creating and sizing all scenarios requiring a pressure relief valve. The scenario list in the Valve Design tab will now be populated with sizing information regarding each scenario. If not done before, use the ‘Sizing Case’ check box on the scenario list, Figure 22, to choose which failure scenario the valve will be sized for.

Figure 22. Scenario List Table Inside Valve Design Tab with Selected Sizing Case Scenario

Selecting a sizing case enables the ‘Line Sizing’ tab for selection. Click the ‘Line Sizing’ tab, as shown in Figure 23, to begin line sizing for the pressure safety valve.

Figure 23. Location of Line Sizing Tab

Under the line sizing tab, the piping in and out of the pressure safety valve can be chosen. If the pipe size chosen by the user is too small to accommodate relief flow or too large such that the pressure gradient will not allow for relief flow, Aspen HYSYS will alert the user using the bar on the bottom of the tab so that an incorrect design is not selected. If the bar is green, it means that an appropriate line size has been selected, while yellow means there is either a fluid pressure or velocity constraint being violated by the chosen line sizing.
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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Specify the nominal diameter and schedule of the piping for the in and out lines. Aspen HYSYS will calculate the flowrate through the pipes, along with the change in pressure and velocity. These results are displayed in the ‘Line Sizing Results’ table. Figure 24 shows the Line Sizing tab layout.

Figure 24. Layout of Line Sizing Tab

Documentation Builder
After completing all design and sizing for a pressure relief valve, filling out documentation is required in order to meet regulated safety compliances and for valve vendor submission. In order to reduce tedium in this area, Aspen HYSYS has a documentation builder function inside the Safety Analysis environment, which pulls data from the simulation and valve sizing to automatically complete required forms. To access the customizable documentation builder, click the ‘Documentation Builder’ option from the home ribbon. Similarly, to obtain a built-in HYSYS report, choose the desired option, located to the left of the ‘Documentation Builder’ option (Figure 25).

Figure 25. Documentation Builder and HYSYS Reports Options While in Safety Analysis Environment

The Built-in HYSYS Reports feature provides instant documentation of valve parameters and relieving conditions gathered directly from the safety analysis relief scenario being analyzed. Built-in HYSYS reports are not editable; the Documentation Builder should be used for more in-depth, editable reporting. Shown in Figure 26 is an example HYSYS Calculation Sheet.

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Figure 26. Example Built-in HYSYS PSV Calculation Report

Clicking the Documentation Builder option initiates Microsoft Access, which houses the customizable forms to be completed after designing and sizing a pressure relief valve. From the documentation builder’s home screen, shown below in Figure 27, a list of relief devices sized in Aspen HYSYS can be edited or viewed. Additionally, process data sheets, mechanical data sheets, calculation summary sheets, or relief load summary sheets can be constructed. Information from the sheets can be exported to Microsoft Excel by selecting any of the respective ‘Export’ options.

Figure 27. Microsoft Access Documentation Builder Selection Screen

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Choosing the edit option for any of the forms from the documentation builder brings up a screen allowing the user to change the information that will appear in the final, viewable report. Many entries are already populated by values pulled directly from Aspen HYSYS. These are denoted in grey. The spaces in white require user input to be completed. A sample edit page for a mechanical data sheet is shown in Figure 28.

Figure 28. Edit Page for Mechanical Data Sheet

After entering the pertinent information for a datasheet on its edit page, return to the documentation builder home screen, then select ‘View’ to see a copy of the finalized version of the document chosen. After opening a document using the ‘View’ option, it can then be saved electronically or printed. Figure 29 shows a completed sample mechanical data sheet, given the input information from the edit page shown in Figure 28.

© 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved.11-3842-0813

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Figure 29. Completed Example Mechanical Data Sheet

Completing documentation using the documentation builder in Aspen HYSYS reduces the time needed to complete safety valve paperwork to submit to regulatory agencies and valve vendors.

© 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved.11-3842-0813

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Jump Start: Pressure Safety Valve Sizing in Aspen HYSYS ®

Conclusions
Pressure relief valve design and sizing can be a tedious, lengthy process. Relief valve sizing in Aspen HYSYS allows the user to design pressure relief valves quickly using a small amount of process information at the location of the valve. Aspen HYSYS now encompasses all facets of the valve design process into one convenient location. In addition, various scenarios involving multiple valves can be explored to find the most optimal relief schedule for a unit. Aspen HYSYS can also serve as an accuracy check to ensure that safety equipment has been properly rated and will perform properly, if needed. It helps designers complete their work faster so that safety equipment can be installed and implemented sooner. All processes need to have proper safety precautions to avoid disaster and Aspen HYSYS continues to help make all processes as safe as possible with each use.

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.

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

© 2013 Aspen Technology, Inc. AspenTech®, aspenONE®, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved.11-3842-0813

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Worldwide Headquarters
Aspen Technology, Inc. 200 Wheeler Road Burlington, MA 01803 United States phone: +1–781–221–6400 fax: +1–781–221–6410 [email protected]

Regional Headquarters About AspenTech
AspenTech is a leading supplier of software that optimizes process manufacturing—for energy, chemicals, engineering and construction, and other industries that manufacture and produce products from a chemical process. With integrated aspenONE® solutions, process manufacturers can implement best practices for optimizing their engineering, manufacturing, and supply chain operations. As a result, AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become more energy efficient. To see how the world’s leading process manufacturers rely on AspenTech to achieve their operational excellence goals, visit www.aspentech.com. Houston, TX | USA phone: +1–281–584–1000 São Paulo | Brazil phone: +55–11–3443–6261 Reading | United Kingdom phone: +44–(0)–1189–226400 Singapore | Republic of Singapore phone: +65–6395–3900 Manama | Bahrain phone: +973–17–50–3000 For a complete list of offices, please visit www.aspentech.com/locations

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