Sizing of relief valves for

supercritical fluids
March 23
rd
, 2011
Alexis Torreele
Overview
Jacobs Introduction
Relief Valve Study An Engineering Approach
Relief Calculation for Supercritical Fluids
Introduction
Theoretical Background
Example Case
Discussion & Evaluation
Jacobs
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Relief Valve Study
An Engineering Approach
Relief Valve Study An Engineering Approach
Gather info:
P&IDs
Equipment data
Etc.
Define relief scenarios:
E.g.: External fire, Blocked outlet, etc.
Use list API 521 as guidance
Use tools as HAZOP, PLANOP, client specific methods
to determine applicable scenarios
Relief Valve Study An Engineering Approach
Calculate relief scenarios
Relief load
Relief valve orifice size
Determine governing case
General approach:
Scenario requiring the largest orifice size
=
Governing case
Relief Valve Study An Engineering Approach
Verify inlet and outlet conditions
Pressure drop over inlet (< 3% of set pressure)
Pressure at outlet (backpressure):
Superimposed backpressure: static pressure (if variable:
NO conventional type valve)
Built-up backpressure: pressure increase as result of relief
flow (< 10% for conventional, < ca. 50% for balanced & >
50% for pilot operated type valves)
Relief Valve Study An Engineering Approach
Determine safety valve type:
Conventional spring-loaded
Balanced bellows
Pilot operated
Mechanical stress analysis
Flare network study
Relief Calculation for
Supercritical Fluids
Introduction
Objective:
Calculate mass relief flow, volume relief flow and required orifice
size of heat-input driven relief cases on systems with supercritical
relief temperature and/or pressure.
Examples:
Fire case for a Vessel
Blocked-in Heat Exchanger
References:
R. Ouderkirk, Rigorously Size Relief Valves for Supercritical Fluids,
CEP magazine, pp. 34-43 (Aug. 2002).
L. L. Simpson, Estimate Two-Phase Flow in Safety Devices, Chem.
Eng., pp. 98-102, (Aug. 1991).
Theoretical Background
Definition of enthalpy:
H = U + pV (1)
dH = dU + Vdp + pdV (2)
dU = Q pdV (3)
Combining (2) & (3)
dH = Q + Vdp (4)
p is constant during relief; hence,
H = Q (5)
And,
H/ t = Q (6)
Theoretical Background
Heat input = Enthalpy change
H
i
(H)
p
H
i+1
t * Q
V
i
t V
i+1
V/ // / t
H: Specific enthalpy
V: Specific volume
Q: Heat input
t: Time
Example Case Information
Fire case for a Vessel
Process Data (normal operation):
Content: Methane
Crit. Temp. -82,7 C
Crit. Press. 45,96 bara
Level: 60% Liquid
Pressure: 10 barg
Temperature: -122 C
Volume: 10 m
Area: 25 m
Q
fire
SP
50barg
Example Case Relief Process Overview
1 2 Heating before Relief: Isochoric process
No volume or mass change (no relief)
2 3 Relief: Isentropic flash
Adiabatic & frictionless flow through relief valve
2 2 Relief Progression: Isobaric process
System at constant pressure (i.e. relief pressure)
P-E Diagram of Methane
0.1
1
10
100
-100 100 300 500 700 900 1100 1300 1500
Enthalpy (kJ/kg)
P
r
e
s
s
u
r
e

(
b
a
r
)
= 1kg/m
3
= 0,1kg/m
3
= 10kg/m
3
= 100kg/m
3
T

=

1
0
0
K
T

=

2
0
0
K
T

=

1
5
0
K
T

=

3
0
0
K
T

=

4
0
0
K
T

=

5
0
0
K
1
2 2'
3 3'
+ Qfire
+ Qfire
Density [kg/m] - Temperature [K] - Entropy [kJ/(kgK)]
= 400kg/m
3
Relief
Press.
Example Case Calculation Steps
Step 1: Select Property Method
Step 2: Gather Relief Case Information
Step 3: Determine Heat Input
Step 4: Calculate Physical Properties
Step 5: Calculate Relief Flow Rate
Step 6: Determine Isentropic Choked Nozzle Flux
Step 7: Determine Required Orifice Size
Example Case Step 1
Select Property Method
Requirements:
Suitable for respective component(s)
Accurate for the relevant pressure and temperature range
(P
r
> 1 // T
r
> 1)
Accurate for both liquid and gas properties
Important:
Always verify property method with empirical property data!
Example Case Step 1
Selected Method: Lee Kesler
Fit for light hydrocarbons
Application range
P
r
: 0 to 10 (up to ca. 460 bara)
T
r
: 0,3 to 4 (ca. -216 to 485 C)
One correlation for both liquid as well as vapor phase
No distinguishable transition from supercritical liquid to
supercritical vapor
Integration of the thermal properties with the other
physical properties
Thermodynamic cohesiveness
Example Case Step 2
Gather Relief Case Information
Relief pressure:
PSV set press.: 50 barg
Fire case relief press.: 121 % of set pressure
Relief press.: 61,5 bara (P
r
= 1,3)
Initial relief temperature:
Considering an isochoric process:
(T
ini
(p
ini
))
ini
(T
rlf
(p
rlf
))
ini
(T
ini
(10barg))
ini
(T
rlf
(61,5barg))
ini
-122C -77C
Example Case Step 3
Determine Heat Input
API 521 external pool fire, heat absorption for liquids:
Q
fire
= 43.200 * f *
0,82
With f = 1 (no fireproof insulation / bare metal vessel)
= 25 m
Q
fire
= 605,05 kW
= 2.178.196 kJ/h
: Wetted surface [m]
f: Environment factor [-]
Q: Heat input [W]
Example Case Step 4
Calculate Physical Properties
Determine the specific volume (V), specific enthalpy (H) & entropy (S)
at initial relief conditions:
Applying property method correlations in Excel spreadsheets
Using property models in Simulation Tools (Pro/II, Aspen Plus, etc.)
Reiterate at increasing temperatures:
At relief pressure
Step size: ca. 3C
# iterations: see later
P-E Diagram Methane
0.1
1
10
100
-100 100 300 500 700 900 1100 1300 1500
Etnhalpy (kJ/kg)
P
r
e
s
s
u
r
e

(
b
a
r
)
= 1kg/m
3
= 0,1kg/m
3
= 10kg/m
3
= 100kg/m
3
T

=

1
0
0
K
T

=

2
0
0
K
T

=

1
5
0
K
T

=

3
0
0
K
T

=

4
0
0
K
T

=

5
0
0
K
1
2 2'
3
3'
+ Qfire
+ Qfire
Density [kg/m] - Temperature [K] - Entropy [kJ/(kgK)]
= 400kg/m
3
Example Case Step 4
0,01459 -8,7 10,079 -38
0,01414 -18,7 10,036 -41
0,01303 -43,7 9,927 -47
0,01259 -53,7 9,882 -50
0,01193 -68,7 9,814 -53
0,01127 -83,7 9,746 -56
0,01062 -98,7 9,676 -59
0,00978 -118,7 9,582 -62
0,00896 -138,7 9,487 -65
0,00781 -168,7 9,341 -68
0,00662 -203,7 9,169 -71
0,00527 -253,7 8,920 -74
0,00455 -288,7 8,742 -77
V, m
3
/kg H, kJ/kg S, kJ/(kg.K) T, C
Example Case Step 5
Calculate Relief Flow Rate
Volumetric flow rate:
Mass flow rate:
H
V
Q V

=
& &
V
V
m
&
&
=
H: Specific enthalpy [kJ/kg]
V: Specific volume [m/kg]
V: Volume flow [m/s]
m: Mass [kg]
m: Mass flow [kg/s]
Q: Heat input [kW]
Example Case Step 5
-
1,899
2,061
2,124
2,232
2,340
2,448
2,588
2,714
2,849
2,891
2,710
2,389
m, kg/s
0,01459
0,01414
0,01303
0,01259
0,01193
0,01127
0,01062
0,00978
0,00896
0,00781
0,00662
0,00527
0,00455
V, m
3
/kg
-
0,02686
0,02687
0,02674
0,02662
0,02638
0,02602
0,02532
0,02432
0,02227
0,01916
0,01427
0,01088
V, m
3
/s
-8,7 10,079 -38
-18,7 10,036 -41
Max. volume flow -43,7 9,927 -47
-53,7 9,882 -50
-68,7 9,814 -53
-83,7 9,746 -56
-98,7 9,676 -59
-118,7 9,582 -62
-138,7 9,487 -65
-168,7 9,341 -68
Max. mass flow -203,7 9,169 -71
-253,7 8,920 -74
-288,7 8,742 -77
H, kJ/kg S, kJ/(kg.K) T, C
Example Case Step 6
Determine Isentropic Choked Nozzle Flux
For each relief temperature calculate the choked
nozzle flux:
Iteratively, at decreasing
outlet pressure:
And, along isentropic path:
Max. flux = Choked flux
( )
b
b 0
V
H H 2
G

=
b 0
S S =
H: Specific enthalpy [J/kg]
V: Specific volume [m/kg]
G: Mass flux [kg/(m.s)]
S: Entropy [kJ/(kg.K)]
0
: Inlet condition
b
: Outlet condition
P-E Diagram Methane
0.1
1
10
100
-100 100 300 500 700 900 1100 1300 1500
Etnhalpy (kJ/kg)
P
r
e
s
s
u
r
e

(
b
a
r
)
= 1kg/m
3
= 0,1kg/m
3
= 10kg/m
3
= 100kg/m
3
T

=

1
0
0
K
T

=

2
0
0
K
T

=

1
5
0
K
T

=

3
0
0
K
T

=

4
0
0
K
T

=

5
0
0
K
1
2 2'
3
3'
+ Qfire
+ Qfire
Density [kg/m] - Temperature [K] - Entropy [kJ/(kgK)]
= 400kg/m
3
Example Case Step 6
Relief temperature: -68 C
17479
17931
18058
16496
14009
10248
-
G, kg/(m.s)
T
0
, p
0
:
-185,0 0,01309 34,5 -92
-179,5 0,01134 39,0 -88
: G
Choked
-174,7 0,00988 43,5 -85
-170,4 0,00924 48,0 -80
-166,4 0,00878 52,5 -76
-162,5 0,00840 57,0 -72
-158,8 0,00808 61,5 -68
H
b
, kJ/kg V
b
, m/kg p
b
, bara T
b
, C
Example Case Step 6
Iteration = time consuming process!!
Alternative method: use simplified correlations to
determine isentropic choked flux
J.C. Leung, A Generalized Correlation for One-component
Homogeneous Equilibrium Flashing Choked Flow, AIChE Journal,
pp. 1743-1746 (Oct. 1986).

0
0
choked
V
p
G

ATTENTION: 2-phase flow

Relief of supercritical fluids can lead to 2-phase flow!
Homogenous Equilibrium Model (HEM)
Assumptions
1. Velocities of phases are equal
2. Phases are at thermodynamic equilibrium
Formula applies:
And H= x
L
.H
L
+ (1-x
L
).H
G
V= x
L
.V
L
+ (1-x
L
).V
G
( )
b
b 0
V
H H 2
G

=
H: Specific enthalpy [J/kg]
V: Specific volume [m/kg]
G: Mass flux [kg/(m.s)]
0
: Inlet condition
b
: Outlet condition
L
: Liquid phase
G
: Gas phase
Example Case Step 7
Determine Required Orifice Size
API 521:
With backpressure correction, K
b
= 1 (backpressure << 10%)
combination correction, K
c
= 1 (no rupture disk)
discharge coefficient, K
d
= 0,975 (assuming vapor)
viscosity correction, K
v
= 1
v d c b choked
K K K K G
m
A
&
=
A: Effective orifice area [m]
m: Mass flow [kg/s]
G
choked
: Choked mass flux [kg/(m.s)]
Example Case Step 7
-
1,899
2,061
2,124
2,232
2,340
2,448
2,588
2,714
2,849
2,891
2,710
2,389
m, kg/s
-
-
-
141
-
-
-
-
152
155
153
-
96
A, mm
0,01459
0,01414
0,01303
0,01259
0,01193
0,01127
0,01062
0,00978
0,00896
0,00781
0,00662
0,00527
0,00455
V, m
3
/kg
-
0,02686
0,02687
0,02674
0,02662
0,02638
0,02602
0,02532
0,02432
0,02227
0,01916
0,01427
0,01088
V, m
3
/s
-8,7 10,079 -38
-18,7 10,036 -41
-43,7 9,927 -47
-53,7 9,882 -50
-68,7 9,814 -53
-83,7 9,746 -56
-98,7 9,676 -59
-118,7 9,582 -62
-138,7 9,487 -65
Req. Nozzle Size -168,7 9,341 -68
-203,7 9,169 -71
-253,7 8,920 -74
-288,7 8,742 -77
H, kJ/kg S, kJ/(kg.K) T, C
Calculation Results
40%
50%
60%
70%
80%
90%
100%
200 210 220 230 240 250
Temperature (K)
Orifice Area
Volume Relief Rate
Mass Relief Rate
Example Case Results
When all values (relief volume flow, mass flow and nozzle size)
decrease with increasing relief temperature: stop iterations.
Determine selected effective orifice (API 526) based on maximum
calculated nozzle size value:
Max. nozzle size value: 155 mm
Selected standard orifice: 198 mm (F - orifice)
Calculate pressure drop over inlet and discharge
Determine safety valve type (conventional, balanced bellows, pilot
operated)

Example Case Conclusions
Specific calculation method is required:
Fluids that are below critical conditions in normal operation
can have super critical relief
Max. mass flow Max. volume flow Min. required nozzle
size
Required nozzle size determined using a simplified method
(API 521 5.15.2.2.2): 254 mm vs. 155 mm
Extra Slides
Safety Valve Types
Bellows
Pilot
Conventional
Balanced
Bellows
Pilot Operated
General flux equation
( ) ( )
( )
|
|
|
|
|
|

\
|
(
(

+
|
|

\
|
+
+
=

t
2
2
f
g
P
P
f g
2
x 1 xS v ) x 1 (
S
xv
dp v ) x 1 xv 2
G
t
r