Date: 09/11/07

Spreadsheet name: relief_rate_rev_0

Revision: 0
Std calculation number: PEL-BMS-CAL-P-0600
Revision Date: 09/11/07
Assigned Owner: JS

INTRODUCTION TO USE OF THIS RELIEF RATE SPREADSHEET.

This spreadsheet is a read only file and is also password protected. Once it has been opened
from the 'Approved Programs' directory it must be saved under a different name in a project directory.

Enter data as necessary in the light blue highlighted cells only. Note that no User Manual has been
produced for this program, all functions are explained within the worksheets.

Project specific information such as Client, Project, Job No. etc. and design conditions are entered
on the 'Input Data' sheet, the main calculation pages are also accessed from this sheet.

Once on an individual relief case page, data should be input in the light blue spaces. Three principal references
have been used to program these calculations, you may wish to refer to them for additional explanation,
they are as follows:
- API 520 / 521
- Crane
- Crane Technical Paper 410
- Masonelian Handbook
As these references provide all the technical backup required to use this program, no additional Technical
Manual has been produced.

Notes on the program have been included at each stage where necessary.

Limitations
This spreadsheet is intended for preliminary sizing only. Care must be taken if using the sizing spreadsheets
for detailed design, as more rigorous methods may give more accurate relief loads.
Relief valve areas are preliminary estimates only for the intention of determining the relief valve sizing case.

This spreadsheet is for use with equipment that have a design pressure in excess of 1 barg.
For design pressures below this, API 2000 shall be consulted.

The approved spreadsheet will be stored in the following directory:

S:\Engineering\Process\Calculation Spreadsheets\Approved software

Feedback: All feedback and any further queries regarding this spreadsheet should be sent to the assigned
owner indicated above

Revision History
Date Prepared Checked Approved
Revision 0 Software validated for use 11/15/2007 JS RL AB
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No.

Date Project
Originator Client
Checker Location
Approver Subject

NOTES:

Fill in basic data regarding relieving device in light blue spaces below.
Scroll to the right and select which relieving cases are valid by typing either
yes' or 'no' as appropriate in the yellow spaces. Where 'yes' is typed,
go to the appropriate worksheet and complete all highlighted cells.
Where 'no is typed, the appropriate worksheet can be ignored as the
summary table on the Results sheet is automatically updated.

BASIC DATA:

Relief Valve/Rupture Disc Number: PSV-43107A/B

Relief Valve/Rupture Disc Location: Fuel Gas KO Drum 10-V-4301

Upper Lower
Design Pressure (barg): 10 -0.005
Design Temperature (°C): 60 -10

RELIEVING CASES:

Define which relieving cases are relevant by typing 'YES' OR 'NO'

against each sizing method shown on the page below to define those cases.

Relief Case 1.1: Blocked Discharge - Gas Flow YES

Relief Case 1.2: Blocked Discharge - Liquid Flow No
Relief Case 1.3: Blocked Discharge - Mixed Flow No

Relief Case 2.1: Gas Blowby No

Relief Case 3.1: Fire - Vessel Containing Gas and Liquid No

Relief Case 3.2: Fire - Vessel Containing Gas Only YES

Relief Case 4.1: ESD Valve Failure & Backflow through NRV (Check Valve) No
Relief Case 4.2: ESD Valve Failure & Backflow Through Compressor No

Relief Case 5.1: Tube Failure - Gas Leak (Equivalent Liquid Volume) No

Relief Case 6.1: Thermal Relief - Liquid Expansion No

Relief Case 6.2: Thermal Relief - Liquid Vapourisation No

FOR ALL OTHER CASES AND ALSO WHERE THE CALCULATION METHOD IS NOT DEEMED APPROPRIATE,
GO DIRECTLY TO THE RESULTS SHEET TO INPUT RELIEF LOAD DATA GENERATED BY OTHER METHODS.
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 1.1: Blocked Discharge - Gas Flow

Percentage Overpressure % 10

Upstream Relief Pressure bara 12.01

Relieving Rate kg/h 1150

Relieving temp o
K 325.23

Compressibility 0.9768

Molecular weight 17.69

Isentropic exponent, Cp / Cv (See Note 1) 1.259
Eff. Discharge coefficient, Kd 0.975
Back pressure corr'n factor, Kb (Note 3) 1

Calculated C 343

Critical flow pressure bara 6.65

Required area (Note 2) mm2 160

Notes:

1. The sensitivity of the result to the value of the isentropic exponent should be observed.

Care should be taken to use a good estimate.

2. Basis for calculated orifice area is API RP 520 part 1.

3. For back pressure< 10% of set pressure, Kb = 1.0. Otherwise, for balanced bellows and conventional relief valves, refer

to API 520-I Figs 30 and 35 respectively.

 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 1.2: Blocked Discharge - Liquid Flow

Percentage Overpressure (Note 2) 10

Upstream Relief Pressure bara 12.01
Mass Flowrate kg/h 105,000
Specific gravity (water = 1) 1.05
Volumetric flowrate m3/h 100.0
Backpressure bara 5.6
Overpressure corr factor Kp. (Note 2) 1
Viscosity correction factor Kv. Based on API 520 Pt 1 Fig 36 1
Eff. Discharge coefficient Kd 0.65
Back pressure corr'n factor Kw. (Note 3) 1
Required area mm2 1222

Notes:
1. Basis for calculated orifice area is API RP 520 part 1 Equation 3.9 for non flashing liquid.
2. Valves in liquid service not requiring capacity certification can have overpressure up to 25%.
These valves can be sized by the same equation applying a correction factor Kp.from API 520 Pt I Figure 37.
3. For conventional valves, Kw = 1.0. For balanced bellows valves, refer to API 520 Pt I Figure 31.
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 1.3: Blocked Discharge - Mixed Flow

THE FOLLOWING METHOD IS TO BE USED AS AN INITIAL ESTIMATE OF THE ORIFICE AREA.

IMPROVED METHODS ARE THOSE DESCRIBED IN API 520 Pt I APPENDIX D (OMEGA PARAMETER).
HOWEVER, THE PREFERRED METHOD, ESPECIALLY FOR DETAILED DESIGN AND WHEN
THIS CASE GOVERNS PSV SIZING, IS THE HEM (HOMOGENEOUS EQUILIBRIUM MODEL) METHOD.

A - LIQUID RELIEF CALCULATION (Note 1)

Percentage Overpressure (Note 2) 10

Upstream Relief Pressure bara 12.01
Mass Flowrate kg/h 105,000
Specific gravity (water = 1) 1.05
Volumetric flowrate m3/h 100.0
Backpressure bara 5.6
Overpressure corr factor Kp. (Note 2) 1
Viscosity correction factor Kv. Based on API 520 Pt 1 Fig 36 1
Eff. Discharge coefficient Kd 0.65
Back pressure corr'n factor Kw. (Note 6) 1
Required area mm2 1222

B - VAPOUR RELIEF CALCULATION (Note 4)

Percentage Overpressure % 10
Upstream Relief Pressure bara 12.01
Relieving Rate kg/h 100000
Relieving temp o
K 323
Compressibility 0.9
Molecular weight 18
Isentropic exponent, Cp / Cv (See Note 3) 1.25
Eff. Discharge coefficient, Kd 0.975
Back pressure correction factor, Kb (Note 5) 1
Calculated C 342
Critical flow pressure bara 6.67
Required area (Note 4) mm2 13195

Total Required Area mm2 14417

Notes:
1. Basis for calculated orifice area is API RP 520 part 1 Equation 3.9 for non flashing liquid.
2. Valves in liquid service not requiring capacity certification can have overpressure up to 25%. These valves
can be sized by the same equationapplying a correction factor Kp.from API 520 Pt I Figure 37.
3. The sensitivity of the result to the value of the isentropic exponent should be observed.
Care should be taken to use a good estimate.
4. Basis for calculated orifice area is API RP 520 part 1.
5. For back pressure< 10% of set pressure, Kb = 1.0. Otherwise, for balanced bellows and conventional relief valves, refer
to API 520-I Figs 30 and 35 respectively.
6. For conventional valves, Kw = 1.0. For balanced bellows valves, refer to API 520 Pt I Figure 31.
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 2.1: Gas Blowby

(Method from Masoneilan Sizing Handbook Page 9 & GPSA Page 4-21)

Source of Blowby Gas - V-20001

Gas Blowby through Valve (Blowby Valve) - PCV-20XXX
Percentage Overpressure considered % 10.00

Body Size of Blowby Valve in 8.00

Type of Blowby Valve - Globe
Estimated Maximum Cv (100% Trim) of Blowby Valve - 92.55 (Note 3)
Pressure Drop Ratio Factor (Note 5) 0.70

Downstream Pressure of Blowby Valve barg 11.0

Upstream Conditions of Blowby Valve:-

Maximum Operating Pressure barg 110.0
Operating Temperature °C 50.0
Molecular Weight - 18.0
Specific Heat Ratio , Cp / Cv 1.25
Z 0.9

Actual Pressure Drop Ratio, DP / P1 0.892

Critical Pressure Drop Ratio 0.625

Gas Expansion Factor, Y 0.67

Flowrate kg/h 127,732

System Relief Pressure bara 12.01

Relieving temp o
K 323
Compressibility 0.9
Isentropic exponent, Cp / Cv (See Note 1) 1.25
Eff. Discharge coefficient, Kd 0.975
Back pressure corr'n factor, Kb (Note 4) 1
Calculated C 342
Critical flow pressure bara 6.67
Required area (Note 3) mm2 16854

Notes:
1. The sensitivity of the result to the value of the isentropic exponent should be observed.
Care should be taken to use a good estimate.
2. Basis for calculated orifice area is API RP 520 part 1.
3. An estimate of the required gas blowby valve Cv can be obtained by using the approved control valve sizing spreadsheet.
4. For back pressure< 10% of set pressure, Kb = 1.0. Otherwise, for balanced bellows and conventional relief valves, refer
to API 520-I Figs 30 and 35 respectively.
5. For Masoneilan this is Xt and values are given for a wide variety of valves in the Handbook Supplement. The equivalent in
GPSA is Xc and typical values are given in Figure 4-32.
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 3.1: Fire - Vessel Containing Gas and Liquid

Vessel Design Code ASME VIII

Percentage Overpressure considered % 21.00

Upstream Relieving Pressure Bara 13.11

Vessel Details:
Internal Diameter m 2.00
Length T/T m 8.00
Liquid Level m 3.00
Head Type (Note 2) VS
Theta (Horizontal only) (°) Not required
Wetted Surface Area - Vessel m² 23.18

Pipework Details:
Pipe Length - Wetted m 0
Pipe OD in 10
Wetted Surface Area - Pipework m² 0.0

Vapourisation Rate:
Total wetted surface area ft² 249.53
Adequate Drainage & Firefighting (Note 3) Yes
Environment Factor, F (Note 4) 1.00
Heat Absorbed, Q Btu/hr 1940267
Latent Heat, L (Notes 1,5) Btu/lb 80
Relieving Flow kg/h 11001

Relieving temp o
K 308
Compressibility 0.7
Molecular weight 16.7
Isentropic exponent, Cp / Cv (See Note 6) 1.75
Eff. Discharge coefficient, Kd 0.975
Back pressure corr'n factor, Kb (Note 1) 1
Calculated C 384
Critical flow pressure bara 6.24
Required area mm2 1060

Notes:
1. For back pressure< 10% of set pressure, Kb = 1.0. Otherwise, for balanced bellows and conventional relief valves, refer
to API 520-I Figs 30 and 35 respectively.
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 3.1: Fire - Vessel Containing Gas and Liquid

Notes:
1. THIS METHOD SHALL ONLY BE USED FOR INITIAL ESTIMATES AND FOR SIMPLE SINGLE COMPONENT SYSTEMS.
FOR MULTI-COMPONENT SYSTEMS, TEMPERATURE AND LATENT HEAT VALUES WILL VARY WITH TIME / RISE TO
RELIEF PRESSURE AND IT IS THEREFORE RECOMMENDED THAT A TIME DEPENDENT MODEL IS DEVELOPED USING
A PROCESS SIMULATION PACKAGE (E.G. HYSYS).
2. Head Type:
HH = Horizontal hemispherical
HS = Horizontal semi-ellipsoidal
VH =Vertical hemispherical head
VS = Vertical semi-ellipsoidal head
3. Based on API RP 521, Section 3.15.2.1.1
4. Environment factors for fire protection:
TYPE OF FACTOR F NOTES
INSTALLATION

1. Bare Vessels 1
2. Insulated Insulation shall resist dislodgement by
Vessels fire hose
(arbitary streams.
conductance*
Btu/hr ft2 °F
values)
W/m2 °C4 0.3
2 0.15
1 0.075
0.67 0.05
0.5 0.0376
0.4 0.03
0.33 0.026
3. Water 1 Deluge or Spray system should use
Application on 0.05-0.20
Keep GPM
top of percool
vessel sq ft.since
(0.15not
to 0.6
Bare Vessels m 3
/hr/m2) of
protected bytotal area.
internal liquid.
No reduction in F since system reliability
affected by weather, etc.

4. Depressuring 1 Reduction of pressure to near

and Emptying atmospheric will avoid vessel rupture and
Facilities. reduce available fuel. Remote control
required.

5. Underground 0 Not less than 15 cm below grade.

Storage
6. Earth Covered 0.03 Not less than 30 cm of earth covering.
Storage

5. For a preliminary estimate API 521 Fig A-1 can be used, with a minimum value of 50 Btu/lb. However, it's applicability is restricted
to single component paraffin hydrocarbons (or 2 components with small MW differences).
6. The sensitivity of the result to the value of the isentropic exponent should be observed.
Care should be taken to use a good estimate.
7. Basis for calculated orifice area is API RP 520 part 1.This worksheet sizes a relief valve for gas flow where flow is critical.
Critical flow occurs when the pressure downstream of the valve outlet nozzle is less than or equal to the critical flow pressure.
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 3.2: Fire - Vessel Containing Gas Only

(Method taken from API 521 Section 3.15.2.1.2)

Vessel Design Code ASME VIII

Percentage Overpressure considered % 21.0

Upstream Relieving Pressure Bara 13.11

Vessel Details:
Internal Diameter m 1.0
Length T/T m 3.0
Horizontal or Vertical V
Liquid Height m 0
Total Volume m3 2.62
Vessel Liquid Volume m3 0.00
Vessel Gas Volume m3 2.62
Wetted Area m² 0.00
Total Vessel Surface Area m² 11.60
Exposed Vapour Surface Area m² 11.60

Pipework Details:
Pipe Length - Wetted m 0
Pipe OD in 3
Wetted Surface Area - Pipework m² 0.0

Relief Load:
Upstream Relieving Pressure, Pr psia 190
Normal operating pressure, Pn Bara 8
psia 116.2
Normal operating temperature, Tn C
o
52
o
R 585.7
Total Surface Area m² 11.6
ft² 125
Percentage Assumed Exposed to Fire % 100
Total Surface Area Exposed to Fire ft² 125
Molecular Weight, MW - 17.69
Compressibility, Z - 0.9768
k = (Cp/Cv) - 1.259
C = 520*sqrt(k (2/(k+1))^((k+1)/(k-1))) - 343.1
Coefficient of Discharge, Kd - 0.975
Vessel Wall Temperature, Tw (Note 1) o
C 593.33
o
R 1560
Temperature @ Relieving Pressure, (Pr/Pn)*Tn o
R 958.5
(Tw - T1) o
R 601
F' - 0.014
Relief Load: lb/h 1,138
kg/h 516

Orifice Area:
Calculated Orifice Area in2 0.130
mm2 84.00

Notes:
1. Typical vessel wall temperature to use is 1100oF
2. The recommended minimum value of F is 0.01; when the minimum
value is unknown, F' = 0.045 should be used.
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 4.1: ESD Valve Failure & Backflow through NRV (Check Valve)

Percentage Overpressure considered % 10.0

Relieving Pressure Bara 12.0

Upstream Conditions (at NRV):

Fluid type V
Maximum Operating Pressure bara 130.0
Operating Temperature °C 80.0
Molecular Weight - 19.5
Compressibility - 0.90
Ratio of Specific Heats - 1.25
Liquid SG 1.00
Fluid density kg/m3 96.0

Pipe size inch 8

Pipe schedule 40
Pipe ID inch 7.981
mm 202.7
Particle size mm 1.0
Pressure drop across NRV bar 118.0
Annular gap width mm 1
Effective Inside diameter mm 200.7
Ratio inner diameter/outer diameter 0.990
Equiv Orifice diameter (Note 2) inch 0.55
mm 13.97
Discharge coefficient (Note 4) 0.60
Expansion factor (Notes 3, 5) 0.9

Backflow through Check Valve (Note 3) kg/h 14186

Vapour Relief (NRV downstream conditions)

Relieving Rate kg/h 14186
Relieving temp o
K 423
Compressibility 0.9
Isentropic exponent, Cp / Cv 1.75
Eff. Discharge coefficient, Kd 0.975
Back pressure corr'n factor, Kb (Note 6) 1
Calculated C 384
Critical flow pressure bara 5.71
Required area mm2 1835

Liquid Relief
Upstream Relief Pressure bara 12.01
Mass Flowrate kg/h 0
Specific gravity (water = 1) 1.13
Volumetric flowrate m3/h 0.0
Backpressure bara 5.6
Overpressure corr factor Kp. (Note 2) 1
Viscosity correction factor Kv. Based on API 520 Pt 1 Fig 36 1
Eff. Discharge coefficient Kd 0.65
Back pressure corr'n factor Kw. (Note 7) 1
Required area mm2 0
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 4.1: ESD Valve Failure & Backflow through NRV (Check Valve)
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 4.1: ESD Valve Failure & Backflow through NRV (Check Valve)

Notes:

1. It should be stressed that this failure is considered extremely unlikely as protection is afforded by two generically dissimilar check valves.

It is also assumed that one valve has failed to close that a solid particle has lodged in the check valve seat of the other and is preventing

the check valve from closing. It is further assumed that the leakage path is a circumferential annulus of width the same as that of the

solid particle diameter. This annulus is converted to an equivalent orifice diameter using a nomogram sourced from Optimum

Pipe Size Selection by Claude B. Nolte, Trans Tech Publications, 1978 (reproduced below).

2. Nomogram extracted from Optimum Pipe Size Selection by Claude B. Nolte, Trans Tech Publications, 1978

3. Based on restriction orifice sizing equations 3-21 and 3-22, Crane Technical Paper no. 410, Flow of Fluid. Applicable for both liquid

and gas service. For liquid service, Y=1.0

4. Flow coefficient C based on A-20 of Crane"Flow of Fluids Through Valves, Fittings and Pipes"

5. Expansion factor based on A-21 of Crane"Flow of Fluids Through Valves, Fittings and Pipes"

6. For back pressure< 10% of set pressure, Kb = 1.0. Otherwise, for balanced bellows and conventional relief valves, refer

to API 520-I Figs 30 and 35 respectively.

7. For conventional valves, Kw = 1.0. For balanced bellows valves, refer to API 520 Pt I Figure 31.
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 4.1: ESD Valve Failure & Backflow through NRV (Check Valve)
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 4.2: ESD Valve Failure & Backflow Through Compressor

Failure of Centrifugal Compressor Discharge ESD Valve

A - Compressor Recycle Valve 100% Open
B - Backflow through compressor casing via NRVs (Note 1)

Percentage Overpressure considered % 10.0

Relieving Pressure Bara 12.0
Compressor Tag Number - C-0403
ESD Valve Failure - PCV-14-NNNN

A - Compressor Recycle Valve 100% Open

Compressor Recycle Valve - PCV-14-NNNN
Body Size of Valve in 1.5
Type of Valve - Globe
(Method from Masoneilan Sizing Handbook Page 9)
Estimated Maximum Cv (100% Trim) of Blowby Valve - 92.55
Pressure Drop Ratio Factor (Note 7) 0.70

Downstream Pressure of Blowby Valve barg 11.0

Upstream Conditions of Blowby Valve:-

Maximum Operating Pressure barg 130.0
Operating Temperature °C 80.0
Molecular Weight - 19.5
Specific Heat Ratio , Cp / Cv 1.25
Z 0.90

Actual Pressure Drop Ratio, DP / P1 0.908

Critical Pressure Drop Ratio 0.625

Gas Expansion Factor, Y 0.67

Flowrate kg/h 150,085
Factor for anti-surge valve bypass (Note 8) 1.2
Sizing Flowrate kg/h 180,101

B - Backflow through Compressor

Ratio of Specific Heats @ upstream conditions - 1.25
Fluid density @ upstream conditions kg/m3 96.0

Pipe size inch 8

Pipe schedule 40
Pipe ID inch 7.981
mm 202.7
Particle size mm 1
Pressure drop across NRV bar 118.0
Annular gap width mm 1
Effective Inside diameter mm 200.7
Ratio inner diameter/outer diameter 0.990
Equiv Orifice diameter (Note 2) inch 0.55
mm 13.97
Discharge coefficient (Note 4) 0.6
Expansion factor (Notes 3, 5) 0.9
Backflow through Check Valve (Note 3) kg/h 14186
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 4.2: ESD Valve Failure & Backflow Through Compressor
Total Gas Flow kg/h 194,287
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 4.2: ESD Valve Failure & Backflow Through Compressor

Vapour Relief (NRV downstream conditions)

Relieving Rate kg/h 194287

Relieving temp o
K 80

Compressibility 0.90
Isentropic exponent, Cp / Cv 1.25
Eff. Discharge coefficient, Kd 0.975
Back pressure corr'n factor, Kb (Note 6) 1

Calculated C 342

Critical flow pressure bara 6.67

Required area mm2 12258

Notes:

1. It should be stressed that this failure is considered extremely unlikely as protection is afforded by two generically dissimilar check valves.

It is also assumed that one valve has failed to close that a solid particle has lodged in the check valve seat of the other and is preventing

the check valve from closing. It is further assumed that the leakage path is a circumferential annulus of width the same as that of the

solid particle diameter. This annulus is converted to an equivalent orifice diameter using a nomogram sourced from Optimum

Pipe Size Selection by Claude B. Nolte, Trans Tech Publications, 1978 (reproduced below).

2. Nomogram extracted from Optimum Pipe Size Selection by Claude B. Nolte, Trans Tech Publications, 1978

3. Based on restriction orifice sizing equations 3-21 and 3-22, Crane Technical Paper no. 410, Flow of Fluid. Applicable for both liquid

and gas service. For liquid service, Y=1.0

4. Flow coefficient C based on A-20 of Crane"Flow of Fluids Through Valves, Fittings and Pipes"

5. Expansion factor based on A-21 of Crane"Flow of Fluids Through Valves, Fittings and Pipes"

6. For back pressure< 10% of set pressure, Kb = 1.0. Otherwise, for balanced bellows and conventional relief valves, refer

to API 520-I Figs 30 and 35 respectively.

7. For Masoneilan this is Xt and values are given for a wide variety of valves in the Handbook Supplement. The equivalent in

GPSA is Xc and typical values are given in Figure 4-32.

 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 4.2: ESD Valve Failure & Backflow Through Compressor

8. Factor is dependent on the relative Cv of the bypass to the Cv of the anti-surge valve.If no bypass present, then use a factor of 1.0.
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 5.1: Tube Failure - Gas Leak (Equivalent Liquid Volume)

(Method: Crane Technical Paper 410)

Basis: Total flow discharging from a ruptured tube is the sum of flows from both sides of
the rupture. Calculation assumes the point of rupture occurs locally to the tubesheet.

Heat Exchanger - H-xxxx

Percentage Overpressure considered % 10.0
Shellside Relieving Pressure Bara 12.0
Tubeside Design Pressure Barg 145.0
Ratio Tube / Shell Design Pressure 0.1
Tube Failure Case is Credible

GAS IS TUBESIDE FLOWING MEDIUM

Tubeside Max Operating Pressure bara 130.0

ID of Tubes mm 19.5
Molecular Weight - 20.0
Relieving temp o
K 323
Compressibility 0.9
Molecular weight 20
Tubeside Density kg/m3 107.6
Pressure Drop bara 118.0
Pressure Ratio - 0.908
Ratio of Specific Heats (at std T and P) k 1.30
Discharge coefficient, C (Crane A-20) 0.60

A - TUBESHEET SIDE OF RUPTURE

Number of Velocity Heads - K1 - 1.5
Expansion Factor - Y1 (A-22 Crane) - 0.78
Pressure Ratio at sonic for K1 (Crane A-22) - 0.55
Expansion Factor at sonic for K1 (Crane A-22) 0.63
Mass Flow through Tubesheet kg/h 13,042

B - TUBE SIDE OF RUPTURE

Friction Factor - f (A-25 Crane) - 0.024
Tube Length - via Tube to rupture m 10
Number of Velocity Heads - K2 - 13.8
Expansion Factor - Y2 (A-22 Crane) - 0.88
Pressure Ratio at sonic for K2 (Crane A-22) - 0.79
Expansion Factor at sonic for K2 (Crane A-22) 0.71
Mass Flow through Tube kg/h 5,797

Total Flow (Tubesheet + Tube) kg/h 18,839

Note: Tube failure will lead to a rapid increase in the shellside pressure. A relief valve is an unsuitable device
to mitigate against this pressure rise, therefore a bursting disc is required.
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 6.1: Thermal Relief - Liquid Expansion

(Method taken from API 521 Section 3.14)

Percentage Overpressure considered % 10.0
Relieving Pressure barg 11.0
Equipment Protected Fuel Gas KO Drum 10-V-4301
Lines Protected NN-NNN-NNNN
Expanding Fluid Cooling Medium
Cubical Expansion Coefficient for Liquid (Note 1) per oF 0.00040
Total Heat Transfer Rate for Exchanger kW 5000
MMBTU/h 17.06
Density of Liquid kg/m3 1050
Specific Gravity of Liquid - 1.05
Specific Heat of Liquid Assumed BTU/lb °F 1.00
Total Relieving Rate USGPM 13.0
m3/h 3.0
kg/h 3100

Backpressure bara 5.6

Overpressure corr factor Kp. (Note 2) 1
Viscosity correction factor Kv. Based on API 520 Pt 1 Fig 36 1
Eff. Discharge coefficient Kd 0.65
Back pressure corr'n factor Kw. (Note 2) 1
Required area mm2 39

Notes:
1. The table below, as taken from API 521, shows typical figures for cubical expansion coefficient:

2. For conventional valves, Kw = 1.0. For balanced bellows valves, refer to API 520 Pt I Figure 31.
 CALCULATION WORKSHEET
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Case 6.2: Thermal Relief - Liquid Vapourisation

Percentage Overpressure considered % 10.0

Upstream Relieving Pressure bara 12.0
Equipment Protected Fuel Gas KO Drum 10-V-4301
Lines Protected NN-NNN-NNNN
Vapourised Fluid Cooling Medium
Total Heat Transfer Rate kW 276
Latent Heat kJ/kg 600
Relieving Rate kg/h 1,656

Relieving temp K
o
308
Compressibility 0.7
Molecular weight 16.7
Isentropic exponent, Cp / Cv 1.75
Eff. Discharge coefficient, Kd 0.975
Back pressure corr'n factor, Kb (Note 1) 1
Calculated C 384
Critical flow pressure bara 5.71
Required area mm2 174

Notes:
1. For back pressure< 10% of set pressure, Kb = 1.0. Otherwise, for balanced bellows and conventional relief valves, refer
to API 520-I Figs 30 and 35 respectively.
 RESULTS SUMMARY AND OTHER RELIEF CASES
Relief Rate Determination
PEL-BMS-CAL-P-0600

NOTE: WHEN USED AS A FORMAL RECORD, SIGNATURE BOXES SHALL BE COMPLETED

IN ACCORDANCE WITH DISCIPLINE QA PROCEDURES

Rev No. 0 1 2 3 Calc No. 0

Date 12/30/1899 Project 0
Originator 0 Client 0
Checker 0 Location 0
Approver Subject 0

Relief Valve/Rupture Disc Number: PSV-43107A/B

Relief Valve/Rupture Disc Location: Fuel Gas KO Drum 10-V-4301

Relief Rates and PSV Area estimates as determined by standard worksheets:

Relief Valve Bursting Disc

Credible Relieving Rate Calculated Inlet by Relieving Rate
Relief Gas Liquid Orifice Orifice Gas Liquid
Case Area by Outlet
kg/h kg/h mm2 kg/h kg/h
Blocked Discharge - Gas Flow YES 1150 - 160 1.5" x F x 2" - -
Blocked Discharge - Liquid Flow No - - - - - -
Blocked Discharge - Mixed Flow No - - - - - -
Gas Blowby No - - - - - -
Fire - vessel containing gas & liquid No - - - - - -
Fire - vessel containing gas only YES 516 - 84 1.5" x E x 2" - -
ESDV failure / backflow through NRV No - - - - - -
ESDV failure / backflow through compressor No - - - - - -
Exchanger tube failure No - - - - - -
Thermal relief liquid expansion No - - - - - -
Thermal relief liquid vapourisation No - - - - - -

Relief Rates and PSV Area estimates for other relief cases not covered by standard worksheets:
Relief Pressure (bara) 12.1

Credible Relief Vap/ Relief Comp Mole Cp/Cv Liquid PSV Kv Kp Kd Kb (vap) C Crit Calc Inlet by
Relief Rate Liq Temp Z Weight Density Back or Flow PSV Orifice
Case Press Kw (liq) Press Area by Outlet
Yes / No kg/h o
K kg/m3 Bara Bara mm2
Control valve malfunction (if not gas blowby) Yes 100000 V 323 0.90 18.0 1.25 1000 5.0 1.0 1.0 0.975 1.0 342 6.7 ### 8" x T x 10"
Machine trip or overspeed Yes 100000 V 323 0.90 18.0 1.25 1000 5.0 1.0 1.0 0.975 1.0 342 6.7 ### 8" x T x 10"
Column Blocked outlet Yes 100000 V 323 0.90 18.0 1.25 1000 5.0 1.0 1.0 0.975 1.0 342 6.7 ### 8" x T x 10"
Power failure Yes 100000 V 323 0.90 18.0 1.25 1000 5.0 1.0 1.0 0.975 1.0 342 6.7 ### 8" x T x 10"
Air failure Yes 100000 V 323 0.90 18.0 1.25 1000 5.0 1.0 1.0 0.975 1.0 342 6.7 ### 8" x T x 10"
Hydraulics failure Yes 100000 V 323 0.90 18.0 1.25 1000 5.0 1.0 1.0 0.975 1.0 342 6.7 ### 8" x T x 10"
Cooling medium failure Yes 100000 V 323 0.90 18.0 1.25 1000 5.0 1.0 1.0 0.975 1.0 342 6.7 ### 8" x T x 10"
Reflux failure Yes 100000 V 323 0.90 18.0 1.25 1000 5.0 1.0 1.0 0.975 1.0 342 6.7 ### 8" x T x 10"
Abnormal entry of volatile liquid Yes 100000 V 323 0.90 18.0 1.25 1000 5.0 1.0 1.0 0.975 1.0 342 6.7 ### 8" x T x 10"
Chemical reaction Yes 100000 V 323 0.90 18.0 1.25 1000 5.0 1.0 1.0 0.975 1.0 342 6.7 ### 8" x T x 10"
Manual maloperation (specify) Yes 100000 V 323 0.90 18.0 1.25 1000 5.0 1.0 1.0 0.975 1.0 342 6.7 ### 8" x T x 10"
Other 1(specify) Yes 105000 L 323 0.90 18.0 1.25 1050 5.6 1.0 1.0 0.650 1.0 342 6.7 1213.7 4" x L x 6"
Other 2 (specify) Yes 105000 L 323 0.90 18.0 1.25 1050 5.6 1.0 1.0 0.650 1.0 342 6.7 1213.7 4" x L x 6"
Other 3 (specify) Yes 105000 L 323 0.90 18.0 1.25 1050 5.6 1.0 1.0 0.650 1.0 342 6.7 1213.7 4" x L x 6"

Note: The inlet / outlet sizes for the PSV orifices given in the above tables are typical only
for purpose of estimating the inlet / outlet line sizes for the preliminary P&IDs.