Rajesh A Assistant Engineer Emp Code: 104321 Tata Consulting Engineers Ltd.
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OUTLINE • Introduction • Types of Depressuring • When to use Depressuring • Design Considerations • Calculation Methods • References
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Vapour Depressuring Introduction • Protective arrangement of valves and piping intended to provide for rapid reduction of pressure in equipment by releasing vapours. • Actuation of the system can be automatic or manual.
• API 521 states: “Provide depressurizing on all equipment that process light hydrocarbons and set the depressured rate to achieve 100 psig (690kPag) or 50% of the vessel design pressure, which ever is lower in 15 minutes.” • In connection with fire protection, particularly in higher-pressure services, the designer should consider vapour depressuring facilities. CONSULTING ENGINEERS LIMITED
Continued
• Controlled depressuring of the vessel reduces internal pressure and stress in the vessel walls.
• Depressuring systems are used to reduce the failure potential for scenarios involving overheating (e.g. fire).
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Depressurization types Controlled Type Depressuring Non-controlled Type Depressuring
Non-controlled Type Depressuring
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Controlled Type Depressuring
When to use Depressurization Vessel requiring depressurization capability • A vessel operated above 690 kPa (100psi) • Contains volatile liquids with vapour pr. above atmospheric • Fire condition may occur that weakens a vessel to below safe strength levels, with in several hours, which may cause significant exposure loses. Vessel which may not require depressurization capability • A vessel operated at or less than 690 kPa • A vessel containing less than 907 Kgs (2000 lb) of vapours • A vessel whose time to rupture from a fire exposure is more than several hours. Detailed Flow Chart CONSULTING ENGINEERS LIMITED
Examples The ASME pressure vessel rupture stress formula is applied to calculate a vessel stress is: S = P(R+0.6t)/Et Where: S = Rupture Stress P = Operating Pressure in Psig R = Shell Inside Radius, Inch t = Shell Wall Thickness, Inch E = Weld t Efficiency (generally assume 100%) Example 1 Example 2 CONSULTING ENGINEERS LIMITED
Design Considerations The following should be considered when deg/specifying the depressurization system:
• • • • • • • • • •
Rupture time Rupture pressure of pipes & vessels Total release of flammables Instantaneous release rate Loss of production, reputation and rebuild cost Damage to internals of equipments Manual controls near the vessel may be inaccessible during a fire. Failure position Metallurgy of the vessel Safe disposal of vented streams. CONSULTING ENGINEERS LIMITED
Depressurization Calculation Methods • Grote Equation • API RP 521 Method • Software Packages • HYSYS • BLOWDOWN/BLOWFIRE • LNGDYN • PRO II
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Grote Equation Assumptions : • Critical flow throughout entire depressuring process • Constant mass flow throughout entire depressuring process • System being depressured is maintained as gaseous throughout entire depressuring process • Constant temperature, molecular weight and compressibility Methodology Following is the derivation of the manual equation. Vapour flow ing an orifice at critical flow condition W C D AO P where, W = Mass flow (kg/h) CD = Discharge Coeff. Ao= Orifice area (mm2) P = Upstream pressure (KPa abs) MW = Molecular weight T = Upstream temperature (K) Z = Upstream fluid compressibility M0= Initial mass
MW TZ
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(a)
A vessel with fixed volume (Vo) depressure from P0 to P1, take time t, assuming flow rate is constant (W0=W1=W2=…),depressure mass, dM dt
W V0 d W
dt
(b)
Assuming Temperature, Molecular weight and compressibility maintain constant through-out the depressuring process, dt
V0 W
MW ZRT
dt
V0 C D A0 R
dP MW TZ
1 dP P
(c)
Integrate above equation with condition P0 @ t0 and P @ t. t W
V0 C D A0 R
MW TZ
ln
P P0
(d)
M0 P ln t P0
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API 521 Method * To reduce the internal pressure in equipment involved in a fire, vapour should be removed at a rate that compensates for the following occurrences: * Vapour generated from liquid by heat input from the fire; * Vapour expansion during pressure reduction; * Liquid flash due to pressure reduction. (This factor applies only when a system contains liquid at or near its saturation temperature).
* The total vapour load = sum of the individual occurrences for all equipment involved. m .t
x
x
x
( q m , f .t ) i i 1
( q m , d .t ) i
( q m , v .t ) i i 1
i 1
qm - vapour mass flow rate, kg/h (lb/h) m - mass flow rate per unit time t - depressuring time interval, hr CONSULTING ENGINEERS LIMITED
(1)
Vapour from fire-heat input Assumption: the vapour generation is a function only of the heat absorbed from the fire and the latent heat of the liquid. The mass, mf, of vapour generated by the fire during the depressuring interval in a vessel, i, of the system can be determined by Equation (2): ( mf t )I = t (Q / L)i
(2)
Q= total heat absorption, W (Btu/h)
Q C·F·A 0.82 ws L= latent heat of liquid, KJ/Kg (Btu/lb) This calculation should be repeated for all vessels in the system.
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Vapour from density change and liquid flash It is necessary to know the liquid inventory and vapour volume of the system. Following equation is used for calculating the vapour load due to density change p.M p.M (q m, d .t) i 0.1205V i (3) Z .T a Z .T b i where
V - volume available for the vapour, m3 (ft3); p - absolute pressure, expressed in kPa (psi); M - relative molecular mass of the vapour; Z - compressibility factor, dimensionless; T - absolute temperature of the liquid or vapour, K (°R); the subscript “a” represents the higher-pressure condition and “b” represents the lower-pressure condition. “i” relates to an individual vessel of the system CONSULTING ENGINEERS LIMITED
Continued Amount of liquid flashed is given by equation (4) (q m, v .t) i where
(q m, a .t) i
Q i .t 2 i (Ta Tb ) i . 2 Li 2 L i i (Ta Tb ) i
qm - vapour mass flow rate, expressed in kg/h (lb/h); t - depressuring time interval, expressed in hours (usually assumed to be 0,25 h); Q - total heat absorption (input) to the wetted surface, expressed in kJ/h (Btu/h); L - average latent heat of the liquid, expressed in kJ/kg (Btu/lb); - average specific heat of the liquid, expressed in kJ/kg·K (Btu/lb·°R); T - absolute temperature of the liquid or vapour, expressed in K (°R); subscripts: a - original condition at the start of the depressuring time interval, b - depressurized condition at the end of the depressuring time interval; i - relates to an individual vessel of the system if more than one vessel is involved v - relates to liquid flash or vapour generated from pressure reduction; CONSULTING ENGINEERS LIMITED
(4)
Depressuring using HYSYS Open a new case in HYSYS Add the required components and select Fluid package Add a stream with the following properties and molar flows: Stream Name
Feed
Temperature
108 C
(226.4 F)
Pressure
1000 kPa
(145.04 psia)
Component
Molar Flow
Methane
30.0 kmol/h
(66.138 lbmol/h)
Ethane
30.0 kmol/h
(66.138 lbmol/h)
Propane
30.0 kmol/h
(66.138 lbmol/h)
i-Butane
30.0 kmol/h
(66.138 lbmol/h)
n-Butane
30.0 kmol/h
(66.138 lbmol/h)
i-Pentane
30.0 kmol/h
(66.138 lbmol/h)
n-Pentane
325.0 kmol/h
(716.495 lbmol/h)
n-Hexane
30.0 kmol/h
(66.138 lbmol/h)
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Continued To attach the Dynamic Depressuring utility to the stream, > open the stream property view, > go to "Attachments" "Utilities" and press "Create > Select "Dynamic Depressuring > Press the "Add Utility" button
3) Select "Dynamic Depressuring"
4) Press "Add Utility" 2) Press "Create…"
1) Go to "Attachments"
"Utilities"
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Continued Enter the following vessel information on the "Design" ->"Connections" page of new window opened.
Height 4.50m Diameter 1.25m Initial Liquid Volume 1.45m3
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Continued Heat Flux Parameters
API Equation (field units)
API Equation (metric units)
Q
Q
21000 F
A0.82
Q = total absorption to wetted surface (BTU/h) F = environmental factor A = total wetted surface (ft2)
Q = total absorption to wetted 0.82 surface (kJ/s F = environmental factor
43.116 F A
A = total wetted surface (m2) CONSULTING ENGINEERS LIMITED
Continued Valve Parameters
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Continued On the "Options" page, enter a PV Work Term of 90%.
On the "Operating Conditions" page, select "Calculate Cv" and enter a final pressure of 500 kPa (50 % of operating pressure).
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Continued Once you have submitted the required information, press the "Run" button to execute the calculations.
Press the "Run" button to start the calculations.
Go to the "Performance"
"Summary" page to view the results.
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Continued Performance Summary
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Design of Depressurization System & scenario information Estimate size of orifice
Improve design/ apply PFP
Calculate P(t) for the process segment and T(t) for the steel
Increase orifice size
Is Flare Capacity utilized?
No
Yes
No
Are the consequence of the rupture acceptable? Yes
Yes
Will equipment/ pipe rupture? No Ok
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Failure criteria
References • API RP 521 Guide for pressure-relieving and depressuring systems, American Petroleum Institute, Fifth Edition, May 2008. • Depressurisation: A Practical Guide, Aspentech Technical Knowledge Base Article, rev 2004-1.1 Feb 2006 • Perry, R. H. Chemical engineering handbook, McGraw Hill, 5th edition, 1973. • Gayton, P.W. and Murphy, S.N. Depressurisation Systems Design. IChemE Workshop “The Safe Disposal of Unwanted Hydrocarbons”, Aberdeen 1995. • Review of the Response of Pressurised Process Vessels and Equipment to Fire Attack, Offshore Technology Rreport OTO 2000 051, June 2000 CONSULTING ENGINEERS LIMITED
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If vapour depressuring is required for both fire and process reasons, the larger requirement should govern the size of the depressuring facilities. A vapour-depressuring system should have adequate capacity to permit reduction of the vessel stress to a level at which stress rupture is not of immediate concern. The required depressuring rate depends on the metallurgy of the vessel, the thickness and initial temperature of the vessel wall and the rate of heat input. Vessels with thinner walls generally requires faster depressuring rate. Depressuring is assumed to continue for the duration of the emergency. The valves should remain operable for the duration of the emergency or should fail in a full-open position.
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Example 1
SEPARATOR (Honzontal) ASSUMPTIONS:
Shell Inside Radius Shell Wall Thickness Liquid Sp. Gr. Material of Construction Operating Pressure Design Pressure Normal Liquid Level
: : : : : : :
60 " -0 " 1/2" 1.0 A515 Gr. 70 50 Psig 90 Psig 5'-0" from bottom
S = P (R + 0.6t)/Et ref.: ASME. DIV. Vlll for circumferential stress) S = 50 (60 + 0.6 x 0.5)/1.0x 0.5 S = 6,030 psi From Figure 2 (API 520 7th edition),Time before rupture at 6,030 psi and 1,300 0F is approximately 5 Hrs. CONCLUSION: Depressurization system is not required. CONSULTING ENGINEERS LIMITED
Example 2
CRUDE STABILIZER ASSUMPTIONS:
Shell Inside Radius Shell Wall Thickness Liquid Sp. Gr. Material of Construction Operating Pressure Design Pressure Normal Liquid Level
: : : : : : :
30 " -0 " 7/16" 0.85 A515 Gr. 70 150 Psig 175 Psig 5'-0" from bottom
Vessel is insulated but no credit given for insulation
S = P (R + 0.6t)/Et ref.: ASME. DIV. Vlll for circumferential stress) S = 150 (30 + 0.6 x 0.4375)/1.0 x 0.4375 S = 10,374 psi From Figure 2 (API 520 7th edition),Time before rupture at 10,374 psi and 1,300 0F is approximately 0.3 Hrs. CONCLUSION: Depressurization system is required. CONSULTING ENGINEERS LIMITED
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