PSV TAG NO.

10A1 SET PRESSURE 1 barg

LOOP CONSIDERED C-22 and HX-27
CALCULATION REFERENCE API-521, 5TH EDITION, MARCH 2007

C-22 HX-27

Operating Flow Rate (LIQUID) 5160 Kg/hr Operating Flow Rate (LIQUID) NA m3/hr
Operating Flow Rate (VAPOR) 30 m3/hr Operating Flow Rate (VAPOR) 2300 m3/hr
Operating Density (LIQUID) 780 Kg/m3 Operating Density (LIQUID) NA Kg/m3
Operating Density (VAPOR) 2.5 Kg/m4 Operating Density (VAPOR) 0.39 Kg/m3

Temp Pressure Temp Pressure

Operating Conditions 320 oC 150 mbara Operating Conditions 195 oC 140 mbara
Design Conditions 350 oC 1.5 barg Design Conditions 240 oC 1.5 barg

Set Pressure 1 barg Set Pressure 1 barg

overpressure 10% its nothing but back pressure overpressure 10% its nothing but back pressure
Relieving Pressure 1.1 barg Relieving Pressure 1.1 barg

INPUT CELLS OUTPUT CELLS

# SULZER CONFIDENTIAL
 OVERFILLING-When P-22 and P-27 discharge and all other discharge (2XV-closed) are blocked and P-04B and flow through D-21 is running
EQUIMENTS CONSIDERED C-22,HX-27
P-04B PUMP FLOW RATE TO C-22 1.1 m3/hr
Discharge pressure of pump P-04B 5.23 barg So pump P-04B can cause overpressurization
FLOW FROM D-21 6.2 m3/hr
STEAM FLOW 30 m3/hr 0.075
Total Flow to HX-08 37.3 m3/hr

SYSTEM VOLUME CALCULATION

SYSTEM VOLUME FOR OERFILLING TOTAL SYSTEM VOLUME
C-22 C-22
DIAMETER (m) 0.61 DIAMETER (m) 0.61
VAPOR SPACE LENGTH (m) (TL to TL Ht-NL Ht -packing Ht) 5.85 HEIGHT (m) (TL to TL) 11.5
TOTAL 'C-01' VOLUME FOR FILLING (m3) 1.708776225 TOTAL 'V-01' VOLUME (m3) 3.35913275

HX-27 HX-27
DIAMETER (m) 0.453 DIAMETER (m) 0.453
VAPOR SPACE LENGTH (m) (TL to Tube Height - NL Height) 2.25 HEIGHT (m) (TL to Tube Height) 2.853
TOTAL 'HX-03' VOLUME FOR FILLING (m3) 0.362450396 TOTAL 'HX-03' VOLUME (m3) 0.459587102

TOTAL SYSTEM VOLUME Available for Filling (m3) 2.07 TOTAL SYSTEM VOLUME (m3) 3.82

TIME FOR SYSTEM FILL UP (MIN) 3.33

Time required for overfilling is less than 30 min i. e. operator response time as per API guidelines. Special
Instrumental control or control logic is required.

TOTAL LOAD ON PSV (Mixed) 37.3 m3/hr

# SULZER CONFIDENTIAL
 BLOCKED DISCHARGE- 2XV-10A4 stuck closed

In this condition P-22 and P-27 are running while vacuum system failed. System pressure will go on increasing. Even accumulation rate will be very less compare to
overfilling conditon as P-22 and P-27 are running continously.

So relife load for this case is always lesser than overpressurization case. And also time required for overfilling will be also high so operator can get enough time.

P-04B PUMP FLOW RATE TO C-22 1.1 m3/hr

Discharge pressure of pump P-04B 5.23 barg So pump P-04B can cause overpressurization
FLOW FROM D-21 6.2 m3/hr
STEAM FLOW 30 m3/hr
Exit Flow from P-22 7.5 m3/hr
Exit Flow from P-27 1 m3/hr
Accumulation Rate 34.03 m3/hr
System Volume Available for Filling 2.07 m3/hr
Time required for System Fill-Up (min) 3.651883552 min
Operator Response Time as Per API Guidelines 30 min

TOTAL LOAD ON PSV (LIQUID) 34.03 m3/hr

# SULZER CONFIDENTIAL
 TUBE RUPTURE - HX-27 tube rupture
Pressure Condition Ptube> Pshell
So tube side liquid will enter in shell side at around 40 C and 190 mbara pressure. But it will be exposed to 320oC
o

Therefore, tubeside fluid will evaporate immediately at 320oC and 190 mbara.
Therefore, Mixed-phase flow should be considered.
TUBE SIDE DESIGN PRESSURE (BAR-A) 8
SHELL SIDE DESIGN PRESSURE (BAR-A) 2.5
TUBE DIAMETER (MM) 19.05
UPSTREAM HIGH LIQUID PRESSURE (bar-a) 5
PSV SET PRESSURE (bar-a) 2
PRESSURE DIFFERENCE (dP) (bar-a) 3
RESISTANCE COEFFICIENT (k) 1.5 PER TABLE-13 API-521, MAY 2008
LIQUID DENSITY (Kg/M3) 998.00

W = 2*0.0003512*D^2*SQRT(dP*Liq. Density/K)

PHASE
Liquid Relief Load (W) kg/s 10.21 LIQUID
Kg/hr 36771.66363 LIQUID
For Two Phase Flow
Mass Flux G=96.3*sqrt(ρl(P1-P))
Liquid Density At Relief Valve Inlet (ρl) lb/ft3 62.30
Pressure at Sfety Valve Inlet (P1) psia 29.40
Down Stream Back-Pressure (P) psia -44.10

Mass Flux lb/(s*ft2) 6516.68

Now area for handaling relief load can be calculated as : A=0.3208*Q*ρl/(G*Kb*Kc*Kd)

In Above equation flow should be adjusted such that the Area will be same as that we considered Initially

9.8125 mm2
Initial area cosidered was twice the cross sectional area of tube
9.8125E-06 m2
ρl 1.50 kg/m3
6516.68 lb/(s*ft2)
G
114519646.94 Kg/(hr*m2)
Correction Factor for Back-Pressure (Kb) 1
Combination Correction Factor For Installation with RD (Kc) 1
Discharge Coefficient of Valve (Kd) 0.8
Flow can be calculated as: Q=A*(G*Kb*Kc*Kd)/(0.3208*ρl)

Flow rate will be 1868.202885 m3/hr

Total Relief Load On PSV will be 1868.202885 m3/hr Mixed Phase Load
# SULZER CONFIDENTIAL
 Fire Case-APPLICABLE FOR EQUIPMENTS HAVING ELEVATION LESSS THAN 25 FT or 7.62m, PER API-521
EQUIPMENT TAG NO c-22 HX-27
DIAMETER (m) 0.61 0.453 m
ELEVATION 6.38 8.55 m
LIQUID LEVEL IN VESSEL (HLL) 1.1 m

EQUIPMENT SURFACE AREA (Only 1.20 m2

Conical for HX-10)
Total Equipement Area 1.20

PIPING SURFACE AREA CALCULATION

PIPIE NO LENGTH DIA SURFACE AREA
m m m2
P-22 SUCTION (PRS-1001 ) 6.4 0.05 0.08
C-22 RECYCLE (PRS-1005) 7.6 0.025 0.05
P-27 SUCTION (PRS-1010) 7.6 0.025 0.05
HX-27 RECYCLE (PRS-1015) 7.6 0.015 0.03
TOTAL SURFACE AREA IN PIPING 0.18 m2
20 % EXCESS AREA 0.22 m2

TOTAL SURFACE AREA 1.42 m2

Q=43200*F*A^0.82 FROM API 521,2007 PP40, eq-6 for SI units

57741.85 J/s ASSUME F 1

Q
207870.66 KJ/hr
LATENT HEAT OF VAPORIZATION 760 KJ/Kg ASSUME

MASS FLOW RATE 273.51 Kg/hr

PHASE VAPOR

# SULZER CONFIDENTIAL
 Control Valve Failure-LCV-9A01
Flow from D-21 to C-22 12080 lb/hr From simulation stream # S88
5484.32 kg/hr
Upstream pressure(P1) 69.75 bara
Downstream Pressure (P2) 29.75 bara
Pressure Drop (ΔP) 40

Since only liquid is flowing through S88 to C-22 fluid is assumed non-compressible.

for non-compressible fluid Cv=Q/0.86*SQRT(ρo/(ρi*ΔP)) Ref: ISA-75.01.01-2007; PP 15 & 25

ρo 5.701 density at control valve inlet (lb/gal)

ρi 5.701 density at control valve outlet (lb/gal)
ΔP 40 pressure drop across control valve (bar)
Q 8.020136818 Volumetric flow rate across control valve (m3/hr)

Flow coefficient Cv 1.47452904 calculated Cv is 1.475. Therefore, valve Cv should be selected such that it will have proper
operating range.

Seletcted Cv 2.5 at 100% opening of valve

flow for selected Cv 13.59779394 (m3/hr)

In case of control valve failure;

13.5977 (m3/hr)
Maximum Relief load (mixed) 20481.11578 lb/hr
9298.426566 kg/hr

For stream S89 flow mass flow rate of liquid and vapor
Total (lb/hr) liquid (lb/hr) vapor (lb/hr)
12080 9495 2585
Wt fraction flow 0.786009934 0.213990066

liquid (kg/hr) vapor (kg/hr)

For mixed flow through control valve 7308.65565 2521.889628

# SULZER CONFIDENTIAL
 Blow by-FCV-10A1
Steam Flow to C-22 180 lb/hr From simulation stream # S88
81.72 kg/hr
Upstream pressure(P1) 3.5 bara
Downstream Pressure (P2) 0.19 bara
Pressure Drop (ΔP) 3.31 bar

Steam is flowing through FCV-10A1 and it is assumed compressible .

for compressible fluid Cv=Q/(0.667*94.8*sqrt(Fγ*XT*P1*ρ1)) Ref: ISA-75.01.01-2007; PP 15 & 25

ρ1 2.6 density at control valve inlet (kg/M3)

ΔP 3.31 pressure drop across control valve (bar)
XT 0.7 Pressure differential ratio factor
Fγ 1.37 Specific heat ratio factor
Q 81.72 Volumetric flow rate across control valve (kg/hr)

Flow coefficient Cv 1.312458082 calculated Cv is 0.437. Therefore, valve Cv should be selected such that it will have proper
operating range.

Seletcted Cv 10 at 100% opening of valve

flow for selected Cv 622.6484571 (kg/hr)

In case of control valve failure

Maximum Relief load (Vapor) 622.6484571 (kg/hr) VAPOR

Total Load on PSV (vapor) 622.6484571 (Kg/hr) VAPOR

# SULZER CONFIDENTIAL