Safety Analysis Environment Workshop

Agenda

• Introduction to Safety Analysis Environment

• Review of Adding and Sizing a PSV
– Workshop 1 - Adding and Sizing a PSV

• Fire Relief Calculations

– Workshop 2 – Adding Fire Scenarios

• Control Valve Failure Calculations

– Workshop 3 – Control Valve Failure

• Tube Rupture Calculations

– Workshop 4 – Tube Rupture Calculations

• Documentation

2 © 2015 Aspen Technology, Inc. All rights reserved

AspenTech Process Safety Tools
Introducing the Safety Solution

PSV
(Safety Analysis Environment)
Utilize these tools in
Safety Solution combination with Aspen
Breakdown HYSYS to complete
Depressuring/Blowdown process safety work

Aspen Plus & HYSYS

Dynamics AspenTech Process Safety
Tools enable users to
complete safety work all
within one software suite
Aspen Flare System
Analyzer
3 © 2015 Aspen Technology, Inc. All rights reserved
AspenTech Addressing Safety
Key Advantage of the Safety Solution

The Safety Solution combines these steps all into one Prior Workflow Pain Points
suite, eliminating the pain points of prior workflows!
Multiple tools necessary, with a
workflow that requires many
iterations

Manual data transfer between

AspenTech and external tools

Extremely time consuming and a

poor use of valuable engineering
hours

Increased risk of data inaccuracy

via transcription errors

4 © 2015 Aspen Technology, Inc. All rights reserved

AspenTech Addressing Safety

See a real example of how

A full solution suite provides many
one customer experienced
important benefits to your customers for
these benefits first-hand:
completing process safety work

No more Save 50% of time sizing

manual data relief devices across entire
transfer workflow
between Increase the accuracy of data
various through reduction in
programs transcription errors http://www.aspentech.com/HGA-Case-Study-PSV-HYSYS.pdf

5 © 2015 Aspen Technology, Inc. All rights reserved

 Safety Analysis Environment within Aspen Plus & HYSYS
Relief Sizing Overview

Analyze multiple Incorporate standards in

scenarios calculations

Optimized User Workflow; Analysis, Documentation Stored with Model

Generate Link results to Aspen

documentation of results Flare System Analyzer

6 © 2015 Aspen Technology, Inc. All rights reserved

Safety Analysis Environment

• The Safety Analysis environment lets you

– Analyse overpressure scenarios
– Determine which contingencies require pressure relieving devices
– Size these devices according to appropriate standards
– Generate appropriate documentation for analysis
– Import PRD (Pressure Relief Device) data and associated scenarios into Aspen Flare System
Analyzer

• Safety Analysis uses the latest design codes and recommended practices.

7 © 2015 Aspen Technology, Inc. All rights reserved

Incorporate Standards

• Pressure Safety Valves calculations are carried out in accordance with API RP 520, 521 and
526.

• Relief Valve Sizing provides a set of routines for the Gas, Liquid, Steam and Mixed-Phase
relieving scenarios. The Mixed-Phase code provides three different calculation routines from
Appendix of API 520. A more rigorous Direct Integration (HEM) method is also available with
sizing by the direct integration of the isentropic nozzle flow.

• Appropriate setting of defaults e.g.

– Kd (discharge coefficient) set to 0.975 for vapour service, 0.65 for liquid, 0.85 for mixed phase
– When selecting Fire Case the program automatically changes the Overpressure to 21%.

• Inlet and outlet lines sizing routines for both single and two-phase fluids are also available to
the user to ensure correct first-pass pipe sizing, following valve orifice calculation and selection.

8 © 2015 Aspen Technology, Inc. All rights reserved

Agenda

• Introduction to Safety Analysis Environment

• Adding and Sizing a PSV

• Fire Relief Calculations

• Control Valve Failure Calculations

• Tube Rupture Calculations

• Documentation (Hands-on Demo)

• Getting Support!

9 © 2015 Aspen Technology, Inc. All rights reserved

Agenda

• Introduction to Safety Analysis Environment

• Adding and Sizing a PSV

• Fire Relief Calculations

• Control Valve Failure Calculations

• Tube Rupture Calculations

• Documentation (Hands-on Demo)

• Getting Support!

10 © 2015 Aspen Technology, Inc. All rights reserved

Adding a PSV

• If you are using Aspen Plus, make sure you have first run the
simulation

• Then go to the Safety Analysis environment

• Then switch to the Home ribbon in the Safety Analysis

environment

• Choose Units of measure

for the PSV work
– SI or EN(glish)

• Click on button to add a PSV

Note: You can also jump to the Safety Analysis environment
by clicking on the button.

11 © 2015 Aspen Technology, Inc. All rights reserved

Adding a PSV

• This switches the cursor into attach

mode. When you hover over
attachable objects on the flowsheet, a
blue box will appear to indicate where
to click to make the attachment to the
stream; click on the blue box to add
the safety valve to that stream.

12 © 2015 Aspen Technology, Inc. All rights reserved

Adding a PSV

• You can also add a PSV from the

Navigation Pane

• Expand the Unit Operations or

Unattached Streams node and use
Right-Mouse-Button click on the
desired block or stream.

• Scroll to highlight either the Create

PSV or Create Rupture Disk option.
The user can add either a PSV or a
Rupture Disk to any stream exiting a
unit operation

13 © 2015 Aspen Technology, Inc. All rights reserved

Adding a PSV

• Double click on the newly added PSV

to open its input form.

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Adding a PSV

• Switch to the Scenarios tab and click on Create Scenario button to make one or more
Scenarios.

• Double click on a Scenario to open its input forms

• Or select the row and click on Open Scenario

• Or select the Scenario in the Navigation Pane

15 © 2015 Aspen Technology, Inc. All rights reserved
Adding a PSV
Scenario Input form
Scenario Type e.g. Reference stream either the one Relieving
Fire, Blocked connected to valve, or pick another conditions and
Outlet … stream using the Override box backpressure

Calculated and
selected Orifice
sizes

Relief flow value or

calculation input
data

16 © 2015 Aspen Technology, Inc. All rights reserved

Preliminary Line Sizing

• When all the scenarios have been considered select

the largest orifice as the sizing case

• Then switch to the Line Sizing tab

17 © 2015 Aspen Technology, Inc. All rights reserved

Preliminary Line Sizing
Define inlet and
outlet piping

Can calculate
equivalent lengths
if required

Results based on
rated flow

Warnings if pipes
are too small

18 © 2015 Aspen Technology, Inc. All rights reserved

Saving Simulation Files

• When you save your HYSYS simulation as a *.hsc file, or your Aspen Plus simulation as
a *.bkp / *.apw file, the Safety Analysis data is saved separately in a *.mdb file in the
same location with the same file name.

• A more secure solution is to save your simulation in the zipped form:

– *.APWZ for Aspen Plus
– *.HSCZ for Aspen HYSYS

• This saves everything together in one file.

• The files will move ok into a newer version.

19 © 2015 Aspen Technology, Inc. All rights reserved

Agenda

• Introduction to Safety Analysis Environment

• Adding and Sizing a PSV

• Fire Relief Calculations

• Control Valve Failure Calculations

• Tube Rupture Calculations

• Documentation (Hands-on Demo)

• Getting Support!

20 © 2015 Aspen Technology, Inc. All rights reserved

Agenda

• Introduction to Safety Analysis Environment

• Adding and Sizing a PSV

• Fire Relief Calculations

• Control Valve Failure Calculations

• Tube Rupture Calculations

• Documentation (Hands-on Demo)

• Getting Support!

21 © 2015 Aspen Technology, Inc. All rights reserved

External Fire Analysis

• API Standard 521 recommends that all pressure vessels under 25 feet in elevation be
protected against overpressure resulting from an external pool fire.

• For a vessel with no liquid inventory, ideal gas expansion can ease the difficulty of the
calculation, but the complexity of the relief load calculation increases substantially at
higher pressure non-ideal conditions

• For two-phase separators, the trapped liquid inventory’s composition, temperature, and
pressure are constantly in flux..

• The Safety Environment in Aspen HYSYS and Aspen Plus offers a variety of calculation
methodologies to quickly calculate the orifice area required to protect a vessel against
overpressure due to the fire contingency.

22 © 2015 Aspen Technology, Inc. All rights reserved

External Fire Analysis

• Fire Scenario in the Safety Analysis environment of Aspen Plus or HYSYS

offers 4 methods for calculating the corresponding relief load:
– API 520 wetted
– API 520 unwetted
– Rigorous Supercritical fluid calculation based on method by Ouderkirk
– Semi-Dynamic Flash using a batch vaporization methodology

23 © 2015 Aspen Technology, Inc. All rights reserved

External Fire Analysis
Unwetted API Calculation

• Unwetted API Calculation for a vessel with all-vapour contents in accordance with API
521. The Unwetted (API) method is generally applicable for ideal-like systems with vapor
compressibility between 0.8 and 1.1

• The Fluid Properties tab lets you easily confirm the

phase of the vessel contents based on the reference
stream used, and the relieving conditions

• It should be Vapour for Unwetted calculations

24 © 2015 Aspen Technology, Inc. All rights reserved

External Fire Analysis
Unwetted API Calculation

• Choose the Unwetted calculation method.

• The Max Wall Temp is the only calculation-

specific input for the Unwetted (API)
calculation, and it defaults to the API-
recommended 593.3 ºC (1100 ºF) for
carbon-steel. The user can change this
value for other metallurgy.

• You can specify, or calculate, the exposed

area for up to three vessels in the same
system

• The required relieving flow and

calculated SV orifice are shown
25 © 2015 Aspen Technology, Inc. All rights reserved
External Fire Analysis
Wetted API Calculation

• This uses the following API equation for heat input from a fire to a vessel containing liquids

where
Q = 21000  F  A 0.82

Q is the total heat absorption (input) to the wetted surface, expressed in Btu/hr
F is an Environmental Factor
A is the wetted surface area in ft2
(Note “21000” changes to “34500” if adequate drainage and
firefighting equipment are not present)

• F can be Entered, or Calculated to allow for insulation

when you must enter insulation thickness and k

• The wetted surface area can be Entered, or Calculated for up to 3 vessels in a similar way to
the Unwetted calculation described previously

26 © 2015 Aspen Technology, Inc. All rights reserved

External Fire Analysis
Wetted API Calculation

• The relieving flow is calculated from the heat input and a latent heat value for the liquid in
the tank.
Flow = Duty / Latent Heat

• API 521 has a default value for the latent heat of 116.3 kJ/kg however this may
significantly over-estimate the relief load. Hence there is an option to estimate a latent
heat value
– You give an initial and final % vaporized and the latent
heat is estimated based on the heat required to vaporize
the specified portion at relieving conditions (excluding
sensible heat, per API 521).

27 © 2015 Aspen Technology, Inc. All rights reserved

External Fire Analysis
Semi-Dynamic Analysis

• The Center for Chemical Process Safety in “Guidelines for Pressure Relief and Effluent
Handling Systems” recommends using a batch vaporization methodology to more
accurately assess the Required Relieving Flow for a vessel that contains liquid inventory.
This is the methodology implemented in the Semi Dynamic Flash calculation.
• It is similar to setting up a series of linked flash
vessels. Some of the initial contents is vaporized
giving a new wetted area and liquid composition –
and hence a new heat input.
• The maximum relief load is the one used to size
relief valve
• User can set the temperature for the last flash and
the number of stages

28 © 2015 Aspen Technology, Inc. All rights reserved

External Fire Analysis
Rigorous Supercritical Method

• Aspen Plus uses the methodology

outlined in the article by Ouderkirk, R.,
“Rigorously Size Relief Valves for
Supercritical Fluids,” Chemical
Engineering Progress, August 2002
• This is consistent with the Francis &
Shackleton methodology outlined in
API 521
• Aspen Plus automatically
– Finds the mass and volume flow for each temperature increment
– Performs a constant entropy flash (Direct Integration Method) to find the maximum flux
– Use the maximum flux to determine the max orifice area

29 © 2015 Aspen Technology, Inc. All rights reserved

Agenda

• Introduction to Safety Analysis Environment

• Adding and Sizing a PSV

• Fire Relief Calculations

• Control Valve Failure Calculations

• Tube Rupture Calculations

• Documentation (Hands-on Demo)

• Getting Support!

30 © 2015 Aspen Technology, Inc. All rights reserved

Agenda

• Introduction to Safety Analysis Environment

• Adding and Sizing a PSV

• Fire Relief Calculations

• Control Valve Failure Calculations

• Tube Rupture Calculations

• Documentation (Hands-on Demo)

• Getting Support!

31 © 2015 Aspen Technology, Inc. All rights reserved

Control Valve Failure

Define inlet and

outlet piping

Calculates Relief
load if this valve
fails open

32 © 2015 Aspen Technology, Inc. All rights reserved

 Control Valve Failure
• Override the Reference stream and
select the stream into the Valve

33 © 2015 Aspen Technology, Inc. All rights reserved

 Control Valve Failure This is the ΔP used in
the control valve
• Confirm the ΔP at relieving conditions, sizing equations
and specify the vendor-supplied valve
data (Cv)

Select the desired

sizing equation –
ANSI/ ISA is the
industry standard for
single-phase flow

Specify the vendor-

supplied valve
constants

34 © 2015 Aspen Technology, Inc. All rights reserved

 Control Valve Failure
• The relieving temperature is calculated
using an isenthalpic flash to relieving
conditions

• The relieving flow is calculated based on

standard control valve sizing equations
(see F1 help for details)

35 © 2015 Aspen Technology, Inc. All rights reserved

Agenda

• Introduction to Safety Analysis Environment

• Adding and Sizing a PSV

• Fire Relief Calculations

• Control Valve Failure Calculations

• Tube Rupture Calculations

• Documentation (Hands-on Demo)

• Getting Support!

36 © 2015 Aspen Technology, Inc. All rights reserved

Agenda

• Introduction to Safety Analysis Environment

• Adding and Sizing a PSV

• Fire Relief Calculations

• Control Valve Failure Calculations

• Tube Rupture Calculations

• Documentation (Hands-on Demo)

• Getting Support!

37 © 2015 Aspen Technology, Inc. All rights reserved

Heat Exchanger Tube Failure/ Rupture

Calculates relief
load due to an
internal tube
rupture on HX-1

38 © 2015 Aspen Technology, Inc. All rights reserved

 Heat Exchanger Tube Failure/ Rupture
• Override the Reference stream and select the stream on the
high pressure side of the exchanger

39 © 2015 Aspen Technology, Inc. All rights reserved

 Heat Exchanger Tube Failure/ Rupture
• Confirm the ΔP (i.e. driving force) across
the heat exchanger at relieving The Direction of Flow
affects the Flow
conditions
Coefficient (C)

• Specify the exchanger tube diameter

Specify the
exchanger tube I.D.

All parameters used

in the sizing
calculation are
summarized here

40 © 2015 Aspen Technology, Inc. All rights reserved

 Heat Exchanger Tube Failure/ Rupture
• The relieving temperature is calculated
using an isenthalpic flash to relieving
conditions

• The relieving flow is calculated based on

flow equations in Crane’s TP-410 for flow
through an orifice (refer to F1 help or to
“PRV sizing for exchange tube rupture”
paper published by Wing. Y. Wong for
more details)

41 © 2015 Aspen Technology, Inc. All rights reserved

Agenda

• Introduction to Safety Analysis Environment

• Adding and Sizing a PSV

• Fire Relief Calculations

• Control Valve Failure Calculations

• Documentation (Hands-on Demo)

• Getting Support!

42 © 2015 Aspen Technology, Inc. All rights reserved

Documentation

• The Safety Analysis Environment has two main types of documentation

(1) Calculation Summary Reports
(2) PSV System Datasheet “Packages”

43 © 2015 Aspen Technology, Inc. All rights reserved

Calculation Summaries

• Objective: Allow engineers to easily validate the inputs and results to the AspenTech PSV
calculations.

• Reports are contextual – reports change depending on what you are viewing.

44 © 2015 Aspen Technology, Inc. All rights reserved

PSV Analysis “Packages”

45 © 2015 Aspen Technology, Inc. All rights reserved

Agenda

• Introduction to Safety Analysis Environment

• Adding and Sizing a PSV

• Fire Relief Calculations

• Control Valve Failure Calculations

• Documentation (Hands-on Demo)

• Getting Support!

46 © 2015 Aspen Technology, Inc. All rights reserved

Agenda

• Introduction to Safety Analysis Environment

• Adding and Sizing a PSV

• Fire Relief Calculations

• Control Valve Failure Calculations

• Documentation (Hands-on Demo)

• Getting Support!

47 © 2015 Aspen Technology, Inc. All rights reserved