Depressuriation Using Hysis PDF

Depressurisation using Hysys PEC-BMS-EN-GDE-P-2548 0
Guide
Depressurisation using Hysys
Petrofac E&C Business Management System

Doc No. PEC-BMS-EN-GDE-P-2548
Revision 0
Date 01-Dec-2008
File Ref. 234145192.doc
Page 1 of 30
Revision history
Rev Date Description of Change
A 17-July-2007 Draft for Approval
B 16-Sept-2007 Draft for approval
0 1-Dec-2008 Approved
Approval Authority: (Head of Project Services)
Owner Developer Reviewer Approver
Lakshmi Bhushan Chonkar Bhagyashree Lakshmi

Venkatesh Lagwankar Venkatesh
&
Jayesh Gandhi
Records of approval are retained in the BMS/Quality Department
Summary
The purpose of this document is to provide a guide for Blowdown &

Depressurisation of system.
Page 2 of 30
CONTENTS
CONTENTS.........................................................................................3
1.0 INTRODUCTION...............................................................................4
2.0 INPUT DATA...................................................................................4

2.1 INTERNAL VOLUME (TOTAL INVENTORY OF THE SECTION)..................................................................................5
2.2 INITIAL LIQUID VOLUME (FOR WET SECTIONS)...................................................................................................5
2.3 WEIGHT OF METAL IN CONTACT WITH VAPOR AND LIQUID ...............................................................................6
2.4 EQUIVALENT WALL THICKNESS.......................................................................................................................6
2.5 COMPOSITION, INITIAL TEMPERATURE AND PRESSURE.........................................................................................6
3.0 EXTERNAL FIRE BLOWDOWN .............................................................7

3.1 CONNECTIONS (SCREEN 1)....................................................................................................................................7
3.2 HEAT FLUX (SCREEN 2)........................................................................................................................................8
3.3 VALVE PARAMETER (SCREEN 3)...........................................................................................................................9
3.4 OPTIONS (SCREEN 4).............................................................................................................................................9
3.5 OPERATING CONDITIONS (SCREEN 5)...............................................................................................................10
3.6 RESULT OF FIRE CASE..........................................................................................................................................12
4.0 ADIABATIC MODE...........................................................................12

4.1 HEAT FLUX (SCREEN 2) .....................................................................................................................................12
4.2 VALVE PARAMETER (SCREEN 3).........................................................................................................................14
4.3 OPTIONS (SCREEN 4)...........................................................................................................................................15
4.4 OPERATING CONDITIONS (SCREEN 5)...............................................................................................................16
..............................................................................................................................................................................17
4.5 RESULT OF ADIABATIC CASE:.............................................................................................................................17
4.6 ISOCHORIC BLOWDOWN......................................................................................................................................18
................................................................................................................................................................................19
.................................................................................................................................................................................19
Page 3 of 30
1.0 INTRODUCTION
Hysys-Dynamic depressuring utility can be used to simulate the depressurisation of gas,

gas-liquid filled vessel, pipelines and systems with several connected vessels or piping
volumes depressuring through a single valve.
There are two cases where this utility is applicable

1. External Fire blowdown: Used to model vessel or pipe under fire conditions.
This is used for determination of peak load in fire blowdown and for sizing of the
blowdown valve.
2. Adiabatic mode: Used to model the blowdown of pressure vessel or piping with
no external heat supplied. This is used to determine the minimum vessel
temperature during non-fire case blowdown.
The use of the Hysys utility is described in this guideline together with a spreadsheet
Blowdown.xls that has been developed to estimate the various input data that is required
for the calculation.
2.0 INPUT DATA

A summary of the data required for the different blowdown cases is listed below:
Tab Subject Fire Case Fire Case Adiabatic

Description Two phase Gas filled
vessel vessel
Connection Stream Name Stream representative of the system to be blown
down
(Vessel-
parameter)
Vessel Horizontal or vertical
Orientation
Vessel Volume Volume of zone including vessel and pipe work
Vessel Height and
diameter
Initial Liquid Liquid Volume in system
Volume
Metal mass in Calculate using metal thickness, density and vap%
contact with
vapor
Metal mass in Calculate using metal thickness, density and liq %
contact with
liquid
Heat Flux Heat loss Model None Detailed
Recycle Efficiency No entry required 100% for vapor, light
(General tab) liquid and heavy
liquid
Ambient No entry required Specify minimum
temperature ambient temp
(General tab)
Thickness of No entry required Specify thickness
metal and
insulation
(Conduction tab)
Page 4 of 30
Valve Valve equation Fisher with 100% valve opening or Masoneilan with
Parameter Cf=1
Operating Mode Fire- API 521 Adiabatic
Condition
Relief Pressure Relief Valve Set Pressure Relief Valve Set
Pressure
Temperature Max. / Min. operating Minimum of ambient
temperature / operating
temperature
De-pressuring 15 minutes Till atmospheric
Time pressure is reached
Final Pressure 50% design pressure or 7 bar flare backpressure
Time Step Size Minimum no. of step size (0.1 sec.)

Option PV work Default 100% for gas filled
contribution term and 70% for liquid
filled
Prior to carrying out the blowdown / depressurization calculations in Hysys, the following
input data need to be estimated for each blowdown section.
a) Internal Volume (total inventory of the Section).

b) Initial Liquid Volume (for Wet Sections).
c) Weight of metal in contact with vapor and liquid.
d) Equivalent Wall Thickness.
e) Equivalent Internal Diameter.
Blowdown.xls spreadsheet can be use for determination of above parameters.
2.1 Internal Volume (total inventory of the Section)
 This is the sum of volume of the vessel and piping.

 The Plot Plan should be used to estimate straight lengths and calculate the
Internal Volume of piping. A design margin of 30% can be considered for the
piping length when initial estimates are based on plot plan in order to reduce
the need for rework due to any increase in piping length and vertical segments
and expansion loops.
2.2 Initial Liquid Volume (for Wet Sections)
 HHLL of the vessel should be used for calculation of initial volume of the
liquid in the vessel.
Vertical cylinder : The volume is equal to cylindrical volume up to height of

the liquid (HHLL).
Liquid Volume= π/4*D2*H
Horizontal cylinder :
Cross sectional area up to height H can be calculated using following formulae
A= D2/4*cos-1 ( 1-2H/D ) - D2/8*sin ( 2cos-1( 1-2H/D ))
Page 5 of 30
Liquid Volume= L*A
 The % of liquid filling for piping is calculated as the ratio of liquid - gas actual
volumetric flow rate of the stream considered as obtained from the Material
Balances.
E.g. if the liquid volume fraction is 20% as per the material balance and the
volume of the pipework has been estimated as 10 m 3 then the initial liquid
volume for this section is 2 m3.
 The % liquid filling for the tubes of exchangers is calculated as the average of
the ratio of liquid - gas actual volumetric flow rate of the inlet and outlet
streams obtained from the Material Balances.
2.3 Weight of metal in contact with vapor and liquid
 The Total Weight of metal is calculated as the product of the Volume of metal
and the density of metal (carbon steel density is considered as 7850 kg/m 3).
 The Volume of metal for a vessel is calculated as the volume of the outer
cylinder minus the volume of the inner cylinder. The inner cylinder volume
uses the internal vessel diameter. The outer cylinder volume is calculated
using a diameter obtained by adding 2 times the thickness of the wall to the
internal diameter. If the mechanical datasheet for the equipment is available
then the weight of the equipment indicated on the datasheet can be directly
used.
 The Weight of metal in contact with Liquid is calculated as the product of the
Total Weight of metal and % liquid filling for Liquid. The Weight of metal in
contact with Vapour is calculated as the product of the Total Weight of metal
and (100% - % liquid filling).
 No margin is required to be added to the weight of metal as this will result in

a more conservative result for Blowdown requirements. The weight of internal
can also be ignored for the same reason.
2.4 Equivalent Wall Thickness
 The Equivalent Wall Thickness is calculated as the sum of the product of the
Wall Thicknesses and Internal Volumes of each item divided by the sum of the
Internal Volumes. This thickness is used in Heat flux-detail-conduction-Metal
thickness
 Wall thicknesses for piping are obtained from the Piping Project Material
Specifications.
 Wall Thickness for vessels are taken from the mechanical datasheet.
2.5 Composition, Initial temperature and pressure

The composition within the blowdown section is based on heat and material balances.
All feeds and outputs streams to and from the system will be assumed to have stopped
and all internal heat sources within the process ceased.
The streams considered must be representative of the depressurization section.
Page 6 of 30
Hysys depressurization utility can accept 4 streams. For more than 4 streams use mixer
block to combine the streams and use the mixer outlet stream in depressurization
utility as feed.
Take initial pressure as set pressure of PSV.
3.0 EXTERNAL FIRE BLOWDOWN

This section explains the step by step procedure for the External Fire case in Hysys
3.1 Connections (Screen 1)

This is used to specify the inlet stream, vessel volume and the initial liquid volume.
More than one stream can be entered (maximum of 4 streams permitted). For each
stream the vessel volume and the liquid volume needs to be entered.
If the depressuring zone is mainly a single vessel then the diameter and height of the
vessel can be entered. If the depressuring zone consists of a number of equipment
then it is a better option to enter the flat end vessel volume. The orientation
(horizontal / vertical) should try to match the actual system as far as possible.
Page 7 of 30
3.2 Heat Flux (Screen 2)
 Go to Heat flux tab and select Fire API 521 as operating mode.
 C1=21000 Btu/hr/ft; C2=0.82 ; C3=1 ( Refer the figure given below)
 This will use API 521 equation for calculation of heat load in case external fire
Heat load = 21000*F*Aw0.82 Btu/hr/ft2
 Heat Loss Model
There are three types of Heat Loss models available:

o None: does not account for any heat loss
o Simple: allows the user to either specify the heat loss directly or have it
calculated from specified values
o Detailed: allows the user to specify a more detailed set of heat loss
parameters. There are four sections to be specified in this model :
General, Conduction, Convention, Correlation constant
For fire case choose heat loss model as “None”.
Page 8 of 30
3.3 Valve Parameter (Screen 3)
 Use Fisher with 100% valve opening or Masoneilan flow equation with critical flow
factor equal to 1.
 For initial sizing of the valve give some guess value of the Cv.
3.4 Options (Screen 4)
Page 9 of 30
In the option tab we need to specify “PV work contribution term”
The “PV work term contribution” is a coefficient that allows the user to tune the
energy balance equation to reflect the actual behavior. This factor should ideally be
100% to follow the thermodynamic equations, but sometime results did not match the
expected behavior: transients were too rapid, therefore this factor was introduced in
order to tune the models.
This is approximately Isentropic efficiency which is used in the blowdown calculations.
It is a measure of the reversibility of the system. This takes into account the frictional
loss within the blowdown system. Thus a higher isentropic efficiency leads to a lower
minimum temperature on blowdown. In the absence of pertinent experimental data or
publications it is recommended to use 0% (default) in fire case and 100% for gas filled
and 70% for liquid containing systems in adiabatic case for this term.
3.5 Operating Conditions (Screen 5)
 Specify depressurisation time and final pressure in operating conditions.
Page 10 of 30
As per API 521 the depressuring system shall reduce the pressure of the
equipment within the fire zone to 50% design pressure or 690 kpa whichever is
lower within 15 minutes. As per DEP 80.45.10.10 the depressuring system shall
reduce the pressure of the equipment within the fire zone to 50% design
pressure within 15 minutes.
 Use Option “Calculate Cv”
Page 11 of 30
3.6 Result of fire case
Important result in fire case depressurisation is peak flow through the valve. This will
be available in Summary of performance tab.
4.0 ADIABATIC MODE

The Adiabatic Case determines the Minimum Temperatures attained during the Blowdown
of the Section.
Screen 1 is identical to that for the Fire Case. In addition to the data specified for the fire
case, the metal mass in contact with liquid and vapour must be specified.
4.1 Heat Flux (Screen 2)
For carrying out adiabatic blowdown select the operating mode as Adiabatic from heat
flux model.
Use “Detailed” heat loss model.
Specify vapor recycle efficiency as 1% and Liquid recycle efficiency as 100%. This will
ensure minimum metal temperature.
Specify minimum ambient temperature
Page 12 of 30
The Conduction parameters allow the user to manipulate the conductive properties of
the wall and insulation.
Specify thickness of metal and insulation in conduction tab. Use default value for rest.
The Convection view allows users to manipulate the heat transfer coefficient for inside
and outside the vessel as well as between vapor and liquid material inside the vessel.
These can be retained as default.
Correlation constant: feature gives users the opportunity to manipulate the

coefficients used in the heat transfer correlation. This is generally not used.
Page 13 of 30
4.2 Valve Parameter (Screen 3)
Use the Cv obtained from fire case in valve parameter tab while keeping the other
parameters same as in Fire case.
Page 14 of 30
4.3 Options (Screen 4)
Use “PV work contribution term” 70% for wet sections and 100% gas section.
Page 15 of 30
4.4 Operating Conditions (Screen 5)
In operating condition tab, select the option “calculate pressure”. Increase the
depressurizing time in a step wise manner so that the system pressure close to the
flare back pressure is attained.
Page 16 of 30
Now run the utility till the final value of the pressure reached. This final pressure will
be backpressure of the flare header.
4.5 Result of Adiabatic case:
Minimum vessel metal temperature is the important value in the adiabatic case.
Page 17 of 30
4.6 Isochoric Blowdown
When equipment is not depressurized immediately after shutdown, the equipment may
cool down before blow down occurs. The start pressure associated with this
temperature will be calculated by performing an isochoric flash (constant volume)
from the normal conditions to the minimum attainable temperature. This minimum
temperature is taken as per project guideline and generally it is equal to minimum
ambient temperature. The pressure associated with this temperature is found out
using isochoric flash. Procedure for this is as follows:
1. Note down the actual volumetric flow rate and mass flow rate of the stream
(Stream-A) which we have used for the adiabatic blow down (stream with
normal operating temperature and pressure).
2. Take one more stream (Stream-B) and specify the composition and mass
flow rate of this stream same as Stream-A
3. Specify temperature of Stream-B equal to minimum ambient temperature
4. Apply adjust block to Stream-B with following setting
Aadjusted variable = Pressure of stream-B
Target variable = Actual volume of stream-B
Specifed target value = Actual volume of stream-A.
5. Final pressure is the start pressure for the adiabatic blow down.
6. Taking this stream as the start point for the adiabatic blow down, follow
the same procedure mentioned in section 4.1 to 4.5.)
Page 18 of 30
Page 19 of 30
4.7
APPENDIX 1 EXAMPLE
Consider the system shown in the following sketch
Input Data :
Unit Value
Fire Case
Vessel diameter m 4.5

Vessel Length m 17
Vessel Orientation Horizontal
Head Type Ellipsoidal
Liquid Ht m 2.83
Vessel thickness mm 70
Pressure Barg 120
Temperature Deg C 27.74
System Volume m3 331
Initial Liquid Volume m3 179
PV Work term Contribution % 0
Control Valve Opening % 100
Depressuring Time Min 15
Final Pressure (50% of D.P) Barg 60
Amb temp Deg C 5
Page 20 of 30
Mole fraction composition is taken as follows (Based on stream data from Material Balance).
Nitrogen 2.78E-02
CO2 0.208927
H2S 8.49E-02
Methane 0.548892
Ethane 5.11E-02
Propane 2.46E-02
i-Butane 3.04E-03
n-Butane 8.31E-03
i-Pentane 2.20E-03
n-Pentane 3.70E-03
Benzene 1.28E-04
Toluene 3.06E-04
m-Xylene 1.48E-04
p-Xylene 1.48E-04
o-Xylene 1.76E-04
cfc6_1* 3.64E-03
cfc7_1* 2.91E-03
cfc8_1* 2.81E-03
F9_1* 2.73E-03
F10_1* 2.47E-03
F11_1* 1.98E-03
F12_1* 2.76E-03
F14_1* 2.35E-03
F16_1* 2.00E-03
F18_1* 1.72E-03
F20_1* 1.48E-03
F22_1* 1.27E-03
F24_1* 1.10E-03
F26_1* 9.51E-04
F28_1* 8.24E-04
F30_1* 7.15E-04
F32_1* 6.22E-04
F34_1* 5.42E-04
F36_1* 4.73E-04
F38_1* 4.14E-04
F40_1* 3.63E-04
F42_1* 3.18E-04
F44_1* 2.81E-04
H2O 8.95E-04
TEGlycol 1.00E-06
Blowdown study :
Initial Volume and mass calculation (Blowdown.xls spreadsheet developed for for
this calculation )
Page 21 of 30
Piping Volume Calculation
Initial
Mass
of
Metal Initial
Actual Actual in Mass of
Liquid vapor Fr Total Initial contact Metal in
Pipe flow flow Liquid Pipe Pipe Diff METAL Liquid with contact
Pipe Dia thk L rate rate Filling ID OD Vol Vol. MASS volume Liq with Vap V*t
inch mm m m3/hr m3/hr mm mm m3 m3 kg m3 kg kg
PIPE-Feed 8 9.52 150 1.3600 13.2 0.093 203 222 0.95 4.9 7,491.28 0.45 699.25 6792.03 0.046309
PIPE-Gas
outlet 10 9.52 100 0.0 13.2 0.000 254 273 0.79 5.1 6,186.86 0.00 0.00 6186.86 0.048239
Pipe Liquid
Outlet 3 4 100 1.4 0.0 1.000 76.2 84.2 0.1 0.5 791.14 0.46 791.14 0.00 0.001824
TOTAL, m3 10.4 14,469.28 0.91 1490.40 12978.88 0.0964

With 30%
margin 13.5 1.18 0.1253
Page 22 of 30
Screen View- Fire Case
Page 23 of 30
Page 24 of 30
Page 25 of 30
Result
Pressure vs time chart
Fire case Blowdown: Pressure vs time
140
120
Pressure in bar
100
80
60
40
20
0
0 100 200 300 400 500 600 700 800 900 1000
Time in sec
Mass Flow rate vs time
Page 26 of 30
Fire Case blowdown: Mass flow rate vs time
250000
Mass flow rate in Kg/hr 230000
210000
190000
170000
150000
130000
110000
90000
70000
0 100 200 300 400 500 600 700 800 900
time in seconds
Page 27 of 30
Screen View- Adiabatic Case
Page 28 of 30
Result :
Page 29 of 30
Pressure vs Min temperature
Min Temp Vs time
30
25
Temperature in Deg C
20
15
10
0
0 25 50 75 100 125 150 175 200 225
time in min
Page 30 of 30

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Depressurisation using Hysys PEC-BMS-EN-GDE-P-2548 0

Depressurisation using Hysys

Petrofac E&C Business Management System

File Ref. 234145192.doc

Rev Date Description of Change

A 17-July-2007 Draft for Approval

B 16-Sept-2007 Draft for approval

Approval Authority: (Head of Project Services)

Owner Developer Reviewer Approver

Lakshmi Bhushan Chonkar Bhagyashree Lakshmi

Records of approval are retained in the BMS/Quality Department

The purpose of this document is to provide a guide for Blowdown &

2.0 INPUT DATA...................................................................................4

3.0 EXTERNAL FIRE BLOWDOWN .............................................................7

4.0 ADIABATIC MODE...........................................................................12

Hysys-Dynamic depressuring utility can be used to simulate the depressurisation of gas,

There are two cases where this utility is applicable

2.0 INPUT DATA

Tab Subject Fire Case Fire Case Adiabatic

Final Pressure 50% design pressure or 7 bar flare backpressure

Time Step Size Minimum no. of step size (0.1 sec.)

a) Internal Volume (total inventory of the Section).

Blowdown.xls spreadsheet can be use for determination of above parameters.

2.1 Internal Volume (total inventory of the Section)

 This is the sum of volume of the vessel and piping.

2.2 Initial Liquid Volume (for Wet Sections)

Vertical cylinder : The volume is equal to cylindrical volume up to height of

Liquid Volume= π/4*D2*H

A= D2/4*cos-1 ( 1-2H/D ) - D2/8*sin ( 2cos-1( 1-2H/D ))

Liquid Volume= L*A

2.3 Weight of metal in contact with vapor and liquid

 No margin is required to be added to the weight of metal as this will result in

2.5 Composition, Initial temperature and pressure

The streams considered must be representative of the depressurization section.

Take initial pressure as set pressure of PSV.

3.0 EXTERNAL FIRE BLOWDOWN

3.1 Connections (Screen 1)

3.2 Heat Flux (Screen 2)

There are three types of Heat Loss models available:

For fire case choose heat loss model as “None”.

3.3 Valve Parameter (Screen 3)

3.4 Options (Screen 4)

In the option tab we need to specify “PV work contribution term”

3.5 Operating Conditions (Screen 5)

 Specify depressurisation time and final pressure in operating conditions.

3.6 Result of fire case

4.0 ADIABATIC MODE

4.1 Heat Flux (Screen 2)

Correlation constant: feature gives users the opportunity to manipulate the

4.2 Valve Parameter (Screen 3)

4.3 Options (Screen 4)

4.4 Operating Conditions (Screen 5)

4.5 Result of Adiabatic case:

4.6 Isochoric Blowdown

Consider the system shown in the following sketch

Vessel diameter m 4.5

Piping Volume Calculation

TOTAL, m3 10.4 14,469.28 0.91 1490.40 12978.88 0.0964

Screen View- Fire Case

Pressure vs time chart

Fire case Blowdown: Pressure vs time

Mass Flow rate vs time

Fire Case blowdown: Mass flow rate vs time

Liquid Volume= π/4D2H

A= D2/4cos-1 ( 1-2H/D ) - D2/8sin ( 2cos-1( 1-2H/D ))