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Feature

Cover Story
Report

Size Safety-Relief
Valves for Ron Darby
Texas A&M University

Any Conditions
Before calculating the size of your safety-relief valve,
make sure you understand the limitations
of the methods available

S
afety-relief valves (SRVs) and inputted to the vessel contents (from here, with a concentration on the basic
rupture disks are typically either external or internal sources, procedure for properly sizing the relief
used to protect equipment from such as external heating or a runaway (either a SRV or rupture disk) under a
excessive overpressure. Typi- reaction) to prevent further pressure variety of conditions for single and two-
cal scenarios that can result buildup. The valve will close when the phase flows. Some of the material has
in such overpressure in excess of the pressure drops to a safe level, thus previously been published (CE, June
vessel’s MAWP (maximum-allowable- containing and protecting the bulk of 2002, pp. 68–74); but it is repeated
working pressure) include external the vessel contents. Since the capac- here for the sake of completeness and
fire, blocked outlet line, power failure, ity of a valve is limited, it cannot ac- because an understanding of the dif-
loss of cooling water or steam, thermal commodate the extreme flowrate that ferent models and methods available
expansion, excess inlet flow, accumu- might be required to protect against continues to elude many engineers. It
lation of noncondensables, failure an extremely high-energy-input rate is also timely information because the
of check or control valve, exchanger such as might result from a very ener- American Petroleum Institute (API)
tube rupture, runaway reaction, and getic runaway reaction, a deflagration is involved in a revision of RP 520
human error (for example, opening or an explosion. Rupture disks are a (Sizing, Selection, and Installation of
or closing the wrong valve). These and less expensive alternative to safety Perssure-Relieving Devices in Refin-
other scenarios are discussed in more valves, especially for very large-capac- eries) that will put more emphasis on
detail elsewhere [1]. ity requirements, but of course do not the HDI method (described below).
Relief devices should be installed on reclose to contain the vessel contents.
all pressure vessels, including reac- Proper design of a relief system re- Required relief rate
tors, storage tanks, towers, and drums. quires not only determining the cor- The first step in the design process for
Other locations where relief devices rect size for the valve or rupture disk, valve sizing is to postulate one or more
are required are blocked in sections but also the proper size and selection credible scenarios that could result in
of liquid-filled lines that are exposed of upstream and downstream piping unacceptable overpressure, and deter-
to external heating, the discharge and effluent handling systems. The mine the corresponding required dis-

from positive-displacement pumps, design procedure can vary, from a rel- charge mass flowrate, m, that would be
compressors and turbines, and vessel ative simple, fairly routine, process for sufficient to prevent the pressure from
steam jackets. Storage vessels contain- single-phase (gas or liquid) flow, to a in exceeding the vessel’s MAWP. The

ing volatile liquids and a vapor space complex procedure for two-phase flow value of m is determined by energy
should be protected not only from ex- requiring considerable expertise and and mass balances on the vessel con-
cessive pressures from external heat or procedures that depend on conditions tents under the conditions of the spe-
flow input but also from the possibility and the nature and characteristics of cific postulated relief scenario, such
of a vacuum due to condensation of the the fluid being discharged. The details as a runaway reaction, an external
vapor. of this total process are beyond the fire, loss of cooling, or a blocked line.

Relief valves are designed to open scope of this article, and authorita- The value of m is determined by the
at a preset pressure, and are sized to tive references should be consulted for requirement that the rate of energy
allow mass flow out of the vessel at a further information [2–5]. The overall discharge from the vessel be equal to,
rate sufficient to remove excess energy considerations that are important in or greater than, the maximum rate at
from the vessel at least as fast as it is the design process are summarized which excess energy is inputted into
42 CHEMICAL ENGINEERING WWW.CHE.COM SEPTEMBER 2005
NOMENCLATURE
A cross sectional area of the nozzle L nozzle length x quality, or mass fraction of gas phase
throat (orifice) in a valve, or open Le relaxation length for non-equilibrium x0 quality at nozzle entrance
area of rupture disk flow = 10 cm xe equilibrium quality at pressure P

G0 theoretical mass flux through an isen- m required relief mass flow rate  volume fraction of the gas phase
tropic nozzle NRe Reynolds number through the valve  ratio of the nozzle diameter to the
Gn actual mass flux through nozzle = nozzle, using volumetric weighted valve inlet diameter (d/D)
KdG0 fluid properties for mixtures.  density of the fluid (mixture) in the
k isentropic exponent for a gas (= cP/ P pressure nozzle at pressure P
cV for ideal gas) Pi pressure at interval i G gas phase density
Kd relief valve discharge coefficient P0 pressure at valve entrance L liquid phase density
KdG gas phase discharge coefficient Pn pressure at the nozzle throat (exit) n fluid density at the nozzle throat at
KdL liquid phase discharge coefficient S slip ratio (ratio of the gas phase ve- pressure Pn
Kv viscosity correction factor for viscous locity to the liquid phase velocity) i average fluid density over interval
fluids s specific entropy i to i+1

the vessel under the assumed sce- determining the heat transfer rate. standard size nozzle orifice area which
nario. It is normal to postulate several Valve sizing is the closest to the resulting value on
credible scenarios, and base the design The required orifice area* for a relief the high side is then selected.
on the worst of them. This strategy, of valve or rupture disk is determined It is important that the relief area
course, involves judgment calls, and from the formula be neither excessively large nor small.
estimates of the probability of a sce- A= m˙ An undersized vent would obviously
K d G0 (1)
nario occurring. not provide the required overpressure
For a runaway reaction involving where G0 is the theoretical mass flux protection, whereas an oversized vent
volatile or gaseous components, data (mass/time.area), calculated for flow will result in excessive flow, which can
from an adiabatic calorimeter or de- through an ideal (isentropic) nozzle. adversely affect the opening and clos-
tailed kinetic information are required The expression for G0 follows directly ing characteristics of the relief valve
to predict the required relief rate. Spe- from application of the general steady- resulting in impaired performance
cialized techniques or equipment, or state energy-balance (Bernoulli) equa- (such as unstable operation or chat-
both, are needed for this, and the pro- tion to the fluid (gas, liquid or two- ter) with possible severe damage to
cess should be left to the experts (see, phase) in the nozzle [10]: the valve. If the valve is oversized, the
for example, References [4–6]).  P 
1/ 2 actual flow rate will be significantly
G0 = ρ n  −2 ∫ dP  (2)
n

For storage vessels containing a greater than the required design rate
volatile liquid, a commonly postulated  P 0
ρ  •
(m) so that if the associated piping
scenario is an external fire which where P0 is the pressure at the en- is sized for the design rate it will be
heats the vessel and contents, result- trance to the valve, Pn is the pres- undersized for the actual rate. This
ing in superheating the liquid. If the sure at the nozzle exit,  is the fluid means the pressure drops through
vapor pressure builds up to a point (or mixture) density at pressure P, the entrance and exit piping will be
which exceeds the vessel’s MAWP, and n is the fluid density at pres- greater than expected, and these pres-
the vessel could rupture, resulting sure Pn, the nozzle exit or throat. Kd sure drops can have serious adverse
in a BLEVE (boiling-liquid, expand- is the (dimensionless) discharge coef- effects on the stability of the valve
ing-vapor explosion). The relief mass ficient that accounts for the difference (see the section “Inlet and discharge
flowrate must be sufficiently high so between the predicted ideal nozzle piping” below).
that the rate of discharge of the total mass flux and the actual mass flux in Although the flow through a relief
sensible and latent heat through the the valve. The value of this coefficient valve is an unsteady (time-dependent)
vent must equal or exceed the rate of is determined by the valve manufac- process, it is customary to base the cal-
heat energy transferred to the fluid turer from measurements using (typi- culations on assumed steady-state con-
through the vessel wall from the fire cally) single-phase air or water flows. ditions corresponding to the expected
exposure. Since the liquid will typi- Further assumptions must be made to flow rate at a pressure which is 110%
cally be superheated, flashing will determine the appropriate value of Kd of the relief set pressure (that is, 10%
occur as the pressure drops through to use for two-phase flow (this is dis- overpressure). The relief set pressure is
the vent, resulting in two-phase flow in cussed later). normally the vessel’s MAWP, although
the relief, which must be accounted for There are a finite number of stan- other relief pressures are allowed by
in sizing the relief, as described below dard valve-nozzle (orifice) sizes to the ASME BPVC for various special
(the relief area required for two-phase choose from, and the calculated area cases (for example, API RP 520 [2]).
flow is normally significantly larger (A) cannot be expected to correspond
than that which would be required for exactly to one of these sizes. In prac- Nozzle models
single phase flow). Methods for esti- tice, a 10% safety factor is automati- The term “model” as applied to valve
mating the heat transfer rate from a cally applied to the calculated area sizing is frequently misunderstood. For
fire to storage vessels are presented [per the ASME Boiler and Pressure example, the commonly referenced ho-
by the National Fire Protection Assoc. Vessel Code (BPVC)], and then the mogeneous-equilibrium model (HEM)
(NFPA) [7] and API [8]. For conditions is not a “complete model” for calculat-
not adequately covered by these docu- *Although the term orifice is commonly used to ing the nozzle mass flux, but simply
describe the minimum flow-area constriction
ments, the author of Reference [9] has in the valve, the geometry more commonly re- a set of conditions and assumptions
presented fundamental relations for sembles a nozzle and the area is determined by which constrain the calculations. The
applying the equation for flow in an isentropic
*All nomenclature is defined in the box above. nozzle, as described in this article. HEM implies that if the fluid through
CHEMICAL ENGINEERING WWW.CHE.COM SEPTEMBER 2005 43
Cover Story

the valve is a two-phase, gas-liquid not aware of data for non-Newtonian conditions could result in flashing,
mixture, it will be sufficiently well flow in relief valves, and there are no condensing, or “frozen” (non-flashing)
mixed that it can be described as a current models that account for such flow. Flashing flow occurs in nozzles
single-phase fluid with properties that properties. However, in the absence of or valves whenever the entering fluid
are a suitable combination of each more specific information, it may be is a saturated or superheated liquid,
fluid, and that the two phases are in assumed that Equation (4) can be ap- a sub-cooled liquid that reaches the
both mechanical and thermodynamic plied to non-Newtonian viscous fluids saturation pressure within the nozzle,
equilibrium. These assumptions are if the Reynolds number is modified or a two-phase, vapor-liquid mixture.
necessary for calculating the nozzle accordingly for the specific non-New- Frozen two-phase flow may occur if the
mass flux, but they are not sufficient tonian rheological model (see Chapter vessel initially contains both gas and a
because additional assumptions or 7 of [10]). non-volatile liquid (for example, a ves-
conditions must be specified with re- Single-phase gas flow: In the case sel with inert-gas blanketing). Either
gard to the properties of the fluid, of an ideal gas, the integral of Equa- frozen or flashing flow could result
which are necessary to determine the tion (2) can be readily evaluated as- from a runaway reaction, for example.
mixture density as a function of pres- suming isentropic flow for which P/k Retrograde condensation may also
sure. It is evident from Equation (2) is constant. However, the result de- occur when the fluid in the vessel is
that the calculated nozzle mass flux is pends upon whether or not the nozzle a dense gas that condenses when the
determined specifically by the manner exit pressure (Pn) is at or below the pressure drops.
in which the fluid density depends on value at which the speed of sound is Two-phase flow is considerably
pressure over the range of pressures reached in the nozzle (that is, choked more complex than single-phase flow,
in the nozzle. The “homogeneous equi- flow). The criterion for choked flow is and there are a number of additional
librium assumption” is inherent in the Pn ≤ Pc, where Pc = P0[2/(k + 1)]k/(k-1). factors that must be considered, such
derivation of Equation (2), but the spe- If the flow is choked the mass flux is as the flow regime (see below), the
cific relation to be used for the func- given by nature of the interaction between the
tion (P), and the manner in which (k+1)/2(k-1)
phases, the method of determining the
the integral is evaluated using this G0 = kP0 ρ0 ⋅  2  (5) properties of the two-phase mixture,
 k + 1
function, must also be specified for the and the method of incorporating these
“model” to be complete. which is independent of the down- properties into evaluation of the mass
Single-phase liquid flow: For sin- stream pressure. If Pn > Pc the flow is flux integral.
gle-phase liquid flow, the nozzle mass not choked (that is, sub-critical), and If a vessel initially contains both liq-
flux integral [Equation (2)] is simple the mass flux depends on both the up- uid and gas or vapor, or a superheated
to evaluate since the fluid density is stream and downstream pressures as liquid, the mass fraction of gas (that
assumed independent of pressure. follows: is, the quality) in the two-phase mix-
Thus, for liquids with a constant den-  2/k ( k+1) / k 
1/2 ture entering the relief device will de-
2 P0 ρ0 k  Pn  P  
sity, Equation (2) reduces to G0 = ⋅   —  n (6) pend upon the amount of gas or vapor
k — 1  P0   P0  
generated within the liquid phase,
G0 = 2ρ( P0 − Pn ) (3)  
If (P0/Pn) ≥ 2 (approximately), the flow the degree of mixing in this phase,
This equation is valid for fully turbu- will probably be choked and Equation the bubble rise velocity, the physical
lent flow (Reynolds numbers above (5) applies. properties of the liquid, and the initial
about 100,000), for which the flow rate Non-ideal gases can be treated void fraction (that is, the vapor space)
can be assumed to be independent of using Equation (2) along with actual in the vessel. The prediction of this
the fluid viscosity. For low-Reynolds- property data or an appropriate equa- initial quality can be a complex pro-
number (that is, high-viscosity) flows, tion of state to evaluate the gas den- cedure, and the pertinent references
the value given by Equation (3) can sity. Alternately, the above equations should be consulted [4].
be multiplied by a correction factor, can be used if a “non-ideal k value” is Flow regime: This refers to the dis-
Kv, that reflects the dependence of G0 used, and the density is divided by an tribution of the two phases in the flow
on Reynolds number as well as on , appropriate value of the compressibil- field, which can be classified as distrib-
the ratio of the nozzle diameter to the ity factor (z) evaluated at the choke uted (such as stratified, wavy, slug, or
valve inlet diameter, d/D [11]: conditions (for a discussion of the suit- bubbly) or homogeneous (well mixed).
ability of using ideal versus non-ideal Because of the high velocities and
K V = 0.975 β 0.1 gas k values, see Reference [12]). high degree of turbulence in typical
0.9+ 950(1 − β ) (4) relief flows, the usual assumption is
 1.4 
/ N Re 
  Two-phase flow that the flow is well mixed and hence
where NRe is the Reynolds number Thousands of relief valves in process homogeneous within the relief device.
through the nozzle. (For a two-phase plants are installed in vessels that op- This assumption means that the two-
mixture, a volumetric average values erate under conditions that can result phase mixture can be represented as a
of density and viscosity is used.) Equa- in two-phase flow through the valve, “pseudo single-phase” fluid, with prop-
tions (3) and (4) also assume that the and the latter must be properly sized erties that are a suitable average of
liquid is Newtonian. The author is to accommodate such flows. Various the individual fluid properties. There
44 CHEMICAL ENGINEERING WWW.CHE.COM SEPTEMBER 2005
are many ways that this average can phase, which means that the proper- made for assuming that the flow in
be defined, but the most widely ac- ties of the mixture are a function only the nozzle is isenthalpic and using
cepted is a volume-weighted average. of the local temperature, pressure and an enthalpy balance to determine the
On this basis, the density of the two- composition. In other words, when the local properties. In some cases (for
phase mixture is given by pressure in a liquid drops to the satu- instance, liquid flow), the isentropic,
ration (vapor) pressure, it is assumed isenthalpic and isothermal paths are
ρ = αρG + (1 − α )ρ L (7)
that vaporization (flashing) will occur virtually identical. For example, if the
where  is the volume fraction of the instantly if the system is in equilib- inlet conditions are subcooled or satu-
gas phase, given by rium. However, flashing is actually a rated, and are sufficiently far from the
α= x rate process that takes a finite time (a critical point, there is usually a negli-
x + S(1 − x)ρG / ρ L (8)
few milliseconds) to develop fully. Dur- gible difference between the isentropic
Here x is the quality (that is mass ing this “relaxation time” a liquid can and isenthalpic paths. However, as the
fraction of the gas phase) and S is the travel several inches (a corresponding critical point is approached, or for low
slip ratio, or the ratio of the gas veloc- “relaxation distance”) in the nozzle of vapor-liquid ratios (low quality), the
ity to the liquid velocity in the mixture a valve under typical relief conditions. difference is more pronounced. Par-
(see below). Under these conditions, the amount of ticularly in the vicinity of the thermo-
Mechanical equilibrium: This im- vapor generated (the quality) is much dynamic critical point, the differences
plies that the two phases are flowing smaller than would occur under equi- may be quite significant. There are no
at the same velocity, with no slip (S = librium conditions, and the mixture definitive studies to show which as-
1). When slip occurs, it is because the density and mass flux are correspond- sumption is the most appropriate, but
gas phase expands as the pressure ingly larger. Experimental data on a the general consensus favors the isen-
drops and hence must speed up rela- number of single-component systems tropic path (which is inherent in the
tive to the liquid phase. Slip becomes [15] have indicated that this relaxation isentropic-nozzle equation).
more important as the pressure gradi- distance is of the order of 10 cm for typ- Physical property data: In order to
ent increases, and is most pronounced ical relieving conditions, which means calculate the two-phase density (and
as the velocity approaches the speed of that flashing flow in nozzles shorter other properties) along the chosen
sound (choking). than 10 cm should be in non-equilib- path (isentropic), a database of ther-
Although there are a variety of rium. Some nozzle flow models have mophysical properties of the fluids is
“models” in the literature for estimat- provision for non-equilibrium effects required. The specific properties and
ing slip as a function of fluid proper- and some do not, as discussed later. the amount of data required depend
ties and flow conditions, it is often Thermodynamic path: As the fluid on the particular model used; but at
neglected under pressure-relief con- flows through the nozzle, the pres- a minimum, the mass fraction of the
ditions because of the high degree of sure and temperature both drop and gas phase (quality) and the densities
turbulence and mixing. For flashing the volume fraction of gas (or vapor) of each fluid phase are required as a
flows, slip effects are normally negli- increases. For frozen flows, the mass function of pressure along the path
gible, since the volumetric expansion flowrate of each phase remains con- (for example, for the HDI model).
due to flashing will overwhelm the ex- stant throughout the flow path, al- For frozen flows, the liquid density
pansion of the gas phase due to pres- though the phase volume fractions is constant so the only property infor-
sure drop alone. However, slip can be change because the gas expands. For mation required is a suitable equation
significant for frozen flows (for exam- a volatile liquid, the quality (the mass of state for the gas (such as the ideal-
ple air and cold water). For example, fraction of gas) will also change from gas law), or appropriate data for the
the authors of References [13] and [14] point to point because of increasing gas. Some models require enthalpies,
found that a slip ratio (S) of 1.1 to 1.5 evaporation as the pressure drops, and entropies, densities, heats of vaporiza-
is consistent with various frozen-flow it is necessary to determine the local tion and specific heats at one or more
data in nozzles. Most frozen-flow data quality as a function of pressure in conditions. For flashing pure compo-
in the literature are for air-cold water order to calculate the two-phase mix- nents, the required data are usually
mixtures, and there are little or no ture density from Equation (7). This available in a thermophysical property
data for industrial fluids. Note that is done by assuming that the fluid fol- database or simulator. The Omega and
Equation (8) shows that an increase in lows a specific thermodynamic path as HNE models (both discussed in more
S results in a larger two-phase density it traverses the nozzle, a path which detail below) require thermophysical
and corresponding higher mass flux may be isothermal, isentropic, or isen- properties at only one state (for in-
than would be predicted with no slip. thalpic, and then determining the gas stance, the stagnation state), and em-
Some models for the nozzle mass flux and liquid densities and the quality ploy an entropy or enthalpy balance
include provision for slip and some do (or phase ratio) along this path. The to determine the vapor fraction (qual-
not, as described later. usual assumption is that this path is ity) of the two-phase flashing mixture.
Thermodynamic phase equilib- isentropic, since the “isentropic-nozzle The API version of the Omega method
rium: It is commonly assumed that equation” is used as the basis for the for mixtures requires thermophysi-
the gas or vapor phase is in local ther- mass flux. cal properties at two states for evalu-
modynamic equilibrium with the liquid On the other hand, a case can be ation of the Omega parameter. For
CHEMICAL ENGINEERING WWW.CHE.COM SEPTEMBER 2005 45
Cover Story

multicomponent mixtures, additional zle conditions and the nature of the density and quality (x) at two sepa-
property data or mixture models must fluid but also the range of pressures rate pressures at constant entropy.
be available and can be used with a in the nozzle For multicomponent systems, this
flash routine to determine the vapor- • The method tends to be unreliable can be done using a flash routine
liquid equilibrium properties (such as in the vicinity of the critical point, or coupled with an appropriate fluid
density and quality) of the two-phase for dense gases that condense when database in a simulator. Accurate
multicomponent mixture as a function the pressure is reduced (retrograde thermophysical property (density)
of pressure. condensation) data are required since small varia-
• It was derived for single-component tions or errors in the thermodynamic
Model assumptions fluids and is not easily adapted to properties can have a large effect on
The assumptions made with regard multicomponent mixtures unless the resulting density values
to the above considerations consti- modified (see the API method below) • Non-equilibrium effects (either ther-
tute the “model” for the nozzle mass or unless the boiling range of the modynamic or mechanical) are not
flux. The most common assumption is mixture is small. Consequently, it is included
the homogeneous-equilibrium model inappropriate for mixtures with light TPHEM: This model, the two-phase
(HEM), which implies that the two- gas components (such as hydrogen) homogeneous model, is implemented
phase mixture is homogeneous and • Neither slip nor non-equilibrium ef- using a computer routine that is avail-
the phases are in equilibrium (both fects are accounted for in the model able on a CD that accompanies the Cen-
mechanical and thermodynamic). Sev- • A special version of the basic model is ter for Chemical Process Safety (CCPS)
eral versions of the HEM are in use, required for slightly subcooled liquids Guidelines book “Pressure Relief and
which differ in the specific assump- API method: The method presently Effluent Handling Systems” [4]. The
tions and methods used to evaluate recommended by API 520 [2] is the mass-flux integral [Equation (2)] is
the two-phase density and the mass- Omega method for single-component evaluated numerically by the program
flux integral [(Equation (2)]. Some of fluids and multi-component mixtures using input data for the densities of the
these variations are described below. with a normal boiling range less than liquid and gas (or vapor) and the mix-
The Omega method: This method 150°F. The heat of vaporization is cal- ture quality at two or three states at
(16, 17) was derived for a single com- culated as the difference between the constant entropy from the stagnation
ponent fluid, and assumes that the vapor and liquid specific enthalpies pressure to the discharge pressure. The
density of the two-phase mixture can of the mixture. For flashing mixtures density data are fitted in the program
be represented by a linearized equa- with a normal boiling range greater by an empirical equation, which is used
tion of state. It requires fluid proper- than 150°F, the  parameter is deter- to interpolate the densities at interme-
ties at only one state (the saturation or mined from the calculated two-phase diate pressures for evaluation of the
stagnation state). Factors that should density of the mixture at two pres- integral. The user can choose from a
be considered when using the Omega sures (P0 and P0.9 = 0.9P0) and con- variety of empirical equations for fit-
method are as follows: stant entropy. Factors to be consid- ting the two-phase P,  data, with one,
• The equations are based on an ana- ered when applying the API method two or three parameters [18, 19].
lytical evaluation of the mass flux include: The densities of the gas and the liq-
integral, using an approximate, • It is basically a two-point linear fit of uid and the quality (x) of the mixture
linearized two-phase equation of the two-phase density at pressures at each of the two or three pressures
state for the fluid density. The equa- P0 and P0.9. This is better than the along an isentropic path are inputted
tions are fairly complex, so care is one-point Omega extrapolation, but into the program. The single-param-
required to insure that the calcula- still may not give accurate results de- eter-density model is equivalent to the
tions are correct pending on the fluid, the conditions, Omega method. The two-parameter
• Fluid property data are required and the pressure range involved model is equivalent to the API method,
at only one state, simplifying the (particularly near the critical point) with P2 = 0.9P0. For flashing of an
required amount of input property • The choke pressure is estimated initially subcooled liquid, the three
data. However, these thermody- using the “single-point  method”, pressures are the saturation pressure,
namic and physical property data which could introduce some error or the nozzle exit pressure, and one in-
must be accurate, since small varia- uncertainty termediate pressure. It is necessary to
tions or errors in the thermodynamic • Since the two-phase density is have an accurate property database
properties can have a large effect on calculated from a fluid-property for the fluids in order to determine
the resulting density values database at two points using the the required input density data. The
• The linearized equation of state may single-component thermodynamic program output is the mass flux at the
not give accurate two-phase density properties, the API method can be specified exit pressure (or vice versa).
values versus pressure for some used for multicomponent mixtures A variety of other output options are
conditions since it extrapolates the if an appropriate property database also available, including viscous or
two-phase density from the relief is available non-viscous flow, and pressure drop in
(stagnation pressure) state. The ac- • A reliable property database must straight pipe with or without fittings.
curacy depends not only on the noz- be used to determine the two-phase The choke pressure and corresponding
46 CHEMICAL ENGINEERING WWW.CHE.COM SEPTEMBER 2005
mass flux are determined by initially the equilibrium-rate model (ERM), resulting density values
specifying the stagnation pressure as which employs an isenthalpic energy • The calculations are simple and easy
the backpressure and then decreasing balance on a saturated liquid to deter- to perform
this pressure in increments until the mine the fraction that is flashed. The • The choke pressure is assumed to be
mass flux reaches a maximum. rapid generation of vapor from the the saturation pressure, but this as-
Some key characteristics of the flash is assumed to result in choked sumption is not always appropriate,
TPHEM model are as follows: flow and the mass flux is evaluated especially for low relief pressures
• It is applicable to frozen or flashing from the definition of the speed of and low subcooling. Better results
flows, as well as subcooled or satu- sound using the Clausius-Clapeyron may sometimes be obtained if the
rated liquids equation to relate the vapor density actual choke pressure is used in-
• The program makes all of the calcu- to the vapor pressure of the flashing stead of Pb in the model equations,
lations automatically, so it is quick fluid and the thermodynamic proper- but this pressure has to be deter-
and easy to implement ties (for instance, the heat of vapor- mined using another method (such
• Two or three (P, , x) data points are ization). The mass flux predicted by as TPHEM or HDI)
required along an isentropic path. this model for a saturated flashing • The assumption of an ideal gas phase
Using more than one data point can liquid is typically about 10% higher is made for the gas phase, which can
improve the property estimates con- than corresponding values predicted introduce errors, particularly in the
siderably over those of the Omega by the HEM model. However, for vicinity of the critical point
method in many cases. Accurate slightly subcooled liquids it has been • The model does not include any pro-
thermophysical-property (density) observed that the actual mass flux vision for slip
data are required since small varia- may be as much as 300% greater than • The relaxation-flow length (10 cm)
tions or errors in the thermodynamic predicted by either model. is based on a relatively small num-
properties can have a large effect on This model has been extended [15, ber of observations
the resulting density values 20] to account for non-equilibrium The HDI method: This method,
• A wide variety of conditions, in- effects resulting from delayed flash- the homogeneous direct-integration
cluding pipe flow or nozzle flow for ing by the rate processes involved. method [21, 22], involves generating
inviscid or viscous fluids, can be The model determines the gas mass multiple (P, , x) data points over an
run using various combinations of flux and liquid mass flux separately isentropic range of pressures from P0
“switches” in the program, for cal- using the respective single-phase dis- to Pn using a thermodynamic-property
culating either the mass flux or the charge coefficients KdG and KdL, and database for a pure fluid, and a flash
exit pressure combines these in proportion to the routine for a multicomponent mixture.
• It can include a slip parameter or respective phase mass fractions. Non- These data are used to evaluate the
a non-equilibrium parameter, but equilibrium is characterized by a de- mass-flux integral, Equation (2), by
there are no guidelines for selecting layed flashing parameter which is a direct numerical integration. This can
the values of these parameters function of the “relaxation length”, be done easily on a spreadsheet by the
• Multicomponent systems can be han- Le = 10 cm. Non-equilibrium condi- simple trapezoidal rule, or a simply
dled using a flash routine to generate tions were found to occur when L < quadrature formula, as follows:
the required (P, , x) data points if a Le, and equilibrium occurs if L > Le. 1/2 1/2
 P   P P −P
suitable property database is avail- Factors which should be considered G0 = ρ n  −2 ∫ dP  ≅ ρ n −2∑ i+1 i  (9)
n n

able when using the HNE model include  P 0


ρ   P
0
ρi 
• Multiple runs are required in order the following: Pressure increments of 1 psi are usu-
to determine the choke pressure and • It is applicable to single-phase (liq- ally quite adequate to provide suf-
maximum (choked) mass flux uid or gas), subcooled or saturated ficiently accurate results. The choke
• The multiple combinations of pro- liquid, or two-phase mixtures. It is point is determined by repeating the
gram switches and options required applicable to flashing flow condi- calculations at successively lower
to run the various cases can some- tions, but not to a condensing vapor values of Pn, starting at P0, until the
times be confusing, and require care • It predicts effects of non-equilibrium mass flux reaches a maximum. If no
to ensure proper implementation conditions (as may arise in short maximum is reached before Pn = Pb,
• The results can be sensitive to the nozzles) the flow is not choked. The method is
choice of conditions for the input data • It requires property data only at the perfectly general, and applies to any
and the range of pressures required, saturation state. This minimizes the fluid, under any conditions (single-
especially near the critical point amount of input data required, but phase gas or liquid, or two-phase) for
• Because of the density-pressure fit- may result in lower accuracy rela- which property data are available.
ting equation, the choke point may tive to those methods that utilize This method can be extended to
not be accurately predicted data at more conditions. Accurate account for non-equilibrium effects
HNE model: This model, the ho- thermophysical-property data are for flashing flow in short (L < 10 cm)
mogeneous non-equilibrium model, required, since small variations or nozzles (in other words, the HNDI or
is based on an energy balance on a errors in the thermodynamic prop- homogeneous non-equilibrium direct
flashing liquid. It is an extension of erties can have a large effect on the integration model), as follows. The ef-
CHEMICAL ENGINEERING WWW.CHE.COM SEPTEMBER 2005 47
������������������������������������������
������
����
Cover Story ������ ������
������

�������������
����������
������ ����
fect of non-equilibrium is to delay the interest. A process simulator
������
development of flashing to a pressure using the property database
below the normal equilibrium satura- can usually generate the re- �����
tion pressure. That is, when the pres- quired data
sure reaches the saturation pressure, • The calculation method is sim- �
the flashing process is not completely ple and direct, and is ideally ������ ����� ���� ��� �
��
developed so that the quality (x) is ac- suited to a spreadsheet solu-
tually lower than it would be under tion
equilibrium flashing conditions . Since • The method is more accurate ����������������������������������������
the equilibrium two-phase density is than those above because no ������
����������
related to the quality by “model approximation” for the
fluid properties is involved ������
1 = x + (1 − x )

�������������
(10) • The method can easily be ap- ����������
ρ ρG ρL ������ ����
plied to short (non-equilibrium)
the density (and hence the mass flux) as well as long (equilibrium) ������
would be higher under non-equilib- nozzles
rium conditions than at equilibrium. • Accurate thermodynamic and �����
Thus the effect of non-equilibrium physical property data, (P), are
can be accounted for by appropriately required to give good results �
������ ����� ���� ��� �
modifying the value of the quality, x. • A flash routine must be used ��
As indicated from the HNE model, ob- for multicomponent mixtures
servations have shown that for typical to generate the (P, , x) data FIGURE 1-4. Good agreement is found be-
flashing flows in nozzles, equilibrium required for the integration, tween calculations, using the HDI method, with
is reached at a distance of about 10 and more data points must be air/water data at 5 bar pressure for four differ-
cm along the nozzle, with non-equi- computed ent valves (P0 = 72.495 psia and Pb = 14.644
psia for all four figures)
librium conditions prevailing for L < • Slip effects can be readily incor-
10 cm. Thus, if we assume that x ap- porated into the method via Equa- Values of Kd for valves and rupture
proaches the equilibrium quality as L tion (8) provided an appropriate disks are determined by the manu-
approaches 10 cm, for L ≤ 10 cm the value for the slip ratio (S) is known facturer in a certified, calibrated test
effective quality at the nozzle throat or can be predicted facility using water or air (sometimes
can be estimated as steam), and are updated annually in
x=x + x −x ⋅ L
(11) The discharge coefficient the “Red Book”*. The Red Book value
0 ( e 0 ) 10 The discharge coefficient (Kd) in Equa- or ASME Kd is based on the actual
where L is the nozzle length in centi- tion (1) corrects for the difference be- area and should be used if the ASME
meters, and x0 is the initial quality of tween the flow predicted by the ideal relief-valve-orifice size (actual area)
the fluid entering the relief device. For isentropic nozzle model and that in is used. The single-phase Kd values
L > 10 cm, x = xe. Considerations ap- an actual valve. Thus the values of Kd are also given in API Standard 526
propriate to the HDI method include depend upon how accurately the theo- “Flanged Steel Pressure Relief Valves”
these: retical isentropic nozzle “model” rep- [23], which are based on standardized
• The method is rigorous within the resents the real valve flowrate. Thus, nozzle (orifice) areas, as opposed to
assumptions inherent in the ideal the value of Kd depends upon both the the actual area. Specifying the API-
nozzle equation and the HEM as- nature (geometry) of the valve as well standardized-nozzle sizes (with the
sumptions, and the precision of the as the accuracy of the fluid property corresponding values of Kd) provides
property data “model”. Values of the gas-phase coef- a uniform method for sizing valves
• It is universally applicable for all ficient KdG are always closer to unity independent of the specific vendor or
fluids under any or all conditions for (implying a perfect model) than the valve dimensions. The values pub-
which the property data are available liquid phase coefficient KdL values. lished by vendors for use with the
• The procedure does not depend on This is because the gas flow coeffi- API standard orifice sizes should only
whether the entering fluid is cold cients are measured under choked be used with these size [2]. In gen-
liquid, subcooled flashing liquid, a flow conditions, for which the isen- eral, the API Kd values are about 10%
condensing vapor or a two-phase tropic ideal-gas model is a much bet- higher than the ASME (Red Book) Kd
mixture, or on whether or not the ter representation of the actual flow. values, and the API standard areas
flow is choked Conditions for liquid flow coefficients are correspondingly smaller. The API
• It is simple to understand and apply are obviously determined under non- values for spring-loaded relief valves
• It is easily applicable to multicom- choked flow conditions, for which the are approximately 2% higher than
ponent systems, provided the mix- entire valve (not just the nozzle) influ- the ASME valves. (The product Kd.A
ture property data are available for ences the flow rate, and therefore, the
performing the required flash calcu- isentropic nozzle model is much less *Pressure Relief Device Certification, National
Board of Boiler Inspectors, www.nationalboard.
lations over the pressure range of accurate. org/redbook/redbook.html

48 CHEMICAL ENGINEERING WWW.CHE.COM SEPTEMBER 2005


���������������������������������������� TABLE 1. VALVE SPECIFICATIONS [18, 20]
������ Valve KdG KdL Orifice Orifice
������
diameter (mm) area (in.2)
������
���� B&R DN25/40 0.86 0.66 20 0.4869
������������

������ ���������� (Bopp & Reuther Si63)


������ ����
ARI DN25/40 0.81 0.59 22.5 0.6163
������ (Albert Richter 901/902)
Crosby 1 x 2 “E” (JLT/JBS) 0.962 0.729 13.5 0.2219
�����
Leser DN25/40 (441) 0.77 0.51 23 0.6440

������ ����� ���� ��� �
�� valves [22] indicate that when Comparison of model predictions
a rigorous method, such as the The authors of Reference [21] compared
HDI or HNDI, is used, a value most of the methods discussed herein
����������������������������������������� of Kd equal to KdG is appropri- for predicting the required relief mass
������ ate when the flow is choked, and flux for several fairly severe cases in-
����
������ of Kd equal to KdL if the flow is volving flashing and (retrograde) con-
������
not choked. This conclusion is densing ethylene at several different
�������������

����������
������ ����
quite logical, because measured conditions. They found that most of
������ KdG values are representative the equilibrium models and the HNE
������ of choked flow conditions (for model for nozzle lengths greater than
which the mass flux is indepen- 6 in. gave mass-flux results that were
����� dent of conditions downstream up to 200% higher or lower than those
of the nozzle) and measured of the HDI model, depending upon the

������ ����� ���� ��� �
KdL values are representative value of the relief pressure relative to
�� of non-choked conditions (where the saturation pressure, for conditions
the mass flux is affected by the well away from the critical point. How-
flow resistance in the body of the ever, in the vicinity of the critical point
�������������������������������� valve as well). At the point where the results varied by up to 600–700%,
������������������
�����
the transition from choked to depending upon how close the relief
non-coked flow occurs the pres- pressure is to the saturation pres-
����� ����
��� sure is discontinuous and the sure (that is, the degree of subcooling).
�����
flow resistance shifts from the These differences illustrate that apply-
�������������

�����
����� ������
nozzle only to the entire valve, in- ing different models to the same case
����� cluding the body resistance. This can yield significantly different results,
����� increased flow resistance causes although the trends shown here may
����� a corresponding reduction in the not be typical of all conditions that may
����� mass flux, which is therefore also arise. Specifically, the Omega, API and

discontinuous at this point. This HNE methods are not recommended
����� ���� ��� � is also the reason that values of in the vicinity of the critical point, but
��
KdG exceed those of KdL, that is may give excellent results under other
FIGURE 5. For water/steam at 8 bar pressure, the choked-flow condition under less-stringent conditions, notably for
the HDNI method is more reliable than the HDI which KdG is determined is more single-component simple fluids far
(P0 = 115.993 psia and Pb = 14.644 psia) accurately represented by the from the critical point, over a small
isentropic nozzle model, which moderate pressure range.
is approximately the same for either does not include the valve body effects The predictions of the HDI method
the ASME or the API values). Use that influence the value of KdL. Since have been compared [22] with data for
the API Kd when API standard size two-phase-flashing flows choke much frozen air-water flows in four differ-
relief orifice sizes are specified and more readily than single-phase-gas ent valves [24–27] at pressures of 5, 8,
the ASME Kd when the actual nozzle flows (that is, choking can occur at and 10 bar. The comparison with the 5
sizes are used. pressures as high as 90% of the up- bar data is shown in Figures 1 – 4 (the
For two-phase flow there are no stream pressure), it is very unusual agreement at other pressures is simi-
validated databases or certified test to encounter subcritical (non-choked) lar). The HNDI method was compared
facilities, so experimental values of conditions with two-phase flows. Thus with steam-water data in a Leser
Kd are not available. The few sug- the use of KdG is generally appropri- valve [24, 25] at pressures of 5.4, 6.8
gestions available in the literature ate for two-phase flows. and 8 bar, and the 5.4 bar comparison
are based on a limited number of Balanced bellows relief valves uti- is shown in Figure 5 (the agreement
experimental observations. Some in- lize a backpressure correction to ac- at the other pressures is similar). The
vestigators suggest various averag- count for the action of the bellows in specifications of the valves are given in
ing methods for the two-phase Kd, compensating for the backpressure Table 1. The manufacturer’s gas-flow
such as a volume-weighted average of and enhancing the lift of the spring. coefficient, KdG, was used in all cases
the liquid- and gas-phase coefficients This backpressure correction uses the when the flow was choked, and the
based on the relative volumes of liq- gas correction factor for choked flow reported liquid coefficients, KdL, were
uid and gas. However, data on fro- and the liquid correction factor for used when the flow was not choked.
zen air-water flows in various relief non-choked flows. Note that non-choked flow occurred
CHEMICAL ENGINEERING WWW.CHE.COM SEPTEMBER 2005 49
Cover Story

only when the entering quality (x) of ing consequences. Although the basic liquid) and two-phase flows. It is not
the mixture was less than 0.001. For nozzle equations are written in terms subject to the many assumptions or
the flashing flows, all data points cor- of the pressures just upstream and restrictions that are inherent in the
responded to choked flow. The HNDI downstream of the valve nozzle, it is various other methods and models.
method was used with an equilibrium common practice to use the pressure These restrictions can be very limiting
relaxation length Le of 40 mm. in the protected equipment (stagna- under certain circumstances, and the
It should be noted that using differ- tion pressure, P0) as the valve-inlet identification of these circumstances is
ent values of the discharge coefficient (upstream) pressure and the back- difficult to determine rigorously. The
for choked and non-choked flow results pressure on the valve, PB, as the down- HDI-HNDI method is not only more
in a discontinuity at the point corre- stream pressure. This practice ignores rigorous, but also simpler to apply than
sponding to the transition between the the pressure drop in the piping from the other methods. Its only limitation
two (see Figure 1, for example). This is the vessel to the valve. This assump- is the availability of a thermodynamic-
realistic, since the actual flow resis- tion does not introduce a serious error data base or model, which enables de-
tance in choked flow is due only to the when the inlet pressure drop is low termining the two-phase mixture den-
nozzle, and is hence lower than that compared to the set pressure, that is, sity as a function of pressure. ■
for non-choked flow where the valve when the “3% rule” is satisfied. Edited by Gerald Ondrey
body resistance is also important. The Similarly, the irreversible-friction
discontinuity is not apparent in the loss in the discharge piping should be Authors
Ron Darby is professor
other Figures, since there are no data kept to less than 10% of the valve set emeritus in the chemical
points in the immediate vicinity of the pressure (gauge), to avoid excessive engineering department of
Texas A&M University (Col-
choke/non-choke-transition point. built-up backpressure which can also lege Station, Tex. 77843.-
adversely affect the chatter charac- 3122; Phone: (979) 845-3301,
Fax: (979) 845-6446, E-mail:
Inlet and discharge line sizing teristics of the valve. This guideline r-darby@tamu.edu), which
It is necessary to size the inlet line applies to normal spring loaded relief he joined in 1965 after three
years as a senior scientist at
from the vessel to the relief valve valves, but different guidelines apply LTV Research Center (Dal-
las). He is a Fellow of AIChE,
large enough that the irreversible fric- to balanced bellows and pilot operated a member of the Soc. of Rheology and ASEE, and
tion loss in this line is less than 3% valves (see API [2]). is a registered P.E. in Texas. Author of two text-
books and numerous technical papers, he has re-
of the valve gauge set pressure. This ceived awards for excellence in teaching as well
“3% rule” is specified by API 520 [2] in Recommendations as for his research publications. Darby earned
his B.S. and Ph.D. degrees in chemical engineer-
order to avoid a condition that results The HDI-HNDI method is recom- ing from Rice University.
in rapid opening and closing of the mended as the calculation method of Note: An example calculation can be found at
valve (chatter), with potential damag- choice, for both single-phase (gas or www.che.com/ceextra

References chanics,” 2nd Ed., Marcel Dekker, New York,


N.Y., 2001.
Relief Design, editors G.A.Melhem and H.G.
Fisher, American Institute of Chemical Engi-
1. Wong, W.Y., “Protect Plants Against Overpres- neers Press, 1995.
sure”, Chem. Eng., pp. 66–73, June 2001. 11. Darby, R. and K. Molavi, “Viscosity Correc-
tion Factor for Emergency Relief Valves,” 20. Fauske, H K, “Determine Two-Phase Flows
2. American Petroleum Institute, “Sizing, Selec- Process Safety Progress, V. 16, No.2, pp 80– During Releases,” Chem. Eng. Prog., pp. 55-
tion, and Installation of Pressure-Relieving 82, Summer 1997. 58, February 1999.
Devices in Refineries,” ANSI/API RP 520,
7th Edition, Part 1 Sizing and Selection, 12. Shackleford, A., “Using the Ideal Gas Specific 21. Darby, R., F.E. Self and V.H. Edwards, “Prop-
Washington, D.C., January, 2000. Heat Ratio for Relief-Valve Sizing”, Chem. erly Size Pressure-Relief Valves for Two-
Eng., pp. 54–59, November 2003. Phase Flow,” Chem. Eng., pp. 68–74, June
3. American Petroleum Institute, “Sizing, Selec- 2002.
tion, and Installation of Pressure-Relieving 13. Jamerson, S.C. and H.G. Fisher, “Using Con-
Devices in Refineries,” ANSI/API RP 520, stant Slip Ratios to Model Non-Flashing 22. Darby, R., “On Two-Phase Frozen and Flash-
5th Edition, Part 2 Installation, Washington, (Frozen) Two-Phase Flow through Nozzles,” ing Flows in Safety Relief Valves. Recom-
D.C., January, 2003. Process Safety Progress, Vol. 18, No. 2, Sum- mended Calculation Method and the Proper
mer 1999. Use of the Discharge Coefficient,” J. of Loss
4. Center for Chemical Process Safety, “Guide- Prevention in the Process Industries, Vol. 17,
lines for Pressure Relief and Effluent 14. Darby R, P.R. Meiler, and J. R. Stockton,
“Flashing Flow in Nozzles, Pipes and Valves,” pp. 255–5259, 2004.
Handling Systems,” American Institute of
Chemical Engineers (AIChE), New York, Chem. Eng. Prog., pp 56–64, May 2001. 23. American Petroleum Institute, “Flanged Steel
N.Y., 1998. 15. Henry, R E and H K Fauske, “The Two-Phase Safety Relief Valves,” API Standard 526, 3rd
Critical of One-Component Mixtures in Ed., Washington, DC, February 1984.
5. The Design Institute for Emergency Relief
Systems (DIERS) Project Manual, “Emer- Nozzles, orifices, and Short Tubes,” Trans. 24. Lenzing, F., Cremers, J. and Friedel, L., “Pre-
gency Relief System Design Using DIERS American Society of Mechanical Engineers diction of the Maximum Full Lift Safety Re-
Tecnology,” AIChE, New York, N.Y., 1992. J., Heat Transfer, pp. 179–187, May 1971. lief Valve Two-Phase Flow Capacity,” ISO TC
16. Leung, J. C., “Easily Size Relief Devices and 185 WG1 Meeting, Paper N106, Rome, Octo-
6. R. Darby, “Experiments for Runaway Reac- ber 29–31, 1997.
tions and Vent Sizing,” Center for Chemical Piping for Two-Phase Flow,” Chem. Eng.
Process Safety, SACHE Program, AIChE, Prog., pp. 28–50, 1996. 25. Lenzing, T. and Friedel, L., “Full Lift Safety
New York, N.Y., November, 2001. 17. Leung, J. C., “The Omega Method for Dis- Valve Air/Water and Steam/Water Critical
charge Rate Evaluation,” in International Mass Flow Rates,” Presented at ISO TC 185
7. National Fire Protection Association, NFPA- WG1 Meeting, Paper N94, Louvain-la-Neuve,
30, “Flammable and Combustible Liquids Symposium on Runaway Reactions and
Pressure Relief Design, editors G.A.Melhem September 3–4, 1996.
Code,” Avon, Mass., 2000.
and H.G. Fisher, pp. 367–393, AIChE, New 26. Lenzing, F., and others, M., “Prediction of the
8. American Petroleum Institute, “Guide for Pres- York, N.Y., 1995. Maximum Full Lift Safety Valve Two-Phase
sure Relieving and Depressuring Systems”, Flow Capacity,” J. of Loss Prev. in the Proc.
ANSI/API RP 521, Washington, D.C., 2005. 18. Simpson, L.L., “Estimate Two-Phase Flow
in Safety Devices,” Chem. Eng., pp 98–102, Ind., Vol. 11, pp. 307–321, 1998.
9. Das, D.K., “Emergency Relief System Design: 1991. 27. Lenzing. T., and others, “Safety Relief Valve
In Case of fire, Break Assumptions,” Chem. Critical Mass Flux as a Function of Fluid
Eng., pp. 34 – 40, February 2004. 19. Simpson, L.L., “Navigating the Two-Phase
Maze,” pp. 394–415, in International Sym- Properties and Valve Geometry,” Presented
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50 CHEMICAL ENGINEERING WWW.CHE.COM SEPTEMBER 2005

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