1.

Define the System

TO FLARE
SDV

TO FLARE
BDV BDV

TO FLARE
SDV
SDV BDV
SDV

SDV
SDV

SDV
SDV

SDV

2 Process System
SDV
2. Calculate each system volume inventory ; both piping and equipment.
Example : Piping Inventory Calculation
Internal Equivale
Equival Pipe Piping Vapour Liquid
Length NPS Diamete nt
ent El. Schedul Volume
From To r Length fraction Volume
Ratio e
(ft) (ft) (inch) (inch) (ft) (ft3) (ft3)
3P-SDV-0013 5000-V-60 161.7 1.2 0.0 4 S40 4.026 199.17 17.607 0.8077 3.3859
5000-V-60 5000-PSV-V-60 3.3 1.3 0.0 2 S80 1.939 4.26 0.087 1.0000 0.0000
3"-300# Valve 4"-B1-PHL-100 16.4 1.3 0.0 3 S80 2.901 21.32 0.979 1.0000 0.0000
5000-V-60 5000-PSE-V-60 32.1 1.3 0.0 2 S80 1.939 41.71 0.855 1.0000 0.0000
5000-V-60 Reducer 3" x 2" 5.2 1.3 0.0 3 S40 3.069 6.82 0.350 1.0000 0.0000
Reducer 3" x 2" 3P-BDV-0016 10.2 1.3 0.0 2 S40 2.067 13.22 0.308 1.0000 0.0000
Reducer 3" x 2" 3P-PV-0023 3.7 1.3 0.0 3 S80 2.901 4.81 0.221 1.0000 0.0000
3"-GP-3P-022-BA1 VALVE 5.2 1.3 0.0 3 S40 3.069 6.82 0.350 1.0000 0.0000
2"-B1-BD-202 3P-PV-0022 16.1 1.3 0.0 2 S40 2.067 20.89 0.487 1.0000 0.0000
2"-B1-BD-202 VALVE 5.6 1.3 0.0 2 S80 1.939 7.25 0.149 1.0000 0.0000
5000-V-60 3P-SDV-0015 20.5 1.3 0.0 2 S80 1.939 26.65 0.546 0.0000 0.5465
5000-V-60 3P-SDV-0014 4.3 1.3 0.0 2 S80 1.939 5.54 0.114 0.0000 0.1137
Total 22.0543 4.0461

Example : Equipment Inventory Calculation

ID Length Orientation HLL NLL LLL Volume HLL NLL LLL Total
Wetted Wetted Wetted
Tag Number Equipment Name Total HLL NLL LLL Area
Area Area Area
(ft) (ft) (ft) (ft) (ft) (ft3) (ft3) (ft3) (ft3) (ft2) (ft2) (ft2) (ft2)
HP TEST 2.00 0.75 0.50 62.9 54.18 15.74
5000-V-60 2.500 12.000 HORIZONTAL 8.812 71.849 36.811 29.174 104.065
SEPARATOR 0 0 0 95 3 6
63.0 54.18 15.74
Total 8.812 71.849 36.811 29.174 104.065
0 3 6

3 Process System
4 Process System
 Tool Utilities

1. Adjust massflow of related stream

to achieve volume flow correspond to
inventory calculation

2. Mix those stream,

the result is as BASIS COMPOSITION

3. Balance it to initial pressure condition,

the result is as BASIS SIMULATION

Initial condition as follow :

# FIRE
at design pressure or PAHH
# ADIABATIC
at operating pressure

4. Tool/ Utilities
or CTRL+U *)

The higher the initial pressure, Because the time is set 15 minutes
the grater the flowrate load to No matter the initial pressure
flare..

*) want to know more HYSYS short cut ?

Process System check in my blog : www.process-eng.blogspot.com
5 Article : useful HYSYS shortcut
 1. “Depressuring
– Dynamic”

2. “Add Utility”

3. “View Utility”

6 Process System
7 Process System
 re name to : FIRE CASE Select stream BASIS SIMULATION : “FIRE”

Select vertical vessel

HYSYS model the entirely
system volume as a vertical
cylinder with flat both
bottom and top.

Automatically calculated
by HYSYS
But , You can manually
keep as it is fill to apply some margin
of total inventory volume

Fill volume of liquid

Based on NLL or HLL
HHL result worst case.
Still remember the heat input ?
Example : Q = 21000FA^0.82
The wetted area based on
HYSYS will adjust vessel size both Diameter and Height so that both HLL bigger than NLL.
the total and liquid volume are correct correspond to the input value. (The greater the wetted area
the greater the heat input
Is it difficult to achieve that volume ? As a matter of fact, it is not. rate to vessel)
Actually, the real problem is, the wetted area based on HYSYS’s
vessel size is not equal with the actual wetted area.
Now, at this stage
we will skip this problem
this will need long explanation
8 Process System
I will include it in another tutorial
 Select : Fire API 521
To be applied only if heat flux of 21.000
BTU/hr ft^1.64 or
Q = : Q = 21000FA^0.82

other cases , such as *)

For fire case :
ForLoss
Heat fire case :
= None
Heat Loss = None
no heat loss should be
assumed in fire case
simulation for worst case
1. Jet fire , the heat flux is 94,500
BTU/ft2/hr.
C1 = 94,500
2. For small system, the fraction
area exposed by fire is 1.0 instead
of 0.82
C2 = 1
3. For vessel with insulation, or
covered by earth, the environment
factor less than 1.0
ex = 0.3

Now, at this stage
we will skip those other problem
this will need long
explanation
I will include it in another tutorial

*)check in my blog for detail explanation : www.process-eng.blogspot.com

9 Process System Article : fire case – heat input rate
 Fill Pb = 0
For initial value, Pb =0
If the vapor flow equation is “SUBSONIC” ,
the value should be updated based on
flareNet study result.
# Pb has no significant effect for other
vapor flow equation.
See table below !

Select : Musoneilan
See table below !, it shows the result of
sensitivity test for each vapor flow
equation method.

Fill Cf = 1
It is critical flow factor, generally the
value close to 1.0
Ex : 0.90 , 0.94 …
Cf = 1 for worst case of peak flow

Parameter Unit Musoneilan Fisher Supersonic, (Cv in inch2) Subsonic, (Cv in inch2)
Pb psig 0 25 50 0 25 50 0 25 50 0 25 50
Cv USGPM ( 60f, 1psi) 4.044 4.052 4.126 8.400 8.406 8.406 0.102 0.1019 0.102 0.102 0.1038 0.109
Peak flow lb/hr 4210 4217 4292 4190 4193 4193 4191 4204 4204 4201 4264 4423

The method selection has no significant effect to the result (peak flow)
Now, you can choose one of the method with no worry about the result,
personally , I prefer using “MUSONEILAN”
In my opinion, Musoneilan is the most simple and easy to be used.
DON’T use SUBSONIC if the system is not in sub-critical condition

10 Process System The back pressure has significant effect only for SUBSONIC method
 This equation show ; the back
pressure has effect to the
depressuring result,,

Do you know,,
Why the back pressure has effect only for
subsonic method ? *)

In sub critical condition, the flowrate

through control valve , nozzle, orifice,
etc., ,will depends on the differential
pressure between inlet and outlet.

In critical condition, the flowrate through

control valve , nozzle, orifice, etc., ,will
only depends on the inlet pressure.

SENSIVITY test result

MUSONEILAN Fill Cf = 0.9 -1.0
Cf 0.9 0.95 1 There is no worry about the result ^_^
Flow 4202.545 4205.035 4205.123
Cv 4.486085 4.252576 4.040034

*)check in my blog : www.process-eng.blogspot.com

11 Process System Article : critical - subcritical
 Fill PV work : 50 % for FIRE CASE

PV Work Term Contribution refers to

the isentropic efficiency of the process.
A reversible process should have a
value of 100% and an isenthalpic
process should have a value of 0%

Recommended value
For gas-filled systems – 80% to 100%
“UN-CHECK” For liquid filled systems – 50% to 70%
will result in greater peak flow rate

More liquid
more interaction between

liquid and vapor.
decrease isentropic
efficiency
For small system inventory
( small vessel model)
more friction
between fluid and the vessel wall

decrease isentropic efficiency
A higher isentropic efficiency results in a lower final temperature.
A lower isentropic efficiency results in a higher final peak flow rate

12 Process System
 Depressurized from design pressure*)

Set depressuring time = 15 minutes *)

Considering of the maximum reduction
of the vessel stress, vessel with thickness
use “Calculate Cv” mode less than 1 inch, generally requires
faster depressuring rate.

Consideration of limiting flare

capacity, the depressuring time longer
than 15 minutes may be applied

“RUN” after “READY TO CALCULATE” Fill initial value

HYSYS will adjust the Cv value to
achieve final pressure (e.g.100psig) at
depressuring time (e.g. 15 min)

Set final pressure = 100 psig

The longer the depressuring time, the higher the depressuring load Or 50 % design pressure *)
-100 psig for thickness less than 1 inch
-and 50% DP for more

*)check in my blog : www.process-eng.blogspot.com

13 Process System Article : basic depressuring - why 15 minutes?
 MAX. Cv

MIN. System
Temperature
(during
depressuring)

MIN. outlet RO
Temperature
(during
“PERFORMANCE” depressuring)

MAX. FLOW for

fire case

Result in peak flow to flare = 10740 lb/hr

Max Cv = 16.63

14 Process System
15 Process System
 HYSYS
Tool / Utilities Select stream BASIS SIMULATION
or CTRL+U *) “ADIABATIC”
Rename : “Adiabatic Case”

1ST step

Fill all of data similar with FIRE CASE

except that volume of liquid
2nd step based on LLL
LLL mean lower liquid
increase
3rd step isentropic efficiency
will result in
lower final temperature
(see page 12)
Lower liquid
lower flashed vapor
formed from liquid phase
will
16 Process System result in shorter depressuring time
 During a fire case the vessel is covered
with flame. In this case, heat loss to the
surrounding atmosphere determined by
Select : Adiabatic taking a normal atmospheric temperature
No heat input is generally not correct as the vessel's
surrounding temperature is very high.
You should use no heat loss, select
“ NONE” for FIRE CASE

Select : None “ NONE” for ADIABATIC

HYSYS does not Can be applied if the fluid temperature is
account for any heat lower than the environment temperature.
loss

“ SIMPLE” for ADIABATIC

I suggest you to use SIMPLE heat loss

model for accurate calculations.
Heat Loss Parameter : Use default values except the AMB
Use “NONE” for FIRE CASE temperature.
Use “ SIMPLE” for ADIABATIC
except for system which is the fluid temperature lower I suggest you to use DETAILED model
than environment , NONE model should be applied (for for accurate calculations
lower final temperature) IF ONLY you know what to do :- )
(I myself don’t know how to use
this option,,suusahhh cuuukkk).
17 Process System
 See page .10 about Pb

Fill CV as FIRE CASE result

Cv = 16.63 see page 14

Cf = Cf in accordance with
FIRE CASE
Cf
0.9 – 1.0

18 Process System
 Fill 100% for worst case

For gas-filled systems – 80% to 100%

For liquid filled systems – 50% to 70%

For small system, or liquid filled

system, engineering adjustment
should be used. The lower efficiency
shall be used for accurate calculation

19 Process System
 Depressurized from
operating pressure*)

TRIAL depressuring time

to meet final pressure 0 psig

HYSYS will calculate final

pressure based on depressuring
time

In some cases, the final pressure

use “Calculate can’t meet 0 psig, (slightly above
Pressure” mode 0 psig).
The system can’t be decrased to
lower pressure.

it’s OK

The fact, the fluid is released to flare. The pressure of the system is correspond
to the back pressure . Therefore, the final pressure is slightly above atmospheric
condition

20 Process System
 Required adiabatic
depressuring time

Min Temperature
outlet RO

Min Temperature
In the system

Adiabatic peak flow

21 Process System
22 Process System
 Select File

Select :
# Temperature
# Pressure
# Mass Flow

VIEW strip chart

Depressuring profile

VIEW result in Table

Depressuring data

23 Process System
 also click PERFORMANCE/ STRIP CHARTS

An example : show table

24 Process System
 Aspen HYSYS does not take the volume of the vessel heads into account so the volume will be the liquid in the
cylindrical portion only.

Aspen HYSYS defaults the volume to be equal to the volumetric flow of the feed ‘BASIS SIMULATION”. This
will be disproportionate to the total volume inventory calculation where the certain margin volume is applied.

Aspen HYSYS defaults the height and diameter vessel in accordance with the volume. This may be
disproportionate to the actual total wetted area calculation.

At present, Aspen HYSYS does not have the option for jet fire case where the heat flux is more than 21.000
BTU/hr ft^1.64. The method of spreadsheet can be used to model jet fire case.

API recommends depressuring to the lower of 50% of the initial pressure or 100 psig / 6.9 barg.

PV work term
gas-filled systems 80% to 100%
liquid filled systems 40% to 70%
A higher efficiency results in a lower final temperature

If one is checking that the minimum temperature of the vessel will not fall below a certain value (for example,
for validating the steel alloy grade), and then 100% will give the most conservative result.

25 Process System
26 Process System