PRESSURE RELIEF THE DOW CHEMICAL COMPANY PRDM-110

DESIGN MANUAL FEBRUARY 2006

Table 5 – Orifice Designations

Orifice API Area, in2 (mm2) Orifice API Area, in2 (mm2)
D 0.110 (71) L 2.853 (1,840)
E 0.196 (126) M 3.60 (2,322)
F 0.307 (198) N 4.34 (2,799)
G 0.503 (325) P 6.38 (4,115)
H 0.785 (506) Q 11.05 (7,127)
J 1.287 (830) R 16.0 (10,320)
K 1.838 (1,186) T 26.0 (16,770)

2.13 Coefficients for Gas, Liquid, and Two-Phase Flows

PRVs are usually flow tested and ASME-certified for gas or liquid – not both. Flow coefficients
for gases are higher than those for liquids, so one must take care to use gas coefficients with gas
cases and liquid coefficients with liquid cases. When a PRV is specified to handle both a liquid
and a gas case, select trim for the controlling case. When a liquid enters the PRV, use liquid trim
and a liquid coefficient. If the fluid entering the PRV is a vapor (gas) or a two phase mixture, use
vapor (standard) trim and a vapor coefficient. Evaluate the non-certified case by selecting the
default coefficient option in SAFSIZ. Evaluate the installation by using the orifice designation
(e.g., a "D" orifice) in SAFSIZ.

3 SAFNET

SAFNET is a computer application used to calculate:

back pressures on pressure relief devices in a complex piping network (often feeding a flare or phase
separator),
flow rate through series-connected piping and vessels (e.g., so-called “dry blow through” cases), and
downstream pressure through series-connected piping and vessels (e.g., complex inlet PRV cases).

SAFNET is designed for high-speed gas flows, although it does have limited two-phase flow capability.
Usually the piping network feeds emergency streams into a flare or phase separator.

The adiabatic flow assumption in SAFNET is good engineering practice. To reduce complexity, some
literature, including API documents, suggests using isothermal flow. However, such sources do not
actually assume isothermal flow, but rather adiabatic flow of a gas having a ratio of heat capacities
(C p/Cv ) = 1.

Although most two-phase estimates should utilize the RELDES program, SAFNET can handle some two-
phase problems with the following technique. First, determine the weight fraction gas (x) at the network
outlet pressure. Then estimate an effective molecular weight from Meff = M/x, where M is the actual
molecular weight of the outlet gas. This method will yield conservatively high estimates of the back
pressures.

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3.1 Starting SAFNET

SAFNET is MS DOS software that can be operated in Windows. The following files must be
available to run the program:

Table 6 – SAFNET Files

File Description
SAFNET.EXE The SAFNET program.
SAFNET.DOC An on-line help file.
SNED.EXE The text editor included with SAFNET. See Appendix 3, Table 6 for
available commands.
SNPANEL.EXE The panel driver accessed through SAFNET.
SNPANEL.SCN A file required by SNPANEL.EXE

To run the program, select Start Menu, then Programs, then GPE Safsoft, and then double click
on SAFNET. The requested input file name must follow standard DOS conventions (maximum
of eight characters plus an optional period followed by a zero-to-three-character suffix). The
suffix .SNx, where x is A...Z, should be used for all SAFNET input files. Output files will have a
suffix .OSN.

3.2 Editing and Panel Input Environments

Cases are prepared by entering data into a text input file or panel driver, one case per file. A text
editor SNED and panel program SNPANEL are integrated with SAFNET to facilitate input
preparation. See Appendix 3, Table 7 for a list of SNED commands. This list is also available as
on-line help.

With the Ctrl-K-R key combination, SNED can import a previous input file as a new case. For
example, if the case under preparation is BACK2.SNA, one can press Ctrl-K-R in the SNED
environment and import another (e.g., BACK1.SNA) into BACK2.SNA – a technique that
simplifies case preparation.

3.3 Preparing Input

The simplest way to begin analysis of a piping network is to first prepare a diagram, lettering the
sources, numbering the pipe sections, and showing how they are connected. Figure 2 serves as an
example.

As many as 80 sources and 240 pipe sections can be used in a given file. The possible source
identifiers are: A...Z, a...z, 0...9, !, @, #, $, %, ^, &, *, +, =, (,), [,], {,}, <, and >.

It is desirable to build the whole network at once (PRDs in a fire zone or involved in a process
upset). As noted below, source flows can be set equal to zero, thus enabling development of
different cases (scenarios) from the same basic network configuration. Source flows can also be
negative, providing the piping segments downstream of the sources have zero lengths and zero
velocity head fitting losses.

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Several cases should be set up so that each case includes the pressure relief devices that are likely
to be open at the same time and so that each pressure relief device opens in at least one of the
cases. Additional considerations that influence fire-exposure case development include:

PRVs that are greatly oversized will be open a small fraction of the time.
It takes longer to heat large vessels to the boiling point than it does small ones.
Bare vessels heat-up faster than insulated vessels.
The temperatures of water-sprayed vessels are unlikely to exceed 100 °C.

Figure 2 – SAFNET Piping Example

1 B A
D 2
3 10 12

E 4 5 9 11 13

F 6 8
7
G

In running SAFNET for the purpose of evaluating back pressure constraints, use the rated flow
rates at 10% overpressure as given in parentheses on the SAFSIZ output. The sizing flow rate
can be used for PRVs with known modulating behavior, provided each modulating PRV meets its
back pressure constraints when evaluated by itself in the network using the rated flow rate at 10%
overpressure.

Both SAFSIZ and SAFNET will warn of high back pressure problems. Conventional PRVs only
tolerate about 10% builtup back pressure, based on gage pressures. Bellows PRVs tend to pass
their full capacity, providing that the total back pressure is less than 30% of the set pressure (for
gases). Moreover, they operate satisfactorily but with reduced capacities at back pressures up to
approximately 50% of the set pressure. Pilot PRVs can tolerate back pressure up to 50 % of the
set pressure and operate correctly.

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Each file will have the following lines of input:

First line for the title and case description.

Second line for the number of sources, number of pipes, outlet pressure (superimposed back
pressure), and pipe sand roughness (optional).

Two lines for each source, the first line containing the sources character, and the pipe
numbers encountered in the direction of flow. The second line is for the flow rate, set
pressure, temperature, molecular weight, ratio of heat capacities (Cp /Cv) or Cp in Btu/lb °F,
and viscosity (optional). The flow rate can be set equal to zero. If equal to zero for a series-
connected piping network, SAFNET will estimate the flow rate.

One line for each pipe, for the pipe number, the length, internal diameter, number of velocity
heads fitting losses, and pipe sand roughness (optional).

3.4 Fitting Losses

The set of fitting losses (N velocity heads) in Table 7 was designed for use with SAFNET. For
screwed fittings, use either two times these values or the values tabulated in available references.

Table 7 – SAFNET Fitting Losses

Flow Element N Comment

Butterfly Valve 0.8 Conservatively high value
Commercial Reducer 0.1 Based on smaller pipe
Elbow 0.3
Flame arrester 0.8
Full-Port Gate Valve 0.1
Full-Port Ball Valve 0.1
Globe valve 6.0
Orifice * K=2.8*(1-B^2)*[(1/B)^4-1]
where B= (Diam)s/(Diam)l
Sudden Contraction 0.5 Based on smaller pipe
Sudden Expansion 0.0 For SAFNET only
Tees 0.0 For SAFNET only
Transflo valve ** **See Appendix 6

Note: The values for N (K values) in the table above are typical values for 4” nominal pipe size.
For other pipe sizes see Figure 2, Section 4.1.4 of the Dow Fluid Flow Manual on the
GPE Fluid Mechanics and Mixing Discipline web page.

As a general rule, you should prepare SAFNET cases using all piping and fittings connected to
the discharge flange of the PRV. Don't include as a piping section any expander directly attached
to the discharge flange.
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3.5 Running Cases

Press the F9 key in SAFNET to run a case. You can also run it from the DOS command line.
For example, typing SAFNET S:\DPRDIO\SAMPLE.SNA from the PRD directory runs
SAMPLE.SNA in the DPRDIO directory and places the output file SAMPLE.OSN in the same
directory.

3.6 Output Record

The output file includes sections titled SOURCE SUMMARY, PIPING SUMMARY, HEADER
OUTLET, and INPUT DATA FILE. The SOURCE SUMMARY includes input data, the
estimated back pressure, percent back pressure, and comments. In addition to also repeating
some input data, the PIPING SUMMARY reports estimated upstream (inlet) and downstream
(outlet) pressures and temperatures for each pipe section.

The outlet Mach Number is given to help identify restrictive sections of pipe. Some contractors
limit Mach Numbers to an arbitrary value, often 0.6 or 0.7. This practice has some merit when
using computer tools that fail to properly account for pressure changes across fittings. The
SAFNET code contains sophisticated technology that accurately predicts phenomena at all piping
junctions for high Mach Numbers. There is no need to limit Mach Numbers when using
SAFNET, SAFSIZ or HEM.

The HEADER OUTLET section includes the reaction force, velocity, pressure, temperature,
stagnation temperature, molecular weight, density, viscosity (usually a value estimated by the
program), and the ratio of heat capacities – all at the exit plane of the header outlet pipe.

3.7 Comments

Comments that may appear in the “Source Summary” are described in Table 8.

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Table 8 – “Source Summary” Comments

Comment Description
Bellows, conv., & Irreversible losses ( P) are less than 10% of the set pressure.
pilot PRVs are OK. Conventional, balanced bellows, and pilot Pressure Relief Valves
(PRVs) are okay in this service.
Bellows and pilot Conventional PRVs are not acceptable. P is between 10% and 30%
PRVs are okay. and flow is sonic. No flow rate reduction for bellows and pilot valves.
Reduced flows: High back pressure (less than 50%) will reduce the flow rate below the
bellows/pilot PRV. input values. The magnitude of the reduction will depend on whether it
is a pilot or bellows type. SAFNET does not correct user-input flow
rates.
dP too high w/bellows Back pressure exceeds 50% of the set pressure, and only pilot-operated
or conv. PRV. PRVs are suitable.
Back pressure exceeds Nothing works; correct the flow rate(s) and/or increase pipe sizes.
set pressure.
Low-pressure vent The set pressure is less than 10 psig (69 kPag).
device.
Estimated flow rate With one source having zero input flow rate, SAFNET has estimated
the flow rate through a series connected piping system.

4 RELDES

RELDES is used for two-phase design calculations. While RELDES has single phase flow capabilities,
single phase flow cases should be evaluated using SAFSIZ and LOWSIZ.

4.1 Introduction to RELDES

RELDES is a computational tool designed to size emergency pressure relief systems and/or
evaluate existing systems. All calculations are based on the DIERS (Design Institute for
Emergency Relief Systems) technology and the applicable ASME Codes. RELDES is capable of
handling multicomponent systems (maximum of 10 components) with two immiscible liquid
phases in all-vapor, sub-cooled liquid, frozen flow, and two-phase flashing flow situations. The
multi component phase equilibrium calculations are based on ideal solutions and ideal gas
behavior. The option to add your own compounds and data adds the ability to handle non-ideal
solutions, providing a pseudo-component can be described which approximates the properties of
the non-ideal mixture being used. An example RELDES output can be found in Appendix 2.

The input data for RELDES is subdivided into four major categories

1. Protected Equipment Data

2. Scenario Data
3. Compounds and Compositions
4. Relief System Data

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