Depressuriation Using Hysis

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

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

Owner
Developer
Reviewer
Approver
Lakshmi
Venkatesh
Bhushan Chonkar
Bhagyashree
Lagwankar
Lakshmi
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
Description
Subject
Connection
Stream Name
Fire Case
Two phase
vessel
Fire Case
Gas filled
vessel
Adiabatic
Stream representative of the system to be blown

down
(Vesselparameter)
Heat Flux
Vessel
Orientation
Vessel Volume
Vessel Height and
diameter
Initial Liquid
Volume
Metal mass in
contact with
vapor
Metal mass in
contact with
liquid
Heat loss Model
Recycle Efficiency
(General tab)
Ambient
temperature
(General tab)
Thickness of
metal and
insulation
(Conduction tab)
Horizontal or vertical
Volume of zone including vessel and pipe work
Liquid Volume in system

Calculate using metal thickness, density and vap%
Calculate using metal thickness, density and liq %
None
No entry required
Detailed
100% for vapor, light
liquid and heavy
liquid
No entry required
Specify minimum
ambient temp
No entry required
Specify thickness
Page 4 of 30
Valve
Parameter
Operating
Condition
Option
Valve equation
Mode
Fisher with 100% valve opening or Masoneilan with

Cf=1
Fire- API 521
Adiabatic
Relief Pressure
Relief Valve Set Pressure
Temperature
Max. / Min. operating

temperature
De-pressuring
Time
15 minutes
Till atmospheric
pressure is reached
Final Pressure
50% design pressure or 7 bar
flare backpressure
Time Step Size

PV work
contribution term
Relief Valve Set

Pressure
Minimum of ambient
/ operating
temperature
Minimum no. of step size (0.1 sec.)

Default
100% for gas filled
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)
b)
c)
d)
e)
Internal Volume (total inventory of the Section).

Initial Liquid Volume (for Wet Sections).
Weight of metal in contact with vapor and liquid.
Equivalent Wall Thickness.
Equivalent Internal Diameter.
Blowdown.xls spreadsheet can be use for determination of above parameters.

2.1
Internal Volume (total inventory of the Section)
2.2
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.
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= /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.
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.
2.4
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
3.4
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.
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
m
m
4.5
17
Horizontal
Ellipsoidal
2.83
70
120
27.74
331
179
0
100
15
60
5
Fire Case
Vessel diameter
Vessel Length
Vessel Orientation
Head Type
Liquid Ht
Vessel thickness
Pressure
Temperature
System Volume
Initial Liquid Volume
PV Work term Contribution
Control Valve Opening
Depressuring Time
Final Pressure (50% of D.P)
Amb temp
m
mm
Barg
Deg C
m3
m3
%
%
Min
Barg
Deg C
Page 20 of 30
Mole fraction composition is taken as follows (Based on stream data from Material Balance).
Nitrogen
CO2
H2S
Methane
Ethane
Propane
i-Butane
n-Butane
i-Pentane
n-Pentane
Benzene
Toluene
m-Xylene
p-Xylene
o-Xylene
cfc6_1*
cfc7_1*
cfc8_1*
F9_1*
F10_1*
F11_1*
F12_1*
F14_1*
F16_1*
F18_1*
F20_1*
F22_1*
F24_1*
F26_1*
F28_1*
F30_1*
F32_1*
F34_1*
F36_1*
F38_1*
F40_1*
F42_1*
F44_1*
H2O
TEGlycol
2.78E-02
0.208927
8.49E-02
0.548892
5.11E-02
2.46E-02
3.04E-03
8.31E-03
2.20E-03
3.70E-03
1.28E-04
3.06E-04
1.48E-04
1.48E-04
1.76E-04
3.64E-03
2.91E-03
2.81E-03
2.73E-03
2.47E-03
1.98E-03
2.76E-03
2.35E-03
2.00E-03
1.72E-03
1.48E-03
1.27E-03
1.10E-03
9.51E-04
8.24E-04
7.15E-04
6.22E-04
5.42E-04
4.73E-04
4.14E-04
3.63E-04
3.18E-04
2.81E-04
8.95E-04
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
Pipe
Pipe
Dia thk
L
inch mm
m
PIPE-Feed
PIPE-Gas
outlet
Pipe Liquid
Outlet
Actual Actual
Liquid vapor
Fr
flow
flow
Liquid Pipe Pipe Diff
rate
rate
Filling ID
OD
Vol
m3/hr
m3/hr
mm mm
m3
Vol.
m3
Total
METAL
MASS
kg
Initial
Mass
of
Metal
in
Initial contact
Liquid
with
volume
Liq
m3
kg
Initial
Mass of
Metal in
contact
with Vap
kg
V*t
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
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
4 100
1.4
0.0
1.000
76.2
84.2
0.5
791.14
0.46
791.14
0.00
0.001824
10.4
14,469.28
1490.40
12978.88
0.1
TOTAL, m3
With 30%
margin
13.5
Page 22 of 30
0.91
1.18
0.0964
0.1253
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
Pressure in bar
120
100
80
60
40
20
0
0
100
200
300
400
500
600
Time in sec
Mass Flow rate vs time
Page 26 of 30
700
800
900
1000
Fire Case blowdown: Mass flow rate vs time
Mass flow rate in Kg/hr
250000
230000
210000
190000
170000
150000
130000
110000
90000
70000
0
100
200
300
400
500
600
time in seconds
Page 27 of 30
700
800
900
Screen View- Adiabatic Case
Page 28 of 30
Result :
Page 29 of 30
Pressure vs Min temperature
Min Temp Vs time
Temperature in Deg C
30
25
20
15
10
5
0
0
25
50
75
100
125
150
time in min
Page 30 of 30
175
200
225

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Depressuriation Using Hysis

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Depressurisation using Hysys

Petrofac E&C Business Management System

Depressurisation using Hysys

Draft for Approval

Draft for approval

Approval Authority: (Head of Project Services)

Depressurisation using Hysys

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

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

Depressurisation using Hysys

Stream representative of the system to be blown

Liquid Volume in system

Depressurisation using Hysys

Fisher with 100% valve opening or Masoneilan with

Relief Valve Set Pressure

Max. / Min. operating

50% design pressure or 7 bar

Time Step Size

Relief Valve Set

Minimum no. of step size (0.1 sec.)

Internal Volume (total inventory of the Section).

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

Internal Volume (total inventory of the Section)

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

Depressurisation using Hysys

Liquid Volume= L*A

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

Composition, Initial temperature and pressure

Depressurisation using Hysys

EXTERNAL FIRE BLOWDOWN

Depressurisation using Hysys

Heat Flux (Screen 2)

There are three types of Heat Loss models available:

Depressurisation using Hysys

Valve Parameter (Screen 3)

Depressurisation using Hysys

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

Operating Conditions (Screen 5)

Specify depressurisation time and final pressure in operating conditions.

Depressurisation using Hysys

Depressurisation using Hysys

Result of fire case

Heat Flux (Screen 2)

Depressurisation using Hysys

Depressurisation using Hysys

Valve Parameter (Screen 3)

Depressurisation using Hysys

Depressurisation using Hysys

Operating Conditions (Screen 5)

Depressurisation using Hysys

Result of Adiabatic case:

Depressurisation using Hysys

Depressurisation using Hysys

Depressurisation using Hysys

Depressurisation using Hysys

Depressurisation using Hysys

Piping Volume Calculation

9.52 150 1.3600

Depressurisation using Hysys

Screen View- Fire Case

Depressurisation using Hysys

Depressurisation using Hysys

Depressurisation using Hysys