Response time requirement sheet
SIF 79
1. Safety Instrumented Function Discription
Overheating protection on MVR-3 by stopping of MVR-3.
Loss of desuperheating liquid (cooling) inside and upstream of MVR-3 (downstream of V-2452). Without desuperheating, temperature downstream of MVR-3 rises to
temperature which will be exceeding design temperature of MVR-3 150 °C). LOC with risk of vapor cloud explosion.
2. Normal Operating Range (NOR) Definition
131 °C
3. Safe Operating Limits (SOL) Definition
150 °C. Hazardous scenario occurs if design temperature of MVR-3 and downstream equipment is exceeded. (Tdes of MVR-3: 150 °C , Tdes of downstream piping and
E-2418: 180 °C).
4. Response Time Calculations
4.1 Basis of Design
-The trip point is set at 140 °C.
-Outlet temperature MVR-3 (without desuperheated liquid supply): 200 °C
4.2 Calculations
In case of failure of desuperheating liquid, the compressed gas will not be cooled. The foremost effects will be a sudden increase in the exit temperature of the gas
and an increase of the required duty to compress the gas to its desired output pressure.
The increase in temperature is expected to be sudden, so that at a 'steep wave' of high temperature gas will propragate further downstream (there is little transition
between the normal temperature and the final exit temperature).
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A specific type of breaker has been selected to stop the VSD within 0,5 s. (To be confirmed).
The design temperature of the MVR is 150 °C.
In case of cooling failure, the gas will be suddenly heated up from 131 °C to 200 °C. But the walls of MVR-3 are at 131 °C (normal operation). The MVR-3 will be
stopped within 0,5 s what is not sufficient to bring the metal walls above its design temperature.
To be confirmed with Sulzer if sudden heat increase could cause problems on mechanical integrity on the MVR-3 for that time frame of 0,5 s.
Further downstream, the hot gas is led to the subsequent piping (DN200) and ethanol vapouriser E-2418 which have design temperature of 180 °C. Below, a
calculation is done to get an indication on the temperature increase above the design temperature of the piping and HEX, in an conservative approach.
In absence of this cooling, one would have the following results
Gas flow in MVR-3 8621 kg/h H&M Balance, rev. BG360502-M-37-0002-D01-100/07
Gas flow out MVR-3 8621 kg/h
cP of gas flowing out 1.330 kJ/kgK H&M Balance, rev. BG360502-M-37-0002-D01-100/07
Temperature of outgoing gas, with desuperheating, H&M Balance, rev. BG360502-
Temperature out normal 131 °C
M-37-0002-D01-100/07
Temperature out upset (max) 200 °C Temperature of outgoing gas, without desuperheating
Duration of upset 0.5 s SIF response time
Amount of 'hot gas' generated 1.2 kg
SOL 180 °C Design temp op piping / HEX (Technical spec. E-2418 (BG360502-M-37-0002-F03-
218-01)
Excess heat that can be delivered, wrt to gas at the SOL level 32 kJ dt x amount of gas x heat capacity
Wall thickness piping 2.6 mm
Total diameter piping 219.1 mm DN200
Area of piping heated 0.002 m2
Piping length from MVR to HEX 5 m Length to be confirmed by ISO's.
Volume of piping heated 0.01 m3
Mass of piping heated 71 kg
Density plate material 8000 kg/m3 (316 alloy)
Heat capacity plate 0.5 kJ/kgK (316 alloy)
Temperature increase 0.9 °C
During this short time span of 0,5 seconds, only a small portion of the heat exchanger will experience an increase in temperature. It is extremely difficult to predict
what portion and how much of the heat exchangers will experience the increase in temperature. Therefore in the following, a calculation is done to get an indication
on how large the effect of the hot gas on the heat exchanger is; to get a sense of the danger to integrity of the equipment. Note that in this calculation, it is assumed
that no heat is transferred to the MVR and the piping between the heat exchanger and the MVR.
Total heat area 100.3 m2 Technical spec. E-2418 (BG360502-M-37-0002-F03-218-01)
Thickness plates 0.0005 m Technical spec. E-2418 (BG360502-M-37-0002-F03-218-01)
Volume of plates heated 0.003 m3 Only 5% of the total heat area gets affected by the hot gas
Density plate material 8000 kg/m3 (316 alloy)
Mass of plates heated 20.06 kg
Heat capacity plate 0.5 kJ/kgK (316 alloy)
Temperature increase 3.18 °C
Thus, if all the heat generated during the 0,5s response time, is focussed on the first 5% of the plates, a temperature increase of less than 3,2 °C would be obtained at
the heat exchanger plates.
Note that in this calculation, the effect of the cooling medium on the other side of the plates was not taken into account. The higher temperature on the shell side
would also result in a higher cooling of the compressed gas, mitigating its effect on the heat exchanger.
Based on the above, it is warranted to assume that the effect on the plate HEX E-2418 and upstream piping will be very limited.
However, to safeguard the integretity of the downstream system, it is recommended that extra measures are performed in case of trip, in order to follow up these
events.
4.3 Conclusion
A 0.5s response time is taken.
Based on this response time, the impact on the downstream piping and heat exchanger of the MVR-3 is expected to be limited.
Nonetheless, the following is recommended as a ways of monitoring the mechanical integrity of the equipment (in particular for the reboilers):
- Every instance exceedence of trip temperature is to be logged;
- After several of these instances, the integrity of the equipment must be verified with NDT. The life expectency of the affected equipment and piping is to be
updated (downwards) if required as a result from NDT.
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