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Relief Load Calculation Note

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1.PSV-1013/1014
Process description:
For fired heaters, one of the primary fuels is NG since it is more reliable and available. For a
specific fired heater, 16000 kg/hr. of NG with operating pressure of 50 barg and temperature of
40C is let-down to operating pressure of 4barg via PV-1011 and later to 1 barg via another control
valve to make it suitable for firing.

First Step: Let’s check if we need a PSV

Since the difference between design pressure of high-pressure side, which is 55 barg and that of
low-pressure side, which is 7 barg is high. So, we need a PSV in case of control valve failure and
the possibility of high flow passage from high-pressure side to low-pressure side.
Second Step: Safety Analysis Environment
1.Go to safety analysis environment and add PSV on the outlet of control valve.
2.Double-click on PSV icon to see the following tab.
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Manual means you are supposed to specify the matter while reference means the information is
taken from the line, which just provides operating conditions.
3.Go to scenario tab, create a scenario and select control valve failure.

4.Now open scenario.

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Under scenario reference stream select stream 1:

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You can also change total backpressure like below:

Select relieving method to be calculated and also choose PSV plus as the calculation method.
Specify the CV to be 44.
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Select a bigger orifice area than calculated orifice which is 52.49 cm2.

Based on the calculation, the orifice designation should be 6Q8.

5.Now go to line sizing tab

Based on calculation, the pressure drop for both inlet and outlet has exceeded the criteria. In
order to resolve the issue, let’s select a line with bigger size for inlet and outlet.
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The problem solved!

Here is the summary of what we have obtained.

Relief load 27780 kg/hr.

Scenario Control Valve Failure

Calculation Method PSV Plus

Selected Orifice 71.29-Q

Orifice Designation 6Q8

Inlet Line Size 8 inch

Outlet Line Size 10 inch

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2.PSV-1031
1.Determine the scenario, using API-521
Since it is R-1001 and exposed to fire then a fire scenario is defined.

Parameters Value Parameters Value

Diameter 4.45 m M 16.54

Height 3.1 m Set Pressure 55 barg

Fluid Natural Gas Relieving Pressure 67.55 bara

Z 1.01 Accumulation 0.21

Cp/Cv 1.18 Material CS

2.Calculate the relief load, using API-520 Part1

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Calculation

Parameters Value Parameters Value

Aw 65 m2 KD 0.975

C9 0.2772 F’ 116

C10 0.0395 Relief Load 3874 kg/hr

C 0.0254

M × P × 100
Ws = 182 × C × Aw × √( )
T + 273

16.54 × 67.5 × 100 kg

Ws = 182 × 0.0254 × 65 × √ = 3874
400 + 273 hr

Note that since F’ is less than 182 the corresponding equation has been used in which F’ is set
to 182. Remember that in F’ calculation T1 is set to max 400 C.

Note : Relieving Temperature Calculation

Relieving Pressure (bara)

Relieving Temperature(K) = × Operating Temperature (K)
Operating Pressure (bara)

67.55
Relieving Temperature (K) = × (380 + 273) = 885.74 K = 612.74 C
49.8

since the ratio between operating pressure and PSV relieving pressure is very high, the relieving
temperature calculated is not consistent (it would exceed the maximum vessel wall temperature
for carbon steel, &o). The relieving temperature for PSV design has been assumed equal to 400°C
(considered the max allowable value for carbon steel). The actual relieving mass flow has been
calculated keeping the discharge capacity of the valve (volumetric flow rate) constant and scaling
the temperature down to 400°C.
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Simulation

Step 1:
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Step 2:

Step 3:
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Step 4:

Step 5:
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Step 6:

Here is the gist of what we have obtained:

Parameters Results Unit

Relief Load-API 3874 kg/hr.
Relief Loaf-Hysys 3734 kg/hr.
Selected Orifice 1.98 cm2
Orifice Designation 1.5 F 2
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3.PSV-1038/1043
1.Determine the scenario, using API-521
Since it is R-1002 and exposed to fire then a fire scenario is defined.

Parameters Value Parameters Value

Diameter 4m M 16.54

Height-TT 2.9 m Set Pressure 55 barg

Fluid Natural Gas Relieving Pressure 67.55 bara

Z 1.01 Accumulation 0.21

Cp/Cv 1.18 Material CS

2.Calculate the relief load, using API-520 Part1

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Calculation

Parameters Value Parameters Value

Aw 53.84 m2 KD 0.975

C9 0.2772 F’ 116

C10 0.0395 Relief Load 3215 kg/hr

C 0.0254

M × P × 100
Ws = 182 × C × Aw × √( )
T + 273

16.54 × 67.5 × 100 kg

Ws = 182 × 0.0254 × 53.84 × √ = 3215.1
400 + 273 hr

Note that since F’ is less than 182 the corresponding equation has been used in which F’ is set
to 182. Remember that in F’ calculation T1 is set to max 400 C.
Note : Relieving Temperature Calculation

Relieving Pressure (bara)

Relieving Temperature(K) = × Operating Temperature (K)
Operating Pressure (bara)

67.55
Relieving Temperature (K) = × (375 + 273) = 887 K = 614 C
49.3

since the ratio between operating pressure and PSV relieving pressure is very high, the relieving
temperature calculated is not consistent (it would exceed the maximum vessel wall temperature
for carbon steel, &o). The relieving temperature for PSV design has been assumed equal to 400°C
(considered the max allowable value for carbon steel). The actual relieving mass flow has been
calculated keeping the discharge capacity of the valve (volumetric flow rate) constant and scaling
the temperature down to 400°C.
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PSV-2019
1.Determine the scenario, using API-521
Since it is exposed to fire then a fire scenario is defined.

Parameters Value Parameters Value

Diameter 0.7 m M 18.02

Height 3.275 m Set Pressure 52 barg

Fluid Steam Condensate Relieving Pressure 63.9 bara

Z 0.78 Accumulation 0.21

Cp/Cv 1.09 Material CS

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2.Calculate the relief load, using API-520 Part1

Where adequate drainage and firefighting equipment do not exist, Equation (8) should be used

Calculation

Parameters Value

Aw 7.73 m2

C2 70900

F 1

λ 2880

Relief load 474 kg/h

𝐶2 × 𝐹 × (𝐴𝑤 0.82 ) 70900 × 1 × (7.730.82 ) × 3.6 𝑘𝑔

𝑊𝑠 = = = 474
𝜆 2880 ℎ𝑟
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Simulation in Aspen Hysys

Step 1:
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Step 2:

Step 3:
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Step 4:
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Step 5:
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Step 6:
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4.PSV-2121/2122
The rated capacity of FT-2002 is 27180 kg/h, so the relief load is 27180 kg/h.
5.PSV-2171/2172
The rated capacity of FT-2001 is 48000 kg/h, so the relief load is 48000 kg/h.
6.PSV-2354/2360
Heat Exchanger E-2020 tube rupture
Please check Appendix A.
7.PSV-2485

1. Heat Exchanger Data Input

High pressure side Reformed Gas

Low pressure side DMW

Design Pressure of high-pressure side 29 barg

Design Pressure of low-pressure side 14 barg

Operating Pressure 24.5 barg

M 12.06

Cp/Cv 1.36

Z 1

Relieving Temperature 138

Tube OD 25.4

Tube Thk. 1.65

2. Check if a PSV is needed

In order to perform this step, do the calculation below:

multiply design pressure of high-pressure side by 10/13:

29 * 10/13 = 22.3 barg
So, design pressure of low-pressure side should be at least 22.3 brag in order not to need a
PSV. Here it is 7.5 bars, thereby requiring a PSV.
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3. Use the formula below to calculate Relief Load

4. Relief Load Result

Ws = KG × (d^2) × P1 × ((M/ZT) ^0.5)

12.06
Ws = 2.93 × (22.1 2) × (24.5 + 1.013) × = 6254.12 kg/hr.
1 ×411

PSV 2376/2377/2378/2379/2380

The total capacity is 430000kg/h (Normal capacity is388329 considering 1.1 times) which is
shared by PSV-2376, PSV-2377, PSV-2378, and PSV-2379; PSV-2380 is spare and its capacity
is the same as PSV-2376~79.
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PSV-2494

1. Heat Exchanger Data Input

High pressure side Reformed Gas

Low pressure side CW

Design Pressure of high-pressure side 29 barg

Design Pressure of low-pressure side 7.5 barg

Operating Pressure 24.2 barg

M 11.24

Cp/Cv 1.39

Z 1

Relieving Temperature 56.4

Tube OD 19.05

Tube Thk. 1.65

2. Check if a PSV is needed

In order to perform this step, do the calculation below:

multiply design pressure of high-pressure side by 10/13:

29 * 10/13 = 22.3 barg

So, design pressure of low-pressure side should be at least 22.3 barg in order not to need a
PSV. Here it is 7.5 bars, thereby requiring a PSV.
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3. Use the formula below to calculate Relief Load

4.Relief Load Results

Ws = KG × (d^2) × P1 × ((M/ZT) ^0.5)

11.24
Ws = 2.93 × (15.75 2) × (24.2 + 1.013) × = 3387.18 kg/hr.
1 ×329
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PSV-2494

1.Heat Exchanger Data Input

High pressure side Syngas

Low pressure side CW

Design Pressure of high-pressure side 99 barg

Design Pressure of low-pressure side 7.5 barg

Operating Pressure 83.7 barg

M 10.07

Cp/Cv 1.37

Z 1
Relieving Temperature 43.6
Tube OD 25.4

Tube Thk. 1.65

2. Check if a PSV is needed

In order to perform this step, do the calculation below:

multiply design pressure of high-pressure side by 10/13:
99 * 10/13 = 76.15 barg
So, design pressure of low-pressure side should be at least 76.15 barg in order not to need a
PSV. Here it is 7.5 bars, thereby requiring a PSV.
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3. Use the formula below to calculate Relief Load

4. Relief Load Result

Ws = KG × (d^2) × P1 × ((M/ZT) ^0.5)

10.07
Ws = 2.93 × (22.1 2) × (83.7 + 1.013) × = 21620 kg/hr.
1 ×323
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Simulation

Step 1:
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Step 2:

Step 3:
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Step 4:

Step 5:
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Here is all we have obtained:

Parameters Values Units

Relief Load-API 21620 kg/hr.

Relief Load-Hysys 21530 kg/hr.

Selected Orifice 71.29 Cm2

Orifice Designation 6Q8

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PSV-3047/3048/3057
Steam Drum D-3003
The normal capacity of steam is about 251000 kg/h and the rated capacity is achieved by
multiplying the normal capacity by 1.1 which equals to 276000 kg/h.
PSV-3163
1.Determine the scenario, using API-521
Since it is D-3001 and exposed to fire then a fire scenario is defined.

Parameters Value Parameters Value

Diameter 4.9 m M 9.37

Height 4.8 m Set Pressure 99 barg

Fluid Methanol + Syng Relieving Pressure 120.79 bara

Z Accumulation 0.21

Cp/Cv 1.37 Material SS

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2.Calculate the relief load, using API-520 Part1

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Calculation

Parameters Value Parameters Value

Aw 100 m2 KD 0.975

C9 0.2772 F’ 328

C10 0.0395 Tw 593C

C 0.026 Relief Load 13236 kg/hr

2.722 × (Tw − T)1.25 × A × √MP

Ws =
T1.1506

2.722 × (866.5 − 478.6)1.25 × 100 × √(120.7 × 100 × 9.37 kg

Ws = 1.1506
= 13236
478.6 hr

Note: Relieving temperature calculation:

Relieving Pressure
T= × Operating Temperature
Operating Pressure

120.79
T= 81
× (48 + 321) = 478.7 C
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PSV-5370
Use the formula below to calculate Relief Load

1.PSV-5370

Parameters value

av (1/k) 0.000454

duty (watts) 160000

specific gravity 0.99

c (J/kg.C) 4176

Q (lit/m) 1.05

Q (kg/h)-API521 63
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av × ∅
q=
1000 × d × C

0.000454 × 160000 × 60000

q= = 1.05 lit/min
1000 × 0.99 × 4176
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2.PSV-5339
Use the formula below to calculate Relief Load

Parameters value

av (1/k) 0.000454

duty (watts) 3600000

specific gravity 0.99

c (J/kg.K) 4176

Q (lit/m) 23.71

Q (kg/h)-API521 1422
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av × ∅
q=
1000 × d × C

0.000454 × 3600000 × 60000

q= = 23.71 lit/min
1000 × 0.99 × 4176
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PSV-5058
Heat Exchanger E-2024 Tube Rupture

Venting Required (Ws) = 2.463× (d ^ 2) × (∆P × ρV/10) ^ 0.5

Parameter Unit Value

Tube ID (d) mm 28.5

∆P bar 9.5

Gas Density (ρV) Kg/m3 20.47

Ws = 2.463× (28.5 ^ 2) × (9.5 × 20.47/10) ^ 0.5 = 8822.15 kg/hr.

PSV-5058
Heat Exchanger E-5001 Tube Rupture

Venting Required (Ws) = 2.463× (d ^ 2) × (∆P × ρV/10) ^ 0.5

Parameter Unit Value

Tube ID (d) mm 27.53

∆P bar 2.44

Gas Density (ρV) Kg/m3 3.37

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Ws = 2.463× (27.53 ^ 2) × (2.44 × 3.37/10) ^ 0.5 = 1692.73 kg/hr.

PSV-5179/5180
Heat Exchanger E-5002 Tube Rupture

Venting Required (Ws) = 2.463× (d ^ 2) × (∆P × ρV/10) ^ 0.5

Parameter Unit Value

Tube ID (d) mm 21.18

∆P bar 1.71

Gas Density (ρV) Kg/m3 7.35

Ws = 2.463× (21.18 ^ 2) × (1.71 × 7.35/10) ^ 0.5 = 1239 kg/hr.

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PSV-5250/5261
Heat Exchanger E-5023 Tube Rupture

Venting Required (Ws) = 2.463× (d ^ 2) × (∆P × ρV/10) ^ 0.5

Parameter Unit Value

Tube ID (d) mm 22.1

∆P bar 18.84

Gas Density (ρV) Kg/m3 9.74

Ws = 2.463× (22.1 ^ 2) × (18.84 × 9.74/10) ^ 0.5 = 5153 kg/hr.

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PSV-5250/5261
Heat Exchanger E-5003 Tube Rupture

Venting Required (Ws) = 2.463× (d ^ 2) × (∆P × ρV/10) ^ 0.5

Parameter Unit Value

Tube ID (d) mm 14.83

∆P bar 0.5

Gas Density (ρV) Kg/m3 3.99

Ws = 2.463× (14.83 ^ 2) × (0.5 × 3.99/10) ^ 0.5 = 242 kg/hr.

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Governing Scenarios

PSV-5058/5059/5060/5061

1. The overall relieve amount of the T5001 overhead is equal to the amount into
condenserAE5004 which is 112490kg/h.
2. Tube rupture scenario for both heat exchangers E-5001 and E-5024 would result in
venting flowrate of 8822 + 1692 = 10514 kg/hr.
3. By comparison between the relief load of these scenarios, the governing scenario is reflux
failure.

PSV-5179/5180

1. The overall relieve amount of the T5002 overhead is equal to the amount into condenser
AE5005 which is 418559kg/h,
2. Tube rupture scenario for heat exchangers E-5002 would result in venting flowrate 1239
kg/hr.
3. By comparison between the relief load of these scenarios, the governing scenario is reflux
failure.

PSV-5250/5251/5261

1. The overall relieve amount of the T5003 overhead is equal to the amount into condenser
E5002 1/2/3/4 which is 440751kg/h.
2. Tube rupture scenario for both heat exchangers E-5023 and E-5003 would result in
venting flowrate of 242 + 5153 = 5395 kg/hr.
3. By comparison between the relief load of these scenarios, the governing scenario is reflux
failure.

PSV-2494

1. The relief load for tube rupture scenario is 3387.18 kg/hr.

2. Also, the hydraulic expansion is an applicable scenario. Here is the calculation for the
hydraulic expansion scenario.

Parameters value

av (1/k) 0.000454

duty (watts) 6500000

specific gravity 0.99

c (J/kg.K) 4176
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Q (lit/m) 42.82

Q (kg/h)-API521

3. By comparison between the relief load of these scenarios, the governing scenario is tube
rupture.

PSV-3143/3146/3149
1. The relief load for tube rupture scenario is 24000 kg/hr.
2. Also, the hydraulic expansion is an applicable scenario. Here is the calculation for the
hydraulic expansion scenario.

Parameters value

av (1/k) 0.000454

duty (watts) 44300000

specific gravity 0.99

c (J/kg.K) 4176

Q (lit/m) 291.88

Q (kg/h)-API521

3. By comparison between the relief load of these scenarios, the governing scenario is tube
rupture.
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Practice
In a HAZOP meeting tube rupture scenario was suggested for methanol reactors. Causes could
be pressure drop differences, leak as a result of corrosion, or both. Investigate the matter and
check if the existing PSVs could handle such relief load as a result of tube rupture.
Let’s check if this scenario is applicable.
High-pressure operating pressure is 79.5 barg
Low-pressure operating pressure is 33.7 barg
Required Pressure = 79.5 × 10/13 = 61.15 barg , So the low-pressure side pressure should be
minimum 61.15 barg so that tube rupture does not occur. So this scenario is applicable.

Parameter Value Unit

Tube Inner Diameter (ID) 57.5

Differential pressure of high- 45.8

pressure side and low side (△P)

Gas density (ρV) 17.9 Kg/m3

Ws = 2.463× (d ^ 2) × (∆P × ρV/10) ^ 0.5

Ws = 2.463× (57.5 ^ 2) × (45.8 × 17.9/10) ^ 0.5 = 73732 kg/hr.
So the PSVs which are designed for blocked outlet with venting capacity of 281000 kg/hr. can
handle such relief load and is in fact the governing scenario.
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Appendix A
The equation for heat exchanger tube rupture for liquid is as follows:

∆P
Ws = 1.68 × ρ × d2 × √
ρ

Parameter Value Unit

Heat Exchanger Inner tube Diameter (d) 48.26 mm

Liquid Density (𝛒) 683 Kg/m3

Differential pressure of high-pressure side 74.7 bar

and low-side (△P)

∆P 74.7 𝑘𝑔
Ws = 1.68 × ρ × d2 × √ = 1.68 × 683 × 48.262 × √ = 883601
ρ 683 ℎ𝑟