1.

Define the System

TO FLARE

SDV

BDV

BDV

TO FLARE

TO FLARE

SDV

SDV

BDV

SDV

SDV
SDV

SDV
SDV

SDV

Process System

SDV

1. Calculate each system volume inventory ; both piping and equipment.

Example : Piping Inventory Calculation
Length
From

To

3P-SDV-0013
5000-V-60
3"-300# Valve
5000-V-60
5000-V-60
Reducer 3" x 2"
Reducer 3" x 2"

5000-V-60
5000-PSV-V-60
4"-B1-PHL-100
5000-PSE-V-60
Reducer 3" x 2"
3P-BDV-0016
3P-PV-0023

(ft)
161.7
3.3
16.4
32.1
5.2
10.2
3.7

3"-GP-3P-022-BA1

VALVE

5.2

2"-B1-BD-202
2"-B1-BD-202
5000-V-60
5000-V-60

3P-PV-0022
VALVE
3P-SDV-0015
3P-SDV-0014

Equival
ent El.
Ratio
(ft)
1.2 0.0
1.3 0.0
1.3 0.0
1.3 0.0
1.3 0.0
1.3 0.0
1.3 0.0

NPS
(inch)
4
2
3
2
3
2
3

Internal Equivale
Pipe
nt
Diamete
Schedul
r
Length
e
(inch)
(ft)
S40
4.026 199.17
S80
1.939
4.26
S80
2.901 21.32
S80
1.939 41.71
S40
3.069
6.82
S40
2.067 13.22
S80
2.901
4.81

Piping
Volume

Vapour

Liquid

fraction

(ft3)
17.607
0.087
0.979
0.855
0.350
0.308
0.221

0.8077
1.0000
1.0000
1.0000
1.0000
1.0000
1.0000

Volume
(ft3)
3.3859
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000

1.3

0.0

S40

3.069

6.82

0.350

1.0000

0.0000

16.1
1.3
5.6
1.3
20.5
1.3
4.3
1.3
Total

0.0
0.0
0.0
0.0

2
2
2
2

S40
S80
S80
S80

2.067
1.939
1.939
1.939

20.89
7.25
26.65
5.54

0.487
0.149
0.546
0.114
22.0543

1.0000
1.0000
0.0000
0.0000

0.0000
0.0000
0.5465
0.1137
4.0461

Example : Equipment Inventory Calculation

ID
Tag Number

Equipment Name

HP TEST
SEPARATOR

Process System

Volume
Total HLL NLL LLL

(ft) (ft) (ft) (ft3) (ft3) (ft3) (ft3)

2.00 0.75 0.50 62.9 54.18 15.74
2.500 12.000 HORIZONTAL
8.812
0
0
0
95
3
6
63.0 54.18 15.74
Total
8.812
0
3
6
(ft)

5000-V-60

Length Orientation HLL NLL LLL

(ft)

HLL
Wetted
Area
(ft2)

NLL
Wetted
Area
(ft2)

LLL
Wetted
Area
(ft2)

Total

71.849

36.811

29.174

104.065

71.849

36.811

29.174

104.065

Area
(ft2)

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,
the grater the flowrate load to
flare..

Process System

Because the time is set 15 minutes

No matter the initial pressure

*) want to know more HYSYS short cut ?

check in my blog : www.process-eng.blogspot.com
Article : useful HYSYS shortcut

1. Depressuring
Dynamic

2. Add Utility

3. View Utility

Process System

Process System

re name to : FIRE CASE

Select stream BASIS SIMULATION : FIRE

Select horizontal vessel
Select horizontal 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
fill to apply some margin
of total inventory volume

keep as it is

Fill volume of liquid

Based on NLL or HLL

HYSYS will adjust vessel size both Diameter and Height so that both
the total and liquid volume are correct correspond to the input value.
Is it difficult to achieve that volume ? As a matter of fact, it is not.
Actually, the real problem is, the wetted area based on HYSYSs
vessel size is not equal with the actual wetted area.
8

Process System

HHL result worst case.

Still remember the heat input ?
Example : Q = 21000FA^0.82
The wetted area based on
HLL bigger than NLL.
(The greater the wetted area
the greater the heat input
rate to vessel)

Now, at this stage we will skip this problem this will need long explanation
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

For fire case :

ForLoss
fire case
:
Heat
= None
Heat Loss = None
no heat loss should be
assumed in fire case
simulation for worst case

other cases , such as *)

1. Jet fire , the heat flux is 95,500
BTU/ft2/hr.
C1 = 95,500
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

Process System

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

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
Pb
Cv
Peak flow

Unit
Musoneilan
psig
0
25
50
USGPM ( 60f, 1psi) 4.044 4.052 4.126
lb/hr
4210 4217 4292

0
8.400
4190

Fisher
25
8.406
4193

50
8.406
4193

Supersonic, (Cv in inch2)

0
25
50
0.102 0.1019 0.102
4191
4204
4204

Subsonic, (Cv in inch2)

0
25
50
0.102 0.1038 0.109
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.
DONT 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.

Cf
Flow
Cv

11

MUSONEILAN
0.9
0.95
1
4202.545 4205.035 4205.123
4.486085 4.252576 4.040034

Process System

SENSIVITY test result

Fill Cf = 0.9 -1.0
There is no worry about the result ^_^

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

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
UN-CHECK
will result in greater peak flow rate

For gas-filled systems 80% to 100%

For liquid filled systems 50% to 70%

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
less than 1 inch, generally requires
faster depressuring rate.

use Calculate Cv mode

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)

The longer the depressuring time, the higher the depressuring load

Set final pressure = 100 psig

Or 50 % design pressure *)
-100 psig for thickness less than 1 inch
-and 50% DP for more

13

Process System

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

Article : basic depressuring - why 15 minutes?

MAX. Cv
MIN. System
Temperature
(during
depressuring)

PERFORMANCE

MIN. outlet RO
Temperature
(during
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

or CTRL+U *)

Select stream BASIS SIMULATION

ADIABATIC
Rename : Adiabatic Case

1ST step

2nd step

3rd

16

Process System

step

Fill all of data similar with FIRE CASE

except that volume of liquid
based on LLL
LLL mean lower liquid increase
isentropic efficiency will result in
lower final temperature
(see page 12)
Lower liquid lower flashed vapor
formed from liquid phase will
result in shorter depressuring time

Select : Adiabatic
No heat input

Select : None
HYSYS does not
account for any heat
loss

During a fire case the vessel is covered

with flame. In this case, heat loss to the
surrounding atmosphere determined by
taking a normal atmospheric temperature
is generally not correct as the vessel's
surrounding temperature is very high.
You should use no heat loss, select
NONE for FIRE CASE
NONE for ADIABATIC
Can be applied if the fluid temperature is
lower than the environment temperature.
SIMPLE for ADIABATIC

Heat Loss Parameter :

Use NONE for FIRE CASE
Use SIMPLE for ADIABATIC
except for system which is the fluid temperature lower
than environment , NONE model should be applied (for
lower final temperature)

17

Process System

I suggest you to use SIMPLE heat loss

model for accurate calculations.
Use default values except the AMB
temperature.
I suggest you to use DETAILED model
for accurate calculations
IF ONLY you know what to do :- )
(I myself dont know how to use
this option,,suusahhh cuuukkk).

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

use Calculate
Pressure mode

In some cases, the final pressure

cant meet 0 psig, (slightly above
0 psig).
The system cant be decrased to
lower pressure.
its 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

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Process System