Whitepaper TwoPhaseOrificeSizing VaporNoise ReactionForces

aspenONE Engineering Safety Analysis Environment
Equations and example benchmark calculations for two-phase orifice

sizing, vapor noise, and reaction forces
Craig Powers, Principal Software Developer, Aspen Technology, Inc.
2015 Aspen Technology, Inc. AspenTech , aspenONE , the aspenONE logo, the Aspen leaf logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights
reserved. All other trademarks are property of their respective owners.
11-2297-1112
EQUATIONS AND EXAMPLE BENCHMARK CALCULATIONS FOR

TWO-PHASE ORIFICE SIZING AND VAPOR NOISE AND REACTION
FORCES
Two forms of the Leung Omega Method are implemented in the Safety Analysis Environment.
One is for cases that are saturated or two-phase at relief conditions, upstream of the relief
valve. The other is for cases that are subcooled liquid upstream of the relief valve, with flashing
occurring across the valve, producing a two-phase stream at the valve outlet.
1. Non-Subcooled Omega Method

a. Equations
The governing equations for application of the Omega Method are obtained from Appendix C of
API Standard 520 Part I. [1] The method is a two-point method, meaning that physical
properties are required at two thermodynamic state points. For the non-subcooled method, the
first state point is relief conditions. The second state point is typically obtained by an isentropic
flash to 90% of the relief pressure. With this information, the required orifice area may be
obtained using the following equations:
= 9(
9
0
1) = 9 ( 1)
0
9
(Eq. 1)
where is the Omega parameter, v0 and v9 are specific volume at upstream and 90%
conditions, respectively, and 0 and 9 are density at upstream and 90% conditions,
respectively.
=
(0.70356+0.014685 ln )
[1 + (1.0446 0.0093431) 0.56261 ]
0
= 0
(Eq. 2)
(Eq. 3)
where c is the critical pressure ratio, Pc is the pressure corresponding to critical flow at the
nozzle throat in the relief valve in absolute units, Pa is the total back pressure at the outlet of the
valve in absolute units, and P0 is the upstream relief pressure in absolute units.
If c exceeds a, then the flow through the relief valve is critical, and the following equation
should be used to calculate the maximum mass flux:
0
0 0
= 1
=
0
(Eq. 4)
where G is the maximum mass flux through the valve in lb/s-ft or kg/s-m, P0 is in psia or Pa, v0
is in ft/lb or m/kg, and 0 is in lb/ft or kg/m. C1 = 68.09 in U.S. customary units, or 1.0 in SI
units.
If c does not exceed a, then the flow through the relief valve is subcritical, and the following
equation should be used to calculate the maximum mass flux:
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0 0
2[ ln + ( 1) (1 )]
1
( 1) + 1
where units are as in (Eq. 4).

= 1
(Eq. 5)
Once the maximum mass flux has been obtained, the required effective discharge area may be
calculated by
2
(Eq. 6)

where A is the required effective discharge area in mm, w is the required relief load in kg/h, Kd
is the discharge coefficient of the valve, Kb is the backpressure correction factor (applicable to
balanced bellows valves only), Kc is the combination capacity factor, and Kv is the viscosity
correction factor. C2 = 0.04 for U.S. customary units, 277.8 for SI units.
=
When an orifice area has been selected, (Eq. 6) may be rearranged to find the rated capacity of
the valve:
= 277.8
(Eq. 7)
b. Example with Critical Flow

The example is based on the following conditions:
Composition: 15% propane, 25% n-butane, 30% n-pentane, 30% n-heptane using the
HYSYS PR package for physical properties
Relief conditions: 8.03 barg / 101.2 C
Required relief load: 63,000 kg/h
Based on the relief pressure of 8.03 barg, the 90% intermediate flash pressure is 7.227 barg.
Setting up a stream in HYSYS at the relief conditions and running it through an isentropic flash
will yield the following properties:
0 = 112.0 kg/m
9 = 91.45 kg/m
The Omega parameter may be calculated using (Eq. 1) as
112.0
=9(
1) = 2.022
91.45
The critical pressure ratio and backpressure ratio may be calculated using (Eq. 2) and (Eq. 3):
= 0.694
=
1.01325
= 0.112
8.03 + 1.01325
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Figure 1. Two-phase critical flow case calculated in Aspen HYSYS
Because c is larger than a, flow across the relief valve is choked, and the maximum mass flux
is calculated using (Eq. 4):
(112)(9.043) 1000 PakPa
= 0.694
= 4,912 kg/s-m
2.022
Assuming that all capacity coefficients are 1.0 aside from the discharge coefficient, which is
0.85 in accordance with guidance from API, the required area is calculated using (Eq. 6):
=
277.8(63,000)
= 4192 mm
0.85(4,912)
For a selected Q orifice with an effective area of 7129 mm, the rated capacity is calculated
using (Eq. 7):
=
0.85(4,912)(7,129)
= 107,100 kg/h
277.8
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The results calculated above are compared to results obtained in Aspen HYSYS in Table 1.
Table 1. Comparison of Example Calculation and Aspen HYSYS Calculation for Critical Two-Phase Flow
Variable
Units
Required Relief Load (w)

Relief Pressure (P0)
90% Pressure (P9)
kg/h
barg
barg
kg/m
Example
Calculation
63,000
8.03
7.227
112.0
Mass Density at 90% (9)
kg/m
91.45
Mass Density at Relief (0)
Omega Parameter ()
Critical Flow Ratio ( )
Flow Type
Maximum Mass Flux (G)
kg/s-m
Required Area (A)
mm
Rated Capacity (wmax)
kg/h
a. Blue = Calculation input
b. Black = Calculated value
2.022
0.694
Critical
4,912
4,192
107,000
Aspen HYSYS
63,000
8.03
Critical
4,448
101,000
c. Example with Subcritical Flow

Composition: 15% propane, 25% n-butane, 30% n-pentane, 30% n-heptane using the
HYSYS PR package for physical properties
Relief conditions: 154 kPag / 85 C
Back pressure: 60 kPa superimposed
Based on the relief pressure of 1.54 barg, the 90% intermediate flash pressure is 1.28 barg.
Setting up a stream in HYSYS at the relief conditions and running it through an isentropic flash
will yield the following properties:
0 = 8.264 kg/m
9 = 7.399 kg/m
The Omega parameter may be calculated using (Eq. 1) as
8.264
=9(
1) = 1.052
7.399
The critical pressure ratio and backpressure ratio may be calculated using (Eq. 2) and (Eq. 3):
= 0.6131
=
1.01325 + 0.6
= 0.6318
1.54 + 1.01325
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Figure 2. Two-phase subcritical flow case calculated in Aspen HYSYS
Because c is smaller than a, flow across the relief valve is unchoked, and the maximum mass
flux is calculated using (Eq. 5), yielding a maximum mass flux G = 867.4 kg/m-s.
=
277.8(20,000)
= 7536 mm
0.85(867.4)
For a selected R orifice with an effective area of 10322.5 mm, the rated capacity is calculated
using (Eq. 7):
=
0.85(867.4)(10322.5)
= 27,400 kg/h
277.8
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Table 2. Comparison of Example Calculation and Aspen HYSYS Calculation for Subcritical Two-Phase Flow
Variable
Units

90% Pressure (P9)
kg/h
barg
barg
kg/m
Example
Calculation
20,000
1.54
1.28
8.264
kg/m
7.399
Mass Density at Relief (0)
Omega Parameter ()
Flow Type
kg/s-m
Required Area (A)
mm
kg/h
1.052
0.6131
Subcritical
867.4
7,536
27,400
Aspen HYSYS
20,000
1.54
Subcritical
7,710
26,780
2. Subcooled Omega Method

a. Equations
As with the non-subcooled Omega Method, the subcooled Omega Method is a two-point
method. The first point remains the same, the conditions at the PRV inlet. For the second
point, the relief stream is flashed to 90% of its saturation pressure corresponding to the PRV
inlet temperature T0. As with the non-subcooled method, flow may be critical or subcritical;
however, the subcooled Omega Method also requires a determination as to whether the relief
conditions correspond to high or low subcooling; that is, whether the fluid will begin to flash in
the inlet line, or whether it will flash at the valve throat.
The omega parameter is calculated using a similar equation to (Eq. 1):
0
1)
9
is the liquid density at the PRV inlet in kg/m
= 9 (
where 0
(Eq. 8)
High or low subcooling is determined via the transition saturation pressure ratio, which is
calculated as
=
2
1 + 2
(Eq. 9)
(Eq. 10)
where st is the transition saturation pressure ratio, s is the saturation pressure ratio, Ps is the
saturation pressure in absolute units, and P0 is the upstream pressure in absolute units.
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If st exceeds s, then relief is considered to lie in the high subcooling region, and flow will
necessarily be critical unless the total back pressure exceeds the saturation pressure (but in this
case, the fluid is liquid across the valve, and the API liquid sizing will be sufficient to calculate
the orifice size). Otherwise, relief is considered to lie in the low subcooling region, and a
check must be made to determine if the flow across the PRV is critical or subcritical. The critical
pressure ratio may be estimated as
2
1 2 1
(
) [1 1 (
)]
2 1
(Eq. 11)
The back pressure ratioa is calculated using (Eq. 3) as with the non-subcooled method.
For low subcooling, the maximum mass flux is calculated using the following equation:
0 0
(Eq. 12)
2(1 ) + 2 [ ln ( 1)( )]
( 1) + 1
For critical flow, = ; for subcritial flow, = . Pressure is in psia or Paa. C1 = 68.09 for
U.S. customary units, 1.0 for SI units.
= 1
For high subcooling, the maximum mass flux is calculated using the following equation:
= 1 2 0 (0 )
(Eq. 13)
Pressure is in psia or Paa.

Given a required relief load in lb/h or kg/h, the required area and rated capacity may be
calculated using (Eq. 6) and (Eq. 7).
b. Example with Low Subcooling, critical flow

Composition: 15% propane, 30% isobutane, 30% n-butane, 25% isopentane using the
HYSYS PRSV package for physical properties
Relief conditions: 242 psig, 205 F
Required relief load: 92,590 lb/h
Setting up a stream in HYSYS at the relief conditions and flashing appropriately yields the
following properties:
0 = 29.23 lb/ft
Ps = 241.4 psia
P9 = 217.3 psia
9 = 17.53 lb/ft
The omega parameter is calculated using (Eq. 8):
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29.23
= 9 (
1) = 6.011
17.53
Figure 3. Low subcooled critical flow case calculated in Aspen HYSYS
The transition saturation pressure ratio is calculated using (Eq. 9):

=
2(6.011)
= 0.9232
1 + 2(6.011)
The saturation pressure ratio is 0.9404; because this is greater than the transition ratio, this
case involves low subcooling, and the critical pressure ratio is calculated using (Eq. 11):
0.9404 (
2(6.011)
1
2(6.011) 1
) [1 1
(
)] = 0.8633
2(6.011) 1
0.9404
2(6.011)
The back pressure ratio of 0.0573 is much lower than the critical pressure ratio, so the flow is
critical. The maximum mass flux is calculated using (Eq. 12) with = ; the result is that
G = 2,150 lb/s-ft.
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=
0.04(92,590)
= 2.650 in
0.65(2,150)
For a selected L orifice with an effective area of 2.853 in, the rated capacity is calculated using
(Eq. 7):
=
0.65(2,150)(2.853)
= 99,680 lb/h
0.04
Table 3. Comparison of Example Calculation and Aspen HYSYS Calculation for Low Subcooled, Critical Flow
Variable
Units

Saturation Pressure (Ps)
90% Pressure (P9)
Mass Density at Relief (0 )
lb/h
psig
psig
psig
lb/ft
Example
Calculation
92,590
242
226.7
202.6
29.23
lb/ft
17.53
Omega Parameter ()
Transition Subcool Ratio (st)
Flow Type
Aspen HYSYS
92,590
242.0
6.011
0.9232
0.8633
Low Subcool,
Critical
2,150
2.650
99,680

lb/s-ft
Required Area (A)
in
lb/h
Critical
2.663
99,180
c. Example with Low Subcooling, subcritical flow

Relief conditions: 44 psig, 87.5 F
Back pressure: 40 psi superimposed
11-2297-1112
Figure 4. Low subcooled subcritical flow case calculated in Aspen HYSYS
0 = 35.17 lb/ft
Ps = 57.13 psia
P9 = 51.4 psia
9 = 13.72 lb/ft
35.17
= 9 (
1) = 14.07
13.72
=
2(14.07)
= 0.9657
1 + 2(14.07)
11-2297-1112
The saturation pressure ratio is 0.9733; because this is greater than the transition ratio, this
case involves low subcooling, and the critical pressure ratio is calculated using (Eq. 11):
0.9733 (
2(14.07)
1
2(14.07) 1
) [1 1
(
)] = 0.9130
2(14.07) 1
0.9733
2(14.07)
The back pressure ratio of 0.9319 is higher than the critical pressure ratio, so the flow is
subcritical. The maximum mass flux is calculated using (Eq. 12) with = = 0.9319; the
result is that G = 765.4 lb/s-ft.
=
0.04(92,590)
= 7.444 in
0.65(765.4)
For a selected Q orifice with an effective area of 11.05 in, the rated capacity is calculated using
(Eq. 7):
=
0.65(765.4)(11.05)
= 137,400 lb/h
0.04
Table 4. Comparison of Example Calculation and Aspen HYSYS Calculation for Low Subcooled, Subcritical
Flow
Variable
Units

90% Pressure (P9)
lb/h
psig
psig
psig
lb/ft
Example
Calculation
92,590
44
42.43
36.7
35.17
lb/ft
13.72
Omega Parameter ()
Flow Type
Aspen HYSYS
92,590
44.00
14.07
0.9657
0.9130
Low Subcool,
Critical
765.4
7.444
137,400

lb/s-ft
Required Area (A)
in
lb/h
Critical
7.450
137,300
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d. Example with High Subcooling

Relief conditions: 242 psig, 188.3 F
0 = 30.34 lb/ft
Ps = 203.1 psia
P9 = 182.8 psia
9 = 17.40 lb/ft
Figure 5. High subcooled critical flow case calculated in Aspen HYSYS
11-2297-1112

30.34
= 9 (
1) = 6.693
17.4
=
2(6.693)
= 0.9305
1 + 2(6.693)
The saturation pressure ratio is 0.7912; because this is less than the transition ratio, this case
involves high subcooling, and the critical pressure ratio is equal to the saturation pressure
ratio. The maximum mass flux is calculated using (Eq. 13):
= 68.092(30.34)(256.7 203.1) = 3,883 lb/s-ft
=
0.04(92,590)
= 1.467 in
0.65(3,883)
For a selected K orifice with an effective area of 1.838 in, the rated capacity is calculated using
(Eq. 7):
=
0.65(3,883)(1.838)
= 116,000 lb/h
0.04
Table 5. Comparison of Example Calculation and Aspen HYSYS Calculation for High Subcooled, Critical Flow
Variable
Units

90% Pressure (P9)
lb/h
psig
psig
psig
lb/ft
Example
Calculation
92,590
242
188.4
168.1
30.34
lb/ft
17.40
Omega Parameter ()
Flow Type
Aspen HYSYS
92,590
242.0
6.693
0.9305
High Subcool,
Critical
3,883
1.467
116,000

lb/s-ft
Required Area (A)
in
lb/h
Critical
1.473
115,600
11-2297-1112
3. Direct Integration Method

The direct integration method involves evaluating thermodynamic properties of the relieving
stream at a number of state points and then numerically integrating the nozzle equation to
determine the maximum mass flux. This equation is the theoretical basis for every orifice
method, so the direct integration method is applicable to any type of flow, single- or multi-phase.
a. Equations
The nozzle equation is
2
(Eq. 14)

2
where G is the mass flux in lb/ft-s or kg/m-s, v is the specific volume in ft/lb or m/kg, and dp is
the differential pressure increment in lbf/ft or Pa.
2 =
This is approximated as
2

2
where is the average specific volume over the pressure increment p.
2
(Eq. 15)
The sum is performed from the relief pressure until either a maximum value of G is reached or
the back pressure Pa is reached. If the maximum in G occurs above Pa, then the flow is choked.
b. Example
Composition: 25% n-octane, 35% n-decane, 30% n-C11, 10% nitrogen using the HYSYS
SRK package for physical properties
Relief conditions: 176 psig, 122 F
A property table may be used to obtain the mass density along an isentropic path for numerical
integration:
Pressure,
psia
190.7
180.7
170.7
160.7
150.7
140.7
130.7
120.7
110.7
100.7
90.7
Mass Density,
lb/ft
23.21
22.48
21.71
20.90
20.06
19.18
18.25
17.28
16.25
15.17
14.04
Specific Volume,
ft/lb
0.0431
0.0445
0.0461
0.0478
0.0499
0.0521
0.0548
0.0579
0.0615
0.0659
0.0712
,
ft/s
0.0
2028
2098
2175
2263
2363
2477
2610
2766
2952
3177
Mass Flux,
lb/ft-s
0.0
1432
1972
2347
2625
2835
2988
3092
3150
3164
3133
11-2297-1112
Note that the mass flux reaches a maximum at a pressure of 100.7 psia, indicating that flow is
choked and the relief mass flux is 3164 lb/ft-s.
Figure 6. Direct integration case calculated in Aspen HYSYS
0.85 in accordance with guidance from API for two-phase flow at relief conditions, the required
area is calculated using (Eq. 6):
=
0.04(136,500)
= 2.030 in
0.85(3,164)
11-2297-1112
For a selected L orifice with an effective area of 2.853 in, the rated capacity is calculated using
(Eq. 7):
=
0.85(3,164)(2.853)
= 191,800 lb/h
0.04
Table 6. Comparison of Example Calculation and Aspen HYSYS Calculation for Direct Integration
Variable
Units
Example
Calculation
136,500
176
122
3,164
2.030
191,800

lb/h
psig
Relief Temperature (T0)
F
lb/s-ft
Required Area (A)
in
lb/h
Aspen HYSYS
136,500
176.0
122.0
3,115
2.065
188,600
4. Noise
a. Equations
The equations for computing noise level for atmospheric relief valves are given in section
5.8.10.3 of API Standard 521. [2] The noise level at 30 m from the point of discharge is
calculated using the following equation:
1
(Eq. 16)
30 = + 10 log10 (
2)
7200
where w is the mass flow through the valve in kg/h, c is the speed of sound in the gas at the
valve in m/s, and L is the sound level in decibels.
The speed of sound may be computed as:
= 91.2
(Eq. 17)
where k is the ideal specific heat ratio in the gas, T is the temperature in K, and M is the
molecular weight of the gas.
The value of L in (Eq. 16) is read from a figure in the text. It may be approximated using two
semilog curve fits:
39.461 ln + 12.648 2.866
={
2.1716 ln + 51.914 > 2.866
where X is the pressure ratio across the pressure relief valve.
(Eq. 18)
11-2297-1112
b. Example
Composition: 100% air using the HYSYS PR package for physical properties
Relief conditions: 330 kPaa, 311 K
Figure 7. Noise example calculated in Aspen HYSYS
Setting up a stream in HYSYS at the relief conditions will yield the following properties:
M = 28.95
k = 1.404
The speed of sound may be calculated using (Eq. 17) as:
(1.404)(311)
= 91.2
= 354.2 m/s
(28.95)
Based on a pressure ratio of 330101.325 = 3.26, the contribution due to pressure ratio may be
estimated by (Eq. 18) to be 54.5 dB. Then, the total noise level is calculated using (Eq. 16):
11-2297-1112
30 = 54.5 + 10 log10 (
1
52,560 (354.2)2 ) = 114.1 dB
7200
Table 7. Comparison of Example Calculation and Aspen HYSYS Calculation for Noise
Variable
Units
Example
Calculation
52,560
330 kPaa
311 K
114.1

kg/h
Relief Temperature (T0)
Sound Level (L30)
dB
Aspen HYSYS
52,560
2.287 barg
37.85 C
112.5
Figure 8. Reaction force example calculated in Aspen HYSYS
11-2297-1112
5. Reaction Forces
a. Equations
The equations for computing reaction forces on the outlet piping of atmospheric relief valves are
given in section 4.4.1 of API Recommended Practice 520 Part II. [3] The reaction force due to
vapor discharge is calculated using the following equation:
=
+ 0.1 3
( + 1)
27.9
(Eq. 19)
where F is the reaction force in N, w is the required relief load in kg/h, k is the ideal specific heat
ratio of the gas, T is the discharge temperature in K, M is the molecular weight of the gas, A is
the area of the pipe at the point of discharge in mm, and p3 is the static pressure at the outlet in
barg (that is, 0 for flow that is unchoked at the outlet, or the choke pressure for flow that is
choked at the outlet).
b. Example
Composition: 30% propane, 70% n-butane using the HYSYS SRK package for physical
properties
Relief conditions: 4.4 barg, 112.4 C
Fluid properties at relief may be observed to be:
M = 53.92
k = 1.078
P* = 0.8152 bara
The reaction force may be calculated using (Eq. 19). Because the choke pressure is less than
atmospheric pressure, the second term may be neglected.
(1.078)(112.4 + 273.15)
1
(36,970)
= 2,552 N
(2.078)(53.92)
27.9
Table 8. Comparison of Example Calculation and Aspen HYSYS Calculation for Reaction Force
Variable
Units
Example
Calculation
36,970
112.4
2,552

kg/h
Relief Temperature (T)
C
Reaction Force (F)
N
Aspen HYSYS
36,970
112.4
2,552
11-2297-1112
REFERENCES
[1] American Petroleum Institute, API Standard 520 Part I 9th Ed.: Sizing, Selection, and
Installation of Pressure-relieving Devices, Washington, DC: API Publishing Services, 2014.
[2] American Petroleum Institute, API Standard 521 6th Ed.: Pressure-relieving and
Depressuring Systems, Washington, DC: API Publishing Services, 2014.
[3] American Petroleum Institute, API Recommended Practice 520 Part II 5th Ed., Reaffirmed,
Washington: API Publishing Services, 2011.
11-2297-1112

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aspenONE Engineering Safety Analysis Environment

Equations and example benchmark calculations for two-phase orifice

Craig Powers, Principal Software Developer, Aspen Technology, Inc.

aspenONE Engineering Safety Analysis Environment

EQUATIONS AND EXAMPLE BENCHMARK CALCULATIONS FOR

1. Non-Subcooled Omega Method

aspenONE Engineering Safety Analysis Environment

where units are as in (Eq. 4).

b. Example with Critical Flow

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Figure 1. Two-phase critical flow case calculated in Aspen HYSYS

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Required Relief Load (w)

Mass Density at 90% (9)

Mass Density at Relief (0)

c. Example with Subcritical Flow

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Figure 2. Two-phase subcritical flow case calculated in Aspen HYSYS

aspenONE Engineering Safety Analysis Environment

Required Relief Load (w)

Mass Density at 90% (9)

Mass Density at Relief (0)

2. Subcooled Omega Method

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Pressure is in psia or Paa.

b. Example with Low Subcooling, critical flow

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Figure 3. Low subcooled critical flow case calculated in Aspen HYSYS

The transition saturation pressure ratio is calculated using (Eq. 9):

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Required Relief Load (w)

Mass Density at 90% (9)

Maximum Mass Flux (G)

c. Example with Low Subcooling, subcritical flow

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Figure 4. Low subcooled subcritical flow case calculated in Aspen HYSYS

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Required Relief Load (w)

Mass Density at 90% (9)

Maximum Mass Flux (G)

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d. Example with High Subcooling

Figure 5. High subcooled critical flow case calculated in Aspen HYSYS

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The omega parameter is calculated using (Eq. 8):

Required Relief Load (w)

Mass Density at 90% (9)

Maximum Mass Flux (G)

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3. Direct Integration Method

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Figure 6. Direct integration case calculated in Aspen HYSYS

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Required Relief Load (w)

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Figure 7. Noise example calculated in Aspen HYSYS

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Required Relief Load (w)

Figure 8. Reaction force example calculated in Aspen HYSYS

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Required Relief Load (w)

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