EHY904.088.01 Student Virtual PDF

PSV - Improve the Pressure
Relief Analysis Workflow

by using Integrated Process
Safety Tools in Aspen HYSYS
AspenTech Customer Education

Training Manual
Application Workshop Number: EHY904.088.01

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Application Workshop Crude Unit Optimization
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EHY904 Application Workshop Safety Tools Workshop
PSV - Improve the Pressure Relief Analysis

Workflow by using Integrated Process Safety
Tools in Aspen HYSYS
EHY904.088.01
Application Workshop Instructions
©2016 AspenTech. All Rights Reserved. 2-1 Aspen Technology, Inc.

Introduction
This workshop will showcase how to leverage HYSYS Dynamics, the Safety Analysis
Environment, and Flare System Analyzer to complete the pressure relief analysis for a system.
The workflow involves running an emergency scenario in HYSYS Dynamics then using the
results to size PSVs in the Safety Environment and finally the PSV design will then be imported
into Flare System Analyzer to assess the adequacy of an existing flare network model.
The simulation process involves isolating propane from an NGL Feed stream. The main piece
of equipment in this flowsheet is the Depropanizer, which is what will be used to isolate the
propane from a mixture of hydrocarbons. Here, we will be analyzing the overhead system of
the Depropanizer to test various emergency cases like what happens when the reflux fails or
what if the duty stream to preheater for the column fails to open using the safety tools available
in Aspen HYSYS and Flare System Analyzer.
Objective
Our aim for this workshop is to dynamically analyze various overpressure scenarios on a
system to accurately size (or rate) the relief device.
Description
This workshop includes the following tasks.
 Task 1: Familiarize yourself with the dynamics file and then set up a sequence of events
to simulate a blockage on the column overhead using the Event Scheduler in Dynamics
 Task 2: Learn how to add and set up a PSV in the Safety Analysis Environment
 Task 3: Using the results from the Event Scheduler, size the relief device for various
emergency scenarios like Blocked Outlet, Control Valve Failure and Exchanger Tube
Rupture.
 Task 4: Learn how to transfer the PSV design to Flare System Analyzer and assess the
adequacy of an existing flare network model.

Task 1 – Setting Up the Event Scheduler in

Dynamics to model a Blocked Column Outlet
The starting point for this task is a prebuilt dynamic simulation of a NGL plant. HYSYS
Dynamics is a transient process simulator available within Aspen HYSYS. We are using this
tool to obtain a more accurate estimate of our relief load. We will set up a scenario which will
cause the relief device to open, and we will be able to extract a number of key variables which
will be used in sizing the column PSV.
Simulation File Familiarization
You will start the workshop by loading the prebuilt simulation.
 Open the file titled Starter1.hsc.
The flowsheet on the right side shows the de-propanization process. Here the NGL feed is first
fed into a knockout drum (KO) to knock out most of the vapor so it does not impact the pump.
The liquid outlet from the KO drum is then pumped to heat exchanger and the heater to heat
the feed for the Depropanizer, which is what will be used to isolate the propane from a mixture
of hydrocarbons. The depropanizer has 24 stages, a partial reboiler, a partial condenser, and
has an operating pressure of 18.25 bar_g. Liquid is fed to the column at 50oC at stage 12 with
a flowrate of 1840 kgmole/hr. The feed stream consists of 41.3% propane, 29.2% n-hexane,
12.2% butane, and 17.3% other hydrocarbons.
On the left side, a reporting tool called a Strip Chart allows you to monitor key variables in
real-time as the dynamic simulation runs. Variables can only be added to a Strip Chart via the
Strip Chart menu. Multiple Strip Charts are allowed, and each strip chart can have an unlimited
number of variables; though it is wise to limit each Chart to six variables or fewer. In this case,
the strip chart has been pre-configured to show how the key variables related to the column
relief system vary as the sequence of events run.

In this task, we will be setting up a Blocked Outlet event using the Event Scheduler. The
Blocked Outlet event will look at what happens when the vapor outlet valve (Propane Valve)
fails. The Blocked Outlet scenario will be analyzed in accordance with API 521 6e Section
4.2.4, which states that “latent failures should normally be considered as an existing condition
[…] For example, latent failures can exist in instrumentation that prevents it from functioning
favorably during an overpressure condition.” To capture both the blocked outlet and any
potential latent failures of instrumentation, the schedule of events in this HYSYS Dynamics
example consists of two separate events, Propane Valve Failure and Latent Failure.
 Click on the Event Scheduler icon on the ribbon under the Dynamics tab.
With the Event Scheduler, it is possible to have Aspen HYSYS perform given tasks while a
simulation is running in dynamics. The tasks can be triggered by a pre-determined simulation
time, a logical expression becoming true, or a variable stabilizing to within a given tolerance
for a set amount of time. Examples of tasks that can be performed with the Event Scheduler
would be emergency shutdown, start-up and some batch processes.
 In the Schedule Options group, click the Add button to create a new Schedule.
 On the bottom right hand corner of the Event Scheduler view, rename the new
Schedule1 to Blocked Outlet Event. Press Enter.

 Click the Add button on the right hand side to create a new sequence.
 Change the name of the added sequence from Sequence A to Propane Valve Failure.
 Click the View button on the right hand side or double click on Propane Valve
Failure.

Propane Valve Failure is configured to cause the Propane Valve to fail shut (i.e. a blocked
outlet scenario). This sequence created in this module will hold one event to be executed at a
predetermined time.
 Click the Add button to create the first event.
 Click the View button to show the window for Event 1 and view the Condition tab.
 Using the radio buttons in the Wait For section, select An Elapsed Amount of Time
and enter a value of 1 second in the Wait For field.
 Click on the Action List tab.

 Click the Add button in the List of Actions For This Event section.

 Give a name IC-100 Control Mode. In the Configuration section, select Specify
Variable as Type and then click on the Select Target button to reveal the Variable
Navigator window.
 Choose the Object as IC-100, and the Variable as Control Mode. Click OK.
IC-100 controller is used to control the composition in the overhead. It is used to keep the mole
fractions of ethane and propane in the overhead sum to a value of 0.95. The control strategy
will vary the Accumulator pressure in an effort to control the propane composition. That is the
reason why the Accumulator-PC is set to Off which is added to control the pressure in the
Accumulator vessel.

 For the Value field, enter a value of 1.0.

Changing the Control Mode value to 1.0 sets it to Manual and a value of 2.0 (Current
Value) implies it was in Auto mode.
 Click the Add button in the List of Actions For This Event section to add another
action.
 Give a name IC-100 OP. In the Individual Action Specification section, click on the
dropdown menu to select Set Controller Mode.

 In the Configuration section, click on the Select Target button to reveal the Available
Controllers Navigator window. Select IC-100.
 In the Configuration section, click on the dropdown menu to select Man as New Mode.
 Then check New OP and specify 0.0% as the Value.

 Save your case as Task1-Propane Valve Failure.hsc when finished.
Next, you will be setting up the Latent Failure event. This event will cause certain controllers
to freeze at their current operating point. Per API 521, we cannot take credit for any reduction
in the relief load the controllers may provide when the vapor outlet is blocked. Other controllers
which will increase the relief load are left to function as normal.
For this case, we will import the sequence file from the Task1 folder.
 Click the Import button on the right hand side to create a new sequence.
 Select the Latent Failure.seq file from the folder
 Click the View button on the right hand side or double click on Latent Failure to
review the list of actions.
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You can review the imported sequence’s three actions and compare the controllers information
with the following table.
Controller Process Variable Process Output Target

Object Variable Target Object Variable
Accumulator Accumulator Liquid Percent Reflux Valve Actuator
LC Level Desired Position
Heater TC Col Feed Temperature Heater -Q Control Valve
Tray23 TC Main TS Stage Steam Valve Actuator
Temperature Desired Position
(23_Main TS)
If you would like to set up each of these sequence of actions. Please follow the steps in the
Appendix File.
 Go back to the Event Scheduler page and click on Status Panel at the bottom right
corner of the window.
 Highlight Propane Valve Failure and Latent Failure and click on Start. The status will
change from Inactive to Waiting.

 Click Run on the Dynamics tab of the ribbon and view the results on the Vapor Outlet
Failure strip chart.
If you get a warning related to the dynamics assistant (as shown below) please select
‘No’.
 Let the simulation run for a few seconds, or until the relief device opening % (red
line) has become constant and then Stop the integrator.
 On the Strip Chart, Right Click and select ‘AutoScale All Axes’ option to be able to
adjust the axes to view all the trends simultaneously and also in the bottom drag the
red bar to left to view the chart better.

After the Propane Valve was closed, the relief device (RV-100) opened to a percentage of
about 56.8%. (The set pressure for RV-100 is 21.04 and when this pressure is reached the
relief valve begins to open). If you allow the simulation to continue running, you will
eventually reach a steady state where the relief device stays open. This is true because we
are not taking any action upstream to avoid feed entering the Depropanizer column. In the
real world, operators would take an action after noting this behavior to avoid pressure
buildup in the column.
Now that we have the peak mass flow and composition for this emergency scenario, we
can use these values in the Safety Environment to more accurately size our PSV. Before
we do that, we should make a copy of the stream so the data is never lost if we choose to
run additional scenarios.
 Return to the main flowsheet then right click on the Bypass to Valve stream and
select Copy from the menu.
 Right click anywhere on the flowsheet and select Paste.
 Rename this stream to Dyn Blocked Outlet RL so we know it pertains to the blocked
vapor outlet scenario. This stream will be used as a reference in the Safety
Environment.
 Save your case as Task1.hsc when finished.
We will now transition over to the PSV portion of this workshop.

Task 2 – Learn how to add and set up a PSV in

the Safety Analysis Environment
The starting point for this task is the solved dynamic case from the previous task. In this task,
you will be adding a PSV to the Depropanizer Ovhd outlet and will set up the initial defaults
for your safety analysis and get oriented to the new environment.
 Continue with the previous workshop file or open Safety Starter.hsc and make sure
you are in the Safety Analysis Environment.
The Safety Analysis Environment is a special area within Aspen HYSYS where the user can
confidently size relief devices without influencing the original simulation. When in the Safety
Analysis Environment, the flow sheet is marked by a red border indicating that the flow sheet
is not editable.
Also, this environment contains a unique Home menu. This menu contains selections and
options for units of measure, valve design codes, output documentation management, and the
ability to add a relief PSV, rupture disk, or storage tank analysis to your model.
 Once you enter the Safety Analysis environment, click the Home ribbon tab and
review the options.

Notice also that the Navigation Pane at the left-hand side of the HYSYS window is different.
The Navigation Pane contains several items: Unit Operations, Unattached Streams, and
Storage Tank Protection. You can use the Unit Operations menu to view all unit operations
in your flowsheet. To each unit operation, you can add a relief device on any effluent stream.
Back in the Home tab, you will notice that there are three types of devices you can use for
your overpressure analysis.
In the Safety Analysis environment, you can size a PSV, a rupture disk, or a venting device
on a storage tank. Your process needs determine which device you will require.
 Select the Add PSV option on the Home ribbon.
 Locate the To Tee stream and attach this PSV to it.

(Small Blue box is highlighted when in attach mode)
 The PSV will now be visibly attached to the outlet stream out on the main flow sheet
of the Safety Analysis environment.

Next you will be providing necessary design conditions for the PSV. The Equipment Tab is
where you can identify the design conditions for the limiting equipment.
 Double click on the newly created PSV valve to enter the design specifications.
 Enter 80°C and 21.04 barG for the Design Temperature and Design Pressure.
 Change the Operating Pressure to Manual and provide a value 16.50 barG.
 Navigate to the PRD Data tab of the PSV. Leave all the defaults but make sure that
the Set Pressure is set to the Design Pressure.

 Save your case as a Compound File-Task2.hscz when finished.
Note: When you enter the Safety Analysis environment in Aspen HYSYS, a database file
(*.MDB) will be created and associated with the simulation file (*.HSC). A temporary
database file with a random name will be created in a temporary directory. Any changes
made in the Safety Analysis environment are written to the temporary database.
If you want to save a single compound file, select Save As and select the compound option.
This single compound file can also contain other associated HYSYS files, such as those for
costing, EDR, and Energy Analysis.

Task 3 – Size the PSV for various emergency

scenarios
In this task, you will learn how to identify Blocked Outlet, Control Valve Failure, Exchanger
Tube Rupture and scenarios in the Safety Analysis environment. You will also learn how to
specify the Required Relieving Flow and size the associated relief device.
(a) Blocked Outlet Scenario
 Continue with the previous workshop file or open Scenario Starter.hscz.
 On the form for 100 PSV 001 click on the Scenarios tab and then select Create
Scenario.
 Scenario100 will be created. Rename this Scenario100 to Blocked Outlet and under
the scenario type dropdown, select Blocked Outlet.
 Double click on Blocked Outlet or Highlight the scenario and click on the Open
Scenario button to launch the Scenario Setup form.

 By default, the stream To Tee will be selected because of where the PSV is attached.
To change this, click the check box for Override next to the reference stream field.
On the form that appears, select Dyn Blocked Outlet RL from the list.
The next step is to make the Relieving Pressure equal to the pressure we observed in
dynamics.
 Go back to the main flowsheet and locate stream Dyn Blocked Outlet RL, you will
see the pressure is 22.62 barG.
 Now, return to the Blocked Out Scenario page, where we will specify this same
value as the Relieving Pressure for the valve.
 To do this, click the Edit text next to the Relieving Pressure field to launch the form
where we can set the Allowable Overpressure. Set the Allowable Overpressure to
7.50% to obtain a Relieving Pressure of 22.62 barG. Click OK when finished.

This number was obtained by dividing the desired Relieving Pressure by the Set
Pressure.
 At the bottom of the form, select Reference as the Relieving Flow Method.
 This will generate a warning at the bottom of the form telling you to use the Direct
Integration method. To do this, select Direct Integration (HEM) from the Relieving
Phase – Method section. The calculation should now complete.
Notice that, simultaneously, the required orifice is also calculated. This represents, at
minimum, the orifice area which would be required to relieving the Required Relieving Flow.
 Select an appropriate Orifice Size (larger than the calculated value) for this scenario.
In this case 18.406 (L).

 Save your case as Task3-Blocked Outlet.hscz when finished.
(b) Control Valve Failure Scenario
Next, we will add a Control Valve failure Scenario. Control Valve failure is a common cause
of overpressure that must be considered for protection with a PSV. Rigorous calculations can
be performed to determine the consequences of the complete opening of a control valve based
on the valve’s CV.
 Continue with the previous workshop file or open Task3bStarter.hscz

 Go to the Scenarios sheet for the PSV, click the Create Scenario button, and name it
CV Failure.
 Select Control Valve Failure as the Scenario Type.

 Double click on CV Failure or Highlight the scenario and click on the Open
Scenario button to launch the Scenario Setup form.
 By default, the stream To Tee will be selected because of where the PSV is attached.
To change this, click the check box for Override next to the reference stream field.
On the form that appears, select Pump Out from the list.
 On the Scenario Setup sheet, keep all the values for Relieving Temperature, Relieving
Pressure, and Total Backpressure.
 Note that the Relieving Phase - Method is Vapor, which is the option we do not
want for this scenario. Change it to Direct Integration (HEM)
(Warning will be shown below as well)
 Keep the Relieving Flow Method selected as Calculated to use the internal
capability to calculate the required relieving flow for the CV failure.
 In the Control Valve Failure Inputs menu define the following parameters:
(Keep all the others default)
In this cell... Enter...

Normal Flow to Process 1.131E+005 kg/h
(2.491E+005 lb/h)
Relieving fluid Inlet Pressure 24 barG (348.1 psiG)
Control valve CV at 100% 520

 Based upon the calculated relieving rate and required orifice size, select and
appropriate standard orifice for this PSV. In this case 18.406cm2 (2.853in2) (L).
Note: With V8.8, there is now automatic detection of phases upstream and downstream
of the control valve. More rigorous control valve sizing calculations are now available
which include ANSI/ISA, PSV Plus, Universal Gas Sizing, and Vendor Specific. Vendor
Specific flow models include a wide range of options such as CCI Drag, Fisher, Introl,
Masoneilan, Mokveld, and Valtek.
 Save the file as Task3-CV Failure.hscz
(c) Exchanger Tube Rupture Scenario
High pressure differences between the shell and tube sides of heat exchangers can result in
significant flow into the low pressure side upon failure of one or more tubes. The relieving
rate due to breakage in the tubes of the heat exchanger can be determined using the
Exchanger Tube Rupture scenario in the HYSYS Safety Analysis Environment. Calculations
can be performed for vapor, steam, liquid, and mixed phase applications.
 Continue with the previous workshop file or open Task3cStarter.hscz
 On the main flowsheet, add a PSV to Shell Out Stream.

 Go to the Equipment Tab and specify the Design Temperature and Pressure values
as shown below.
 Go to the Scenarios tab for the PSV, click the Create Scenario button, and name it
Tube Rupture and select Exch. Tube Rupture as the Scenario Type.
 By default, the stream Shell Out will be selected because of where the PSV is
attached. Change the reference stream to Process In.
(To change this, click the check box for Override next to the reference stream field. On
the form that appears, select Process In from the list.)

 Make sure the Relieving Phase Method is the Direct Integration (HEM).
 Make sure the Relieving Flow Method is set as Calculated and that the Direction of
Flow is From Tube to Shell.
 Select the High Pressure Side Method as Reference. (It will read the values from
the reference stream)
 Based upon the calculated relieving rate and required orifice size, select and
appropriate standard orifice for this PSV. In this case 11.858cm2 (1.838in2) (K).
Note: New to V8.8, there is automatic detection of phases upstream and downstream of the
rupture. By default, the rupture will be modelled as a two orifice break, but you can modify
the Flow Coefficient value (from Crane’s TP-410 chart A-20 for flow coefficients). Note that
Crane’s TP-410 chart A-20 is referenced when you hover the mouse over the Flow
Coefficient input box.
 Save the file as Task3-Exch.Tube Rupture.hscz
After identifying all of the appropriate overpressure scenarios for a relief application the next
step is to select the scenario that will be the sizing case for the relief system. For this
workshop, we will choose the sizing (design) case for the one with the largest required
relieving load.

Choosing a single valve configuration to satisfy all scenarios can be difficult since selecting a
valve that satisfies the case with the largest required relieving load may result in relief valve
chatter for the lower flowing scenarios. A multiple valve configuration may be needed to
properly address all applicable overpressure scenarios.
 Based upon this for 100 PSV 001 the sizing case is the Blocked Outlet Scenario.
(For 100 PSV 002 there is only one scenario that will be the sizing case)

Task 4 – Learn how to transfer the PSV design

to Flare System Analyzer and analyze the flare
network model.
Now that all of the PSVs have been sized for each scenario, we can transition over to Flare
System Analyzer to import our PSVs in order to determine the adequacy of the flare network.
 Open the case Flare Starter.fnwx

 Click on File | Import Sources | Aspen Plus/HYSYS Relief Sources…
 On the form that appears, click Browse and navigate to where the file Safety
Solution PSV.hscz is saved and click Open.
(Use this file only as this made specifically for Task4)
 After the file has been opened, click on Upload File as shown in the image below.

 After you upload the file the data from the safety environment will be transferred as
shown in the image below.
Note: Since the first PSV name from HYSYS matches the PSV name in Flare System
Analyzer, the two are automatically mapped together. For the other PSV, names did not
match, you would need to manually select the correct PSV for each device in the drop
down menus.
 Now that the PSVs are imported from HYSYS, we will create two new scenarios.
 On the left side of the form, click <Add New> to create a new scenario and name it
CV Failure
 Repeat this process again and name the new scenario Exch Tube Rupture. Click on
the Auto-Map Scenarios button to define these scenarios.
 A new form will appear. On the first line, select the scenario CV Failure from the
drop down for Flare Scenario. Change the Rule to Type is and set the Criterion to
Control Valve Failure.

 Compare your results with the image below. You can use the Show Rule List button on
the side of the form to make sure your scenario has been defined correctly.
 Repeat this process again and select the Exch Tube Rupture scenario. For the Rule
select Name Contains and for the Criterion type Tube Rupture. Click the Show Rule
List button again to ensure the scenario has been defined correctly.
 Click OK to return to the previous form. Toggle between the two newly created scenarios
to ensure everything has been defined correctly. Click Done when you are finished. A
dialog will appear mentioning you can save your input set if you wish to reuse it later.
Click No in this case as we will not be reusing it.

 Select one of the two newly created scenarios from the drop down at the top of the
screen. This option is available under the Run section of the ribbon.
 Double click on 100 PSV 001 and navigate through the various tabs to view the
information which has been imported from HYSYS PSVs.
Shown above is the comparison of 100 PSV-001 in both the environments. Note that in
Flare System Analyzer displays pressure in absolute and in Safety Environment in gauge
units.

 You can also double click on Tailpipe 1 to view the information entered based off of
data from the HYSYS PSVs.
 Save the file as Task4.fnwx
(Appendix file has information on how to run the scenarios and check the warnings)

Summary:
This workshop has shown how various tools available in HYSYS can provide an efficient way
to study the process relief system.
In this case, the dynamics study of the overhead system (Propane Valve Failure) provided a
more accurate estimate of the relief conditions. Using the Event Scheduler, a scenario was set
up that caused the relief device to open and using Strip Charts the key variables were studied.
From this dynamics study, the key variables were extracted to be used in sizing the PSV.
In the safety environment, PSVs were defined, various scenarios were analyzed, and the PSVs
were sized. Finally, the PSVs were imported into Flare System Analyzer to assess the adequacy
of an existing flare network model.

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PSV - Improve the Pressure

Relief Analysis Workflow

AspenTech Customer Education

Application Workshop Number: EHY904.088.01

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PSV - Improve the Pressure Relief Analysis

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Task 1 – Setting Up the Event Scheduler in

Simulation File Familiarization

You will start the workshop by loading the prebuilt simulation.

 Open the file titled Starter1.hsc.

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 Click the Add button to create the first event.

 Click on the Action List tab.

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 For the Value field, enter a value of 1.0.

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 Then check New OP and specify 0.0% as the Value.

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 Save your case as Task1-Propane Valve Failure.hsc when finished.

 Select the Latent Failure.seq file from the folder

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Controller Process Variable Process Output Target

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 Right click anywhere on the flowsheet and select Paste.

 Save your case as Task1.hsc when finished.

We will now transition over to the PSV portion of this workshop.

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Task 2 – Learn how to add and set up a PSV in