SCIENTIFIC DESIGN COMPANY, INC. A SABIC-Siid-Chemte Partnership Company SD Project No. 5181 3.0 PROJECT DESIGN BASIS INDEX Process Design Data General Raw Material Feed Miscellaneous Chemicals Product Specification Units Utilities Conditions Mechanical Design Data Site Conditions Confidential Information of Scientific Design Company, Inc.SCIENTIFIC DESIGN COMPANY, INC. ASABIC- sd-Chente Partnership Company SD Project No. $181 Page No. 3.01 Process Design General A. Project No. Plant Title, Plant Location SD Project No. 5181 Plant Title: Petroquimica Morelos, SA. De C.V. Plant Location: Coatzacoalcos, Veracruz, Mexico B. Plant Capacity (8,000 hiyr) EOE 360,000 MTPY Purified EO 240,000 MTPY MEG 150,000 MTPY C. Provisions for expansion None Confidential Information of Scientific Design Company, Ine.SCIENTIFIC DESIGN COMPANY, ING. ASABIC- Siia-Chemie Partnership Company Raw Material Feeds Ethylene Source ‘Temperature °C Pressure (at B.L.), kg/em’g Available Analy Ethylene, mol% Methane + Ethane, mol ppm Hydrogen, vol ppm Ethane, mol ppm Propylene, mol ppm Acetylene, mol ppm Carbon Monoxide, mol ppm Carbon Dioxide, mol ppm Oxygen, mol ppm max Sulfur (total), mol ppm max Methanol, mol ppm ‘Water, mol ppm Nitrogen, mol ppm B. Oxygen Source ‘Temperature °C Pressure (at B.L.), kg/cm’g min Analysis Purity, vol% min Argon and Nitrogen, vol% max c. Methane Source Temperature °C Pressure (at B.L.), kg/cm’g Analys ‘Methane, mol% Ethylene, mol% Hydrogen, ppm vol% Carbon Monoxide, ppm vol% Acetylene, vol ppm Sulfur Compounds (as 8), ppm Chilorides (as Cl), vol ppm Ethane, vol ppm Nitrogen SD Project No. 5181 Page No. 3.0-2 Pipeline at B/L. 378 Ambient 5 99.90 min, 1000 max. 10 max. 500 max. 10 max, 5 max. 2 max. 5 max. 5 max. 2 max. 5 max, 3 max. 100 max. Pipeline at B/L 378 Ambient 21 99.5 05 Pipeline at B/L Ambient Ambient 26 26 Available Diseno 73.29 78.64 22.59 19.6 0.18 213 220 ND 3.82 22 0.02 Confidential Information of Scientific Design Company, Tne.SCIENTIFIC DESIGN COMPANY, INC. ASABIC-Stid-Chemse Partnership Company SD Projecto. 5181 Page No. 3.0-3 Miscellaneous Chemicals A. — Sodium Hydroxide Source Pipe line (50%) Concentration, wt% 10% Temperature, °C Ambient Purity Standard Commercial B. Ethylene Dichloride (EDC) Source Small drums Temperature, °C Ambient Analysis EC, wt% min 99.84 Acidity (as HCD, wt% traces Moisture, wt ppm 30 Residue, wt% 0.16 C. Potassium Carbonate Source Bags 50kg. Analysis of solid K2CO3 K3COs, wt% min 99.5 KOH, wt% max 0.2 Iron, wt ppm max 3 D Antifoam For Cycle Water System Source Liquid in drums Quality Oleyl alcohol or Ocenol (Commercial grade) For CO; Removal System Source Liquid in drums Quality UCON 50-HB-5100 (Union Carbide) E Sulfuric Acid Source Pipe Line Concentration, wt% min, 98.0 ‘Temperature, °C Ambient Purity Standard Commercial Pressure (at B.L.), kefom?g min. Skg/em? Confidentiat Information of Scientific Design Company, Inc.SCIENTIFIC DESIGN COMPANY, INC. | ASABIC-siid-Chenie Parmership Company SD Project No. $181 Page No. 30-4 Miscellaneous Chemicals (Continued) F. Borie Acid Source Drums or bags Quality ‘Technical granular Analysis BOs, wt% min 99.8 G. Vanadium Pentoxide Source Drums or bags Quality Technical granular Analysis Vanadium (as V20s), wt% min 99.5 Product Specification A. Purified Ethylene Oxide (EO) Appearance Clear, Purity, 99.90 Color, Pt-co units, max 10 Water, wt ppm max 100 Aldehydes (as acetaldehyde), wt ppm max 10 Acidity (as acetic acid), wt ppm max 10 Carbon Dioxide ppm wt, max 10 Pressure (at B.L.), kg/em?g 12.0 Monostilengitcol Grado Fibra (MEG) Pureza, wt% min. 99.9 Dietilenglicol, %owt max 0.05 Cenizas, %wt max 0.003 Acidez (como acido acetico), wt ppm max 20 Aldehidos librea, wt ppm max 15 Cloruros (como C1), wt ppm max 0.20 Metales, wt ppm max 0.05 Agua, wt ppm max 500 Color, Pt-co max 5 Transmitancia U.V. (220 nm), min 80 ‘Transmitancia U.V. (275 nm), min 93 Fase Liquida Presion, kg/em?g, min 10 Apariencia Clara libre de materia en suspension pH 60-75 Confidential Information of Scientific Design Company,SCIENTIFIC DESIGN COMPANY, INC. ASABIC-Sta-Chente Partnership Company SD Project No. 5181 Page No. 3.0-5 Product Specification (Continued) Dietilenglicol (DEG) Pureza, wi% min. 99.50 Acidez (como acido acetico), wt ppm max 50 Agua, wt ppm max 1000 Color, Pt-co max 15 Fase Liguida Presion, kg/em”g, min 70 Apariencia Clara libre de material en suspension Trietitenglicol (TEG) Pureza, w1% min, 97.00 Agua, wt ppm max 0.05 Color, Pt-co max 25 Fase Liquida Presion, kg/em’g, min 7.0 ‘Temperatura, °C 49 Apariencia Clara libre de ‘material en suspension Confidential Information of Sefentific Design Company, Inc.far SCIENTIFIC DESIGN COMPANY, ING. ASABIC~Siid-Chomie Partnership Company SD Project No. 5181 Page No. 3.0-6 Units (To be Applied in Designing The Plant) Volume m Temperature °C Length m,mm Pressure ‘kg/cm’g, ke/om?a Vacuum mm Hg abs Flow ~ liquid For PFD's, Instrument Data Sheets and equipment data sheets kg/hr For pump data sheets m/hr Flow ~ gases, steam, vapor kg/hr Standard gas volume (1.033 kg/cm’a & 0 °C) Nm Weight kg Heat Value keal/hr Concentrations Gas Liquid Pipe Sizes, nominal Equipment Nozzle Sizes Density Viscosity For Heat Exchanger data sheets: Specific Heat Thermal Conductivity Fouling Resistance Heat Transfer Coefficient Confidential Information of S tific Design Company, Inc. ppm or mol% ppm or wi% in. in, kg/m? e keal/kg.2C keal/hr.m.°C hm?°C /kcal keal/hr.m?.°CSCIENTIFIC DESIGN COMPANY, INC. ASABIC-Sia-Chemie Partnership Company Utility Conditions (at battery limits) A High Pressure Steam (Import) Min Nor Max Pressure, kg/cem?g 42.0 43.6 45.5 Temperature, °C 371 399 440 ‘Medium Pressure Steam (Produced in the plant) saturated Min ‘Max Pressure, kg/em?g no no. ‘Temperature, °C no no Min Max Pressure, kg/em?g no no. ‘Temperature, °C no no Cooling Water Min Max Supply Pressure (@ 35 5.0 grade) kg/em?g Return Pressure (@ 2.0 grade) kg/cm’g Supply Temp. °C 29 32 33 Return Temp. °C B 46 47 Fouling Resistance h.m’.°C/kcal: 0.0006 Chloride as Cl, wt ppm 03 0.6 1 Steam Condensate Return Pressure, kg/cm*g ‘Temperature, °C Nitrogen Low Pressure, ke/em?g 7.0 ‘Temperature, °C Purity Oxygen, vol ppm Quality Source cryogenic plant Dewpoint @ 7.0 kg/em’g, °C -196 C Confidential Information of Scientific Design Company, Inc. SD Project No. 5181 Page No. 3.0-7 BR F k S BeyHL SCIENTIFIC DESIGN COMPANY, INC. ASABIC-Sia-Chenie Partnership Company Instrument Air Pressure, kg/em’g ‘Temperature, °C Dew Point @ 7.0 kg/em’g, °C Oil Content, ppm Eq E i E for 36 -40 Oil Free SD Project No. 5181 Page No. 3.0-8 Des | Note: In case of power failure, instrument air will be made available at full rate for 30 minutes to shutdown the plant safely. Plant Air Pressure, kg/em’g Temperature, °C il Content, ppm Process Water Pressure, kg/em*g Temperature, °C pit Conductivity, ps/em @ 25°C SiOz, wt ppb Fuel Gas Type Eleetric Power Voltage Level Motors up to 150 kW Motors over 150 kW Lighting Instrumentation For Solenoids ups ig IZ E E [I] & ‘Methane/Bthane/Propane 440Volts, 60Hz, 3 phase 4160Volts, 60Hz, 3 phase 220Volks, 2 phase, 24Volts 120 V, 1 Phase, 60Hz 120 Volts F i | | | [I ‘A separate uninterruptible power supply system (UPS) for 30 minutes duration will be provided for all critical DCS, PLC and fire monitoring, instruments. Confidential Information of Scientific Design Company, Inc.a SCIENTIFIC DESIGN COMPANY, ING. H A SABIC~Stid-Chemie Partership Company Mecha SD Project No. 5181 Page No. 3.0-9 al Design Data A. Codes and Stand: Equipment is specified to satisfy process requirements and to generally conform to the pertinent SD Specifications and Job Standards to comply with the applicable U.S. codes and standards. Equivalent codes and standards, as agreed to by the detailed engineering contractor and the client, may be used as appropriate, providing they are in accordance with the EO/EG process and safety requirements. Hydraulic Calculations SD's hydraulic calculations are preliminary. It is the responsibility of the detailed engineering contractor to verify all items related to the hydraulic calculations, including but not limited to the following: Pump heads Pump NPSH's Pipeline sizing Vessel Skirt heights (Elevation) a. b c. 4 Stress analysis is the responsibility of the detailed engineering contractor. Relief Valve Loading and Sizing Relief Valve Loading and Sizing will be based on SD Engineering Standards 11A 11L-1, 11A 111-2, 11A 112-1 and 1LA 120-0 included in this section. Confidential Information of Selentifie Design Company, Inc.SCIENTIFIC DESIGN COMPANY, INC. ASABIC- Sia-Chemio Parinership Company Core Site Conditions A Elevation Meters above sea level Atmospheric Temperature ‘Maximum Temperature in the hottest month, average, °C Minimum temperature in the coldest month, average, °C Design temperature for ait-coolers, °C, dry bulb ‘Design temperature for coolers, wet bulb °C ic Pressure Atmosphe Design Barometric Pressure, mm Hg ‘Maximum Barometric Pressure, mm Hg Minimum Barometric Pressure, mm Hg Relative Humidity Average year around Relative design humidity (in summer), % Relative design humidity (in winter), % Confidential Information of Scientific Design Company, Ine. SD Project No, 5181 Page No. 3.0- 10 41 26SCIENTIFIC ENGINEERING STANDARD TIA Liini DESIGN 04/06/92 COMPANY, INC. RELIEF VALVES PAGE 1 OF 14 USA FIRE LOADINGS 1.0 SCOPE AND RESPONSIBILITY 1.1 a. his Standard presents the minimum loadings for relief valves for fire exposure in the USA (unless otherwise noted) in general conformance with OSHA Standards. b. It is the responsibility of the engineering contractor to conform to local codes, regulations, insurance requirements, etc., which may require more conservative loadings than are specified by this Standard. 2.0 DEFINITIONS 2.1 Relieving Conditions ~ The pressure and temperature that will exist at the relief valve (or rupture disc) inlet when it is fully loaded. The relieving pressure is greater than the set pressure (both pressures expressed as psig) by a Percentage that is specified in the applicable code (generally, 25% for thermal expansion, 20% for fire exposure and 10% for all other hazards). The relieving temperature is the comparable temperature. 2.2 Fluid Definitions The following terms are used to define the fluid inside a vessel: Gas ~ A fluid that does not have a liquid phase at the relieving conditions. Liguid - The liquid phase that exists within a vessel at relieving conditions. LVL ~ Low Volatile Liquid - Any liquid with a vapor pressure not greater than 40 psia at 100°F. This will cover most of the liquids other than LPG and cryogenic materials that are encountered.SCIENTIFIC ENGINEERING STANDARD TIA 111-2 DESIGN 04/06/92 COMPANY, INC. RELIEF VALVES PAGE 2 OF 14 Us: FIRE LOADINGS Liguified Gas ~ Any liquid with a vapor pressure greater than 40 psia at 100°F. This comprises LNG, LPG, and LXG (cryogenic materials), which are defined below. ING ~ Liquified Natural cas - Predominantly methane with minor quantities of ethane, propane, nitrogen, or other components normally found in natural gas. LPG - Liquified Petroleum Gas - predominantly Propane, propylene, butanes (normal butane or iso- butane) ‘and butylene. LXG - Liquified gas other than LPG and LNG. 2.3 Nomenclature A= Exposed wetted area, sq ft, as defined in Section 8, Conductance of insulation, BTU/hr., °F, sq ft F = Environmental factor as defined in Section 9 H = Normal heat input (heat leakage), BTU/hr L = Latent heat of vaporization of the liquid, BTU/1b., at relieving conditions as defined in Appendix A. M-= Molecular weight of the fluid P= Relieving pressure, psia Pn = Normal operating pressure, psia Qn = Normal Exchanger Duty, BTU/hr T= Relieving temperature, °R (°F + 460) Tn = Normal operating temperature, °R (°F + 460) Tw = Temperature at which the vessel will be seriously weakened, °R (°F + 460)SCIENTIFIC ENGINEERING STANDARD TIA 114-1 DESIGN 04/06/92 COMPANY, INC. RELIEF VALVES PAGE 3 OF 14 UsA FIRE LOADINGS t = Relieving temperature, °F W= Fire loading, lb/hr 2.4 Bixe Loading - The minimum required relief valve (or rupture disc) capacity for protection of the vessel from overpressure due to fire exposure. 2.5 In those cases where the possibility exists that the relief valve can be submerged in liquid, the relieving capacity shall be calculated as the "Liquid Volumetric Equivalent" of the vapor generated by fire exposure. This liquid equivalent shall be used as the basis of the relief valve area calculations which shall take into account the possible generation of flash vapor as the fluid passes through the valve. 3.0 LVL FIRE LOADING (Liquids with a val por pressure not greater than 40 psia at 100°F) 3.1 Eire in a. for A < 20 sq. ft. W = 400,000 x F L b. for 20 < A < 200 sq. ft. W = 20,000 x Ax F L for 200 s A < 1,000 sq. ft. W = 199,300 x AS » F L qd. for 1,000 < A < 2,800 sq. ft. W = 963,400 x A™ x F LSCIENTIFIC ENGINEERING STANDARD TIA 111-4 DESIGN 04/06/92 COMPANY, INC. RELIEF VALVES PAGE 4 OF 14 usa FIRE LOADINGS e. for A > 2,800 sq. ft. 1. when the vessel design pressure is greater than 1 psig W = 21,000 x A” x F L 2. when the vessel design pressure is 1 psig or less W = 14,000,000 x F L f. for air cooled exchangers W = 21,000 x A + On (F always = 1.0) L L Qn/L represents the loss of normal cooling or condensing duty corrected for relieving conditions. (See Paragraph 8 ~ Note 3) A is defined in Paragraph 8.1 F is defined in Paragraph 9.1 3.2 Sources a. Fire loading formulas: NFPA-30 (OSHA-29 CFR 1910.106) b. Exposed wetted area: | NFPA-30 (OSHA-29 CFR 1910.106) modified ¢. Environmental factor: NFPA-30 (OSHA-29 CFR 1910.106) a. Air cooled exchanger: API-RP-521 modifiedSCIENTIFIC DESIGN COMPANY, USA nc. ENGINEERING STANDARD IA 111-4 04/06/92 RELIEF VALVES PAGE 5 OF 14 FIRE LOADINGS 4.0 LPG FIRE LOADING (Predominantly C's and/or ¢,’s) Fire Loading 41 Fin for process vessels W = 34,500 x AY x F L A is defined in Paragraph 8.2 ¥ is defined in Paragraph 9.2 for air cooled exchangers 34,500 x A + On (F is always = 1.0) L L Ww Qn/L represents the loss of the normal cooling or condensing duty corrected for relieving conditions. (See Paragraph 8 - Note 3.) for storage tanks The rate of discharge is SCFM or air for the safety relief valves is given in Appendix A. A is taken as the total area of the vessel Fe 1.0 Sources Fire loading formula: NFPA-58 (OSHA -29 CFR 1910.110) and NFPA-59 Exposed wetted area API-RP-520 modified Environmental factor API-RP-520 modified Air cooled exchanger: API-RP-521 modifiedSCIENTIFIC ENGINEERING STANDARD TXA 111-1 DESIGN 04/06/92 COMPANY, INC. RELIEF VALVES PAGE 6 OF 14 USA FIRE LOADINGS 5.0 LNG FIRE LOADING (Predominantly methane) 5.1 Fire Loading W = (1,560 x c x A) + L mula_is to be used onli stor: ers and other processing equipment require special study and the approval of sD. In this formula, C = mean value of conductance of insulation for the temperature range -260 to + 1660°F, BTU/sq. ft., hr., °F. A is defined in Paragraph 8.2 5.2 Sources a. Fire loading formula: NFPA-59A b. Exposed wetted area: API-RP-520 6.0 LXG FIRE LOADING 6.1 Fire Loading a. Uninsulated Vessels W = 34,500 x A‘ x F L b. . Insulated Vessels 4x (1200 = t) x c x Al” L W For relieving temperatures lower than -40°F: this formula is to be used only for storage tanks. Vaporizers and other processing equipment require special study and the approval of SD.SCIENTIFIC ENGINEERING STANDARD TIA 114-1 DESIGN 04/06/92 COMPANY, INC. RELIEF VALVES PAGE 7 OF 14 USA FIRE LOADINGS c. air cooled exchangers W = 34,500 x A + Qn/L (F always = 1.0) L Qn/L represents the loss of the normal cooling or condensing duty corrected for relieving conditions. (See Paragraph 8 - Note 3.) A is defined in Paragraph 8.2 F is defined in Paragraph 9.4 6.2 Sources a. Fire loading formula: CGA-S-1.3 (OSHA-29 CFR 1910.103 (Hydrogen) and 1910.10 (Oxygen b. Exposed wetted area: API-RP-520 modified ¢. Environmental factor: CGA~S-1.3 a. Air cooled exchangers: API-RP-521 modified 7.0 GAS FIRE LOADING (No liquid present at relieving conditions: 7.1 Fire Loading Ws 1406 2A Ww Ex 5 x (tw =7)'35 ax Tn TeP xT, Pn A is defined in Paragraph 8.3. When air cooled exchangers are included in the system exposed to fire, Qn/L must be added to W to allow for the loss of normal cooling duty. (See Paragraph 8 - Note 3.) For carbon steel vessels: Tw should be 1560°R or less 7.2 Sources a. Fire loading formula: API-RP-520, Appendix D-3SCIENTIFIC DESIGN COMPANY, INC. us: ENGINEERING STANDARD TIA 111-2 04/06/92 RELIEF VALVES PAGE 8 OF 14 FIRE LOADINGS Exposed (wetted) area: See Paragraph 8.3 7.3 Remarks Gas fire loading is usually small, and the vessels are generally uninsulated. For this reason, an environmental factor is not provided. 8.0 EXPOSED WETTED AREA The exposed wetted area "A", in the fire loading formulas is that portion of the area that is simultaneously exposed and wetted. Note 1: Note 2: Note 3: Note 4: Grade = ground level and any elevated platform, deck, floor, etc., that substantially surrounds the vessel and that can hold a pool of boiling liquid, (e.g. - checker plate, etc.) The subcooling area of air cooled condenser shall be taken as the bare tube area On exposure to the hot products of combustion of a fire, the cooling effect of an air cooled exchanger is destroyed. In addition, the products of combustion are hot enough to transfer heat into the system by convection, as well as radiation. Since air coolers produce a chimney effect (even without the fans running) and pull hot combustion products into their plenum, the 30 ft. height limit on exposure to fire is inapplicable and air cooled exchangers should normally be considered as being exposed to fires. When the air cooled exchanger can be considered to be remote from the source of a fire, as verified by special study, part or all of the air cooled exchanger surface can be considered to be unaffected by exposure to a fire.SCIENTIFIC ENGINEERING STANDARD TIA 111-1 DESIGN 04/06/92 COMPANY, INC. RELIEF VALVES PAGE 9 OF 14 usA FIRE LOADINGS Note 5: Bare tube area rather than finned area is used since most types of fins are destroyed within the first few minutes of exposure to fires. 8.1 LVL (liquids with a vapor pressure of 40 psia or less at 100°F) a. Exposed Area Spheres and spheroids: 55 percent of the total area Horizontal cylinders: 75 percent of the total area Vertical cylinders: The first 30 ft. above grade of the vertical shell plus the bottom head, if exposed. Air cooled Exchangers: Bare tube area b. Wetted ar Storage tanks: the total area Fractionating columns, etc: the total area Reflux drums, knockout pots, etc: if equipped with automatic level controls and high level alarms - the normally wetted area. Air cooled Exchangers: Coolers = Bare tube area Condensers = 0.3 x Bare tube area Source NFPA-30 (OSHA-29 CFR 1910.106) with addition of the wetted area definition and amplification of the exposed are definition for vertical cylinders. API-RP-521 for air cooled Exchangers.SCIENTIFIC ENGINEERING STANDARD TIA 111-1 DESIGN 04/06/92 COMPANY, INC. RELIEF VALVES PAGE 10 OF 14 USA FIRE LOADINGS 8.2 Liquified Gases (liquids with a vapor pressure greater than 40 psia at 100°F) a. Sphere and spheroids: the first 30 ft. above grade or the surface below the maximum horizontal diameter, whichever is greater. Storage tanks for LPG: the total area Horizontal cylinders: the total area Vertical cylinders: the first 30 ft. above. grade of the vertical shell plus the bottom head, if exposed. Air cooled Exchangers: Bare tube area b. Wetted Area Storage Tanks: the total area Fractionating columns, etc: the total area Reflux drums, knockout pots, etc: if equipped with automatic level controls and high level alarms - the normally wetted area. Air cooled Exchangers: Coolers = bare tube areas Condensers = 0.3 x bare tube area c. Sources API-RP-520 with modification of the wetted area definition to make it more conservative, and amplification of the exposed area definition for vertical vessels. API-RP-521 for air cooled exchangers 8.3 Gases (no liquid at relieving conditions a. Exposed Area For vessels: The total area. (For vertical vessels, the area higher than 30 ft. aboveSCIENTIFIC ENGINEERING STANDARD TIA 114-1 DESIGN 04/06/92 COMPANY, INC. RELIEF VALVES PAGE 11 OF 14 USA FIRE LOADINGS grade is not to be included in the exposed area). the bare tube Notes 4 and 5.) For air cooled exchanger: area. (See Paragraph 8 Wetted area Not applicable Sources For vessels: This is not specified in any of the standards cited herein For air cooled Exchangers: API-RP-521. 9. ENVIRONMENTAL FACTOR Note 1: In general, water spray systems will not have a sufficient water supply to qualify for the environmental factor. However certain water spray systems may qualify for the environmental factors. 9.1 LVL (liquids with a vapor pressure not greater than 40 psia at 100°F) a. Environmental Factors only one of the following factors may be used: Description Drainage (a slope of not less than one percent away from the tank to the drainage system), for tanks of over 200 £t? wetted area. 0.5 Insulation (a minimum conductance value of 4.0 BTU/hr, sq. ft., ft., °F, with the outer surface at 1660°F and a mean temperature of 1200°F). 0.3SCIENTIFIC DESIGN COMPANY, INC, USA ENGINEERING STANDARD IIA 211-1 04/06/92 RELIEF VALVES PAGE 12 OF 14 FIRE LOADINGS b. 9.2 Leg a b. 9.3 ING Water spray (in accordance with NFPA~15 and drainage. (See Paragraph 9 ~ Note 1.) 0.3 Water spray, insulation and drainage. (See Paragraph 9 - Note 1.) 0.15 source NFPA~30 (OSHA-29 CFR 1910.106) Environmental Factors Only one of the following factors may be used: Description EF Insulation with the following conductance values (at a mean temperature at least 500°F above the relieving temperature) . 4.0 BTU/hr, sq. ft., °F 0.3 2.0 0.15 1.0 0.075 Earth covered or buried storage 0.03 Sources API-RP-520 but with the buried storage increased to be the same as earth covered. No factor other than insulation which is included in the’ fire loading formula.SCIENTIFIC ENGINEERING STANDARD TIA 1ii-i DESIGN 04/06/92 COMPANY, INC. RELIEF VALVES PAGE 13 OF 14 usa” FIRE LOADINGS 9.4 LXG (liquified gases other than LPG and LNG) a. Environmental factors for uninsulated tanks. Only one of the following factor may be used: Description ~ Underground storage 0.3 Non-flammable storage isolated from flammable liquid storage by the distance specified to: 6.3 the nearest side on any public way in NFPA-30, Table II(flammable LVL) . public ways, railroads, and property lines in NFPA-50B, Table 2 (liquified hydrogen) The nearest important building, etc., in NFPA-59, Table 3 or Table 5, as appropriate (LPG) the property line in NFPA-50A, Table 2-1(LNG) Non-flanmable storage equipped with a water spray (in accordance with NFPA-15) or a suitable fire extinguishing system. (See Paragraph 9 ~ Note 1) 0.3 b. Insulated tanks: No factor other than insulation, which is included in the fire loading formula. c, Source CGS-S-1.3 but with the NFPA reference added.SCIENTIFIC ENGINEERING STANDARD TTA lisa DESIGN 04/06/92 COMPANY, INC. RELIEF VALVES PAGE 14 OF 14 USA FIRE LOADINGS APPENDIX A LPG FIRE LOADING FOR STORAGE TANKS Surface | Flow Rate | Surface Surface | Flow Rate | Surface | Fiow Rate FM Ale crm ar | Area’ | crm air Sa. Fe. 8a. Ft. Sq. Ft. 20 or tess | 626 140 3080 320, 6080 s200__| 17960 | 2 71 145, 3170 330 6230 1250__| 19570 30 72 150 3260 30. | 6350 1300_| 19180 3 990, 155, 3350 350 $540 1350 _| 19700 “0 100 160 3440 360 690 s400__| 20560 45 1220 15, 3530 370 e840 uuso__| 2ove0 50 1550 a0 3620 380 7000 4s00_| 21570 55 1630 175 3700 390 7150 1550__| zeteo eo 1540 10 3790 400, 7300 soo __| 2270 6 1640 105, 3280, 450, 040 ses0_| 2320 n +750 190 3960 500 870 s7o0__| 23900 B 1850 195 4050 550 9470 s7s0_| 2aa7o 80 1950, 200 4130 600. 10170 1g00__| 25050 5 2050 210 4300, 650 10860 1a50_| 25620 30 2150 220 sar 700 11550 1900 | 2eta0 5 220 230 4630 750 12220 1950_| 2e750 100 2340 260 4800 800 +2880 2000 __| arsio 105 240 250, 4960 850 13540 110 2530 260 5150 990 14190 15 2630 270 5290, 950 14830 120 2720 200 5450 1000 | 15470 1% zat 200 5610 1050 __| 16100 130 2900 300 5760 4100 16720 135 2590 310 5920, 1150 | 750 Greater than 2000 sq. ft: Flow Rate CFM Air = 53.632 x AM? Source: NFPA - 58 (Table D-1)SCIENTIFIC ENGINEERING STANDARD TIA 111-2 DESIGN 04/06/1992 COMPANY, INC. RELIEF VALVES PAGE 1 OF 3 Usa; FIRE LOADINGS 2.0 GENERAL 1.1 This Standard presents (in tabular form) the design heat transfer rate for vessels exposed to fire and containing various fluids (as indicated) for a range of commonly encountered exposed wetted areas. For calculation of heat input for these items refer to the appropriate paragraphs of Standard IIA 111-1. 1.2 In many applications it may be more convenient to use these tables, rather than the formulae that are given in Standard IIA 111-1. 1.3 Definition of terms used in this Standard is as follows: LVL = Low Volatile Liquid LPG = Liquified Petroleum Gas ING = Liguified Natural cas A = Exposed Wetted Area, sq ft F = Environmental Factor (See IIA 111-1) L = Latent heat of vaporization, BTU/1b Q = Design Heat Transfer, BTU/hr W = Fire Loading, 1b/hr CAUTTO! THESE TABLES ARE NOT APPLICABLE TO STORAGE TANKS FOR LPG AND FOR ATR COOLED EXCHANGES. Note: Tabulation on following pages.SCIENTIFIC DESIGN COMPANY, INC. ENGINEERING STANDARD RELIEF VALVES TIA 111-2 04/06/1992 PAGE 2 OF 3 UBER FIRE LOADINGS a Pe process vessets omy | exo - wilNsuLaTeD 8] un = vesseis er Sola | vesseLs Gots (i) | ae a= Siseotn oe 36,500 x A a = 400,000 1] 400,000 000 34,000 1.000 2] ito‘eoe Bi oeo ét'a00 ins 5 | deosooo 8/000 53.000 ale 2} dao‘ore 198000 108/900 sr & | feofooo 450/000 ‘50/000 rg 8 | dolooo 490/000 {90/000 Sihce 10 | feo‘o0o 226/000 228,000 oar 15 | to'a00 is‘ 000 Sis'o00 esd x | to's 292.000 iseiaoo ieee a 20,000 x A x0 | 600,000 51,000 561,000 is | stor Fiacaoo Ht0:a00 50 | 1.200000 3/000 es'e00 30 | {"200ce00 991/000 $1000 fo | 400/000 13/000 1.426000 3 | isdz0‘ec0 1738¢/0e0 1B e!o00 % | 1.000000 1381-000 11581000 seo | o00;s00 13eeco00 ed $20 | 2coo‘o00 "709/000 1709-400 iio | Seo0‘e00 pac! ger! 460 | 3200600 212000 2c!a00 4so | 3:d00/000 et S000 z00_| tor0‘ere 21a59.000 zerc00 @ = 199,300 x A" 250 3,192,000 3,192,000 2.56 Sco Scrar‘one 3707000 ores = iszar‘eoe icder‘ono f0 rgscfon0 Tepe S00 $\e36-000 436/900 ies: 00 6505-000 31505" a00 teen 70 eiar-oo0 Pkar000 3.30 eo Siac. 000 8386000 x02 00 | 16%o00' 000 5126-000 3.326000 ie 50 1300 5380000 $1980.000, itecio @ = 963,400 x A. (2) 10,595,000 roo | 33-009 11,554,000 11,554,000 31.90 400 | $1/car‘an0 {3sst1cooe 43/344/000 r0-00 too | ta'0v0/e00 14528000 128/000 ieee too | 3reasrecn 46/138/000 16!t12'0 reo 2000 | 3:"a6‘000 4366/c00 17'348!000 sonst 3400 | {4000000 20/396; 000 2039009 5130 500 Biren siierso00 a ¥ veoxr veoue t tSCIENTIFIC ENGINEERING STANDARD TEA 111-2 DESIGN 04/06/1992 COMPANY, INC. RELIEF VALVES PAGE 3 OF 3 uUsBA FIRE LOADINGS 1. See Standard IIA 111-1 Paragraph 3.1 a - e. 2. These numbers are from Appendix A of NFPA-30 "Flammable and Combustible Liquids Code"; they differ slightly from the values that are obtained by using the formulaSCIENTIFIC ENGINEERING STANDARD XIA 112-1 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 1 OF 20 usa NON-FIRE CASES 2.0 SCOPE AND RESPONSIBILITY 11 This Standard presents a listing of minimum relieving conditions that should be considered for establishing loading for pressure relief valves for non-fire exposure in the USA (unless otherwise noted) in general conformance with API-RP-520 and API-RP-521. Fire loadings are covered in Standard IIA 111-1. It is responsibility of the engineering contractor to conform to local codes, regulations, insurance requirements, etc., if they require more conservative loadings than are specified by this standard. For each system, each likely case non-fire relief load is to be investigated, along with an evaluation of the fire load. The governing case is to be used for relief valve design. “Multiple jeopardy situations are to be evaluated and incorporated into the calculated relief loading when absolutely necessary. This Standard also applies to determining non-fire relieving rates for rupture (bursting) discs, as appropriate. 1.3 This Standard does not apply to vacuum relief valve protection, nor to requirements for protection against internal explosion. Refer to Standard IIA 120-0 for these requirements. DEFINITIONS 2.1 Relieving Conditions are the pressure and temperature that will exist at the relief valve (or rupture disc) inlet when it is fully loaded. The set pressure is taken as the design pressure of the equipment to be protected. The relieving pressure is greater than the set pressure (bothSCIENTIFIC ENGINEERING STANDARD TIA 112-1 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 2 OF 20 UsA NON-FIRE CASES pressures expressed in psig) by a percentage that is specified in the applicable code (generally, 20% for fire exposure and 10% for all other hazards). ‘The relieving temperature is the comparable temperature at the relieving pressure. 2.2 Fluid Definitions For discussions and reference purposes the following terms are used to define the fluid inside a vessel: Gas: a fluid that does not have a liquid phase at the relieving conditions. Liguid: the liquid phase that exists within a vessel at relieving conditions. Flashing Liquid: a fluid that is a liquid at the relieving conditions but which is supersaturated at the relief valve outlet conditions. 2.3 Nomenclature A = Exchanger Area, sq ft, as defined in parts 3.4 and 7.0. B = Cubical coefficient of expansion for liquids, volume/volume/°F © = Adiabatic expansion coefficient; function of specific heat ratio k = cp a CG = — Specific heat of liquid, BTU/1b/°F G = Specific gravity of liquid (relative to water = 1.0) cpm Liquid relieving rate, gallons per minute ID = Pipe inside diameter, inchesSCIENTIFIC ENGINEERING STANDARD TIA 112-1 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 3 OF 20 USA NON-FIRE CASES L = Latent heat of vaporization of the liquid, BTU/1b M = — Molecular weight of the fluid P = Relieving pressure, psia Pd = Equipment design pressure, psig Ph = Normal operating pressure, psia Q = Heat input, Bru/nr or Heat of reaction, BTU/hr T = Relieving temperature, °R(*F + 460) T™ = Normal operating temperature, °R(°F + 460) = Relieving temperature, °F us = _—s Exchanger heat transfer coefficient - Design, BTU/hr/ft?/°F Uc = Exchanger heat transfer coefficient ~ Clean, BTU/hr/ft?/°F W = Gas or vapor relieving rate, lb/hr Z = Gas compressibility factor, dimensionless x Multiplication operator 2.5 Relieving Situations The following table is extracted from API-RP-520. Appropriate references for determining required relieving loads are made to this Standard, as well as other SD Engineering Standards.TIA 412-1 04/03/1992 PAGE 4 OF 20 NON-FIRE CASES ENGINEERING STANDARD RELIEF VALVE LOADING INC. “EOSURTSAASIIS Jo BURD|ONE 4a ang se2|aap 49} }04 yeuo| wenveD Aq pa}jossuc roy | sees suojsoydxe yeusoauy 4 wee “4 P=ysaAe wos} ayqisuapuoa¥oN 9" sudesbnu0g io soden urmjxou poneuiasg | seen 40 133004 pasts eden 40 3904 a SAT AGE uauo,yrbou ‘suauaynbos yeuotaesede on | yeua{aesede on 4 9 wlesBeseg soden pasuepuocun Ayyemsou qesop fo sae 2 sjozu09 a}xewnane 40 2uny ie ‘ : ‘won 8 Ts sor ony 8 wdesseveg suoqsesoupty poyse) 3 sucquesouphy 381] -g 4 wdeuseseg Sresuepuog pauselg Ve toy onus agence Z “yee Pus weoas iim paxeunies se6 syqisuapuos-vou jo mos ese] | wees 9 ee es ei 5 TOR SSST BILAN] Fue BUYISTS TOGA WeeRTOG SARIETTIT 7 SSUES GY TEI TOOT = ST STOTT ‘4 posuspuoo Jodan 589) ‘ual xe,0do yeauou Jopun tao 2 wlesbeseg Poressuss seys smd ‘uoden pue weass Cujwoout yere, | sease cl COTTE Ta Tap £ wdosseseg peresouss yoys ame *y ‘198500 uo 639) 90 95019 b Pe ‘sun sousiejoy, so4ee 10dep 205 ome sone vwomspuog | -on wey, SCIENTIFIC DESIGN COMPANY, USATIA 112-1 04/03/1992 PAGE 5 OF 20 RELIEF VALVE LOADING NON-FIRE CASES ENGINEERING STANDARD 6 wdesseses y wdesseved shane Aout pur yeaiou ‘Usemieq 30123033 1p aya sop seajen ozts Pinon sues uo}22tau Aeneuns # wo1p Uo} ze 2u98 zonpoud so} senjea az15_ “1}e4 Pnon weadts Supieres 49 youanb ay pub do3s pynon Suyuiae 40 Uo}3e% 162 ol 2 "OM B21 UE 88 saRjeA azis 1123 pynon JaxeH 64} 1009 pie ames yeu yrsas ayl aim lumep aq Ines sdind Ty 4 s21g “aunyte wopIeTTeasus ays ANAS eR uo} 4puED 3ss0M OY sO} aRyHA ‘nod jo 298)30 ay aujwiete Serer RTO (uaipe Jo ‘21832918 sugans) un) se} Janta INc. st OF RTT THT WIT BuRIRTS oe 395 W anys oe ss020ud § wdevonveg § Weeveeeg s “STIRS pay yon TUosaA oy wlesteveg ue yeaou y0q woss oj eJ0ua6 Jeden paieelass woy3260) jeormayy a SCIENTIFIC DESIGN COMPANY, UBASCIENTIFIC ENGINEERING STANDARD ITA 112-1 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 6 OF 20 USA NON-FIRE CASES 3.0 BLOCKED VALVE LOADING (Reference: API-RP-521) 3.1 Systems With Centrifugal Pumps and Compressors The design pressure of the piping system and affected equipment should be established to allow for the shutoff head of the pump or compressor. In most cases, allowing for the maximum suction pressure (the relieving pressure in the suction vessel plus the maximum hydrostatic heat at the suction) plus 1.20 times the design differential head will avoid the need for relief valves. This must be checked when the pump or compressor curves are available. Relief valves may, of course, still be required to protect the circuit against fire loadings. b. After review of the equipment performance curve, a relief valve may still be necessary. The valve capacity shall then be taken as the flow rate at the differential head at the relieving pressure. In gas service, the location of the relief valve does not influence the pressure setting. However, in liquid service, the relief valve set pressure shall be governed by the location of the relief valve in relation to the equipment being protected. Where the relief valve is above equipment being protected, the relieving pressure shall be reduced by an amount equivalent to the elevation difference. In addition, where the relief valve discharges into a closed system, the relief valve calculations should allow for the static pressure in the discharge line if this line is not self draining. If the closed system is itself protected by relieving devices, the downstream pressure should be governed by its relief valve setting.SCIENTIFIC ENGINEERING STANDARD IIA 112-1 DESIGN COMPANY, USA; 04/03/1992 INC. RELIEF VALVE LOADING PAGE 7 OF 20 NON-FIRE CASES 3.2 Systems With Positive Displacement Pumps or Compressors The relieving flow capacity shall be taken as the design capacity of the equipment. Note that for compressible fluids this is slightly conservative, but for the usual margins between the operating and relieving pressures this difference can be neglected. Regenerative turbine pumps shall generally be considered as positive displacement Pumps unless certified pump curves are available. Non-Fired Steam Generators a. Where the rate of steam generation is independent of the temperature at which the hot side operates, the relief valve flow capacity shall be the design capacity of the exchanger being protected. b. Where the rate of steam generation can increase as the temperature of the heating medium increases, the increased rate of steam generation shall be used at the maximum expected hot side temperature. If the rate of heat input becomes flux limited, the heat flux shall be used for establishing the steam generation rate. Steam Heated Vaporizers The vapor relieving rate may take into account the reduction in LMTD that occurs as the temperature increases, corresponding to the relieving pressure on the vaporizing side. In making this allowance, assume that the heat exchange surfaces are unfouled and the steam heating side is at the full steam pressure (with no control valve pressure drop present) . The temperature and latent heat of the vaporizing material shall be taken at the relieving pressure (set pressure plus overpressure allowance).SCIENTIFIC ENGINEERING STANDARD TTA 112-1 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 8 OF 20 USA NON-FIRE CASES The heat input shall be calculated as follows: Q = Uc x Ax (Ts - T), where Ts is the steam temperature, °R. The relieving rate shall be taken as, w=Q L 3.5 Eired Steam Generators The provisions of the Section I of the ASME Fired Pressure Vessel code shall be followed. The required devices are to be supplied by the boiler manufacturer. 3.6 Fired Vaporizers and Reboilers The relieving rate shall be based upon maximun design firing rate and the additional possibility of vapor generation due to thermal decomposition of the process fluid. Primary concern for protection of fired heaters is normally directed towards limitation of excessive tube temperatures. Therefore, process fluid flows are to maintained (rather than reduced) at firing upset conditions to keep tubes cool and avoid stagnation. Instruments are to be provided to stop the firing if the process flow fails. 4.0 EXOTHERMIC CHEMICAL REACTION (Reference: API-RP~521) 4.1 Provisions for Relief Valve Protection Relief valve protection shall be provided according to the following criteri: a. The relieving rate shall be assumed to occur in conjunction with block valves at inlet and outlet connections, i.e., reaction feed and product rates have been stopped.SCIENTIFIC ENGINEERING STANDARD IIA 112-1 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 9 OF 20 usa; NON-FIRE CASES Where a chemical reaction normally occurs but where the provisions for removing the heat of reaction are inadequate for handling possible upset conditions which could increase the heat of reaction markedly, relieving capacity shall be provided for removing products of normal plus excess heat of reaction. c. Where the heat of reaction is removed by cooling water of where heat removal is dependent on the operation of circulating pumps, agitators, or other mechanical equipment, the relieving capacity shall be based upon failure of these mechanical devices and cooling systems. d. Where the heat of reaction is removed by steam generation using a thermosyphon system and steam drum whose operation is independent of the availability of cooling water or electricity, the calculation of the relieving rate shall be based upon failure of the steam generation system (such as loss of makeup water). e. Emergency process quench systems are sometines provided to rapidly reduce the rate of a chemical reaction during a process upset condition. ‘The emergency quench system shall not be taken credit for in the design of relief valve system nor in the determination of emergency relieving loadings. 4.3 Vapor Relief. In general, the heat of the chemical reaction generates vapor. The vapor generation rate shall be calculated using the latent heat and heat of reaction at the relieving conditions, i.e W = or LSCIENTIFIC ENGINEERING STANDARD TIA 112-1 DESIGN 04/03/1992 COMPANY, INC, RELIEF VALVE LOADING PAGE 10 OF 20 usA NON-FIRE CASES If reaction equipment is also subject to fire loading, a possible double jeopardy relieving situation shall be considered. Gases that are released under relieving conditions can entrain considerable liquid. ‘The nature and quantity of the liquid can influence both the mechanical design and sizing basis for the relief device as well as the downstream KO Drum. The design of vapor relieving facilities should be such as to minimize entrainment. 4.4 Liquid Relief a. For reactors which are liquid filled and whose contents do not flash at reliving conditions, the required liquid relief capacity shall be taken as: cpm = or x B 500 x Gx ¢ b. Where the liquid will flash at relief valve downstream conditions, the relief valve capacity shall be established accordingly. 5.0 HYDRAULIC EXPANSION (Reference: API-RP-521) Provision for relief due to thermal expansion shall be provided for liquid filled systems that can be blocked in as follows: 5.1 Vessels The liquid relieving capacity is based upon heat input due to heating coils, heat tracing or ambient heat gain. The liquid flow is calculated as: cM = Ox B 500 x Cc, x G This procedure is also to be used for pipeline protection (See Paragraph 12).SCIENTIFIC ENGINEERING STANDARD TIA 112-1 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 11 OF 20 USA NON-FIRE CASES Refer to API-RP-521, Appendix A for detailed procedures for calculation of ambient heat gain including the effect of solar radiation. 5.2 Exchangers A 3/4" x 1" relief valve should be used if the cold liquid is below its atmospheric flash point. If the cold liquid is above its atmospheric flash point, the heat input shall be taken as the design heat duty and the relief valve capacity based on flashed vapor relief. 6.0 CONTROL VALVE FAILURE (Reference: API-RP-521) General: Relieving loads shall be determined based on control valve failure to the danger position. 6.1 Pressure Control Valve Closed A tower or reflux drum may be provided with a pressure control system whose normal function is to maintain the desired pressure in the equipment by controlled discharge of gas or liquid form that equipment. If the discharge control valve fails closed, the relieving rate shall be taken as the uncondensed gas flow calculated at relieving conditions. 6.2 Reflux Control Valve Closed (or other reflux failure) Upon failure of reflux for any reason, the relieving rate shall be taken as the total overhead vapor to the condenser calculated at relieving conditions. 6.3 Other Control Valves Closed Generally, except for failure of reflux and pressure control valves, control valves failing closed do not impose a requirement for relieving capacity. However, each case must be considered individually.SCIENTIFIC ENGINEERING STANDARD TIA 112-1 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 12 OF 20 Us; NON-FIRE CASES 6.4 Control valves open Particular attention must be paid to those cases where the control valves fail open, particularly where, the control valves separate systems with different pressure ratings, b. there is flashing across the valve and the capability of the downstream equipment is limited to handle the flashed vapor. Credit should not be taken for the performance of limit stops in preventing valves from fully opening (or fully closing). The required relieving capacity is the difference between the maximum inlet flow and the normal outlet flow at relieving conditions, assuming that other valves it the system are stili in normal operating position. Therefore, the maximum flow rate is to be taken at the available valve Cc, when fully open. 6.5 Other Considerations In evaluating relieving requirements for any cause other than control valve failure, it can be assumed that the control valves remain in their normal position. When electronic controls are used the possibility of simultaneous power failure and control valve failure (open or closed) is real unless there is an adequate backup emergency instrument power supply. Consideration should be given to the effect of relieving pressure and corresponding relieving temperature on the operation of the control valve. Often, the increased temperature under relieving conditions may result in liquid flashing across a control valve (with a reduction in throughput) and in some cases may even result in partialSCIENTIFIC ENGINEERING STANDARD IIA 112-1 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 13 OF 20 USA NON-FIRE CASES solidification or crystallization of the flowing fluid. These considerations affect the design of the control system and may influence the valve design and valve operator selection. 7.0 COOLING WATER FAILURE TO CONDENSER (Reference: API-RP~521) The vapor that may be generated due to feed flashing (corrected to relieving conditions), vapor feed, and/or steam injection must be added to the reboiler vapor rate. The vapor generating capacity of the reboiler shall be corrected for the effect of the increased system pressure on the vapor generation rate. The relieving rate shall take into account the full steam pressure on the reboiler, the clean coefficient and the latent heat at relieving conditions. The reboiler vapor rate is given by: Q = Uc x A x (Ts - T), where Ts is the steam temperature, w= L The latent heat shall be taken for the column feed liquid composition. The temperature in the process side of the reboiler shall be taken for the normal bottoms liquid composition. credit may be taken for vapor that may be condensed by side stream reflux. Credit may not be taken for automatic reboiler shutdown on coolant failure. 8.0 BURST TUBE (Reference: API-RP-521) Where considered appropriate, the case of a collapsed tube failure may be used instead of a burst tube. The relief valve should be mounted on the equipment as close to the source of leakage as possible. there the possibility exists that the leakage can be trapped inSCIENTIFIC ENGINEERING STANDARD TIA 112-1 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 14 OF 20 UBA NON-FIRE CASES the equipment due to internal obstructions (e.g., shell baffles), multiple relief valves of partial capacity should be provided. A typical case is a vertical reboiler with hot oil flowing in the shell and high pressure hydrocarbon vaporizing in the tubes. Relief valves should be provided at the top and bottom of the shell to prevent liquid from being pocketed between shell baffles. 8.1 Pressure Differentials Not Requiring Relief Valve Protection When the design pressure of the low pressure side is equal to or greater than two thirds of the gperating pressure of the high pressure side relief protection is not required for the case of tube rupture. 8.2 Pressure Differential Re: Protection Relief protection to prevent overpressure is required when the design pressure of the low pressure side is less than two-thirds of the normal operating pressure of the high pressure side. Calculation in all cases are derived from the assumption of adiabatic expansion across the rupture point. 8.3 Flow Rate Basis The calculated leakage flow rate shall be based on two times the cross-sectional area of the ruptured tube, using an orifice coefficient of 0.7, and a pressure differential equal to the normal operating pressure on the high pressure side, less 110% of the design pressure on the low side. The calculated rate shall take into account any flashing that may result from the pressure drop across the tube rupture If the calculated leakage rate through the burst tube is greater than the normal flow on the high pressure side, the normal flow shall be usedSCIENTIFIC ENGINEERING STANDARD TIA 112-1 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 15 OF 20 USA NON-FIRE CASES 8.4 Rate For Non~ i iui. rough A_Burst Tube For liquids, the required relieving capacity is calculated as: GPM = 41.7 x (1D)? x 4| P2= 2.20 (Pd + 24.7) Where Pn = operating pressure of high pressure side, psia Pa = design pressure of low pressure side, psig When the high pressure liquid leaks into a normally liquid containing low pressure system and where the leakage liquid does not vaporize on contact with the low pressure liguid, credit can be taken for the liquid handling capacity of the inlet and outlet piping. This assumes that isolation valves which are normally open will be open and control valves will be in a position equivalent to the minimum normal flow requirements, except where the emergency situation would cause automatic closure of the control valve. 8.5 Flow Rate For Flashing Or Vaporizing Liquids Through A Burst Tube a. The high pressure leakage across the burst tube is calculated by the equation in Paragraph 8.4. The liquid vaporizes either partially (flashing) due to adiabatic expansion to the lower pressure region, or entirely due to contact with the hotter fluid in the low pressure region. The vaporized portion of the liquid leakage expands into the low pressure side of the exchanger, and displaces the fluid normally contained therein.SCIENTIFIC ENGINEERING STANDARD IIA 112-1 DESIGN COMPANY, UsA 04/03/1992 INC. RELIEF VALVE LOADING PAGE 16 OF 20 NON-FIRE CASES 8.6 A number of variations are possible in calculating the relieving flow rates depending upon the temperature conditions in the low pressure side. The relief valve may discharge liquid, vapor, or a liquid-vapor mixture. The relieving situation must be analyzed and the appropriate flow requirements calculated b. Rupture disks may be provided instead of relief valves as the likelihood of tube rupture is quite low. c. The consequences of the loss of inventory of the low pressure liquid (such as contamination of the low pressure stream should be considered, and appropriate alarms or interlocks should provided. low Rate For Gas Through rst Tube The gas flow rate is calculated using a variation of the standard relief valve formula at critical flow conditions: ye) teases Clxprni ce (xD)2) ow, ax where Pn = operating pressure of the high pressure side, psia Flow Rate For Steam Through A Burst Tube (Reference: Crane Tech. Paper 410) For the special case where the higher pressure medium is steam, the modified Napier formula is used to calculate the require flow rate. Two forms of the formula are available: a. For back pressures less than the critical pressure ratio (58% of the inlet pressure, expressed in psia), W, = 56.6 x (ID)? x PnSCIENTIFIC ENGINEERING STANDARD IIA 112-1 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 17 OF 20 USA NON-FIRE CASES where Pn = steam operating pressure, psia For back pressures exceeding the critical pressure ratio, WM © 94.2 x Pn x (xD)? x 3 (Pn ~ 1.10 Pa + 14.7 2 (1.40 Pa + 1407) where Pd = design pressure of low pressure side, psig Superheat and wet steam effects are neglected. No credit is to be taken for steam condensing on contact with the colder fluid. 9.0 AIR COOLED EXCHANGER FAILURES (Reference: API-RP~521) 9.1 Electrical Power Failure Although the fans will stop on power failure, natural convection will provide sufficient air flow to maintain a partial condensing capacity of about 20% of design, and credit may be taken for this after the actual rate has been established. The "fan-off" rate must be established by the vendor of the equipment. ‘The relieving rate is then the incoming vapor rate minus the "Fan-off" rate, calculated at relieving conditions. 9.2 Louver Failure Where air cooled exchangers are provided with louvers, failure of the louvers in the closed position (due to control or mechanical failure) must be considered. Normally, louver failure closed will result in a total loss of cooling capacity. A partial residual condensing capacity can be taken only if it can be verified by the equipment vendor that such a residual capacity exists with the louvers closed. The relieving loads for this case are to be calculated as per Paragraph 7 of this Standard.SCIENTIFIC ENGINEERING STANDARD IIA 112-1 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 18 OF 20 USA NON-FIRE CASES 10.0 SIMULTANEOUS FAILURES In general, the relieving capacity for a system should be selected on the basis of the largest single condition of failure. However, the probability of two or more simultaneous occurrences (multiple jeopardy and their relationship should be considered The following guidelines are to be followed in all cases in addition to those given in previous sections. 10.1 When air cooled condensers are used in a tower system, the condensing duty should be taken together with the combined fire load for the system. 10.2 The combination of tower heat input, fire loads and loss of condensing capacity, should not norma red_as 's eous occurrences. This is based on the assumption that if the fire is severe enough to seriously damage the reflux system, the reboiler heating system will also become inoperative 10.3 If the fire damage to the instrumentation transmission system will cause simultaneous closing of the reflux control valve and opening of the steam (or other heating medium) control valve the relieving load shall be based on this combination of circumstances. 11.0 PIPING The piping systems in the plant are generally assumed to be at the normal operating condition and protected by the relieving system provided for the equipment Piping shall be designed for the most severe conditions of coincident pressure and temperature that can be expected in normal operation both steady state and cyclic. The code for Petroleum Refining Pressure Piping, ANSI B 31.3, states that, for ductile materials and for materials where the allowable stress does not exceedSCIENTIFIC ENGINEERING STANDARD IIA 112-1 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 19 OF 20 USA NON-FIRE CASES 2/3 of yield stress, temporary increases in stress can be permitted as follow: . The allowable pressure rating (or stress) can be exceeded by up to 33% if the increased operating condition will not last more than 10 hours continuously, nor more than 100 hours per year The allowable pressure rating (or stress) can be exceeded by up to 20% if the increased operating condition will not last more than 50 continuously, or more than 500 hours per year Using the above criteria, relief valves are generally not Used to protect piping systems except: a. when adequate protection is not provided by the equipment relieving system and where upsets outside the permissible variations noted above might occur. b. at a major pressure "break" where pressure reducing valves are provided and the danger position for the reducing valve is the open position. ©. when volatile liquids can be trapped between block valves, and the maximum attainable pressure exceeds the pipe rating. 12.0 SPECIAL CONSIDERATIONS 12.1 Double pipe heat exchangers should not be considered as requiring protection for a burst tube case because of the relatively thick pipe wall used. 12.2 Installation of safety interlocks serve only to minimize the chance of relief valve activation. Relief valves are to be sized for the upset condition regardless of whether or not safety interlocks are provided.SCIENTIFIC ENGINEERING STANDARD TIA 112-4 DESIGN 04/03/1992 COMPANY, INC. RELIEF VALVE LOADING PAGE 20 OF 20 usa NON-FIRE CASES 12.3 In order to conserve energy, the prevalent practice is to incorporate heat recovery systems where practical. In distillation column groupings, a condensing overhead vapor from one column may be used to provide reboil heat to another lower temperature column. The safety relief analysis for any interconnecting systen such as this must account for the mutual effects of any failure on the entire system.SCIENTIFIC ENGINEERING STANDARD IIA 120-0 DESIGN 04/03/1992 COMPANY, INC. EFS STANDARD PAGE 1 OF 12 UsA VACUUM PROTECTION 1.0 SCOPE AND RESPONSIBILITY 1.1 a. his Standard covers sD/s practices in the application of devices installed for the specific purpose of preventing excess vacuum within equipment. It is the responsibility of the engineering contractor to determine if local codes, regulations, insurance requirements, or the client require greater protection or different means of protection than that recommended in this Standard. 1.2 This Standard also covers the sizing criteria for primary and secondary vacuum prevention devices. 2.0 GENERAL REQUIREMENTS 2.1 Equipment that will be damaged if subjected to excess vacuum should be protected against excessive vacuun. The following circumstances should be investigated. a. The equipment could be subject to excessive vacuum during normal operational upsets. b. The equipment could be subject to excessive vacuum during shutdown and’ subsequent emptying of the equipment liquid inventory. 3.0 NORMAL OPERATIONAL UPSETS 3.1 The following are considered to be normal operational upsets: a. Atmospheric Cooling or Condensation: ‘The potential vacuum is calculated by assuming that the contents of the vessel areSCIENTIFIC DESIGN COMPANY, USA INC. ENGINEERING STANDARD TIA 120-0 04/03/1992 EFS STANDARD PAGE 2 OF 12 VACUUM PROTECTION cooled from the normal operating conditions to the coldest atmospheric temperature. Loss of Heat Supply: The potential vacuum is calculated by assuming that the contents of the vessel are cooled from the normal operating conditions to the coldest atmospheric temperature or to the cooling medium supply temperature, whichever is lower. Loss of Feed: Loss of feed shall be taken as simultaneously occurring with other upset conditions, such as loss of heating medium. Compressor Suction: When the possibility exists that a compressor can evacuate the contents of a vessel, the potential vacuum shall be assumed to be absolute vacuum, unless it can be proven that the compressor suction pressure is reliably limited at no-flow by the inherent features of the machine. Unvented Drain or Pumpout: this includes the accidental flooding and subsequent emptying of columns, towers, scrubbers, absorbers, strippers, decanters, settlers, contactors and other vessels that are subject to rapid change of liquid inventory. Vessels that operate essentially ary are excluded. The potential vacuum shall be assumed to be absolute vacuum, unless it can be proven: 1, The vapor pressure of the fluid under the coldest possible conditions is such that this could not occur.SCIENTIFIC ENGINEERING STANDARD TIA 120-0 DESIGN 04/03/1992 COMPANY, INC. EFS STANDARD PAGE 3 OF 12 USA VACUUM PROTECTION 2. A reliable means of stopping flow from the vessel is provided, such that this could not occur. Excessive Absorption (or adsorption): The possibility of a vacuum condition occurring when vapor feed is stopped should be looked at, though in most circumstances this is not a problen. Instrument Failure: Generally, this will lead to one of the other cases that is discussed herein. Cross Connection: This can arise from misoperation of a valve (manual or automatic) or heat exchanger tube rupture. The potential vacuum shall be assumed to be the normal vacuum of the system to which the connection can be made. 4.0 NON-OPERATING CONDITIONS 4.2 The following are not considered to be normal operational upsets: a. b. Unvented draining of equipment that arises form hydrostatic tests. Unvented draining or pumpout of equipment that arises from broken piping. Atmospheric condensation of vapor that arises from "steaming-out" equipment prior to inspection or maintenance. Cross-connection through hoses and other temporary "piping"SCIENTIFIC ENGINEERING STANDARD IIA 120-0 DESIGN 04/03/1992 COMPANY, INC. EFS STANDARD PAGE 4 OF 12 Us; VACUUM PROTECTION 5.0 PRIMARY PROTECTION Primary protection is mandatory for all cases where vapor pressure of operating contents at minimum temperature is below atmospheric pressure, unless equipment is designed to with stand vacuum. Any one or a combination, if appropriate, of the following may be used for the primary protection against excessive vacuum: 5.1 An open bent to the atmosphere: Manual valves are not permitted (even if they are sealed open), if the vent is counted as part of the primary systen. If the vent contains a flane arrestor, it must be adequately protected against freezing or plugging when this is appropriate. 5.2 A vacuum breaker (Note 1). 5.3 An assured source of inert gas where the control valve fails open. 5.4 An equalizing line connected to an adequate inventory of acceptable gas in other process equipment. Isolating valves (if provided) must be sealed open. A backup gas injection system of the type described in Section 6 for secondary protection must be provided also. 5.5 A fail-safe shutdown system for the source of vacuun, For most practical purposes this means a low gauge pressure alarm interlocked to a compressor or pump motor or turbine trip (Note 2). 5.6 Liquid seals Notes: In circumstances where ingress of air may produce a flanmable mixture, or where leakageSCIENTIFIC DESIGN COMPANY, INC. usa; ENGINEERING STANDARD IIA 120-0 04/03/1992 EFS STANDARD PAGE 5 OF 12 VACUUM PROTECTION of vapor to atmosphere through a vacuum breaker may result in hazardous conditions, the use of a primary protection device other than a vacuum breaker or, alternately, the design of the equipment for the appropriate vacuum’ should be considered, and a vacuum breaker used only as a last resort Except for turbine trip valves, a shutdown system that depends on an automatic valve is not acceptable for primary protection. 6.0 SECONDARY PROTECTION The following applies to all process equipment but not. to storage tanks: 6.1 Where a vacuum breaker is used for primary protection, a secondary protection system consisting of facilities for the injection of a suitable oxygen-free gas shall be provided whenever a flammable mixture can be formed in the vapor space when the vacuum breaker opens 6.2 The secondary protection system as a minimum shall comprise the following: a Vacuum indication and a high vacuum alarm at the control panel. Instruments that are provided for other purposes may be used for this, if suitable. The alarm should be set at as low a vacuum as possible. A permanently connected supply of oxygen-free gas with a pressure reducing valve for automatic injection of the gas when required. This reducing valves shall be independent of all other instrument loops including the above-mentioned vacuum indication alarm The pressure reducing valve shall be sized and set so that it will deliver gas as required to prevent the operation of the vacuum breaker.SCIENTIFIC ENGINEERING STANDARD IIA 120-0 DESIGN 04/03/1992 COMPANY, INC. EFS STANDARD PAGE 6 OF 12 USA VACUUM PROTECTION Antifreeze protection may be required downstream of the pressure reducing valve. Depending on the relationship between the process equipment design pressure and the gas supply pressure, back flow protection more reliable than that shown may be required. The gas injected piping shall be laid out to drain from the pressure reducing valve to the process piping. ‘This requirement may be waived if it is certain that the process vapors cannot condense in the gas injection piping. The instrument air required for the control valve is to be inert gas obtained form upstream of the control valve. Tight shutoff valve is required. 6.3 Secondary protection system is also required where there is a possibility of blockage of the primary protection system due to failure of heat tracing. 7.0 OTHER CONSIDERATIONS 7.1 Equipment Damage Collapse of equipment is the primary concern when there is the possibility of excessive vacuum. However, the following failures should be considered: a. Distortion or failure of brick linings, membranes, and loose metal linings, etc., shall be considered when appropriate. b. Equipment damage due to failure of internals. c. Even through compressors, pumps and similar machinery may not be seriously damaged by excessive vacuum, seal damage may result.SCIENTIFIC ENGINEERING STANDARD IIA 120-0 DESIGN 04/03/1992 COMPANY, INC. EFS STANDARD PAGE 7 OF 12 Us: VACUUM PROTECTION 7.2 Process Effects While equipment damage may not result form vacuum or excessive vacuum, effects on the process should be evaluated in regard to safety and resultant product specification for air ingress during operating periods when vacuum is present in equipment not normally under vacuum. If evaluation leads to the conclusion that serious consequences could result, protective padding with an inert gas should be considered, or other appropriate protective equipment installed. 8.0 SIZING OF VACUUM PROTECTION DEVICES 8.1 Two important factors should be determined in sizing a vacuum protection device. They are: a. The necessary gas flow rate that the vacuum protection device must pass as to limit or prevent the vacuum in the system served by this device. The design external pressure of the equipment (or, design vacuum) and the set point of the vacuum protection device (or, vacuum set point). 8.2 The gas flow rate may be determined as follows: a. Unvented drain or pumpout: The gas flow rate is equal to the volumetric emptying of the vessel. Pumpout rate should generally be taken at "run-out" capacity of the pump. b, Atmospheric Condensation Q=Ax Ux (Ts - Tw) Where: Q = heat loss rate (BTU/hr) U_= heat transfer coefficient (BTU/hr ft? °F) Ts = system temperature (°F)SCIENTIFIC DESIGN COMPANY, usa INC. ENGINEERING STANDARD IIA 120-0 04/03/1992 EFS STANDARD PAGE 8 OF 12 VACUUM PROTECTION Tw = design winter temperature (°F) A = surface area (ft*) U may be determined from the Table in Appendix 1. Wwe=o L Where: W = condensation rate (1b/hr) L = latent heat of condensation of vapor (BTU/1b) The gas flow is equal to the volumetric condensation rate. Atmospheric and low pressure non-refrigerated storage tanks: The gas flow rate requirements for contraction of vapors caused by maximum decrease in atmospheric temperature is given in Appendix 2. The inbreathing capacity for sizing of a vacuum protection device shall be at least the sum of the flow requirements for unvented drain or pumpout (Paragraph 8.2 a), and vapor concentration. Loss of heat supply in a distillation column: An approximate but conservative method is to take the rated capacity of the vacuum protection device as the design volumetric condensation rate. This, however, may lead to unnecessary large sizes of vacuum breakers er control valves. There are other methods to calculate the flow rate which lead to more reasonable sizes, by taking into account the following factors: 1. The vacuum protection device will admit noncondensible gas into the condenser until the condenser is filled with noncondensible and then ‘the vacuumSCIENTIFIC DESIGN COMPANY, INC. Us: ENGINEERING STANDARD IIA 120-0 04/03/1992 EFS STANDARD PAGE 9 OF 12 VACUUM PROTECTION increase due to cooling in the condenser stops. 2. The condensation rate will decrease as the condenser is being filled with noncondensible gas. 3. As the column pressure drops, there will be some evaporation from the liquid inventory which will partially compensate for the condensate. 8.3 Design Vacuum and vacuum set point. a b. a. The design vacuum shall ordinarily be the potential vacuum of the system described in Paragraph 3, Normal Operational Upsets. In a case of a system with a condenser where a vacuum breaker is the primary protection, the set point of the vacuum breaker should’ be such as to let air completely blanket the condenser before the design vacuum of the equipment is reached. In the general case of a system with a condenser where both a vacuum breaker (primary protection) and an inert gas injection, system (secondary protection) are used, the set point of the secondary protection should be such as to let inert gas completely blanket the condenser before the set point of the vacuum breaker is reached. Although the design vacuum must not be exceeded, it may reached since safety factors are inherent in the vessel mechanical calculations for external pressure. Where feasible, the possibility of designing a vessel for the vacuum conditions rather than providing vacuum protection should beSCIENTIFIC ENGINEERING STANDARD IIA 120-0 DESIGN 04/03/1992 COMPANY, INC. EFS STANDARD PAGE 10 OF 12 usa” VACUUM PROTECTION considered. This may be the most economical solution in some cases and is usually safer. In calculating the potential vacuum that can be reached under upset conditions, allowance should be made for normally present noncondensible or non-absorbable gases.SCIENTIFIC ENGINEERING STANDARD IIA 120-0 DESIGN 04/03/1992 COMPANY, INC. EFS STANDARD PAGE 12 OF 12 UsBA VACUUM PROTECTION APPENDIX 2 Thermal Venting Capacity Requirements for atmospheric and Low Pressure Storage Tanks Tank capacity (‘Barrels) Flow rate (SCFH of air. 60 60 100 100 500 500 1,000 1,000 2,000 2,000 3,000 3,000 4,000 4,000 5,000 5,000 10,000 10,000 15,000 15,000 20,000 20,000 25,000 24,000 30,000 28,000 35,000 31,000 40,000 34,000 45,000 37,000 50,000 40,000 60,000 44,000 70,000 48,000 80,000 52,000 90,000 56,000 100,000 60,000 120,000 68,000 140,000 75,000 160,000 82,000 180,000 90,000 () 1 Barrel = 42 gallons Source: API Standard 2000: Venting Atmospheric and Low Pressure Storage Tanks. a),