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  • Scaling Up Safely: Making Smarter Decisionsabout Rate Dependency

    Zubin Kumana, P.E., Venkata Badam,P.E.,

    and Achilles Arnaez, P.E.

    7600 W. Tidwell Rd., Ste. 600 | Houston, TX 770400(713) 802-2647 | SmithBurgess.com

  • GCPS 2016 __________________________________________________________________________

    1

    Scaling Up Safely: Making Smarter Decisions about Rate Dependency

    Zubin Kumana, P.E. Smith & Burgess LLC

    7600 W. Tidwell Rd, Ste 600 Houston TX 77040

    Zubin.Kumana@smithburgess.com

    Venkata Badam, P.E. Smith & Burgess LLC

    Venkata.Badam@smithburgess.com

    Achilles Arnaez Smith & Burgess LLC

    Achilles.Arnaez@smithburgess.com

    Smith & Burgess LLC grants AIChE permission for itself and its designated agents to reproduce, sell, or distribute this paper. Copyright to this paper is retained by Smith & Burgess LLC, from whom permission to reproduce must be obtained by any other party. All information deemed reliable but may not be applicable to any given installation.

    Any risk assessment or safety analysis should be independently verified by a qualified engineer. 2016, Smith & Burgess, LLC

    Prepared for Presentation at American Institute of Chemical Engineers

    2016 Spring Meeting 12th Global Congress on Process Safety

    Houston, Texas April 11-13, 2016

    AIChE shall not be responsible for statements or opinions contained in papers or printed in its publications

    mailto:Zubin.Kumana@smithburgess.commailto:Venkata.Badam@smithburgess.commailto:Achilles.Arnaez@smithburgess.com

  • GCPS 2016 __________________________________________________________________________

    Scaling Up Safely: Making Smarter Decisions about Rate Dependency

    Zubin Kumana, P.E. Smith & Burgess LLC

    7600 W. Tidwell Rd, Ste 600 Houston TX 77040

    Zubin.Kumana@smithburgess.com

    Venkata Badam, P.E. Smith & Burgess LLC

    Venkata.Badam@smithburgess.com

    Achilles Arnaez Smith & Burgess LLC

    Achilles.Arnaez@smithburgess.com

    Keywords: Process Safety, Safe Design, and Venting and Emergency Relief

    Abstract

    Over the lifetime of a facility, it is almost a certainty that the throughput of a process will be increased, often repeatedly. Rate-dependency is frequently used as a way to identify pressure relief system sizing that would be affected by the scaling up of process throughput. This paper will define rate-dependency as it relates to pressure relief systems and describe the various ways in which rate-dependent classifications may be affected by the mechanical and thermodynamic constraints of the process and equipment. In addition, examples of when the "rate-dependent" designation may no longer apply due to common assumptions and methodological choices will be provided.

    1 Introduction

    In the refining and chemical processing industries, increasing throughput through a processing unit is often considered as a means of maximizing value with existing capital or minimal additional investment. Often, the throughput will be increased many times over the lifetime of the facility. The pressure relief system for a process is designed in part based on the throughput of the unit; therefore, the change in the throughput may affect the adequacy of the pressure relief system design.

    Verifying the design of the process units pressure relief system for these increased rates is typically done by identifying overpressure scenarios as either rate-dependent or rate-independent. A rate-dependent overpressure scenario is one whose required relief rate varies with changes in process throughput. A common example is a blocked outlet scenario on a separator. With higher

    mailto:Zubin.Kumana@smithburgess.commailto:Venkata.Badam@smithburgess.commailto:Achilles.Arnaez@smithburgess.com

  • GCPS 2016 __________________________________________________________________________

    the process throughput, the quantity of mass that must be relieved to limit the pressure to the allowable accumulation is expected to increase.

    Conversely, rate-independence refers to overpressure scenarios whose required relief rate is independent of process throughput. A common example is exterior fire, where the required relief rate depends on the heat of vaporization of the liquid mixture inside the vessel, the density of the vapor and liquid phases, and the wetted area of the vessel the fluid is residing in. Changing the feed rate to the vessel is not expected to result in a change to the required relief area for the exterior fire scenario. In some circles, these scenarios may also be termed equipment-dependent. While the equipment and piping remains constant, the required relief rate remains constant. However, as rate scale-up increases, the equipment and piping may be changed to accommodate the additional capacity.

    Figure 1: Rate-dependent scenarios increase in required relief rate (and therefore area) with process flow rate increase, while equipment-dependent scenarios are effectively constant until a change to equipment is required.

    1.1 How Rate Dependency is used in Pressure Relief System Design

    The common practice in pressure relief system design is to select a unit process basis that the user believes represents both the actual operation of the process as well as the worst case for the relief system design specifically, the case that will result in the largest required areas and piping diameters. Since process units can have a range of operating modes and rates, selection of these cases tends to favor the following:

    Modes of operation with lighter feed, as this can result in more vaporization and therefore larger vapor and two-phase relief loads

    Higher process throughput rates; often the peak rate achieved, or some percentage above the peak rate

    Requ

    ired

    Relie

    f Rat

    e

    Process Flow Rate

    Rate-Dependent v. Equipment-Dependent Scenarios

    Rate

    Equipment

    Dependency

    Change to Equipment Required

  • GCPS 2016 __________________________________________________________________________

    The conscientious user might separately specify a worst-case heavy liquid relief load basis in order to properly design the liquid handling capabilities of the disposal system.

    As the pressure relief system design is completed, the engineer performing the design will typically identify overpressure scenarios as rate-dependent as the analysis proceeds. This designation is then used when the throughput rate is modified in the future. This allows engineers to minimize the amount of recalculation that needs to be performed, by only performing new calculations for the overpressure scenarios that are dependent on rates; the scenarios that had been identified as rate-independent are believed to be static and are left unchanged.

    A generalized expression for pressure relief device sizing is given in API Std 520 Part I (9th ed.) Annex B, equation B.5, rearranged to solve for required area [1]:

    = []

    (Eq. 1)

    Where

    G is the theoretical mass flux through the nozzle

    W is the mass flow through the PRV

    A is the effective discharge area

    [K] is the product of all applicable correction factors

    The scale-up of the pressure relief system design is typically done using the assumption that the only change is to the flow rates through the unit; variables such as fluid composition, operating pressures and temperatures are assumed to remain constant. This effectively limits the relationship between the throughput rate and the relief system required areas to a linear one; as the fluid mass flux is considered constant, and the applicable correction factors are generally constant (exceptions are always possible based on Reynolds number and actual backpressure resulting from flow), the values of A and W are directly proportional.

    For the evaluation of the pressure relief system design, this has led to the following widespread practice:

    1. The user takes the heat and material balance at the previous throughput rate 2. The user obtains a list of calculations that had been identified as rate-dependent 3. The user takes the percentage increase in flow and factors this value into the required

    relief rates 4. The user re-evaluates the pressure relief device requirements vs. capacity (along with

    other associated concerns where relevant, e.g. pressure losses if calculated at required relief rates)

    This process rarely involves revalidating the process unit simulation to confirm the heat and material balance. Typically this practice has been followed for small changes to throughput rates. However, once the procedure has been implemented, the potential exists for repeated applications

  • GCPS 2016 __________________________________________________________________________

    to increase the degree of deviation from a validated baseline even further. This poses a danger, as excessive extrapolation and repeated application of the scale-up process without carefully considered heat and material balance revalidation can quickly lead to larger and larger deviations, and the potential for undersizing the pressure relief system.

    This paper focuses on rate scale-ups that do not involve any change to the as-built system. The rate scale-ups considered are therefore limited to the maximum throughput that the existing equipment can support. Debottlenecking the equipment in the process unit (rotating equipment, exchanger heat transfer area, and pipe sizing) may be required to accommodate further rate scale-up. As a capital project, this effort typically includes development of a new project baseli

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