R4 Salt Cooler - Tube Side PSV Sizing
Closed Outlet
Temperature = 95 Deg C
Density = 60.1143 lb/ft3
Max BFW Rate = 134 gpm ( Salt Gate Valve Wide Open Case)
= 17.9 ft3/min
= 64611 lb/hr
Steam Mass Flow Rate = 64611 lb/hr
Pressure = 265 psig
PSV Set Pressure = 306 psig
W = 64611 lb/hr
% Over pressure = 10
P1 = 351.3 psia
Kd = 0.975
Kb = 1
Kc = 1
KN = 1
KSH = 1
Required Area, A = 3.66 inch2
API Orifice Selected = N
Orifice Area = 4.34 inch2
PSV Size = 4N6
Inlet Size = 4 inch
Outlet Size 6 inch
Outlet Pipe Schedule = 40
Inside Diameter = 6.065 inches
Flow Area = 28.89 inch2
PSV Capacity Calculation
Installed Orifce Area, A = 4.34 inch2
𝑊=𝐴∗51.5∗𝑃_1∗𝐾_𝑑∗𝐾_𝑏∗𝐾_𝐶∗𝐾_𝑁∗𝐾_█(𝑆𝐻@)
W = 76556.1 lb/hr
PSV Reaction Force Calculation for Open Discharge
From API 520 Part II, Section 4.4.1.1 2003 E
PSV Reaction Force
W = 76556.1 lbm/hr Rated Capacity of PSV
k = 1.38 Ratio of Specific Heats at Outlet Conditions
T = 222.2 Deg C Temperature at Outlet Conditons
431.96 Deg F
891.96 Deg R
M = 18 lb/lbmol Mol.Wt of Relief Stream
A = 28.89 inch2 Area of Outlet at the Point of Discharge
P = 145.87 psig Static Pressure within the Outet at the Point of Discharge
k/(k+1) = 0.5798
Reaction Force
Momentum Term = 1121.2 lbf
Pressure Term = 4214.2 lbf
Reaction Force = 5335.4 lbf
520 Part II, Section 4.4.1.1 2003 Edn
at the Point of Discharge
Exit Pressure Calculation for PSV Outlet Pipe 10-Jul-2020
Process Data
PSV Set Pressure, Pset = 306 psig
Overpressure = 10 % Non-Fire Scenario
Accumulated Pressure, Po = 336.6 psig
𝑚 ̇ =
Specific Enthalpy, hg = 1204.23 Btu/lb
PSV Rated Capacity,
76556 lb/hr
Inlet Temperature, To = 222.27 Deg C Saturation Temperature
= 432.09 Deg F
= 892.09 Deg R
Fluid Data
Dry Saturated
Fluid =
Steam
Ratio of Specific Heats, ϒ = 1.38 Dimensionless From Steam Tables at Po
Mol.Wt, M = 18.02 lb/lbmole
PSV Outlet Pipe P3=Atm
Pipe Size = 6" NPS P2
P1
Sch = 40
ID = 6.065 inches
Po
= 0.5054 ft
Length, L = 6.0 ft
Flow Area = 0.2006 ft2
Pipe Roughness = 0.0018 inches
Fittings
90 Deg LR Elbow = 1
Calculations
The critical pressure is calculated for the PSV inlet pressure and this value is compared to
the pressure(P3) of the location the PSV is discharging to. In this case the PSV discharging to
atmosphere through an outlet pipe. If P3 is less than the calculated critical pressure P*,
then PSV oultet presssure will be critical. But since there is an outlet pipe attached to the PSV,
the pressure will reach critical at the exit of the PSV outlet pipe instead at the PSV
outlet flange. If P3 is greater than critical pressure then the flow will be subsonic and hence
P2 =P3=Atm
1 Step 1 : Estimation of Mach Number at the Exit of PSV Outlet Pipe
Critical Pressure Ratio Calculation
Ref: Unit Operations of Chemical Engg, 5th Edn
McCabe and Smith Page 150 / 1154
Po = 336.6 psig
ϒ = 1.38
1-1/ϒ = 0.275
P*/Po = 0.532
P* = 178.96 psig Critical Pressure
P3 = Atm
= 14.70 psia
= 0 psig
Since atmospheric pressure, P3 is less than the calculated critical pressure P*, the pressure P2
at the pipe exit will be critical which means fluid velocity at pipe exit will be sonic and hence
the Mach number there would be equal to 1.
Therefore
Outlet Mach Number,
= 1
Nma, 2
Mass Velocity, G = 105.996 lb/ft2-sec
2 Step 2 : Calculation of Pressure and Temperature at PSV Outlet Flange
Mach Number at PSV nozzle outlet is assumed and the pressure is calculated. Expanding the fluid
iso-enthalpically, the temperature at the PSV nozzle outlet or the pipe entrance is calculated.
𝑃_1/𝑃_0 =1/[1+((𝛾−1)/2) 𝑁_(𝑀𝑎,1)^2 ]^(1/((1−(1/𝛾)) ))
Po = 336.6 psig
P1 = 270.8 psig
ϒ = 1.38
(ϒ-1)/2 = 0.2
1-(1/ϒ) = 0.3
Nma,1 = 0.570 Assumed Value, Iterated
LHS = 0.8
RHS = 0.8
diff = 0.0 Goal seek to zero by adjusting P1
To = 222.272 Deg C
For isentropix expansion
𝑇_1/𝑇_𝑜 =1/⌊1+((𝛾−1)/2) 𝑁_(𝑀𝑎,1)^2 ⌋
T1/To = 0.9419 Deg C
T1 = 209.3 Deg C
The PSV Outlet Flange
Pressure, P1 = 270.8 psig
Temperarture, T1 = 209.3 Deg C
3 Step3 : Calcuation of Friction Factor and Verification of Pipe Inlet Mach Number, Nma,1
Fluid Viscosity, µ1 = 0.016382 cP Fluid viscosity at T1
= 1.10E-05 lb/ft-sec ( 1cP = 0.0006719 lb/ft-sec )
Nre,1 = 4867054.6 Reynolds number at Pipe Entrance
1/√𝑓 = -4 log[(0.27 ∈/𝐷)+(7/𝑁_𝑅𝑒 )^0.9 ]
Churchill Equation
From Perry Section 6-10
e/D = 0.000297
Nre = 4867054.6
(7/Nre)^0.9 = 0.00000552
1/Sqrt(f) = 16.27
f = 0.0037781 Fanning Friction Factor calculated at Pipe Entrance
Adiabtaic Friction Loss Formula
1/(𝑁_(𝑚𝑎,1)^2 )−1/(𝑁_(𝑚𝑎,2)^2 )−(𝛾+1)/2 ln[(𝑁_(𝑚𝑎,2)^2)/(𝑁_(𝑚𝑎,1)^2 ) ((1+((γ−1)/2) 𝑁_(𝑚𝑎,1)^2)/(1+(( 𝛾−1)/2) 𝑁_( 𝑚𝑎,2)^2 )) ])
Ref : Unit Operations of Chemical Engg by McCabe and Smith,
5th Edn, Page 155 / 1154
Equivalen Length, (L/D)
Pipe = 11.9
90 Deg Elbow = 30.0 From Crane TP 410, A-29
Total, L/D = 41.9
Total, L/rH = 167.5 De= 4* Hydraulic radius
LHS = 0.633
RHS
Nma,1 = 0.57 A value is assumed and iterated till the LHS and LHS match
Nma, 2 = 1 Knowing that fluid attains sonic velocity at pipe
exit
ϒ = 1.38
(1/ϒ) = 0.725
1/(Nma,1 ^2) = 3.075
1/(Nma,2 ^ 2) = 1
(ϒ+1)/2 = 1.19
Nma,1 ^ 2 = 0.325
Nma,2 ^ 2 = 1
(ϒ-1)/2 = 0.19
(1+((𝛾−1))/2 𝑁_(𝑀𝑎,1)^2 )
= 1.0618
1+((𝛾−1))/2 𝑁_(𝑀𝑎,2)^2
= 1.19
𝑁_(𝑀𝑎,2)^2 (1+((𝛾−1))/2 𝑁_(𝑀𝑎,1)^2 )
= 1.062
𝑁_(𝑀𝑎,1)^2 (1+((𝛾−1))/2 𝑁_█(𝑀𝑎,2@)^2 )
= 0.387
RHS = 0.63
LHS = 0.63
Difference = 0.00 Goal Seek to zero by adjusting NMa,1
Nma,1 = 0.57
This value is checked with Nma,1 assumed in Step 2. If doesnot match then the assumed value in
Step2 is replced with this one and iterated till they both match.
4 Step 4: Verification of Correctness of Nma,1
In this step the Nma,1 is checked for correctness by estimating the fluid velocity at point 1
using density calculated from pressure and temperature at point 1.
√((𝑔_𝑐
Acoustic Velocity at Pipe
= 𝛾𝑅𝑇_1)/𝑀)
Entrance, a1
gc = 32.17 lbm-ft/sec2/lbf
ϒ = 1.38
R = 1545.26 lbf-ft3/lbmole-Deg R
T1 = 209.35 Deg C
= 408.83 Deg F
= 868.83 Deg R
M = 18.02
a1 = 1818.68 ft/sec
𝑁_(𝑚𝑎,1
)=𝑢_1/𝑎_1
Nma, 1 = 0.57
Fluid Velocity at Pipe
= 1037.13 ft/sec
Entrance, u1
Calculating the u1 from density estimated at Point 1
m = 76556 lb/hr
T1 = 209.35 Deg C
= 408.83 Deg F
= 868.83 Deg R
P1 = 270.79 psig
= 285.49 psia
Mol,wt, M = 18.02 lb/lbmole
R = 10.73 psi-ft3/lbmole-Deg R
Density, RHO = 0.55 lb/ft3
Volumetric Flow Rate, Q = 38.54 ft3/sec
Outlet Pipe ID, D = 6.065 inches
= 0.51 ft
Outlet Pipe Flow Area, A = 0.20 ft2
u1 = 192.09 ft/sec
Calculation Status = Calculations are Incorrect
5 Step 5: Calculation of Pressure at Pipe Exit
/𝑃_2 =(𝑁_(𝑀𝑎, 2)/𝑁_(𝑀𝑎, 1) ) √((1+((𝛾−1)/2) 𝑁_(𝑀𝑎,2)^2)/(1+((𝛾−1)/2) 𝑁_(𝑀𝑎,1)^2 ))
Pressure Ratio for Adiabatic Frictional Flow
Ref : Unit Operations of Chemical Engg
McCabe and Smith, Page 155/1154
Nma,1 = 0.57
Nma,2 = 1
Nma,1 ^ 2 = 0.33
Nma,2 ^ 2 = 1
ϒ = 1.38
1+((𝛾−1))/2 𝑁_(𝑀𝑎,2)^2
(ϒ-1)/2 = 0.19
1+((𝛾−1))/2
= 1.19
𝑁_█(𝑀𝑎,1@@) = 1.062
^2
P1/P2 = 1.86
P1 = 270.79 psig
P2 = 145.9 psig Pressure at Pipe Exit
PSV Outlet Pressure Drop = 124.9 psi
= 40.8 % of PSV Set Pressure
Safety Valve Reaction Force Calculation
Reaction Force at Discharge Elbow Exit, F1
per ASME B31.1 Section II-2.3.1
Pressure At Discharge Elbow Exit, P1
Velocity at Discharge Elbow Exit, V1
W = 21.27 lbm/sec Relieving Capacity of the Safety Valve
A1 = 28.89 in2 Discharge Elbow Area
a = 823 Btu/lbm For Saturated steam >=90% quality
b = 4.33 15 psia <P1<1000 psia
ho = 1204.23 Btu/lbm
J = 778.16 ft-lbf/Btu
gc = 32.17
(b-1)/b = 0.769
(2b-1) = 7.66
P1 = 27.78 psia 13.08 psig
V1 = 1578.5 ft/sec
Momentum Term = 1043.5 lbf
Pressure Term = 377.8 lbf
F1 = 1421.27 lbf
Pressure Relief Valve Orifice Sizes
API Std Size API Letter ASME Orifice Size Set Pressures Typical Body Size
in² in²
0.110 D 0.1279 5-6000 psig 1x2
0.196 E 0.2279 5-6000 psig 1x2
0.307 F 0.3568 5-5000 psig 1½x2
0.503 G 0.5489 5-3705 psig 1½x3
0.785 H 0.9127 5-2700 psig 2x3
1.287 J 1.4960 5-2200 psig 2x3
1.838 K 2.1380 5-1500 psig 3x4
2.853 L 3.3170 5-1500 psig 3x4
3.600 M 4.1860 5-1100 psig 4x6
4.340 N 5.0470 5-1000 psig 4x6
6.380 P 7.4170 5-1000 psig 4x6
11.050 Q 12.8500 5-1500 psig 6x8
16.000 R 18.6000 5-300 psig 6x8
26.000 T 28.6200 5-300 psig 8x10
