Jump Start: Relief Sizing in Aspen HYSYS and Aspen Plus V8.6

Jump Start: Relief Sizing in Aspen HYSYS and
Aspen Plus V8.6

A Brief Tutorial (and supplement to training and online documentation)
Anum Qassam, Product Management, Aspen Technology, Inc.
Jennifer Dyment, Product Marketing, Aspen Technology, Inc.
Wilfried Mofor, Product Management, Aspen Technology, Inc.
2014 Aspen Technology, Inc. AspenTech, aspenONE, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen Technology, Inc. All rights reserved.11-5538-0614
Jump Start: Relief Sizing in Aspen HYSYS and Aspen Plus V8.6
Table of Contents
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Initial Set Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Adding a Pressure Relieving Device to a Simulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Entering the Simulation Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Adding a PRD to the Safety Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Initial PRD Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Equipment Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PRD Data Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rating Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Creating A Scenario . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Scenarios Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Scenario Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sizing Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Custom Orifice Sizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Line Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Equivalent Length Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Documentation Builder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Importing Valve Sizing and Scenarios within Aspen Flare System Analyzer from Aspen HYSYS/Plus . . . . . . . . . . . . . . . . . . . 19
Relief Valve Sizing and Dynamic Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
CVb
Introduction
When designing a chemical process and its equipment, safety is of substantial concern. All possible strategies should be
considered to eliminate the risk of accident and injury when implementing a process design. One safety concern that
frequently occurs in a plant is the over-pressurization of equipment or piping. In order to prevent dangerous bursts,
explosions, and fires, pressure relief valves are designed and installed to bleed out excess liquid or vapor causing pressure
build-up.
Process conditions vary at each location of a pressure relief valve. Because of this, and the strict regulation of safety
equipment, completing a design of a pressure relief valve by hand can be a time-consuming and laborious exercise. To
solve this problem, Aspen HYSYS and Aspen Plus have a pressure safety valve sizing feature available within the Safety
Analysis Environment, which uses data from a process simulation to help automate PSV calculations.
The Safety Analysis Environment uses common valve design standards, most notably API 520, 521, to determine pressure
relief valve sizing information and values. Twenty-five common overpressure scenarios are included in the software, which
can be analyzed and sized. The Safety Analysis Environment also features a line sizing functionality, allowing the user to
quickly choose the schedule and diameter according to pressure drop and fluid velocity constraints for piping entering and
leaving the pressure safety valve. Line sizing is completed in the Safety Analysis Environment without having to perform
any fluid flow computations.
The Documentation Builder pulls valve sizing and process variable information directly from simulation to automatically
complete required forms that normally require manual incorporation.
This guide will walk the reader through the process of using the pressure relief valve features within the Safety Analysis
Environment of Aspen HYSYS and Aspen Plus to design a pressure relief valve. AspenTech recommends that a range of
other resources be called upon in conjunction with this document to give the user a comprehensive view of how to use
Aspen HYSYS and Aspen Plus. These may include:
AspenTech support website (support.aspentech.com) this website has a wealth of information on the use of
AspenTech products and provides answers to frequently asked questions
AspenTech courseware available in on-line and in-person versions
AspenTech business consultants
This document will show how to size pressure safety valves using Aspen HYSYS and Aspen Plus. It assumes that the user
has Aspen HYSYS or Aspen Plus V8.6 or higher installed on her or his computer and a functional process design
completed.
Initial Set Up
All examples and screenshots in this guide are based on the example file PRESSURE RELIEF STARTER.hsc in Aspen
HYSYS. If more familiar with Aspen Plus, users can use the Safety Analysis without PRD.bkp file instead. Make sure that
the correct units are selected when specifying parameters.
Adding a Pressure Relieving Device to a Simulation

This section of the document describes how to enter the Safety Analysis Environment and how to add a relieving device to
the flowsheet.
Entering the Simulation Environment

In order to add a pressure safety valve to a process flowsheet, the user must enter the Safety Analysis Environment. This
environment provides a setting for relief scenario setup and PSV sizing and documentation.
After designing a process in Aspen HYSYS or Aspen Plus and converging the simulation, click on Pressure Relief in the
Home ribbon of the Simulation Environment to enter the Safety Analysis Environment. Alternatively, the Safety Analysis
button, located on the bottom left of the program, can be used. The various options to enter the Safety Environment are
shown in the figures below.
Figure 1: Pressure Relief Button on Home Tab in Aspen HYSYS
Figure 2: Pressure Relief Button on Home Tab in Aspen Plus
Figure 3: Safety Analysis Button on Navigation Pane
Adding a PRD to the Safety Environment

After entering the Safety Analysis Environment, select the Unit Operations heading in the navigation pane on the left side
of the screen. This will display all the unit operations and subflowsheets present in the simulation for which a pressure
safety valve can be designed. Also in the navigation pane is the Unattached Streams heading, in which floating/dangling
streams with no connections to process models are listed. The last heading, Storage Tank Protection, lists any additional
low pressure storage tanks created in the Safety Analysis Environment. Storage tank protection is discussed more in detail
in Jump Start: Storage Tank Protection in Aspen HYSYS and Aspen Plus.
Figure 4: Location of Unit Operations and Unattached Streams Menus in Safety Analysis Panel
To add a PRD to a simulation, click the Add PSV or Add Rupture Disk button on the Home tab of the ribbon in the Safety
Analysis Environment, shown in Figure 5.
Figure 5: Add PSV Button in Safety Analysis Environment
This switches the cursor into attach mode. When you hover over attachable objects on the flowsheet, a blue box will
appear to indicate where to click to make the attachment to the stream. Click on the blue box to add the safety valve to
that stream. See Figure 6 for more detail.
Figure 6: Attach Mode in Safety Analysis Environment
A PSV or Rupture Disk can also be added using the navigation pane. Expand the Unit Operations or Unattached Streams
node and right click the desired block or stream. Scroll to highlight either the Create PSV or Create Rupture Disk option.
The user can add either a PSV or a Rupture Disk to any stream exiting a unit operation (Figure 7).
Figure 7: Adding a Pressure Safety Valve From Navigation Pane
For users that are following along with the example file, the flowsheet should now look like the flowsheet in Figure 8.
Figure 8: Flowsheet with Added PSV in Aspen Plus and Aspen HYSYS
Initial PRD Set Up

This section of the document highlights the Equipment, PRD Data, and Rating tabs. Double click the relief device on the
flowsheet to open the PRD form.
Equipment Tab
The PRD form opens to the Equipment tab. The Equipment tab, shown in Figure 9, allows the user to specify the operating
and design conditions of the limiting unit operation within the PRD system.
Figure 9: PRD Form - Equipment T

Tip: On the equipment tab, the user can manually specify the operating and design temperatures and pressures by
selecting Manual in the dropdown menu. Reference the temperatures and pressures of the stream to which the PRD
is attached by selecting Reference in the dropdown menu. If the stream conditions in the flowsheet are changed,
referenced values will automatically update.
PRD Data Tab

The PRD Data tab, shown in Figure 10, allows you to fully specify PRD-specific parameters. This tab is also used to create
multiple valves to protect the system and is discussed more in detail in Jump Start: Multiple Relief Valve Analysis in Aspen
HYSYS and Aspen Plus.
Figure 10: PRD Form - PRD Data Tab
Rating Tab
The Rating tab, shown in Figure 11, allows you to design one or more valves for the sizing case scenario. The Rating tab
further allows you to see the effect of the chosen PRD configuration on all scenarios.
Figure 11: PRD Form - Rating Tab
Creating A Scenario
This section of the document describes how to create a scenario for analysis.
Scenarios Tab
The Scenarios tab, shown in Figure 12, allows the user to manage multiple overpressure scenarios in the system. In this
tab, the user can also specify which of the scenarios is the sizing case. The sizing case will be used to design the PRDs that
protect the system.
Figure 12: PRD Form - Scenarios Tab
The user can create a scenario by clicking the Create Scenario button, shown in Figure 13. Open the scenario by selecting
it and clicking the Open Scenario button or delete scenarios using the Delete Scenario button. In Aspen HYSYS, the user
can Duplicate a scenario by clicking the Duplicate & Rename button. This capability is not available in Aspen Plus.
Figure 13: Scenario Tab Options
Click the Create Scenario button to add a scenario to the table as shown in Figure 14.
Figure 14: Newly Created Scenario
Double click the scenario from the table to open the Scenario Setup form.
Scenario Setup
After double-clicking on a scenario from the Scenarios tab or choosing a scenario from the navigation pane, the Scenario
Setup tab, shown below, appears (Figure 15).
Figure 15: Scenario Setup Tab
The user can enter the Scenario Name, which is used for documentation purposes. Next, select the Scenario Type from
the dropdown menu. Scenarios that are highlighted in the dropdown have additional optional associated calculation
methodologies to determine the Required Relieving Flow.
Enter the relieving temperature necessary for the given relief scenario being analyzed before proceeding to the calculation
of the relieving pressure. Click the Edit button next to the Relieving Pressure box to bring up the window shown in Figure
16.
Figure 16. Relieving Pressure Calculation Window
In the Relieving Pressure Calculation window, you can specify the Allowable Overpressure for the scenario. The Relieving
Pressure is determined from the specified Allowable Overpressure. Verify that the relieving pressure is correct, then click
OK to continue.
Similar to the Relieving Pressure Calculation window, clicking Edit next to the Total Backpressure box opens the window
displayed in Figure 17. In this window, you can specify the Variable Superimposed BP and Built-up Backpressure to
calculate the Total Backpressure. Furthermore, you can specify the Maximum Allowable BP % and the Backpressure (BP)
Factor (Kb). Verify that the parameters are correct, then click OK to continue.
Figure 17. Backpressure Calculation Window
To obtain a relieving flow load, a manually calculated value can be entered or the reference flow value from the Reference
Stream can be used. Figure 18 shows a completed scenario calculation.
Calculating a Required Relief Flow is discussed in more detail in Jump Start: Fire Overpressure Analysis in Aspen HYSYS and
Aspen Plus.
Figure 18: Completed Example of Scenario Calculation
When all scenario input is complete, the PSV Results box will display the valve sizing results in the table on the right-hand
side of the tab, detailed in the next section of this guide.
Sizing Results
After finishing parameter input in the Valve Design and Scenario Setup tabs, the valve sizing results will be displayed in
the Valve Results table (Figure 19), located within the Scenario Setup tab.
Figure 19. Valve Results Table Inside Scenario Setup Tab
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The results table includes important information required to choose an appropriate safety valve for installation. The
calculated orifice area and valve coefficient are given. Also provided is the level of noise, in decibels, that the valve will
make at a given height when in use.
Using the calculated orifice area, the user is prompted to select an actual standardized orifice size for the valve from a
dropdown menu in the Valve Results table. It is recommended to pick the next largest orifice size from the calculated
orifice size in order to ensure correct valve operation. For example, in Figure 20, because the calculated orifice is 9.152 in2,
you should select the 11.050 in2 option from the dropdown menu. After selecting an orifice size, the valves rated capacity
and capacity used is displayed, along with orifice design information and in and out flange sizing.
Figure 20. Selected Orifice Dropdown Box with Options
If the scenario being analyzed is the basis case for which the valve is sized, select the Sizing Case box, next to the
Scenario Name input box. Then, return to the Valve Design tab to proceed to line sizing for the relief valve.
For Rupture Disk (RD) devices, a list of commonly available disk sizes is used based on common disk sizes as shown
below (Figure 21).
Figure 21. Rupture Disk Device Orifice Selection
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Custom Orifice Sizing

The selectable orifice sizes that come standard in Aspen HYSYS and Aspen Plus are based off of API 526 standards. If
different orifice sizes are necessary, custom orifice sizes can be specified by going to the Customize tab on the ribbon in
the Safety Analysis Environment and clicking the Custom Orifices option (Figure 22).
Figure 22. Accessing Custom Orifice Editing
Clicking the Custom Orifices option opens a window in which the selectable orifice areas and displayed names can be
updated to fit the users needs. To edit an orifice, check the box under the Add Custom column, and then type the
appropriate name and orifice area. The Custom Orifices window is shown in Figure 23.
Figure 23. Custom Orifice Area Editing
Line Sizing
After the orifice area has been selected for the appropriate sizing scenario, return to the Valve form. The scenario list in
the Valve Design tab will now be populated with sizing information regarding each scenario. If not done before, use the
Sizing Case check box on the scenario list (Figure 24) to choose which failure scenario the valve will be sized for.
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Figure 24. Scenario List Table Inside Valve Design Tab with Selected Sizing Case Scenario
Selecting a sizing case enables the Line Sizing tab for selection. Click the Line Sizing tab, as shown in Figure 25, to begin
line sizing for the pressure safety valve.
Figure 25. Location of Line Sizing Tab
Under the Line Sizing tab, the piping in and out of the pressure safety valve can be chosen. If the pipe size chosen by the
user is too small to accommodate relief flow or too large such that the pressure gradient will not allow for relief flow, the
Safety Analysis Environment will alert the user using the bar on the bottom of the tab, so that an incorrect design is not
selected. If the bar is green, it means that an appropriate line size has been selected, while yellow means there is either a
fluid pressure or velocity constraint being violated by the chosen line sizing.
Specify the nominal diameter and schedule of the piping for the in and out lines. The Safety Analysis Environment will use
the rated flowrate through the pipes to calculate the change in pressure and velocity (For most cases, rated flowrate is
used. The design/required flow through the PSV is used for liquid or fire scenarios. This value can be changed if the Safety
Analysis Environment defaults do not match.) These results are displayed in the Line Sizing Results table. Figure 26
shows the Line Sizing tab layout.
Figure 26. Layout of Line Sizing Tab

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The pressure drop and fluid velocity constraints for line sizing are preset according to API standards. To change these
constraints, click the Constraint Setting button in the Line Sizing tab, and the following window (Figure 27) will open
allowing the user to change line sizing constraints as desired.
Figure 27. Line Sizing Constraint Settings
Equivalent Length Calculation

The equivalent length of the piping can be entered in the appropriate field inside the Line Sizing tab. There is also a feature
in the Safety Analysis Environment which calculates the equivalent length of the piping. To access this feature, check the
Calculate Equivalent Length box. This will bring up a menu within the Line Sizing tab in which the quantity of the present
pipe fittings can be specified, along with their L/D ratios. After entering the number of fittings, a calculated equivalent
length will appear, as shown in Figure 28.
Figure 28. Calculate Equivalent Length Function
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Documentation Builder
After completing all design and sizing for a pressure relief valve, filling out documentation is required in order to meet
regulated safety compliances, and for valve vendor submission. In order to reduce tedium in this area, the simulators have
a Documentation Builder function inside the Safety Analysis Environment, which pulls data from the simulation and valve
sizing to automatically complete required forms. To access the customizable Documentation Builder, click the
Documentation Builder option from the home ribbon. Similarly, to obtain a built-in PRD report, choose the desired
option located to the left of the Documentation Builder option, shown in Figure 29.
Figure 29. Documentation Builder and Built-in Simulator Reports Options While in Safety Analysis Environment
The Built-in Safety Analysis Environment Reports feature provides instant documentation of valve parameters and
relieving conditions gathered directly from the Safety Analysis relief scenario being analyzed. Built-in reports are not
editable; the Documentation Builder should be used for more in-depth, editable reporting. Shown in Figure 30 is an
example built-in calculation sheet .
This calculation sheet is the report used for the storage tank analysis and works either in context with the tank protection
system or while on the Tank Manager form. For Storage Tanks and Fire Relief Load Calculation reports, the built-in
reports are available in both SI and EN sets.
Figure 30. Example Built-in Safety Analysis Environment PSV Calculation Report (Only Report Available for Storage Tanks)
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Clicking the Documentation Builder option initiates Microsoft Access, which houses the customizable forms to be
completed after designing and sizing a pressure relief valve. From the Documentation Builders home screen, shown below
in Figure 31, a list of relief devices sized in the Safety Analysis Environment can be edited or viewed. Additionally, process
data sheets, mechanical data sheets, calculation summary sheets, or relief load summary sheets can be constructed.
Information from the sheets can be exported to Microsoft Excel by selecting any of the respective Export options.
Figure 31. Microsoft Access Documentation Builder Selection Screen
Choosing the edit option for any of the forms from the Documentation Builder brings up a screen allowing the user to
change the information that will appear in the final, viewable report. Many entries are already populated by values pulled
directly from the Safety Environement. These are denoted in grey/green. The spaces in white require user input to be
completed. A sample edit page for a mechanical data sheet is shown in Figure 32.
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Figure 32. Edit Page for Mechanical Data Sheet
After entering the pertinent information for a datasheet on its edit page, return to the Documentation Builder home
screen, then select View to see a copy of the finalized version of the document chosen. After opening a document using
the View option, it can then be saved electronically or printed. Figure 33 shows a completed sample mechanical data
sheet, given the input information from the edit page shown in Figure 32.
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Figure 33. Completed Example Mechanical Data Sheet
Completing documentation using the Documentation Builder reduces the time needed to complete safety valve
paperwork to submit to regulatory agencies and valve vendors.
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Importing Valve Sizing and Scenarios within Aspen Flare System

Analyzer from Aspen HYSYS and Aspen Plus
When using Aspen HYSYS V8.4 and Aspen Plus V8.6 or higher, relief valve sizing and scenarios can be imported within
Aspen Flare System Analyzer V8.6 or higher, in order to assist in the designing and rating of a process flare system.
To successfully import relief valve sizing results, the Aspen HYSYS/Plus file must first be saved as either an Aspen
HYSYS/Plus Compound File (.hscz/.apwz) (prefered), or as an Aspen HYSYS/Plus Simulation Cases (.hsc/.bkp/.apw)
in the same folder as the relief valves Microsoft Database (.mdb) file. To do this, navigate to the Save As window from
the File menu in Aspen HYSYS/Plus, and then save the file as a compound file, as depicted in Figure 34. Alternatively, a
saved file message will also be displayed if the simulator is closed before saving.
Figure 34. Saving as a Simulation Case or a Compound File
Once the simulation file is saved in the proper format, open Aspen Flare System Analyzer. When the program is open,
navigate to the File menu, scroll over Import Sources, and then click the Aspen Plus/HYSYS Relief Valve Sources
option, shown in Figure 35.
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Figure 35. Importing Aspen Plus/HYSYS Relief Valve Sizing Results
The import window for relief valves sized in Aspen HYSYS/Plus will be queued. Click the Browse button, and select the
simulation file in which relief valves were sized. Finally, click the Upload File button to bring in the information.
Figure 36. Uploading an Aspen HYSYS/Aspen Plus File for Import
When a simulation file has been uploaded, the window displays the device names for each PSV imported from Aspen
HYSYS/Aspen Plus. Rupture disk devices are ignored for these flare systems. Flare sources should then be specified for
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each valve being used in the flare network. Flare sources can either be selected from blocks present on the flare flowsheet,
or can be created by typing a name in the Flare Source column and hitting enter.
Aspen Flare System Analyzer V8.6 will automatically detect and map PSVs with similar names between the simulators
and the flare. After the mapping is done once, the other flare scenarios will remember the source mapping to simplify the
creation of extra scenario mappings. The user can also decide to rename the flare sources to match the Apen
HYSYS/Aspen Plus names, so that these names are automatically recognized by Aspen Flare System Analyzer for future
importing. The information imported from Aspen HYSYS/Aspen Plus can also be used for multiple flare cases using the
Flare Scenario view on the left. To create a new flare scenario, click the <Add New> option and enter a name. A single
import file is used to house all the mappings for multiple flare scenarios from one simulation case.
Figure 37. Entering Flare Sources and Multiple Flare Scenarios
Adding overpressure protection scenarios for each flare source can either be done manually, or through the Auto-Map
Scenarios feature. The Auto-Map Scenarios feature allows for quick search and selection of overpressure protection
scenarios that adhere to a certain criteria. For example, if a flare scenario was being designed to only handle fire relief
contingencies, the Auto-Map tool could be used to look up all fire contingencies imported.
First, after opening the Auto-Mapping form, choose the flare scenario for which overpressure cases are being selected.
Then, choose whether to search Aspen HYSYS or Aspen Plus valves and contingencies by overpressure scenario type or
name. Figure 38 shows a flare scenario being mapped for only fire protection cases.
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Figure 38. Auto-Mapping for Different Scenarios
It is recommended to save the imported set of valve sizes by clicking Save Import Set before continuing with subsequent
flare system design and rating. In Aspen Flare Analyzer V8.4 and higher, exiting this form will prompt you to save the file.
After importing and saving the relief valve sizing results from the simulators into Aspen Flare System Analyzer, click OK
to continue to flare system design.
Relief Valve Sizing and Dynamic Simulation

The Safety Analysis Environment in Aspen HYSYS is compatible with dynamic simulation using Aspen HYSYS Dynamics.
This feature is useful when relieving conditions and fluid properties differ from those at steady-state operation, namely
when a relief scenario is triggered by a disturbance to steady-state operation. Dynamic simulation allows the user to
obtain precise fluid property measurements at a given point that can then be automatically referenced by the relief valve
sizing tool.
In Aspen Plus Dynamics, a relief valve unit operation can also be added, but this analysis is completely independent of the
Safety Analysis Envrionment in Aspen Plus steady-state. In Aspen Plus, the Pressure Relief module is also kept for
alternate Pressure Relief Device (PRD) analysis. This section describes the interaction of the Safety Analysis Environment
with the Aspen HYSYS dynamics mode.
To use Aspen HYSYS Dynamics and relief valve sizing together, a dynamic model must first be set up and run in Aspen
HYSYS Dynamics. For more information on completing this task, please refer to the Aspen HYSYS Dynamics Jump Start
Guide by going to: http://www.aspentech.com/Jump_Start-HYSYS_Dynamics_V8/.
When the dynamic simulation has reached the process conditions at which relief valve sizing is desired, simply stop the
dynamic simulation by selecting the Stop option under the Dynamics tab on the Aspen HYSYS ribbon, as shown below
in Figure 39. Strip charts are helpful in showing the progression of a dynamic simulation and can be used to determine
when to stop it.
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Figure 39. Stopping Dynamic Simulation
After dynamic simulation has stopped, proceed to the Safety Analysis Environment using one of the options displayed in
either Figure 1 or Figure 2. Then, the workflow for setting up and completing sizing for pressure relief valves that was
described in the previous sections of this guide, should be followed in order to size a PSV.
Aspen HYSYS Dynamics can also be used to rate relief valves after obtaining a valve size in the Safety Analysis
Environment. After adding a relief valve block to a simulation from the model palette, the set pressure and full open
pressure for the valve should be defined in the Design tab, followed by entering the sizing information under the Rating tab
for the valve, as shown in Figure 40.
Figure 40. Adding and Defining a Relief Valve for Dynamic Simulation
Once the valve is set up, a dynamic simulation can be run to see the valves performance when a processs steady-state
operation is disturbed.
23
Conclusions
Pressure relief valve design and sizing can be a tedious, lengthy process. Relief valve sizing in Aspen HYSYS and Aspen
Plus allows the user to design pressure relief valves quickly using a small amount of process information at the location of
the valve. Aspen HYSYS and Aspen Plus now encompasses all facets of the valve design process into one convenient
location. In addition, various scenarios involving multiple valves can be explored to find the most optimal relief schedule
for a unit.
Aspen Plus and Aspen HYSYS can also serve as an accuracy check to ensure that safety equipment has been properly
rated and will perform properly. It helps designers complete their work faster, so that safety equipment can be installed
and implemented sooner. All processes need to have safety precautions to avoid disaster, which is why these solutions
will continue to make all processes as safe as possiblewith each use.
References
1. American Petroleum Inst., Sizing Selection, and Installation of Pressure-Relieving Devices in Refineries, ANSI/API RP
520, 8th Ed., Part 1: Sizing and Selection, Washington D.C., Dec. 2008.
Additional Resources
Public Website:
http://www.aspentech.com/products/aspen-hysys.aspx
http://www.aspentech.com/products/aspen-plus.aspx
Online Training:
http://www.aspentech.com/products/aspen-online-training
AspenTech YouTube Channel:

http://www.youtube.com/user/aspentechnologyinc
24
About AspenTech
AspenTech is a leading supplier of software that optimizes process manufacturingfor energy, chemicals,
engineering and construction, and other industries that manufacture and produce products from a
chemical process. With integrated aspenONE solutions, process manufacturers can implement best
practices for optimizing their engineering, manufacturing, and supply chain operations. As a result,
AspenTech customers are better able to increase capacity, improve margins, reduce costs, and become
more energy efficient. To see how the worlds leading process manufacturers rely on AspenTech to
achieve their operational excellence goals, visit www.aspentech.com.
Worldwide Headquarters
Aspen Technology, Inc.
20 Crosby Drive
Bedford, MA 01730
United States
phone: +17812216400
fax: +17812216410
info@aspentech.com
Regional Headquarters
Houston, TX | USA
phone: +12815841000
So Paulo | Brazil
phone: +551134436261
Reading | United Kingdom
phone: +44(0)1189226400
Singapore | Republic of Singapore
phone: +6563953900
Manama | Bahrain
phone: +97317503000
2014 Aspen Technology, Inc. AspenTech, aspenONE, the Aspen leaf logo, the aspenONE logo, and OPTIMIZE are trademarks of Aspen
Technology, Inc. All rights reserved.
11-5538-0614
For a complete list of offices, please visit

www.aspentech.com/locations

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Aspen Plus V8.6

Adding a Pressure Relieving Device to a Simulation

Entering the Simulation Environment

Figure 1: Pressure Relief Button on Home Tab in Aspen HYSYS

Figure 2: Pressure Relief Button on Home Tab in Aspen Plus

Figure 3: Safety Analysis Button on Navigation Pane

Adding a PRD to the Safety Environment

Figure 5: Add PSV Button in Safety Analysis Environment

Figure 6: Attach Mode in Safety Analysis Environment

Figure 7: Adding a Pressure Safety Valve From Navigation Pane

Initial PRD Set Up

Figure 9: PRD Form - Equipment T

PRD Data Tab

Figure 10: PRD Form - PRD Data Tab

Figure 11: PRD Form - Rating Tab

Figure 12: PRD Form - Scenarios Tab

Figure 13: Scenario Tab Options

Figure 14: Newly Created Scenario

Figure 15: Scenario Setup Tab

Figure 16. Relieving Pressure Calculation Window

Figure 17. Backpressure Calculation Window

Figure 18: Completed Example of Scenario Calculation

Figure 19. Valve Results Table Inside Scenario Setup Tab

Figure 20. Selected Orifice Dropdown Box with Options

Figure 21. Rupture Disk Device Orifice Selection

Custom Orifice Sizing

Figure 22. Accessing Custom Orifice Editing

Figure 23. Custom Orifice Area Editing

Figure 25. Location of Line Sizing Tab

Figure 26. Layout of Line Sizing Tab

Figure 27. Line Sizing Constraint Settings

Equivalent Length Calculation

Figure 28. Calculate Equivalent Length Function

Figure 31. Microsoft Access Documentation Builder Selection Screen

Figure 32. Edit Page for Mechanical Data Sheet

Figure 33. Completed Example Mechanical Data Sheet

Importing Valve Sizing and Scenarios within Aspen Flare System

Figure 34. Saving as a Simulation Case or a Compound File

Figure 35. Importing Aspen Plus/HYSYS Relief Valve Sizing Results

Figure 36. Uploading an Aspen HYSYS/Aspen Plus File for Import

Figure 37. Entering Flare Sources and Multiple Flare Scenarios

Figure 38. Auto-Mapping for Different Scenarios

Relief Valve Sizing and Dynamic Simulation

Figure 39. Stopping Dynamic Simulation

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