Stress Analysis of PSV connected Piping Systems Using Caesar Il sd whatispiping.com/stress-analysis-of psv-connected-piping-systoms ‘Anup Kumar Dey What is PSV? PSV or pressure safety valves are a type of valve and are very common to any process industry. To protect any equipment from overpressure PSV systems are used in lines. When the pres sstem/equipment exceeds a pre-determined level (normally Set Pressure), they are activated automatically and release the pressure by popping up and bring the equipment pressure to a safe operating level. ssure inside the s ‘Two types of PSVs are extensively used in process industri * Open discharge PSV * Closed discharge PSV Are PSV Connected Systems Critical? Due to an uncertain event if the pressure of any equipment becomes higher than the set pressure of the installed PSV s then they pop up and reduce the system pressure. During popping up activity the PSVs exert huge reaction force over the system. During the analysis of PSV connected stress systems, we have to consider this reaction force. This is the main reason that PSV connected systems become stress critical. The following write up will try to explain the methods used during the analysis of such systems using Caesar II. Required Documents for Stress Analysis The following documents are required while inputting in Caesar IT. + Stress isometries.+ P&ID and line list. + PSV datasheet with reaction force and PSV weights. + Equipment GA and datasheet if the equipment is part of the stress system. PSV Reaction Force Calculation & Application Philosophy Before we start the actual analysis we should first know the reaction force. Normal practice is to obtain the reaction force from the PSV vendor or manufacturer. However if during the preliminary stage of analysis, data is not available then the reaction force for open discharge PSVs can be calculated using the below-mentioned formula (from API RP 520) for gaseous/vapor services. But later it must be corrected for forces received from the vendor. ANCHOR Fig. 1: Typical Open Discharge PSV Connection PSV Reaction force at the point of discharge for Gas Services in Ibf, F= [(W/366)* V{K*T/(K+1)"M)]+A*P+ Here, W=flow of any gas or vapor in Ibm/hr + K-ratio of specific heats (Cp/Cv) at the outlet condition + ‘T=temperature at the outlet in Degree R molecular weight of the process fluid + Azarea of the outlet at the point of discharge in inch*2 + P=Static pressure within the outlet at the point of discharge in psig. + Cpand Cv=Specific heat at the constant pressure and at constant volume respectively. For liquid services the PSV reaction force (Fg) due to outflow of PSV can be calculated following AD 2000-Merkblatt standard (Clause 6.3.3) using the following equations: PSV Reaction Force for Liquid Services in N, Fp=(dm*Vn/3600) Where, * m=Mass flow in Kg/hr * y,=velocity in the blow out opening=(qn*10°)/(3600*0,*An) * gy=density of the fluid in the blow out opening at the end of the pipe in kg/m? + Aq=Clear cross sectional area at blow out end of line in mm? For closed discharge PSV systems, there is no specific method to calculate the reaction force. Complex time history analysis can be used to exactly calculate the reaction force for closed discharge PSV systems. The reaction force application philosophy for open discharge PSV (PSV output discharges into the atmosphere) connected systems is the same throughout the process industries. But for closed discharge, PSV connected system the force application philosophy vari organization to organization. Some organization applies the reaction force for closed discharge PSVs but some organizations do not consider it. So user to follow the company- specific project guidelines is such cases. from Where to apply the PSV reaction force? The following figure (Fig. 2) shows the points where the reaction force is required to be applied for open discharge PSVs.Revove JDowavsards at exit fnorizemtalty and es vertically for east we AT Jasschorge with 45 lice elbow oan Garde PSV. [Fett down > Gade “Axial St. Frid dew Fig.2: Reaction force Application point for open discharge PSV connected systems Fig. 3 shows the application point (If required) of reaction forces for closed dis connected systems. sharge PSVApply reaction force at this bend Closed discharge PSV system Fig.3: Reaction force Application point for Closed discharge PSV connected systems Caesar Il Load Cases for PSV Connected Systems: PSV forces are considered as oceasional forces. So occasional Stress due to PSV reaction force has to be calculated and to be limited within 1.33 times Sh (As per code ASME B 31.3). Here Sh=Basic allowable stress at hot condition. Based on company practice PSV reaction force is added either with a design temperature case or with operating temperature case. Also, some organizations have the practice of making One PSV popping up and others stand by load cases. Accordingly, make the load cases as shown below:From. |10 Cena (Reducer te ONane | Eig (sree Tees 20 Cle wpanson done Restraints [Displacements ov 0h Changes Cy ange checks te Gere Hee E]NozdeLnt Cheok Dtitsete { » WEMtnvoen cade Diarreter: 10.7500 OWind / wave wusch03650 | Click this check box to mput forces: Note (102}590 | Allowable Stess Di Seem'welded Feo = Meteo Elete Mca) 2 S500 Coroton oui | Eadie), 2565007 fee can Etec Meds 12) | 286006007 FuitDent Ease Node) 2006 007 > Feisons Riso [02500 | SS Fig.4: Caesar II methodology to enter the reaction forceaes Lead Case Edicr [Load Cave Options WindLoade Leeds Defed Input Load Cases ‘Suess Type ani W Went TT Thermal Caco tt PI -Preseus Case it [vane IweTt Pa Iwert HP-Hyd. Pressure FI Cone Feroe Cace wert tra F2 Cone Force Cane t2 IweTt Paro Www Water File Weight LaLa WNE- Weight no cantents iz ia ist eet rat ig (rs HYD —— Hydrotest ‘GPE — Operating SESE a Lass ye ope ope cee eee Operating with PSv reaction force added —_{inpostLoad Cases| cE occasional eases stress CEC > (eherking as per code EP — Pury expancion for ones checking 2=per cade Fig.5: Caesar II simple load cases for analysis PSV connected system The following load cases assume two temperatures (T1=Operating temperature, T2=design temperature) along with Wind and Seismic load cases:Load Case Stress Description Type ul WwsHP HYD Hydrostatic Case L2 W+T14P1 OPE Operating temperature case L3. W+T2+P1 OPE Design temperature case 4 W+T14P 14F1 OPE Operating temp+PSV reaction ( PSV 1 popping up) L5 WHT14P14F2 OPE Operating temp+PSV reaction ( PSV 2 popping up) Le W#T14P 14WIN1 OPE Operating temp+Wind from North 7 W+T1+P 1+WIN2 OPE Operating temp+Wind from South Ls W#T1+P14WIN3 OPE Operating temp+Wind from East Lo W+T14P 1+WIN4 OPE Operating temp+Wind from West Lito W+T14P14U1 OPE Operating temp+Seismic from North un W+T1+P1-U1 OPE Operating temp+Seismic from South L12 WHT1 +P 1+U2 OPE Operating temp+Seismic from East L13 W+T14P1-U2 OPE Operating temp+Seismic from West Lia w+Pt SUS Sustained case Lis L4-L2 occ Pure PSV Reaction Li6 L5L2 occ Pure PSV Reaction 17 L6-L2 occ Pure Wind Lig L7-L2 occ Pure Wind Lig Le-L2 occ Pure WindL2o Lo-L2 occ Pure Wind Lat L10-12 occ Pure Seismic L22 Lat-L2 occ Pure Seismic L23 L122 occ Pure Seismic La L132 occ Pure Seismic Las L15+L14 occ Pure Occasional+Sustained L26 Lie+L14 occ Pure Occasional+Sustained Lar La7+L14 occ Pure Occasional+Sustained Las Lis+L14 occ Pure Occasional+Sustained Las Lig+L14 occ Pure Occasional+Sustained L30 L20+L14 occ Pure Occasional+Sustained L31 Lott occ Pure Occasional+Sustained L32 L22+L14 occ Pure Occasional+Sustained L33 L23+L14 occ Pure Occasional+Sustained L34 L24+L14 occ Pure Occasional+Sustained L35 L3-L14 EXP Pure Expansion L36 L214 EXP Pure Expansion Output Study: * Check Code stres: * Check forces for load cases from L1 to Liq. .s for load cases La, L14 and 1.25 to 136. Itis better to keep stresses for Li and L14 below 60% and for the rest within 80%. Better Engineering Practices + Itis a better practice to use 3-way restraints in both inlet and outlet piping of PSV connected systems if fe: ible (As shown in figure 2 and 3 above). However if not possible then try to provide 3-way restraint in outlet only by layout modification.+ In normal operating case Safety valve inlet line temperature will be operating temperature up to inlet of safety valve and Safety valve outlet line will be in ambient temperature up to the header. + Sometimes a Dynamic Load Factor (DLF) of 2 is used for calculating PSV reaction force. + Ifany stress failure or abnormal routing changes are required, then certain local area from header can be used average temperature for 2 meters or 5D which is higher (Safety valve outlet joining at header junction point) and also shall be taken process engineer's approval. + If required stress engineer shall provide R.F pad for the trunnion type support. + Ifconnection of PSV closed system is emerging from the header with 45° put SIF for this tapping. If required tapping point of the outlet line and outlet header shall be reinforced to reduce SIF. In case of any safety valve assembly is placed on top platform of any vessel, Support can be taken either from top platform or support can be arranged from the top portion of vessel taking clip from the vessel. In both the cases the load and locations of support or clip equipment vendor must be informed through the mechanical group along with the clip information. + Do not provide spring below safety valve inlet line Few more references for you Modelling Relief Valve (Pressure Safety Valve) Thrust force Routing Of Flare And Relief Valve Piping: An article Various types of pressure-relieving devices required for individual protection of pressure vessels in process plants References: + http://www -fem.unicamp.br/~lafer/im437/Capo3.pdf + https://www.sciencedirect.com/topics/materials-science/stress-analysis