Instrucalc 5 1 Manual 3p442y

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:\setup.exe from the Start menu where cdrom is your CD dive letter. Windows NT or Server (see special instructions in package)

For installation or minor technical help, call Gulf Publishing Company at: (713) 520-4428 or Fax (713) 525-4668 Or log onto our technical section of our website under "Software” at : www. gulfbub.com

For extensive inquiries (calculations, cosmetic, etc.) email the author directly at [email protected].

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What INSTRUCALC does for you INSTRUCALC is a set of engineering programs for calculating control valve, relief valve, pressure-relief devices and various flow element sizes. It also prepares data sheets and instrument summary reports. It is an engineering program rather than an application program inasmuch as it is capable of determining the basic engineering data and requirements for the equipment rather than just using the data to determine the size required.

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It consists of more than 74 programs divided into four main parts: 1 . Control Valves for liquid, gas, steam, and two-phase flow using the ISA formulas. There are programs for calculating Cv and analyzing for citation within the valve, critical flow and flashing through the valve, and noise generated by the valve. The Cv is compensated where necessary for these and the piping geometry effects. Messages are displayed to guide you to an optimum valve selection. 2. ISO Flow Elements for flow and restriction orifice plates; flow nozzles and venturies; gas, steam, vapor, and liquids; flange, radius, pipe, and comer taps. Concentric, eccentric, segmental, quadrant edge, and conical plates. Calculates Beta ratio and orifice bore. Calculates flow for a selected bore. Compatible with ISO 5167.

3. Relief Valves for pressure-relief devices, rupture discs, and breather valves. Liquid and gas application. Calculates API or ASME size for known flow, thermal expansion, and external fire. -The external fire program has the option of either the API or the NFPA heat input methods. It also calculates the maximum flowrate for the selected valve and the maximum back pressure, which maintains the required flow as well as the relieving forces.

Also included is a set of Auxiliary programs that determines line pressure drops for gas and liquids, calculates compressibility factor, flowing density, vapor pressure and temperature, latent heats at pressure and temperature and physical properties of mixtures. These programs are useful for many other engineering activities such as centrifugal pump line loss calculations and determining pressure available for control valve pressure drop. All device calculation and data sheet information can be saved for later recall. Printouts can be obtained of calculations, data sheets, and instrument summary reports. Any type of engineering unit can be used in the calculations. All conversion factors are contained within the programs to

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) change from one unit to another and to convert the values of the input data. Data can be imported and exported to and from the programs using ASCII files. Each module of INSTRUCALC allows you to perform these functions:

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Make calculations Prepare data sheets Prepare summary reports

Use the auxiliary programs to size more than 50 different instruments with this easy-to-use and accurate sizing program. The program not only calculates the sizes of control valves, flow elements, and relief devices, but it also produces data sheets for the calculated items. In addition, it lets you prepare instrument summaries and use the data sheets as a database for generating reports.

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What's new in Instrucalc Version 5.1

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Control Valves now have dynamic valve sizing as an additional option. Based on changing percentage of flow, the program has added a scrolling system to instantly give variety of data calculations.

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All Flow Elements programs (4) now have an option to calculate the dynamic inlet pressure for increased accuracy. (Never been available)

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For all devices, INSTRUCALC now provides, on an installed basis as compared with the old way of sizing on a shelf basis. This will go a long way to eliminate start-up problems.

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Procedures have been added to enable s to easily edit all technical data files. The can now easily customize the data to his own satisfaction.

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Automatically generate the paths that the data files are installed in. (This should solve the network problem)

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In the Relief Valve/Steam calculation section, the program used the steam density in error. This is now corrected

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The Flow program is applicable for sizes below 2" and beta values outside the limits of .2 to .75 . It is for the to define the limits which are applicable to the s project

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ASME nozzle losses are now printed.

Ofd Data Files Are Still Compatible All data files from previous versions are compatible. The file data for the changed programs remain as is unless the data are retrieved, recalculated, and saved. If the latter occurs, the data are then converted to the new formula requirements. xiii

New Ability to Transfer Data between Files A relational database system is used to store the data. The data for each record are stored in a random access file and the tag numbers and specification data are stored in sequential files. This provides the simplest data recall method with the most efficient use of memory and the fastest access time. The file size is only limited by computer memory. If the files for each project are kept separate (i.e., different disks or different paths), INSTRUCALC can handle any number of projects and keep all of the data separate and clean without any input. It is possible to transfer individual data between projects by calling up the data on path, editing the path and saving to a different file. Data can be imported to, and exported from, the programs.

We think you will find the INSTRUCALC 5.1 for Windows better than ever. If you have any suggestions, please write us and let us know. We will consider them for a newer version.

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Getting Around in This Manual The word “ program” can mean a variety of things. INSTRUCALC is a software program that contains five main programs that include calculation programs, a data sheet program and a summary program. Since this could get confusing, we will use other words to signify certain portions of INSTRUCALC. We will use the word "module" to refer to the five main programs: Control Valves, Auxiliary Programs, ISO Flow Elements, Relief Valves and Relief Devices. \

The options available in each module include sizing calculations, an option for producing a data sheet, and an option for generating summaries. These will be referred to as “ programs” or “ options.” The word “ program” will also be used to refer to INSTRUCALC as a whole. The more than 50 separate sizing programs will be referred to as “ routines” (for example, “ the Orifice Plate Concentric Flange Tap Sizing Routine” ). This should help you differentiate between the parts of INSTRUCALC as we explain them in this manual. This manual is divided into parts. Some parts of INSTRUCALC are common to INSTRUCALC modules and only require one explanation. The sizing programs are each different and so require separate explanations.

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Chapter 1

CONTROL VALVES Liquid Flow Gas Flow Two-Phase Flow Sizing Principles The control valve is a vital part of most control systems and is the most widely used final control element. To make a proper selection of the size and type can be very simple or very complex and it is not always obvious which it will be. INSTRUCALC assumes the worst and always does a complete engineering analysis of flowing

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conditions. Because many reliability and control problems can be created by installing the wrong valve, the time to avoid that is now.

Oversizing and Undersizing There is a tendency to oversize a control valve by taking the largest flow it will have to , doubling it to make it operate at the mid-point, and then picking the next available larger size. This can lead to poor control on low flows, with the control valve trying to regulate flow and bouncing on its seat.

For a control valve to regulate flow it must cause some pressure loss in the system. For this reason control valves are usually smaller than line size. If the pressure loss is unknown, then use the Line Pressure Drop program in the Auxiliary Routines and draw a system pressure curve. Then extract the pressure drop from this. Refer to the ISA Handbook of Contol Valves for the procedure. It is a rale of thumb that in a properly designed system the control valve size should be one size less than the line size. Spot checks over the years for deviations from this rule have shown that either the line was unintentionally too small or that some special circumstances applied , such as an unavoidable high pressure drop. Also it should be noted that published control-valve capacities are based on line-size valves, and a piping geometry correction factor is required and is provided in the program. The undersized-valve problem is very often caused by increased plant throughput. It can be solved by cracking open the by valve, but with variable flowrates this is likely to lead to control problems. A far better solution is to purchase the valve with a larger body and a reduced trim if future increased flowrates can be anticipated.

Selecting Body Style Selecting the body style is the most difficult decision to make when specifying a valve. Butterfly and similar high capacity valves offer most Cv per dollar, but there are many examples of misapplication that have caused considerable operating problems. For liquids the FL factor is the most useful guide to a logical selection of body style. Cavitation occurs more often than most people expect and should have the most influence in selecting the body style. Cooling water and heat transport fluids at moderate pressure drops have been found to cavitate. If cavitation is ignored, the valve may only control successfully for a short period of time before requiring maintenance or replacement. The FL factor does not offer a guide for body style selection for gases. Noise may determine the body style because of noise reduction trim, but generally, economics would determine the body selection.

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Noise Levels Valves in gas and vapor service experiencing large pressure drops can be the noisiest pieces of equipment in a plant (even while performing well and lasting a long time). The noise level may well be unacceptable these days and while it might be possible to reduce the noise with extra insulation, it is far better to recognize the problem now and find the best way of avoiding it by re-engineering the process to reduce the pressure drop or specifying special noise-reducing trim for the valve. !. .

Predicting the noise level generated by a control valve is not an exact science. Manufacturers tend to have their own methods for their own products and a standard calculation method has not yet evolved. The program uses the Masoneilan method to determine if there is a noise problem. This may not be accurate for all manufacturers but will be sufficient to make you aware that a problem may exist, so that you can take a remedial course of action immediately. The selected manufacturer will always have the final responsibility to propose equipment that meets all of the job requirements, so it will ultimately determine the noise value for the proposed valve for the service.

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The cost of not selecting the right valve for the job can be enormous. Anti-cavitation and low-noise control valves may seem expensive compared to standard valves, but their extra cost is minuscule when compared to an unplanned plant shutdown. A recent example was the failure through erosion of a valve on cooling water service. The cost of the shutdown which it caused was in excess of S250,000. Had INSTRUCALC been used, it would have predicted that there was an erosion problem but unfortunately it was not checked until after the event.

Formulas Used The formulas used in the calculations are those in ANSI/ISA-S75.01 and in ISA Handbook for Control Valves by J. W. Hutchison, and the Masoneilan noise prediction formula.

Materials of Construction

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The materials of construction for a control valve are normally selected to meet the . temperature and pressure requirements of the process and resist corrosion by the process fluid. Valves in severe service, in addition, may need special materials to resist erosion caused by cavitation or high pressure drops or to ensure a tight shutoff. The program will advise you of these possibilities.

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Sizing the Actuator

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The sizing of the actuator is the manufacturer's responsibility. Manufacturers are aware of the out-of-balance forces which are inherent in their designs and are most capable of selecting the best actuator for them. Be sure to specify the control air pressure range for the actuator sizing.

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Control Valve Rangeability

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The rangeability of a control valve is the range of flow conditions over which it can effectively control. This varies with control valve design. Therefore after the first run of the calculation has been made and the body style, trim style, and valve size have been selected, further calculations should be made to ensure that the valve will control over the range of flowrates and pressure drops that will be encountered in service. The Cv calculated is that for the data entered in the calculations.

Valve manufacturers list the rangeability of various types of valves, which can be as high as 50:1. This means that if the calculated Cv value for normal flow was 10 and it was expected that the valve would operate half open then a valve with a rated Cv of 20 would be selected which would be expected to provide satisfactory control down to a Cv of 0.4.

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So, determine the minimum flowrate and the maximum pressure drop that is expected and enter these values. Is the Cv more than the .4 minimum?. Now enter the maximum flowrate and the minimum pressure drop. Is the Cv less than the 20 maximum? If there are any other special conditions which must be met, then enter them. If the valve Cv range is exceeded, try different valve sizes or different valve body styles until the optimum is reached. Extreme cases may require more than one valve. For example, you may need a large valve for the high flows and a small one for the low flows, piped in parallel with the small one opening first and becoming wide open at 50% of the control signal, then the large one opening and becoming wide open at 100% of the control signal. By performing these calculations it is possible to select the optimum valve for the service and reduce the possibility of expensive surprises in the future.

Considerations for Liquid Flow The internal contours of some valve bodies are such that because of the relationship between velocity and pressure of the flowing fluid, the velocity of the liquid at one

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place in the body may have risen so high that the pressure falls below the vapor pressure of the liquid and pockets of vapor form. Farther along in the valve body the velocity may have \

decreased enough for the pressure to increase above the liquid vapor pressure. The vapor pockets implode with considerable noise and energy and can be extremely erosive. This is cavitation. It happens more often than most people expect and water is a common culprit. INSTRUCALC always checks for cavitation. To predict cavitation, manufacturers publish a liquid recovery coefficient (FL) to quantify the characteristic. A low FL number (e.g., 0.5 for an angle valve) signifies a valve which will cavitate quicker than a valve with a higher FL will ( e.g., 0.9 for a globe valve). The lower the FL the greater the tendency to cavitate. The program will calculate a minimum FL from the process conditions and display it at the time the selected valve FLis to be entered. To avoid cavitation, a valve with a larger FL should be used. If this is not possible, an anti-cavitation trim should be selected. This is a special hard trim designed to keep the implosions away from the softer metal in the body. If this is not possible, a heavier valve body should be considered to avoid premature failure because of metal erosion.

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Cavitation chokes the valve and reduces its capacity. The program recognizes this condition and compensates for it. When the discharge pressure is lower than the liquid vapor pressure, the liquid will flash into a vapor as it es through the valve. This is erosive on the valve body but not usually as severely as cavitation. Hardened trim is usually justified. Flashing also affects valve capacity and is allowed for in the calculation. The viscosity of the liquid must be compensated for if the Reynolds number is less than 4000 . For this, the valve-style modifier Fd is required.

Considerations for Gas and Steam Flow The first problem considered in the program is the minimum size valve for sonic velocity. It is very often possible to select a valve having an adequate Cv and yet still have sonic velocity at the outlet port. This creates a noise problem which cannot be overcome with a low-decibel trim. If the noise level of the valve is too high (and it most likely will be for all but the smallest valves), a valve larger than the sonic size must be selected to reduce the velocity to below sonic.

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The final Cv has corrections for the gas expansion factor and for piping geometry similar to those for the liquid calculation. The program will calculate the noise level if the optional data is entered. When the noise exceeds the allowable level (usually 80 dBA) and sonic velocity is not the problem, the level can be reduced by selecting a 5

special low-noise trim, by installing pipe with thicker wall, or by selecting a special valve. Extreme cases may require extra insulation on the pipe and auxiliary devices to take part of the pressure drop. Noise is normally calculated at actual operating conditions. Therefore, run this calculation for the operating flowrate, pressure drop and FL value for the percentage of valve open . It is not normally necessary to consider worst conditions because they are usually short-term, and noise will usually be tolerated for that time period.

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Considerations for Two-Phase Flow

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The program is a combination of the two previous programs and calculates Cv based on the effective specific weight of the mixture. Cavitation is checked for and should be handled as for liquid flow. « /

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CONTROL VALVES

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Program Overview

Version 5 has the capability of sizing the valves on an installed basis. First, the valve is sized for normal static flow as Case 2. Scroll bars in Case 1 increase the flow, the program computes the system flow and calculates the inlet pressure, valve pressure drop and fluid properties. The maximum controllable flow for the selected valve can be easily determined. Similarly scroll bars for Case 3 determine the minimum controllable flow. This solves the mystery of system flow. It clearly shows how the available pressure drop and fluid properties can vary considerably for different rates of flow and the optimum control valve size and type can be found . Three Programs are provided

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Liquid Flow Gas Flow Two Phase Flow Each program will calculate and save three different cases of flow conditions and has access to a sub program which will calculate the available control valve inlet pressures and pressure drops in the piping system for each case.

Options for each valve calculation are Calculate Valve Size Calculate Flow Rate Calculate Pressure Drop

Each uses the same formulas, rearranged to calculate the unknown variable.

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Once the pressure and temperature is entered the process data can be automatically entered using the Properties option and selecting the pure or mixture of process fluids from the Fluid Properties data bank.

The valve pressure drop can then be calculated using the Calculate System Pressure Drop option .

In Version 5.0 an additional input box was added for the control valve elevation, the headings of boxes for input and discharge pipe elevations was changed to inlet pipe start elevation and discharge pipe end elevation. The inputs to these boxes are now the plant elevations. This clarifies and simplifies the data and will require a change to exising data.

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In this calculation, after entering the source and destination pressure and details and elevations of the piping system, it will calculate the inlet pressure and pressure drop for each case. This data can be transferred to the valve calculation. Back in the calculation, the pressure has most likely changed making it necessary to reelect the process data from the fluid properties option, if the numbers are significantly different, rerun the pressure drop program. I

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The programs have a data base of Typical Valves so that different valve data can be entered into the calculation in order to make the best selection. Try several and calculate until a valve style and size is selected which has the rangeability and does not have cavitation or noise problems. When a final selection is made the exact manufacturers data can be entered for a final calculation. j

Finally, for liquid valves, take the option for the Minimum Closing Time this is the Water Hammer program to determine if a special closing time is required to avoid water hammer. General

If changes are made to data recalled from file, the data will he displayed in the color selected for changed data. This will assist in recognizing the affect the changes make to other calculations and the data sheet. Sizing Philosophy

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Each manufacturer has his own formula for determining the valve size, the valve noise and the cavitation characteristics. This program uses the ISA sizing formulas, it uses the Masoneilan noise prediction method and incipient cavitation technique. The object of the program is to determine the valve size, the cavitation, flashing and noise problems and prepare a data sheet suitable for bid purposes. Some manufacturers may differ from these conclusions, usually the variations are minor and do not change the size and style. Occasionally the noise and cavitation characteristics will differ so that some engineering judgment will be called for. The failure of a valve because of 7

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cavitation erosion is not unheard of and can be extremely expensive. Sometimes a change in body style is sufficient to eliminate the problem, hardened trim may be required . The cost at this time is usually small.. Some s will not even tolerate incipient cavitation. Be wary of the person trying for a cost advantage, months later when the valve has failed, he will sell you a new valve and you may have a huge bill. (Ver 5.0) The typical valve data file is an ASCII text file, three options of files are now available. They can be modified from within the program. The standard file is based on Masoneilan data. If you prefer another manufacturer then edit the other valve files to whatever you choose. If the manufacturer does not use the incipient cavitation factor (Kc) then enter a zero or leave the box empty. ISA S75 shows data for a typical file.

The pressure drop can then be calculated using the Calculate Pressure Drop option. In Version 5.0 an additional input box was added for the control valve elevation, the headings of boxes for input and discharge pipe elevations was changed to inlet pipe start elevation and discharge pipe end elevation. The inputs to these boxes are now the plant elevations. This clarifies and simplifies the data and will require a change to existing data. In this calculation, after entering the source and destination pressure and details and elevations of the piping system, it will calculate the inlet pressure and pressure drop for each case. This data can be transferred to the valve calculation. Back in the calculation, the pressure has most likely changed making it necessary to reelect the process data from the fluid properties option, if the numbers are significantly different, rerun the pressure drop program.

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The programs have a data base of Typical Valves so that different valve data can be entered into the calculation in order to make the best selection. Try several and calculate until a valve style and size is selected which has the rangeability and does not have cavitation or noise problems. When a final selection is made, the exact manufacturer’ s data can be entered for a final calculation.

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Finally, for liquid valves, take thè option for the Closing Time . This is the Water Hammer program to determine if a special closing time is required to avoid water hammer.

CONTROL VALVE - Program Features :

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Perform sizing calculations

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Calculate either control valve size, flow rate or pressure drop Calculate piping system pressure drop Calculate the cavitation index Calculate the noise level Supply typical valve data Supply fluid properties at flow conditions Supply steam data Supply pipe sizes Use English or SI engineering units in any mixture Use mass or volume flow units Import process data Print a calculation sheet using the Windows Print Manager Save the data

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Prepare instrument data sheets

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WYSIWYG style Initially generate sheets for bid purposes Supply database of standard specification items After vendor selection, revise for permanent records Print a data sheet using the Windows Print Manager Save the data

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Print a summary of saved records Print all records Print selected records Print only records having required characteristics

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This is a program for calculating the size of control valves. The available options are: Liquid flow Gas, steam or vapor flow Two phase flow

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CONTROL VALVE Program Menu Options

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New calculation Select the required calculation option and the fluid option, then select OK (or double-click if at least one of the options is already selected). File

Default files Recalls file data using the files in the default drives and paths. Other files Recalls file data using the Windows file selection procedure. Data file maintenance Edit Tag Numbers Provides the facility to change the Tag Numbers on file. Or delete records from file. Sort data file Rearrange the Tag Numbers in ascending order. Delete the items marked if the edit was saved .

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File default path

Data files Path for the default calculation data files. units Path for the default engineering units. Headings Path for the printout headings. There are three paths. If a Drive and Path different from the Default Path and Drive provided in the initial Set Up Procedure was used, the program will update them to the Drive and Path which was installed. They are saved in sequential file CVWCALC.DRV which resides with the programs. To check or change the paths, either call up the Drive and Path for edit or use a text editor to or change the file contents. Convert V3 file stage 2 Edit Tables (Version 5.1) InstruCalc uses Data Tables for Gas, Liquid, Pipe Size and Pipe Modulus properties, these contain data from which exact properties for the flow conditions are calculated . It also has 3 tables for Valve data. These option provides an easy means of customizing them. Items can be added, inserted , deleted and changed. Restrictions are built into the Materials Coefficient of Expansion table on insertion and deletion because the row number is used to save data in the calculations. Each program can edit the tables used in the program. Take note that some, such as the Gas, Liquid and Pipe Size are used by other programs and may include data required only by them. Editing is performed by either clicking the appropriate line in the Grid or entering the line number in Row to Edit and clicking Recall Row. Edit the data and Load Row to the Grid. When a box in the edit line is clicked, infonnation on the data required is displayed above. Save Grid overwrites the old file. A backup file is recommended before you start. The file name is in the heading of the Edit Form and the files are in the program directory. Note that data cannot be edited directly in the grid.

Exit Exits from Instrucalc to Windows Program Manager. Color

Provides color options for InstruCalc displays, using the Windows palette.

Note that colors for scroll bars, command buttons, disabled text, borders etc., are selected through the Windows Control Print Summary Goes to the print summary program.

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CONTROL VALVE Program Lead Sheet The program will only stop at the Lead Sheet if it fails to find the default paths file. To continue, type in the paths and save the file. The Data Files are specific to a project and an instrument type The Units File may be common for all projects and specific for an instrument type The Headings File may be specific for a project and common for all instruments

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Control Valve Size - Liquid Calculation 5

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Three calculation cases are available. The data sheet program uses Case 1 as the maximum flow condition, Case 2 as the normal flow condition and Case 3 as the minimum flow condition. Other than this, cases can be used as required. If the piping configuration and the source and destination pressure are known, the inlet pressure and the pressure drop across the valve can be calculated using the Calculate Pressure Drop option. (Version5 ) Three Typical valve data selections

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for many different valve types are available to into the calculation. The selections should be edited for the requirements. Refer to ISA S75 for a guide. Kc is the incipient cavitation factor, If the manufacturer does not provide it, then substitute the FL factor. Process data for many different fluids and mixtures can be ed into the calculation . If the valve is controlling a long column of liquid, the minimum valve closing time should be calculated using the closing time option. The data files are in ASCII format and can be customized to the s preference.

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Units

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There are four standard unit sets and one selected set available: !

Mass Flow - English Units . Volume Flow - English Units .

Pounds per hour and degrees Fahrenheit US gallons per minute and degrees Fahrenheit Kilograms per second and degrees Centigrade Liters per second and degrees Centigrade A set of units selected from the Liquid Flow Engineering Unit screen To make or change a Unit set select this option . The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file.

Mass Flow - SI Units. Volume Flow - SI Units . Units. Review units

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Unit Selection

A new calculation defaults to Mass English Units . :

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The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity is not available, the flow is set to zero. Units for any individual input entry can be changed

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by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen.

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Base Conditions

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The Base Conditions option will display the current values of base pressure, base temperature and barometric pressure. They should be checked and modified and saved to suit the operating conditions. AGA specifies a base pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°.

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Fluid Properties

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The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply.

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For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered.

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For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties data base is updateable. Calculation options are: Valve size Flowrate Pressure drop

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Select the calculation option and the necessary input data is enabled. The required variable will be disabled and will receive the calculated value. The Pressure drop and Flowrate options are back calculations with those being the only unknowns in the valve calculation .

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Procedure The enabled input boxes define the data required for the calculation .

To calculate the valve size

1

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Enter the flow rates, the percent of system flow the flow temperature and your best estimate of the inlet pressure. Either Select the option Case 1 properties and select the fluid. Repeat for Case 2 and 3. Or enter the process data

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Enter then inlet and outlet nominal pipe sizes. Select wall and the wall thickness. If the pressure drop is unknown then select the option Calculate pressure drop. The Pressure Drop Calculation Form will be displayed. Enter the piping configuration, the pipe lengths, the pipe material and the pipe condition. Enter the source pressure and the inlet equipment losses. Enter the outlet equipment losses and the destination pressure. Calculate by clicking Case 1, Case 2 and Case 3 Analyze the data, if the source pressure is a pump the pressure will decrease with an increase of flow. Change and calculate. Click Case 1, 2 and 3 to transfer data to the valve calculation. Click OK to go back to the Valve Calculation. The new inlet pressure and the pressure drop have been added. If the new inlet pressure is significantly different, the process data again. Select the Typical Valve Data option and choose the valve type. Click Case 1, Case 2, and Case 3. Editing Data

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The output data should be examined for adequacy. The flow status should be normal. If not try different valve styles. If cavitation persists, specify cavitation trim. If flashing is occurring, hard trim should be specified . The valve size is larger than the line size then the flowrate or line size is incorrect. Will the valve control at the pressure drops and percent of valve Cv in the output data? 15

)

Change data as required and recalculate until a satisfactory valve is found.

If you are going out for bids, then this data is adequate. If the manufacturer has been determined, then overwrite the typical data with the manufacturer’ s data for the selected valve style and recalculate. Dynamic Valve Sizing

(Version 5.1)

Very often the only process data available is for normal flow. This is adequate for calculating the normal Cv but is not adequate for sizing the maximum and minimum flows.

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The pressure loss in a piping system varies with the flowrate and since the object of the control valve is to vary the flowrate, it follows that the control valves inlet pressure and pressure drop and fluid properties will also vary with each change of flow and therefore the required calculated Cv will not be linear with the rate of flow.

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The manufacturers publish the range of Cv which a valve will successfully control. Typically 2% to 100%. But because of the non-linearity of Cv and rate of flow, what range of flows will the combined control valve and piping system allow? (The system rangeability).

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Static control valve sizing requires that considerable manual data entry to be made to find this out. It is a function of valve selection and pipe size with different process data for each rate of flow

i

In the program, the valve and piping installation can be modeled to dynamically find the system rangeability using the Scroll bars at the top of the Case 1 and Case 3 buttons. This procedure requires the use of the subroutines in the options for Typical valve data, Fluid properties and Calc system pressure drop. First the valve is sized using static conditions for normal flow in Case2. Select the Typical valve data option, Enter the normal pressure and temperature, select the Fluid properties option, select the option to Calc the system pressure drop, enter the system data and the static normal flow conditions in Case2 and calculate. If the source pressure varies with flowrate, as it will for centrifugal pumps and compressors, enter the static source pressures for the maximum and minimum flowrates. Transfer Case2 data and click OK. to go back to the Valve sizing form. If the valve inlet pressure is now different from that calculated in the system pressure drop calculation, re-select the fluid properties and repeat the above procedure.

Now, use the scroll bars to change the flowrates. Using the normal conditions as a base, the program will recalculate the equipment losses , recalculate the valve inlet 16

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)

pressure and pressure drop, recalculate the fluid properties and recalculate the valve Cv. If values for source pressure at maximum and minimum flowrates were entered in the Pressure drop calculation form, then the source pressure is also recalculated for each flowrate. If the input boxes are left blank, the normal static source pressure is used. While scrolling for the maximum flow, if the calculated Percent of Cv exceeds 100 then a message box will ask if a larger valve is required. A No answer will complete tire calculation showing the Percent of Cv to be greater than 100, a Yes will change the valve size and the show the appropriate value and will require the recalculation of the other two cases.

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Control valves very often have a rangeabilty of 50:1 . If the maximum flow is scrolled up to 100 Percent of valve Cv and the minimum flow is scrolled to 2 Percent of valve Cv, (a range of 50:1), then the system rangeability is the maximum flowrate divided by the minimum flowrate. It is usually a lot less than the 50:1 for the valve. i :i

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Is the rangeability adequate? Is a larger pipe required? At 100% of system flow does the valve have a margin of extra capacity? Does it have too much? Is a smaller valve required?. Can the flow be turned down far enough without the valve bouncing on the seat? Is the pipe too large? Change the data to find the optimum conditions.

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The number at the bottom of the screen is the number of calculations performed to achieve the results.

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Filing and Moving On ;j

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The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New Record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New Using the default path, it saves an existing record as a new record (Used to duplicate similar items i .e. Recall an existing record. Edit as required and Save New) Save As.,. . Uses the Windows file access system. Saves to a file anywhere. Import case data (1, 2 or 3) - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation

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The default paths are: The Data Files.

(CVWDAT.TAG and CVWDAT.DAT). i

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The Unit Files. (CVWDAT.UNS) The Printout Headings File (HEADINGS.DAT) Print valve calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager

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The screen shows the process variables used in a liquid calculation and list the available options. To assure full coverage, (Except Flow Time Base) each has an Other option. This is a defined unit. Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list. The screen shows the current selection . Any unit may be selected and will be used in the calculation if OK is selected. To create a File for the File Unit option in the calculation, select the desired units and click the save button. A double click on any unit option selects that option and returns to the calculation. Data conversion For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted. The Flow Quantity option has Mass 18

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and Volume options. The relationship between mass flow and volume flow is a multiplier and the specific gravity of the fluid. If the flow units are changed from mass to volume, or volume to mass and the specific gravity is not available the flow rate is set to zero. Conversion factors and units are based on API 2564

Definition of units

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Mass flow units : lb = pounds kg = kilograms tonne = 1000 kg 1Mg g = gram UKton = 2240 lb USton 2000 lb Other = defined mass unit Volume flow units :

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USgal = US gallons litre = litres ft3 = cubic feet UKgal = UK gallons m3 cubic metres bbl = barrels (42 US gallons) cm3 = cubic centimetres Other defined volumetric unit Flow time base : /s = per second /m = per minute /h = per hour /d = per day Gauge pressure : psig = pounds per square inch gauge kPag = kiloPascals gauge atg = atmospheres gauge inhgg = inches of mercury gauge MPag = megaPascals gauge inH20g = inches of water gauge mmhgg = millimetres of mercury gauge barg = bars gauge kg/cm2g = kilograms per square centimetre gauge Other = defined gauge pressure unit Pressure drop : psi = pounds per square inch

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inhg = inches of mercury MPa = megaPascals inH20 = inches of water mmhg = millimetres of mercury bar = bars kg/cm2 - kilograms per square centimetre Other = defined pressure drop unit Absolute pressure : psia = pounds per square inch absolute kPaa = kiloPascals absolute ata = atmospheres absolute inhga = inches of mercury absolute MPaa = megaPascals absolute inH20a = inches of water absolute mmhga = millimetres mercury of absolute bara = bars absolute kg/cm2a = kilograms per square centimetre absolute Other = defined absolute pressure unit Temperature : degF = degrees Fahrenheit degF = degrees Centigrade degR = degrees Rankine degK = degrees Kelvin Other = defined temperature unit Velocity ft/s = feet per second m/s - metres per second Other - defined velocity Viscosity : = centipoises Pa.s = Pascal seconds cs = centistokes kPa.s = kiloPascal seconds Other = defined viscosity unit Pipe and valve diameter : in = inches

mm = millimetres cm = centimetres ft = feet m = metres Other = defined size Length and elevation : ft = feet m = metres Other = defined length

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This is a combination of the liquid and gas programs. It is based on the effective specific weight of the two-phase mixture. Cavitation is handled as a liquid , if there is a large amount of gas then cavitation is unlikely. Three calculation cases are available, the data sheet program uses Case 1 as the maximum flow condition, Case 2 as the normal flow condition and Case 3 as the minimum flow condition . Other than this, cases can be used as required.

If the piping configuration and the source and destination pressure is known, the inlet pressure and the pressure drop across the valve can be calculated using the Calculate pressure drop option . )

Typical valve data for many different valve types is available to into the calculation. 21

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— -) Process data for many different fluids and mixtures can be ed into the calculation. If the valve is controlling a long column of liquid, the minimum valve closing time should be calculated using the closing time option.

The data files are in ASCII format and can be customized to the ’s preference. :

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Engineering Units

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There are four standard unit sets and one selected set available:

Mass Flow - English Units . Volume Flow - English Units.

Mass Flow - SI Units Volume Flow - SI Units . Units

Gas and liquid in pounds per hour and degrees Fahrenheit Gas in standard cubic feet per minute and degrees Fahrenheit Liquid in US gallons per minute and degrees Fahrenheit Gas and liquid in kilograms per second and degrees Centigrade Gas in standard cubic decimeters per second and degrees Centigrade Liquid in litres per second and degrees Centigrade A set of units selected from either the Liquid Flow Engineering Unit or the Gas Flow Engineering Unit screen

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To make or change a Unit set select the option Review units. The Liquid or Gas Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file.

Unit Selection

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A new calculation defaults to Mass English Units .

The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity is not available the flow is set to zero. Units for any individual input entry can be changed by selecting the Review Units option and choosing from the Liquid or Gas Flow Engineering Unit screen .

Base Conditions The Base Conditions option will display the current values of base pressure, base temperature and barometric pressure. They should be checked and modified and saved to suit the operating conditions. AGA specifies a base pressure of 14.73 psia for 22

natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°. ISO specifies 14.696 psia and 59°. Fluid Properties

The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for either pure liquids or gases and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply.

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For a pure liquid or gas find the name and select (or double-click) the name, the fluid properties will be entered. )

For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties data base is updateable

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Calculation options are: Valve size Pressure drop

1

Select the calculation option and the necessary input data is enabled. The required variable will be disabled and will receive the calculated value. The Pressure drop and Flowrate options are back calculations with those being the only unknowns in the valve calculation.

Procedure The enabled input boxes define the data required for the calculation. To Calculate the Valve Size Enter the flow rates, the flow temperature and your best estimate of the inlet

pressure. Select the option Case 1 properties and select the fluid . Repeat for Case 2 and Case 3. The program expects that Case 1 will he the maximum flow, Case 2 the average and Case 3 the minimum. The standard typical file supplies valve data for 100 % 50% and 10% of valve capacity The process data are calculated from published formulae, it is sufficiently accurate for most calculations. If you have more accurate data it can be manually entered. The percent of system flow input enables the valve size and valve rated to be calculated for the typical valve data in each case. Enter then inlet and outlet nominal pipe sizes 23

>

Select wall and the wall thickness. If the pressure drop is unknown then select the option Calculate pressure drop . The Pressure Drop Calculation Form will be displayed. Enter the piping configuration, the pipe lengths, the pipe material and the pipe condition. Enter the source pressure and the inlet equipment losses. Enter the outlet equipment losses and the destination pressure. Calculate by clicking Case 1, Case 2 and Case 3

I

Analyze the data, if the source pressure is a centrifugal pump, the pressure will decrease with an increase of flow. Change and calculate. The input boxes for minimum and maximum flow source pressures are only used for the dynamic sizing described below. Click Case 1,2 and 3 to transfer data to the valve calculation. Click OK to go back to the Valve Calculation. The new inlet pressure and the pressure drop have been added . If the new inlet pressure is significantly different, the process data again. Select the Typical Valve Data option and choose the valve type. If Kc (the incipient cavitation index) is not available then leave the box blank. Click Case 1, Case 2, and Case 3 The number appearing in the bottom right hand comer is the number of calculations (i.e. the square root of (1+X) is 3) and logic operations (IF, And, OR), performed.

r

) Editing Data

If changes axe made to data recalled from file, the data will be displayed in the color selected for changed data. This will assist in recognizing the affect the changes make to other calculations and the data sheet. If the calculated percent of valve is more than the percent of system flow an error message will ask if you -wish to increase the valve size, this will enable you to optimize the valve size. Once a value for the valve size is available, the program will only overwrite it via the error message,. If you wish to start over, then zero out the valve size and recalculate, or just overwrite your desired valve and rated sizes and recalculate. The relationship between the percent of system flow and the percent of valve capacity is an indication of the valve rangeability, the excess capacity of the valve and the normal operating capacity of the valve. It should be noted that the typical valve data values for are based on the system percentage flow whereas they are really dependent on the percentage of valve opening. This is normally insignificant but can be overwritten if desired.

The output data should be examined for adequacy. The flow status should be normal . If not try different valve styles. If cavitation persists, specify cavitation trim.

24

The valve size is larger than the line size then the flowrate or line size is incorrect. Will the valve control at the pressure drops and percent of valve Cv in the output data? Is the rangeability adequate? At 100% of system flow does the valve have a margin of extra capacity? Does it have too much?. Is a smaller valve required Change data as required and recalculate until a satisfactory valve is found . If you are going out for bids, then this data is adequate. If the manufacturer has been determined , then overwrite the typical data with the manufacturers data for the selected valve style and recalculate. Dynamic Valve Sizing

(Version 5.1)

Very often the only process data available is for normal flow. This is adequate for calculating the normal Cv but is not adequate for sizing the maximum and minimum flows. The pressure loss in a piping system varies with the flowrate and since the object of the control valve is to vary the flowrate, it follows that the control valves inlet pressure and pressure drop and fluid properties will also vary with each change of flow and therefore the required calculated Cv will not be linear with the rate of flow. The manufacturers publish the range of Cv which a valve will successfully control. Typically 2% to 100%. But because of the non-linearity of Cv and rate of flow, what range of flows will the combined control valve and piping system allow? (The system rangeability).

Static control valve sizing requires that considerable manual data entry to be made to find this out. It is a function of valve selection and pipe size with different process data for each rate of flow

In the program, the valve and piping installation can be modeled to dynamically find the system rangeability using the Scroll bars at the top of the Case 1 and Case 3 buttons. This procedure requires the use of the subroutines in the options for Typical valve data, Fluid properties and Calc system pressure drop. ,

First the valve is sized using static conditions for normal flow in Case2. Select the Typical valve data option, Enter the normal pressure and temperature, select the Fluid properties option, select the option to Calc the system pressure drop, enter the system data and the static normal flow conditions in Case2 and calculate. If the source pressure varies with flowrate, as it will for centrifugal pumps and compressors, enter the static source pressures for the maximum and minimum flowrates. Transfer Case2 data and click OK. to go back to the Valve sizing form. If the valve inlet pressure is

25

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now different from that calculated in the system pressure drop calculation, re-select the fluid properties and repeat the above procedure.

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Now, use the scroll bars to change the flowrates. Using the normal conditions as a base, the program will recalculate the equipment losses, recalculate the valve inlet pressure and pressure drop, recalculate the fluid properties and recalculate the valve Cv. If values for source pressure at maximum and minimum flowrates were entered in the Pressure drop calculation form, then the source pressure is also recalculated for each flowrate. If the input boxes are left blank, the normal static source pressure is used. While scrolling for the maximum flow, if the calculated Percent of Cv exceeds 100 then a message box will ask if a larger valve is required. A No answer will complete the calculation showing the Percent of Cv to be greater than 100, a Yes will change the valve size and the show the appropriate value and will require the recalculation of the other two cases.

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Control valves very often have a rangeabilty of 50:1. If the maximum flow is scrolled up to 100 Percent of valve Cv and the minimum flow is scrolled to 2 Percent of valve Cv, ( a range of 50:1), then the system rangeability is the maximum flowrate divided by the minimum flowrate. It is usually a lot less than the 50:1 for the valve. Is the rangeability adequate? Is a larger pipe required? At 100% of system flow does the valve have a margin of extra capacity? Does it have too much? Is a smaller valve required?. Can the flow be turned down far enough without the valve bouncing on the seat? Is the pipe too large? Change the data to find the optimum conditions.

J

The number at the bottom of the screen is the number of calculations performed to achieve the results Filing and Moving On

The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New Using the default path, it saves an existing record as a new record (used to duplicate similar items, i.e. recall an existing record . Edit as required and Save New). Save As.... - Uses the Windows file access system. Saves to a file anywhere. Import case data (1, 2 or 3) - Select the units and read Input data supplied in sequential files.

-

-

26

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:

File default path - Changes the default paths for the calculation records. The default paths are The Data Files. (CVWDAT.TAG and CVWDAT.DAT). The Unit Files. (CVWDAT.UNS) The Printout Headings File (HEADINGS.DAT) Print valve calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program

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CONTROL VALVE Calculation Data Printout This program will print the input and output calculation data and one associated comment . The comment is included in the data sheet for reference purposes.

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It also creates the default printout headings. The headings are printed at the top of all printouts. They are saved in the HEADINGS.DAT file. This is the third default path. If all programs are set to the same path, this becomes the default headings for all program printouts .

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CONTROL VALVE Data Sheet Octogon Enginering Corporation Control Valve - Liquid flow Spec.

Plant Co nv el'sion 2001 Update

Project 2314

Sheet Rev.

Req. By

Date 11/18/01 Appr .

Tag Number: FCVM 00

Valve Body

Actuator

Positioner

Transducer Options

Service

Conditions

Selected Valve

1 ) Body Type:

Port Size: Number of ports:

3 in 2) Body size: 3) Guiding: 4) End connections: 5) Body material: 6) Shaft material: 7) Lubricator: 8) Bonnet type: 9) Seat and plug material: 10} Seat tightness: 11 ) Model and size: 12) 13) 14) 15 ) 16) 17 )

Type:

Rating: Packing material: Isolating valve: Trim form:

Allowable sound level:

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Close at:

Open at:

Row to open or close? Fail position: Handwheel and location: Make and model: 18) Filter regulator: 19) Input signal: 20) Air supply pressure: 21) Make and model: 22) Input signal : 23) Option l . 24) Option 2: 25 ) Option 3: 26 ) Service; 27) Line number: 28) Inlet pipe size: 29) Outlet pipe wall thickness: 30) Fluid name: 1135000 lb/h 31) Maximum flow: 1135000 lb/ h 32) Normal flow: 900 33) Valve Cv: 185 psig 34) Normal inlet pressure: 35) Maximum inlet pressure: 185 psig 36) Maximum shutopp differential pressure: 290 degF 37) Normal temperature: 38 ) SG at FTP: .97 6 . 39 ) Viscosity at FTP: 40) Vapor pressure: 58 psia 41) Valve sound level dbA:

| By:

Gages:

Output signal:

Output signal:

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42) Manufacturer:

.

Outlet pipe size:

Fluid state: Liquid 275.5 Normal Cv: 2 Valve FL: Pressure drop: 70 psi

185 psi Max temperature: 290 degF

Critical pressure: 3205 psia

. .. .

.

'

43) Model:

28

..

. '

The first use of the data sheet is to obtain competitive bids. It should initially emphasize the engineering requirements and be fairly general regarding the details. When a vendor is selected it should be updated to the exact details so that the data sheet is a record of the instrument purchased.

The relevant data from the calculation is automatically displayed. Minor editing, such as rounding can be performed. Major editing should be done in the calculation routine in order to preserve the integrity of the calculation.

! L

A defined database is available to enter data for those inputs which have a limited number of options. To activate this, double click the input box, the data on file is displayed. Double click the required option and the data is transferred to the data sheet form.

!

The data base should be customized for the project requirements. To edit the data; click the selected item. Edit the data in the active top line, select Replace, continue with the edit and Save on completion. The Input data menu option has option to enter either the first or the second item in the list for all items. If the data base is constructed so that the first item is the first standard selection and the second item is the second standard selection then two standard data sheets are available for a single keystroke. This feature only enters data into empty input boxes.

[

Some input boxes require unique data which is typed in. Space is provided to enter information for non standard options. Enter the title and data, it will be saved with the other data. Three lines of notes of special instructions are available at the bottom of the data sheet. The input data is limited to 25 characters and 60 characters for each of the notes. i

•

Data Sheet File options Print data sheet - Prints the data sheet using the Windows Print Manager. Refer to Windows Help. Go to calculation - Returns to the calculation form using the same record Update headings - Overwrites the headings with the current default set

29

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Control Valve Size - Gas Calculation

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Three calculation cases are available, the data sheet program uses Case 1 as the maximum flow condition, Case 2 as the normal flow condition and Case 3 as the minimum flow condition. Other than this, cases can be used as required.

If the piping configuration and the source and destination pressure is known, the inlet pressure and the pressure drop across the valve can be calculated using the Calculate pressure drop option. Typical valve data for many different valve types is available to into the calculation . Process data for many different fluids and mixtures can be ed into the calculation. The data files are in ASCII format and can be customized to the s preference. ?

:-

30

1

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Engineering Units


Mass Flow - English Units. Volume Flow - English Units. Mass Flow - SI Units. Volume Flow - SI Units. Units.

Pounds per hour and degrees Fahrenheit Standard cubic feet per minute and degrees Fahrenheit Kilograms per second and degrees Centigrade Standard cubic decimeters per second and degrees Centigrade A set of units selected from the Gas Flow Engineering Unit screen

To make or change a Unit set select the option Review units . The Gas Flow Engineering Unit screen will be displayed . It shows the available options and the current unit selection.

Select the required units and save the file.

Unit Selection

A new calculation defaults to Mass English Units . The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity is not available the flow is set to zero. Units for any individual input entry can be changed by selecting the Review Units option and choosing from the Gas Flow Engineering Unit screen.

Base Conditions The Base Conditions option will display the current values of base pressure, base temperature and barometric pressure. They should be checked and modified and saved to suit the operating conditions . AGA specifies abase pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°.

Fluid Properties

The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure gases and 31

!

)

mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply. For a pure gas find the name and select (or double-click) the name, the fluid properties will be entered.

:

For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is updateable.

• 1

Calculation options are:

Valve size Flowrate Pressure drop Ml

:

Valve size Os Flowrate • . Pressure dro

^

Select the calculation option and the necessary input data is enabled. The required variable will be disabled and will receive the calculated value. The Pressure drop and Flowrate options are back calculations with those being the only unknowns in the valve calculation. Procedure The enabled input boxes define the data required for the calculation .

To calculate the valve size Enter the flow rates, the percent of system flow the flow temperature and your best estimate of the inlet pressure. Either Select the option Case 1 properties and select the fluid. Repeat for Case 2 and 3.

Or enter the process data Enter the inlet and outlet nominal pipe sizes. Select wall and the wall thickness. If the pressure drop is unknown then select the option Calculate pressure drop. The Pressure Drop Calculation Form will be displayed. Enter the piping configuration, the pipe lengths, the pipe material and the pipe condition. 32

)

)

Enter the source pressure and the inlet equipment losses. Enter the outlet equipment losses and the destination pressure. Calculate by clicking Case 1 , Case 2 and Case 3. Analyze the data, if the source pressure is a pump the pressure will decrease with an increase of flow. Change and calculate. Click Case 1, 2 and 3 to transfer data to the valve calculation. Click OK to go back to the Valve Calculation. The new inlet pressure and the pressure drop have been added. If the new inlet pressure is significantly different, the process data again. Then run the pressure drop calculation again. Select the Typical Valve Data option and choose the valve type. Click Case 1, Case 2 , and Case 3.

Editing Data

)

The output data should be examined for adequacy. The flow status should be normal. If not, try different valve styles. Noise is only a problem at normal flows. If the noise level is too high a low db valve. If it is still too high, other devices may be necessary to reduce the pressure drop. If the valve size is larger than the line size, the flowrate or line size is incorrect. Will the valve control at the pressure drops and percent of valve Cv in the output data? Change data as required and recalculate until a satisfactory valve is found. If you are going out for bids, then this data is adequate. If the manufacturer has been determined, overwrite the typical data with the manufacturer’ s data for the selected valve style and recalculate.

Filing and Moving On

The options in the File menu are: Program menu Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save Using the default path, it saves a new record if not previously saved or saves changes to an existing record .

-

-

33

:

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Save New - Using the default path, it saves an existing record as a new record (used to duplicate similar items, i.e. recall an existing record. Edit as required and Save New) Save As . . .. - Uses the Windows file access system. Saves to a file anywhere. Import case data ( I, 2, or 3) - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records The default paths are: The Data Files. (CVWDAT.TAG and CVWDAT.DAT). The Unit Files. (CVWDAT.UNS) The Printout Headings File (HEADINGS.DAT) Print valve calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager

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CONTROL VALVE Gas Engineering Units

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Control

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The screen shows the process variables used in a liquid calculation and lists the available options. To assure full coverage, each (except Flow Time Base) has an “ Other” option . This is a defined unit. Double click the option and it will 34

!

display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list. The screen shows the current selection. Any unit may be selected and will be used in the calculation if OK is selected.

To create a File for the File Unit option in the calculation, select the desired units and click the save button. A double click on any unit option selects that option and returns to the calculation.

Data Conversion For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted. The Flow Quantity option has Mass and Volume options. The relationship between mass flow and volume flow is a multiplier and the molecular weight of the gas conversion can only be made when the molecular weight has been entered.

Definition of units

)

)

Mass flow units : lb = pounds kg = kilograms tonne = 1000 kg = lMg g = gram UKton = 2240 lb USton = 2000 lb Other = defined mass unit Volume flow units : sft3 = standard cubic feet sdm3 = standard cubic decimetres sm3 = standard cubic metres Msft3 = million standard cubic feet Other = defined volume unit Time base : /s = per second /m = per minute /h = per hour /d - per day Gauge pressure : psig = pounds per square inch gauge kPag = kiloPascals gauge atg = atmospheres gauge 35

\

inhgg = inches of mercury gauge MPag = megaPascals gauge inH20g = inches of water gauge mmhgg = millimetres of mercury gauge barg = bars gauge kg/cm2g = kilograms per square centimetre gauge Other = defined gauge pressure unit Pressure drop : psi = pounds per square inch kPa = kiloPascals at = atmospheres inhg = inches of mercury MPa = megaPascals inH20 = inches of water mmhg = millimetres of mercury bar = bars kg/cm2 = kilograms per square centimetre Other = defined pressure drop unit Density lb/ft3 = pounds per cubic foot kg/m3 = kilograms per cubic metre g/cm3 = grams per cubic centimetre lb/in3 = pounds per cubic inch Other = defined density unit Absolute pressure : psia = pounds per square inch absolute kPaa = kiloPascals absolute ata = atmospheres absolute inhga = inches of mercury absolute MPaa = megaPascals absolute inH20a = inches of water absolute mmhga = millimetres of mercury absolute bara = bars absolute kg/ cm2a = kilograms per square centimetre absolute Other = defined absolute pressure unit Temperature : degF = degrees Fahrenheit degF = degrees Centigrade degR - degrees Rankine degK = degrees Kelvin Other - defined temperature unit Velocity ft/s = feet per second m /s = metres per second Other = defined velocity 36

)

I

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1

:

)

)

Viscosity :

= centipoises Pa.s = Pascal seconds cs = centistokes kPa.s = kiloPascal seconds Other = defined viscosity unit Pipe and valve diameter : in = inches mm = millimetres cm = centimetres ft = feet m = metres Other = defined size Length and elevation : ft = feet m = metres Other = defined length

1:

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; I 7

PRINT (CONTROL VALVE) Summary

j :

The program will provide a printout summary of data sheet records on file. It is accessed from the main Control Valve program options screen. It can provide a printout of either:

All fields Selected fields Fields equal to Fields not equal to Fields equal to or less than Fields equal to or greater than Fields less than Fields more than

:

Procedure for a new Summary

Select Options

Clears all checks on the form Clear checks Clears all other data on the form Clear Other Data Make new field selections Each field has four boxesA check box to select the field

37

"

\

A box to specify the field width A box to enter data to compare A box to specify the compare method (Double click for data) Select data relationship And or or

)

Click Select Printer to print using Windows Print Manager

!

File Options Go to Program Menu Form Returns to program menu for further work on this module Save print options Saves a standard printout Exit Returns to the Windows Program Manager

Procedure for a standard printout Select Options

Recall saved options Print Procedure to print all fields Select Options

Check all Print Other Options

Select font Windows font selection procedure Select Printer Windows Print Manager

38

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: 1

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Control Valve Calculation Routines Liquid 1 Calculate the vena-contracta pressure drop -

pm

P - 0.96 - 0.28 P * vc = r 1

1 Pc

V

2 Calculate the critical drop -

PVAP /

FCRIT FL PVC ~

il

3 Calculate preliminary valve sizing coefficient -

CV

i

W 500 àPG

-

-

-

^/ 4. Calculate Reynolds Number -

REV =

• 'A

!

, 1

2 2 F rL C

34.6FdW

4

+1

PcrfiA, L 890d

l2

!

5. Calculate Reynolds Number Factor -

FR

, 0.655 ^ C vs ^ 1.044 - 0.358 vCyjy

-

Where /

Cvs and

N

1 ~ FS V 23500GfAPj

/

0.6667

Fs = Id 333

-

!!

\ 0.1667

r 2 r^ 2

:

rL W + 1

v 890d2

Fl

0.6667

/

6. Calculate the pressure recovery and piping geometry factors

KBI =

f dV 1-

\4

KB2

vD., /

(K, + KB1)FL C; ;

FLP = FL

‘

890d

,

/

d2 \ K 1 = 0.5 1- 2 D1 y V

d = 1D2 /

-0.5

“1

+1

i;

2

d2 K 2 = 1- 2 ^ D2 V /

'

2

il i! !l

M

r K K ( + 2 + Kb1 - KB 2)Cy +1 pP = 890d4

x

-0.5

: !

7 Calculate the final valve size Turbulent flow -

Cv =

Prelim inaryCv

FP

or

Transitional flow -

or

Cv = FR Laminar flow Cv = ^ vs

Pre !iminaryCv

! 1

39

::

V

:

:

or

Choked or flashing flow -

-

w Cv = 500FLp yj APCR TGf |

) !

8 Calculate the noise level

SL = 10LogCv + 20LogAP - 30Log( t) + 5 For incipient cavitation add

--

.

AP

-K

P - rP 5 rt 2 VAP

FL - KC

X

Log(P2 + 1

*

PVAP )

r

For full cavitation subtract from incipient cavitation

f

--

5Log(AP + 1- APCrit ) Gas

1 Calculate the pressure drop ratio factors

X1 =

AP

K

p _

'

Pi

k K

“

1.4

2 Calculate the minimum size for sonic velocity

7 : ;

dmin = 0.0454 , P vM M 2

^

;•

;

inches

:

3 Calculate the preliminary valve size

W

CV

/

X ,P

^ ^

63.3

:

4 Calculate the piping geometry factor

r

KB2 = 1~

KB1

d2 \ K 1 = 0.5 1- 2 DJ

D

2 f (K + K + 2 KB1 - KB2 )C 1

Fr = V

890d4

2

K, = 11—

d D2

A -0.5 /

5 Calculate the pressure drop ratio factor

XT (K 1 + KB1)C XTP - xT2 1000d4 FP

-1

2

+1

6 Calculate the expansion factor

Y =1

^— 2

3FtXT

7 Calculate the final size

FinalC v =

Prelim inaryCv

FPY

8 Calculate the valve sound pressure level

Logf 28CvFLP P D Tl Y | + SL t J

SL1 = 10

2

V

1 2

40

G

i.

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>.

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; ;

9 Calculate the outlet noise

(

Sl2 10. If

:

22 d D M T ) + SL 2

= 10Log 0.18P

,

SL

2

1

8

G

>7

- SL 2

then ;

SL = SL1

:

Else

SL = SL 1 + SL2

\

Two Phase Flow 1 Calculate the vena-contracta pressure drop /

P rvc

-r P

1

VAP

- 0.96 - 0.28

VAP

V .

2 Calculate the critical drop

- F 2P

P

3 Calculate the specific volumes of the gas and liquid

vg = .4

1

V

yN

,

-

0.016033

Gf

Calculate the volume fraction and the weight fraction of the gas W9 V

_ g

9

fg =

wgvg + wfvf

_W

9‘

Wg +Wf

!

5 Calculate the pressure drop ratio factors

AP pi

K

h“ = 1.4

6 Calculate the expansion factor Y

Y =1

1

—

3FkXT

7 Calculate the effective specific volume for the mixture

ve = -YMY- + 63.3 Gf 2

8 Calculate the preliminary valve size

(w, + wa) r 63.3 \l X,P, '

~

^

9 Calculate the piping geometry factor

KBI

d = 1- D 1 /

FP

=

A

KB2 = I

-

d D2

(K 1 + K 2 + KS1 - KB2 )C 890d4

4

K, -0.5

2

-

r

d2 0.5 1 D12 V

^

'

2

d2 A K 2 = 1- 2 D2 / \ /

2

+1 /

10 Calculate the final size

:

41 :

Prelim inaryCv

Nomenclature n v Valve sizing coefficient d Nominal valve size

dimensionless inches

Inside diameter of inlet piping

inches

Inside diameter of outlet piping

inches

Fluid density at operating temp and pressure

pounds per cubic foot

Valve style modifier Ratio of specific heats

dimensionless dimensionless

Ratio of specific heats factor

dimensionless

Rated pressure recovery factor

dimensionless

Combined liquid pressure recovery factor

dimensionless

Piping geometry factor

dimensionless

Reynolds number factor

dimensionless

Specific gravity at flow temperature

Molecular weight


Mach number at flow conditions

dimensionless

Upstream absolute pressure

psia

Downstream absolute pressure

psia

Critical pressure

psia

Vapor pressure Valve pressure drop Sound pressure level

psia

psi dBA

Gas property factor Pipe wall thickness

dBA inches

Absolute upstream temperature

degR

Reynolds number

dimensionless

ve

Effective two phase specific volume

ft3/lb

Vf

Specific volume of liquid

V9

Specific volume of gas

ft3/lb

W

Volume fraction of gas Total rate of flow

dimensionless Ib/h

wf

Rate of liquid flow

Ib/h

^

2

^

k

fL

^ ^

~

LP

~p

^ 2 p

1

P2

p

c

p

VAP

AP SL SL G

t R

EV

V3

ft3/lb

)

42 -

i

;

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9

Rate of gas flow

1

Pressure drop ratio

Y Y

Ib/h

dimensionless

;

:

T

Rated pressure drop ratio factor

dimensionless

TP

Value of XT for valve/reducer assembly

Y

Expansion factor


^

Acoustic efficiency

dimensionless \

References Control Valve Sizing Equations ANSI/ISA S 75.01 Masoneilan Noise Control Manual Masoneilan Dresser ISA Handbook of Control Valves. J. W. Hutchison

-

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43

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CONTROL VALVE Data Files INSTRUCALC V5 Random access file specification for control valves CVWDAT.Dat. Tag Numbers are stored in the sequential file CVWDAT.TAG. Its number in the file is the record number in the random access file.

! i!

Type FileData ProgNums As Integer PipeConds As Integer PipeMatls As Integer ValveTypes As String * 25 GasBasiss As String * 3 LiqBasiss As String * 3 FS(0 To 27) As Single GS 0(O To 27) As Single GS1(0 To 27) As Single GS2 (0 To 27) As Single UnS(0 To 27) As String * 8 PDC0(1 To 6) As Single PDC1(1 To 6) As Single PDC2(1 To 6) As Single PDSs( l To 6) As Single PDIs( l To 14) As Integer WHs(0 To 11) As Single

2 bytes 2. bytes 2 bytes 25 bytes. 3 bytes 3 bytes. 112 bytes.Units conversion factor 112 bytes. 12 bytes. 112 bytes. 224 bytes.Unit Name 24 bytes . 24 bytes. 24 bytes. 24 bytes. 28 bytes. 48 bytes

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Data sheet info SDS(1 To 7) As Single

28 bytes.Spec inputs INorm dbA, 2Max Flow,3Max inlet press,4max SO press,5max temp,6Maxliqflo(2Ph) 60 bytes.Calc array selections Calcs(l To 4) As String * 15 850 bytes.Data sheet array selections AraS( l To 34) As String * 25 bytes .Data sheet service, line num, 125 String ) 25 * Services( l To 5 As fluid 180 bytes.Data sheet notes Notess( l To 3) As String * 60 . Data sheet String bytes * 1070 Sheets( l To 7) As num,spec,rev,date,req,by, appr Record len=2194 End Type I

PipeConds See pressure drop program PipeMatls ValveTypes

ditto Valve design type

44

i! )

GasBasiss LiqBasiss

"Mas " for gas mass calc, " Vol " for volume "Mas " for liquid mass calc, "Vol " for volume

If ProgNum = 1 Then Program = ’ ’ Control Valve - Liquid flow ” FS(1) UnS ( l ) GSx(l ) = Flow UnS(2) GSx(2) = Flow temperature (3) UnS ) ( 3 FS pressure Inlet 3 ) ( GSx =

)

FS(4) UnS (4) GSx(4) = Valve pressure drop GSx(6) = Specific gravity at FTP FS(7) UnS(7) GSx(7) = Viscosity at FTP FS(8) UnS(8) GSx (8) = Vapor pressure FS(26) UnS(26) GSx(26) = Critical pressure GSx(14) = FL Coefficient at % flow GSx(15) = Calculated CV GSx (19) = Percent Flow FS(16) UnS(16) GS 0(16) = Valve size GS1(16) = Valve rated Cv GS2(16) = Valve Fd GS 0(17) = Valve rated FL GS 1(17) = Valve rated XT GS2(17) = Valve ratedKC FS(17) UnS(18) GS0(18) = Inlet pipe size FS(17) UnS(18) GS1(18) = Outlet pipe size FS(18) UnS (18) GS 2(18) = Outlet pipe wall thickness UnS (21) GS 0(21) = Base temperature ( ) FS 22 UnS(22) GS 0(22) = Base pressure FS(23) UnS(23) GS0(23) = Barometric pressure SD(1) = Normal dbA FS (1) UnS ( l ) SD(6) = Maximum liquid flow FS(3) UnS(3) SD(3) = Maximum inlet pressure SD(4) = Maximum shut off differential pressure FS (4) UnS (4) UnS(2) SD(5) = Maximum temperature

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Water hammer sub program WHS( l ) = Maximum flow WHS(2) = Flow temperature WHS (3) - Operating pressure WHS (4) = Maximum allowable pressure WHS(5) Specific gravity at FTP WHS(6) = Liquid bulk modulus WHS(7) = Line elastic modulus WHS(8) Line length

FS(1) UnS( l ) UnS(2) FS(3) UnS (3) FS(3) UnS(3)

-

:

FS(27) UnS(27) FS(27) UnS(27) FS(25) UnS (25)

-

45

WHS (9) = Pipe inside diameter WHS( IO) = Pipe wall thickness WHS(11) - Selected time secs SDS(7) = Minimum time secs

FS(18) UnS(18) FS(18) UnS(18)

I

Control Valve - Gas, Steam and

If ProgNum = 2 Then Program Vapor flow ”

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FS(0) UnS(O) GSx(O) Flow UnS(2) GSx (2) Flow temperature FS(3) UnS(3) GSx(3) = Met pressure FS (4) UnS(4) GSx(4) = Valve pressure drop GSx(5) = Molecular weight FS(9) UnS(9) GSx(9) = Compressibility factor GSx( lO) = Ratio of specific heats FS(11) UnS( l 1) GSx( l 1 ) = Critical pressure UnS (12) GSx(12) = Critical temperature GSx(14) = FL Coefficient at % flow GSx(15) = Calculated CV GSx (19) Percent Flow GSx(27) = Acoustic efficiency GS0(13) - Gas property dbA GS1(13) = Valve rated efficiency FS(16) UnS (16) GS 0(16) — Valve size GS1(16) Valve rated Cv GS0(17) = Valve rated FL GS1(17) = Valve rated XT FS (17) UnS(18) GS 0(18) = Met pipe size FS(17) UnS(18) GS1(18) Outlet pipe size FS (18) UnS(18) GS2(18) = Outlet pipe wall thickness UnS(21) Base 21 temperature GS0( ) = FS(22) UnS(22) GS 0(22) = Base pressure FS(23) UnS(23) GS 0(23) = Barometric pressure SD(1) = Normal dbA FS(0) UnS (O) SD(2) = Maximum gas flow FS(3) UnS(3) SD(3) = Maximum inlet pressure UnS(4) SD(4) = Maximum shut off differential pressure FS(4) UnS(2) SD(5) = Maximum temperature

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GSx (O) = Gas flow GSx( l ) = Liquid flow GSx(2) = Flow temperature GSx(3) = Inlet pressure 46

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GSx(4) = Valve pressure drop FS(4) UnS(4) GSx(5) = Molecular weight GSx(6) = Specific gravity at FTP GSx(7) = Viscosity at FTP FS(7) UnS(7) GSx (8) = Vapor pressure FS(8) UnS (8) GSx(9) = Compressibility factor FS(9) UnS(9) GSx(lO) = Ratio of specific heats GSx( l 1) Critical pressure FS( ll ) UnS( ll ) GSx(12) — Critical temperature UnS(12) GSx (14) = FL Coefficient at % flow GSx(15) = Calculated CV GSx(19) = Percent Flow GSx(26) = Liquid critical pressure FS(26) UnS(26) GSx(27) = Acoustic efficiency GS 0(13) = Gas property dbA GS 1 (13) = Valve rated efficiency GS0(16) = Valve size FS(16) UnS(16) GS1(16) = Valve rated Cv GS 2(16) = Valve rated Fd GS 0(17) = Valve rated FL GS 1(17) = Valve rated XT GS2(17) = Valve rated Kc GS0(18) = Inlet pipe size FS(17) UnS(18) GS 1(18) Outlet pipe size FS(17) UnS(18) GS2(18) = Outlet pipe wall thickness FS (18) UnS(18) GS0(21) = Base temperature UnS(21) GS 0(22) = Base pressure FS(22) UnS (22) GS 0(23) = Barometric pressure FS(23) UnS(23) SD(1) = Normal dbA SD(2) = Maximum liquid flow FS(1) UnS ( l ) SD(3) = Maximum inlet pressure FS(3) UnS(3) SD{4) = Maximum shut off differential pressure FS (4) UnS(4) SD(5) = Maximum temperature UnS(2) SD(6) = Maximum gas flow FS(0) UnS(O)

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PDSS( l ) Inlet pipe length PDSS(2) = Inlet pipe ID PDSS(3) = Inlet pipe elevation PDSS(4) = Outlet pipe length PDSS ( 5) = Outlet pipe ID PDSS(6) Discharge pipe elevation

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PDIS ( l ) = Inlet gate valves PDIS (2) = Inlet globe valves PDIS(3) = Inlet check valves PDIS(4) = Inlet 90Deg elbows PDIS(5) = Inlet 45Deg elbows PD IS(6) = Inlet thru tees PDIS(7) = Inlet branch tees PDIS(8) = Outlet gate valves PDIS(9) = Outlet globe valves PDIS( IO) = Outlet check valves PDIS(11) = Outlet 90Deg elbows PDIS(12) = Outlet 45Deg elbows PDIS(13) = Outlet thru tees PDIS(14) = Outlet branch tees PDCx(3) = Source pressure PDCx(4) = Inlet equipment loss PDCx(5) = Outlet equipment loss PDCx(6) = Destination pressure

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FS(3) FS (4) FS (4) FS (3)

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Miscellaneous Files CVWDAT.UNS CVWDAT.STP CVWSPEC.TXT HEADINGS.DAT CVSUMM.DAT CVWCALC.DRV CVWCALC.COL

Sequential file. unit data Sequential file. Base conditions Sequential file. Data sheet item selections Sequential file. Printout titles Sequential file. Standard summary selections Sequential file. Default drives and paths Sequential file. Color selections

CONTROL VALVE Import Process Data Make a sequential file for each calculation . Files to have a filename (Suggest the tag number) with no extension (ie TCV-100.). After INSTRUCALC reads the file it will rename the file to "FILENAME.OK". This will divide the files into two lists, those which have been processed and those which have not .

To read a file. 1. Go to the required calculation and select the required units. 2. Take the Import data menu option. 3. Find the required file. (Using standard Windows procedures)

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4. Select the file and the data will be loaded. 5. Proceed with the calculation and save the data. ( Now in the INSTRUCALC file) 6. The sequential file will be assigned the extension M .OK ". and will disappear from the list. 7. If a review is required, use the Windows file procedures for files with an extension ".OK" 8. Revised process data should be provided without extensions. The Instrument engineer will then have an instant review of work not yet performed.

Data input Sequential File Requirements (In input order)

Control Valve Gas Flow

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Variable name (Seq file) Service(4) G(Case,0) G(Case,19) G(Case,2) G(Case,3) G(0,23) G(Case,4) G(Case,5) G(Case,10) G(Case,7) G(Case,9) G(Case, ll ) G(Case,12) G(0,18) <3(1,18) G(2,18) Service(2) Service( l ) ARA(18)

1 Tag number 2 Fluid name 3 Maximum flow 4 Percent of maximum flow 5 Temperature 6 Inlet pressure 7 Barometric pressure 8 Pressure drop 9 MW 10 /Cv 11 Viscosity 12 Density 13 Critical pressure 14 Critical temperature 15 Inlet Pipe size 16 Outlet pipe size 17 Outlet pipe wall 18 Line number 19 Service 20 Valve failure position

Control Valve Liquid Flow 1 2 3 4 5 6 7

Variable name (Seq file) Service(3) G(Case,0) G(Case,19) G(Case,2) G(Case,3) G(0,23)

Tag number Fluid name Maximum flow Percent of max Temperature Inlet pressure Barometric pressure 49

Control Valve Two Phase Flow 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

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G(Case,4) G(Case,6) G(Case,7) G(Case,8) G(Case, ll ) G( l , 18) G(2,18) Service(2) Servi ce( l ) ARA(18)

8 Pressure drop 9 SG @ FTP 10 Viscosity 11 Vapor pressure 12 Critical pressure 13 Outlet pipe size 14 Outlet pipe wal 15 Line number 16 Service 17 Valve failure position

Variable name (Seq file) Service(4) Service(3) G(Case, 0) G(Case, 19) G(Case, 2) G(Case, 3) G(Case, 4) G(Case, 5) G(Case, 9) G(Case, 10) G(Case, 11) G(Case, 12) G(Case, 1) G(Case, 6) G (Case, 7) G(Case, 8) G(Case, 26) G(0, 23) G(0, 18) G( l , 18) G(2, 18) Service(2) Service( l ) ARA(18)

Tag number Gas name Liquid name Gas flow % Flow Temperature Inlet pressure Pressure drop Gas MW Gas Density Gas / Cv Gas critical pressure Gas critical temperature Liquid flow Liquid specific gravity @ FTP Liquid viscosity Liquid vapor pressure Liquid critical pressure Barometric pressure Inlet pipe size Outlet pipe size Outlet pipe wall Line number Service Valve fail position

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CONTROL VALVE Pressure Drop Calculation This program uses the units selected in the control valve calculation program. To access choose Options in the Control Valve Input screen then select Calc system pressure drop .

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CONTROL VALVE Pressure Drop Calculation

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This program uses the units selected in the control valve calculation program. To access choose Options in the Control Valve Input screen then select Calc system pressure drop . Calculation options

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Select the Pipe Material . Options are: Steel, Tubing, Cast iron, Galv iron, Asphalted, Concrete, Wood Select the Pipe Condition. Options are: New, Good, Old

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Enter the piping configuration and the pipe lengths, pipe sizes and elevation change. Enter the process data not ed down from the valve calculation. .

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The pipe sizes are available in a program look-up table. To find the size, select the Pipe ID button (or Wall) to display the pipe size screen, enter the nominal size of the pipe and select the search button. The available wall thickness and the corresponding inside diameters for the nominal size are displayed. Select the required size and the data will be ed to the calculation.

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Metric dimensions are in millimeters and nominal sizes are based on 25 mm per nominal inch. If units other than inches or millimeters are used, the data transferred back to the calculation will be converted to the calculation units. ’

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Analyzing and editing Data

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A control valve needs a minimum pressure drop across the valve in order to control. The amount is a complex problem, there are several guidelines: The greatest of, 15 psi or, 33 % of the dynamic loss in a pumped circuit. The greatest of, 50% of the dynamic loss or, 10% of the destination pressure where the source pressure is static. The greatest of 10% of the absolute pressure, or 5 psi for control of steam supply. The greatest of 5% of the suction absolute system pressure, or 50% of the dynamic losses for control of a centrifugal compressor.

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The valve characteristic This is another complex problem One set of guidelines are: If the difference between the maximum and minimum pressure drops is less than 20%, use a linear trim. If it is greater than 20% and less than 200 %, use the equal percentage trim. 52

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If it is greater than 200%, use the quick opening trim. Change data as required and recalculate. If satisfactory, transfer the data to the valve calculation by Clicking Case 1, Case 2 and Case 3. Return to the calculation by clicking OK. !

CONTROL VALVE Liquid Water Hammer Calculation *

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Engineering Units

There are four standard unit sets and one selected set available: Mass Flow - English Units. Volume Flow - English Units.

Mass Flow - SI Units. Volume Flow - SI Units.

Pounds per hour and degrees Fahrenheit US gallons per minute and degrees Fahrenheit Kilograms per second and degrees Centigrade Litres per second and degrees Centigrade 53

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Units .

A set of units selected from the Liquid Flow Engineering Unit screen

To make or change a Unit set, select the option Review units . i *

The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file.

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A new calculation defaults to Mass English Units . .

The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available, the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen. Fluid Properties •

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For a pure liquid, find the name and select (or double-click) the name, the fluid properties will be entered.

For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties data base is upgradeable. ;

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Input Data

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The enabled input boxes define the data required for the calculation. Enter the data and select the pipe elastic modulus and inside diameter. Choose the Fluid and pipe properties menu option for values. |

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Click the Calculate button. The program will validate the input data,

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Calculate the Critical closing time conditions, the closing time for the allowable pressure and enable the selected time input box. Enter the Selected closing time. Calculate to display the selected time conditions. i

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Editing Data

The output data should be examined for adequacy. Is the closing time conservative enough? Change data as required and recalculate


The options in the File menu are

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Go to valve calc - Returns to the valve calculation. Print calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. The calculation is saved along with the other data in the valve calculation options.

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ISO FLOW ELEMENTS Flow Element Sizing Orifice Flow Element Programs Orifice Plate - Concentric - Flange taps Orifice Plate - Concentric - D and D/2 taps Orifice Plate - Concentric Corner taps Orifice Plate - Concentric - 2 1/2D and 8D taps Orifice Plate - Eccentric - Flange side taps Orifice Plate - Segmental - Flange taps Orifice Plate - Quadrant Edge - Flange or Corner Orifice Plate - Conic - Corner taps Restriction Orifice Plate - Liquid Flow / Gas Flow Venturi - Machined Inlet Venturi - Cast Inlet Venturi - Welded Sheet Inlet Venturi - Universal Lo-Loss Tube Flow Nozzle - ASME Long Radius Flow Nozzle - ISA Flow Nozzle - Venturi Nozzle »

They are all are Liquid or Gas and compatible with ISO 5167. 57

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ISO Flow Elements - Program Overview

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Version 5. An option has been added to calculate the system losses from a known source pressure to provide the flow element inlet pressure. The accuracy of this pressure has a considerable impact on the accuracy of the flow measurement. To use the pressure in the vessel which is the source of the flow can cause considerable error because of head and system losses. The fluid density of gases vary considerably with pressure and liquids may have vapor pressure problems or require a specific gravity correction for pressure.

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An orifice plate is a circular flat plate that is inserted between flanges to measure flow in pipelines. It has a precision bored hole in its center that causes a pressure drop. Bernoulli in 1738 determined that flow rate was proportional to the square root of pressure drop. These programs determine the relationship between the flow rate, the pressure drop and the size of the hole. The programs are based on ISO 5167 and follow the procedures described in The Flow Measurement Engineering Handbook by R. W. Miller. They are suitable for use with all gaseous and liquid fluids that are clean, single phase, homogenous and Newtonian . All gases, most liquids and most dense phase fluids associated with the petroleum petrochemical and natural gas industries are Newtonian.

The should be aware of the design, application and limitations’ requirements set forth in The Flow Measurement Engineering Handbook order for the accuracy percentage calculation to be applicable. All devices measuring flow by differential pressure need some straight pipe upstream and downstream from the device. ASME and AGA publish data showing requirements for various piping configurations. A typical value is 20 upstream and 5 downstream.

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There are programs for 16 different flow elements designs and one for restriction orifice plates. Liquids and gases are covered separately, making a total of 34 different options. Each design has its peculiar advantages. The flat orifice plate is least expensive and well understood . The most common design is the flange taps, concentric, square edge, orifice plate. It has a permanent pressure loss of 50% to 90%, depending on the beta ratio. Typically 1.1 psi for a 50 inches of water differential. On horizontal lines it is a dam in the line that allows debris to collect behind it .

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Segmental and eccentric orifice plates overcome the dam problem. They are more difficult to make and install accurately. i

Quadrant edge and conic edge orifice plates provide a constant discharge coefficient over a wide range of Reynolds Numbers and are used for viscous fluids.

There are various pressure tap locations. The flange tap design is accurately made and relatively foolproof to install. Radius taps and pipe taps are sometimes less

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expensive to use on large diameter or alloy pipe. They are however, field installed where the quality control is more difficult to achieve. In North America, comer taps are used for small diameter lines to get the measurement of the differential closer to the orifice plate, elsewhere they are used instead of flange taps.

Venturies and flow nozzles offer low pressure loss, no dam problems, long term repeatability, high accuracy and high cost. The LO-Loss design is a propriety device that has the lowest permanent pressure loss. The calculations assume that the pipe is reasonably round, straight, smooth, and the correct size and that the taps are cylindrical and burr free. Prefabricated meter runs are available, these are made from selected pipe under shop quality control. They can be calibrated if the cost can be justified .

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Sizing Principles Since the flowrate is proportional to the square root of the differential, the device has a limited turn down ratio. Flow less than 30% of the upper range value is difficult to read. If the rangeability must be larger than 3:1 consider two transmitters.

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Size the orifice plate so that the normal flow is 70% to 80% of the upper range value. This is slightly over the mid-range of the differential and allows for reasonable deviations above and below normal. Instead of having an even chart multiplier and a special size orifice, consider standard orifice sizes and special chart multipliers. This limits the inventory of orifice sizes and since a computer is probably calculating the material balances, it does not need an even number. A differential range of 100 inches of water fits most flow situations. It provides a good compromise of instrument sensitivity, ease of calibration and minimum permanent pressure loss.

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To reduce gas expansion factor inaccuracies, limit the numerical value of the differential range in inches of water to the numerical value of the inlet pressure in psia. (I.e., a gas differential of 100 inches of water requires an inlet pressure of lOOpsia). For best overall accuracy the beta ratio should be between 0.25 to 0.7, preferably 0.55. If it falls outside these limits, change the differential range. If it is still not satisfactory consider an oversize meter run.

Accuracy The program calculates the statistical accuracy for the application.

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Typical discharge coefficient accuracies are: 0.5% for universal venturi tube 0.6 % for a concentric orifice plate with flange comer or radius taps 0.8% for pipe taps 2% for segmental and eccentric

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2.5% for quadrant and conical edge 1% for venturi with machined inlet 1.5% for venturi with welded sheet inlet 2% for ASME nozzle

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The displayed values are the RMS values of these plus the RMS values of the errors of the inlet data weighted for their affect on the calculation. The orifice size is calculated for the upper range values, the correction factors are calculated for the normal flow in order to achieve the maximum usable accuracy.

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ISO Flow Element - Program Features

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Programs will: Perform sizing calculations

Calculate either.- Orifice size, Flow rate or Differential range Calculate vent or drain hole size if required Calculate the minimum plate thickness Calculate permanent pressure and power loss Calculate accuracy percentage Supply fluid properties at flow conditions Supply steam data Supply pipe sizes Provide material selection

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Use English or SI engineering units in any mixture Use mass or volume flow units Import process data Print a calculation sheet using the Windows Print Manager Save the data Prepare instrument data sheets WYSIWYG style Initially general- sheets for bid purposes Supply data base of standard specification items After vendor selection, revise for permanent records Print a data sheet using the Windows Print Manager Save the data

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Print a summary of saved records Print all records

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Print selected records Print only records having required characteristics :

This I a program for calculating the size of ISO 5167 flow elements. The available options are: Concentric Flange Taps Gas or Liquid Concentric D and D/2 Taps Gas or Liquid Concentric Comer Taps Gas or Liquid Concentric 2 Vi and 8D Taps Gas or Liquid Eccentric Flange Side Taps Gas or Liquid Segmental Flange Taps Gas or Liquid Quadrant Edge Comer Taps Gas or Liquid Conic Comer Taps Gas or Liquid Restriction Orifice Plate Gas or Liquid Venturi Machined Inlet Gas or Liq uid Venturi Cast Inlet Gas or Liquid Venturi Welded Sheet Inlet Gas or Liquid Venturi Universal Gas or Liquid Gas or Liquid Lo Loss Tube Flow Nozzle ASME Long Radius Gas or Liquid Gas or Liquid Flow Nozzle ISA Gas or Liquid Flow Nozzle Venturi Nozzle

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ISO Flow Elements - Program Menu Options •

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New calculation Select the required calculation option and the fluid option, then select OK (or double-click if at least one of the options is already selected). File Default files

Recalls file data using the files in the default drives and paths.

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Other files

Recalls file data using the Windows file selection procedure. Data file maintenance Edit Tag Numbers Provides the facility to change the Tag Numbers on file. Or delete records from file. file data Sort Rearrange the Tag Numbers in ascending order. Delete the items marked if the edit was saved. File default path Data files Path for the default calculation data files. units Path for the default engineering units file. Headings Path for the printout headings file.

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There are three paths. If a Drive and Path different from the Default Path and Drive provided in the initial Set Up Procedure was used, the program will update them to the Drive and Path which was installed. They are saved in sequential file ISOCALC.DRV which resides with the programs. To check or change the paths, either call up the Drive and Path for edit or use a text editor to or change the file contents.

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Convert V3 file stage 2 Instrucalc version 3 file conversion to Windows format. Exit Exits from Instrucalc to Windows Program Manager.

Color

Provides color options for Instrucalc displays, using the Windows palette.

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Edit Tables

(Version 5.1)

InstruCalc uses Data Tables for Gas, Liquid, Pipe Size and Material properties, these contain data from which exact properties for the flow conditions are calculated. It also has tables for equipment data. These option provides an easy means of customizing them. Items can be added, inserted, deleted and changed. Restrictions are built into the Materials Coefficient of Expansion table on insertion and deletion because the row number is used to save data in the calculations. Each program can edit the tables used in the program. Take note that some, such as the Gas, Liquid and Pipe Size are used by other programs and may include data required only by them.

Editing is performed by either clicking the appropriate line in the Grid or entering the line number in Row to Edit and clicking Recall Row. Edit the data and Load Row to the Grid. When a box in the edit line is clicked, infonnation on the data required for that box is displayed above. Save Grid overwrites the old file. A backup file is recommended before you start. The file name is in the heading of the Edit Form and the files are in the program directory. Note that data cannot be edited directly in the grid. )

Print Summary Goes to the print summary program.

ISO Flow Elements - Program Lead Sheet The program will only stop at the Lead Sheet if it fails to find the default paths file. To continue, type in the paths and save the file.

The Data Files are specific to a project and an instrument type The Units File may be common for all projects and specific for an instrument type The Headings File maybe specific for a project and common for all instruments

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ISO Flow Element - Liquid Calculation.

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All liquid flow element calculations only differ in the formula involved . The procedures for each are the same. The pipe taps orifice plate and the restriction orifice plate both have a permanent pressure loss of their differential and use the same procedure.

Version 5. Option added. If the exact inlet pressure is not known, but a source pressure is known then use the option to calculate the flow element inlet pressure. First use an approximate inlet pressure and calculate the flow element to set up the variables, take the option and calculate the system losses, three cases are available. Transfer the selected case to the flow element calculation, re-select the fluid properties and recalculate the flow calculation. Light hyrocarbons may require a specific gravity correction . Volatile liquids may have a vapor pressure problem.

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Engineering Units , There are four standard unit sets and one selected set available -

Mass Flow - English Units .

Pounds per hour and degrees Fahrenheit .

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Volume Flow - English Units .

Mass Flow - SI Units.

Volume Flow - SI Units . Units .

US gallons per minute and degrees Fahrenheit. Kilograms per second and degrees Centigrade. Litres per second and degrees Centigrade. A set of units selected from the Liquid Flow Engineering Unit screen

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To make or change a Unit set select the option Review units . The Liquid Flow Engineering Unit screen will be displayed. It shows the available . options and the current unit selection . Select the required units and save the file. :

Unit Selection

A new calculation defaults to Mass English Units.

The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen .

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For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered . For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is updatable.

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Calculation options are:

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Orifice size. Flowrate.

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Select the calculation option and the necessary input data is enabled. The required variable will be disabled and will receive the calculated value.

Vent Hole option

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If the flowing liquid contains gas bubbles, a vent hole will enable them to the orifice plate. A yes selection will select the recommended hole size and compensate for it in the calculation.

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To look up the pipe dimensions, click the pipe inside diameter button.

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The pipe sizes screen will be displayed. Enter the nominal pipe size. Click the Search button to display the available sizes. Select the required inside diameter (Double-click or click OK).

ISO Material Selection

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The sheet displays the material options and the current selection. The temperature thermal expansion coefficients are selected with the material. A thermal correction for both pipe and orifice plate is included. Either make a new selection (Double click or click then click OK). Or click Cancel to return with no change. The program will return to the calculation. !

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Element Material

Click the Element material button to display the materials screen. On the element materials screen, select the required material.

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Click the pipe material button to display the materials screen. On the Pipe materials screen, select the required material.

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The options selected enable the input boxes of the data required for the calculation and disable the input boxes for the calculated outputs and the data not required. The maximum flow rate is the upper range value. The normal flow will be the point of greatest accuracy. Specific gravity at base conditions is only required for volumetric flow.

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Calculate Click the Calculate button. The program will validate the input data. If not valid it will display the unsatisfactory data. If valid it will Calculate the output data. Display the results . Enable the calculation printout. Enable the data sheet option .

68

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Calculation Results The output data should be examined for adequacy. Best accuracy is for beta ratio in the area of 0.55. Change data as required and recalculate. The plate thickness is the recommended minimum. :

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The options in the File menu are:

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Program menu - Clears the calculation and returns to the main menu. Prepare data sheet -Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record . Save New Using the default path, it saves an existing record as a new record (Use to duplicate similar items i.e. Recall an existing record . Edit as required and Save New). Save As... - Uses the Windows file access system. Saves to a file

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anywhere. Import data - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records. The default paths are: The Data Files . ( ISODAT.TAG and ISODAT.DAT). The Unit Files . (ISODAT.UNS). The Printout Headings File (HEADINGS.DAT). Print flow calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit Leaves the program and returns to the Windows Program Manager.

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The screen shows the process variables used in a liquid calculation and list the available options. To assure full coverage each (except Flow Time Base) has an “ Other” option. This is a defined unit. Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list.

The screen shows the current selection. Any unit may be selected and will be used in the calculation if OK is selected. To create a File for the File Unit option in the calculation, select the desired units and click the save button. A double click on any unit option selects that option and returns to the calculation . Data conversion

For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted . The Flow Quantity option has Mass and Volume options. The relationship between mass flow and volume flow is a multiplier and the specific gravity of the fluid. It is conventional when measuring flow by volume that it be at a standard temperature (Usually 60 degrees Fahrenheit). Two specific gravity values are necessary for a volumetric flow calculation, mass /

70

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flow cannot be converted to volume flow until the specific gravity at standard conditions is available. Conversion factors and units are based on API 2564. Definition of units

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Mass flow units : lb = pounds kg = kilograms tonne = 1000 kg = 1 Mg g = gram UKton = 2240 lb USton 2000 lb Other = defined mass unit Volume flow units : USgal = US gallons litre = litres ft3 = Cubic feet UKgal = UK gallons m 3 = cubic metres bbl = barrels (42 US gallons) cm3 = cubic centimetres Other = defined volumetric unit Flow time base : /s = per second /m = per minute /h = per hour /d = per day Gauge pressure : psig = pounds per square inch gauge kPag = kiloPascals gauge atg = atmospheres gauge inhgg = inches of mercury gauge MPag = megapascals gauge inH20g = inches of water gauge mmhgg = millimetres of mercury gauge barg = bars gauge kg/ cm2 g = kilograms per square centimetre gauge Other = defined gauge pressure unit Absolute pressure : psia = pounds per square inch absolute kPaa = kiloPascals absolute ata = atmospheres absolute inhga = inches of mercury absolute MPaa = megaPascals absolute inH20a = inches of water absolute

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mmhga = millimetres of mercury absolute bara - bars absolute kg/ cm2a = kilograms per square centimetre absolute Other defined absolute pressure unit Temperature : degF = degrees Fahrenheit degF = degrees Centigrade degR = degrees Rankine degK = degrees Kelvin Other = defined temperature unit Viscosity : = cèntipoises Pa.s = Pascal seconds cs = centistokes kPa.s = kiloPascal seconds Other = defined viscosity unit Differential pressure : inH20 = inches of water kPa = kiloPascals inhg = inches of mercury mmH20 = millimetres of water mBar = millibars Other = defined differential Pipe and orifice diameter : in = inches mm = millimetres cm - centimetres ft = feet m = metres Other = defined size

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ISO Calculation Data Printout (Print flow calculation)

This program will print the input and output calculation data and one associated comment. The comment is included in the data sheet for reference purposes. It also creates the default printout headings. The headings are printed at the top of all printouts. They are saved in the HEADINGS.DAT file. This is the third default path. If all programs are set to the same path, this becomes the default headings for all program printouts.

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Save headings. Saves the headings .

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Cancel. Returns to the calculation form without printing. OK. Prints the headings and calculation using the Windows Print Manager, then returns to the calculation form .

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) 73

ISO Flow Element Data Sheet (Prepare Data Sheet) Octagon Engineering Corporation

ISO Flow Nozzle - ASME Lone Radius - Liquid Flow Spec. Project 2314 Req.

Plant Convert ion 2001 Update

Sheet Rev. Date Appr.

By

Element data

Flange data

Tap data Flowmeter data

Process data

Tag Number 1 ) Design tpe 2) Design standard 3) Element material 4 ) Ring oint data 5 ) Manufacturer 6) Model 7) Beta ratio (d/ D) 8) Orifice diameter 9) Pipe & flange inside diameter 10) Flange type 11) Vent hole diameter 12 ) Element thickness

1 ) Flange type 2) Flange material 3) Supplied with flow element 4) Flange rating & facing 1) 2) 1) 2) 3) 4) 5) l) 2)

Pressure tap location Pressure tap size Sensor type Differential range Static pressure range Chart or scale range Chart multiplier Service Line number Fluid name Fluid state Maximum flowrate Normal flowrate Operating pressure Operating temperature

3) 4) 5) 6) 7) 8) 9) Operating specific gravity 10) Base specific gravity 11) operating viscosity

Flow nozzle - ASME long radius

304 stainless steel

Not required

.125 in

Carbon steel

In nozzle

10 in H20

Liquid lb/h Ita/h psig degF

Not required for mass flow

Notes

The first use of the data sheet is to obtain competitive bids. It should initially emphasize the engineering requirements and be fairly general regarding the details. When a vendor is selected it should be updated to the exact details so that the data sheet is a record of the instrument purchased. The relevant data from the calculation

74

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.

is automatically displayed. Minor editing, such as rounding can be performed. Major editing should be done in the calculation routine in order to preserve the integrity of the calculation.

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A defined database is available to enter data for those inputs which have a limited number of options. To activate this, double click the input box, the data on file is displayed. Double click the required option and the data is transferred to the data sheet form.

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The data base should be customized for the project requirements. To edit the data; click the selected item. Edit the data in the active top line, select Replace, continue with the edit and Save on completion. The Input data menu option has an option to enter either the first or the second item in the list for all items. If the data base is constructed so that the first item is the first standard selection and the second item is the second standard selection then two standard data sheets are available for a single keystroke. This feature only enters data into empty input boxes. Some input boxes require unique data which is typed in.

|

•

Space is provided to enter information for non standard options. Enter the title and data, it will be saved with the other data. Three lines are available at the bottom of the data sheet. The input data is limited to 25 characters and 60 characters for each of the notes.

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Print Data Sheet Prints the data sheet using the Windows Print Manager. Refer to Windows Help Go to calculation. Returns to the calculation form using the same record Update headings Overwrites the headings with the current default set

) 75

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ISO Orifice Size - Gas Calculation

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Basecond Inlet pressure Help

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All liquid flow element calculations only differ in the formula involved, the procedures for each are the same. The pipe taps orifice plate and the restriction orifice plate both have a permanent pressure loss of their differential and use the same procedure. Engineering Units There are four standard unit sets and one selected set available :

Mass Flow - English Units . Volume Flow - English Units. Mass Flow - SI Units. Volume Flow - SI Units .

Pounds per hour and degrees Fahrenheit. Standard cubic feet per minute and degrees Fahrenheit . Kilograms per second and degrees Centigrade. Standard cubic decimeters per second and degrees Centigrade.

76

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Units .

A set of units selected from the Gas Flow Engineering Unit screen.

To make or change a Unit set select the option Review units . The Gas Flow Engineering Unit screen will be displayed . It shows the available options and the current unit selection. !

Select the required units and save the file. Unit Selection

A new calculation defaults to Mass English Units. The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the molecular weight is not available the flow is set to zero. Units for any individual input entry can be changed by selecting the Review Units option and choosing from the Gas Flow Engineering Unit screen.

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Base Conditions ]

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The Base Conditions option will display the current values of base pressure, base temperature and the barometric pressure. They should be checked and modified and saved to suit the operating conditions. ISO specifies a base temperature of 14.696psia (101.325kilopascals) and 59° (15 degC). AGA specifies abase pressure of 14.73psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°.

:

| :

Fluid Properties i

The Fluid properties option is enabled when the pressure and temperature are entered . The properties required for a calculation are available for pure gases and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply.

For a pure gas find the name and select (or double-click) the name, the fluid properties will be entered . For a mixture select the first component. In the component box , enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database can be maintained.

77

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Calculation options are: Orifice size. Flow rate.

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Differential Range .

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Orifice size !

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Flowrate

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range

Select the calculation option and the necessary input data boxes are enabled. The required variable will be disabled and will receive the calculated value. Drain Hole option

If the flowing gas contains moisture droplets a drain hole will allow the liquid to the orifice plate. A yes selection will select the recommended hole size and compensate for it in the calculation of the orifice bore.

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To look up the pipe dimensions, click the pipe inside diameter button . The pipe sizes screen will be displayed. Enter the nominal pipe size. Click the Search button to display the available sizes. Select the required inside diameter (Double-click or click OK).

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ISO Material Selection The sheet displays the material options and the current selection. The temperature thermal expansion coefficients are selected with the material. A thermal correction for both pipe and orifice plate is included . Either make a new selection (Double click or click then click OK). Or click Cancel to return with no change. The program will return to the calculation.

Element Material

Click the Element material button to display the materials screen. On the element materials screen, select the required material.

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310 stainless steel 31 S stainless steel if 330 stainless steel

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Pipe Material

Click the pipe material button to display the materials screen. On the Pipe materials screen, select the required material . i V./sSr ?à KS?<

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Input Data. The options selected enable the input boxes of the data required for the calculation and disable the input boxes for the calculated outputs and the data not required. The maximum flow rate is the upper range value. The normal flow will be the point of greatest accuracy. Calculate. Click the Calculate button. The program will validate the input data. If not valid it will display the unsatisfactory data. If valid it will: Calculate the output data. Display the results. Enable the calculation printout. Enable the data sheet option.

Calculation Results The output data should be examined for adequacy. Best accuracy is for beta ratio in the area of 0.55. Change data as required and recalculate. The plate thickness is the recommended minimum. 80

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The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet -Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New - Using the default path, it saves an existing record as a new record (used to duplicate similar items, i.e. recall an existing record. Edit as required and Save New). Save As.... - Uses the Windows file access system. Saves to a file anywhere. Import data Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records. The default paths are The Data Files . (ISODAT.TAG and ISODAT. DAT). The Unit Files. (ISODAT.UNS). The Printout Headings File (HEADINGS.DAT). Print flow calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager.

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ISO Gas Engineering Units ;•:

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The screen shows the process variables used in a liquid calculation and list the available options. To assure full coverage each (except Flow Time Base) has an “ Other” option. This is a defined unit. Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list.

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The screen shows the current selection. Any unit may be selected and will be used in the calculation if OK is selected. To create a File for the File Unit option in the calculation, select the desired units and click the save button. A double click on any unit option selects that option and returns to the calculation. Data Conversion For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted. The Flow Quantity option has Mass and Volume options. The relationship between mass flow and volume flow is a multiplier and the molecular weight of the gas conversion can only be made when the molecular weight has been entered .

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Definition of units

Mass flow units : lb = pounds kg - kilograms tonne = 1000 kg = lMg g = gram UKton = 2240 lb USton = 2000 lb Other = defined mass unit Volume flow units : sft3 = standard cubic feet sdm 3 = standard cubic decimetres sm.3 = standard cubic metres Msft3 = million standard cubic feet Other = defined volume unit Time base : /s = per second /m = per minute /h = per hour /d = per day Gauge pressure : psig = pounds per square inch gauge kPag = kiloPascals gauge atg = atmospheres gauge inhgg = inches of mercury gauge MPag = megaPascals gauge inH20g = inches of water gauge mmhgg = millimetres of mercury gauge barg = bars gauge kg/cm2g = kilograms per square centimetre gauge Other = defined gauge pressure unit Absolute pressure : psia = pounds per square inch absolute kPaa kiloPascals absolute ata = atmospheres absolute bara = bars absolute Mpaa = megaPascals absolute kg/cm 2a = kilograms per square centimetre absolute inhga - inches of mercury absolute mmhga = millimetres of mercury absolute Other = defined absolute pressure unit Temperature : degF = degrees Fahrenheit degF = degrees Centigrade

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degR = degrees Rankine degK = degrees Kelvin Other defined temperature unit Viscosity : = centipoises Pa.s = Pascal seconds cs = centistokes kPa.s = kiloPascal seconds Other = defined viscosity unit Differential pressure : inHPO inches of water kPa = kiloPascals inhg = inches of mercury mmH20 = millimetres of water mBar = millibars Other = defined differential Pipe and orifice diameter : in = inches mm = millimetres cm = centimetres ft = feet m = metres Other = defined size Density lb/ft3 = pounds per cubic foot kg/m3 = kilograms per cubic metre g/cm 3 = grams per cubic centimetre lb/in3 = pounds per cubic inch Other = defined density unit

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Print (ISO Flow Element) Summary The program will provide a printout summary of data sheet records on file. Access from the flow element selection screen. It can provide a printout of either: All fields

Selected fields Fields equal to Fields not equal to Fields equal to or less than Fields equal to or greater than Fields less than Fields more than 84

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ISO Data Files INSTRUCALC V5 Random access file specification for ISO flow elements ISODAT.Dat. Tag Numbers are stored in the sequential file ISODAT.TAG. Its number in the file is the record number in the random access file.

Type FileData

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Calculation info ProgNum As Integer ElemMatlNom As Integer PipeMatlNum As Integer FloBasis As String * 3

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2 bytes.Program number Liq <18 :Gas>20 2 bytes.Element material number 2 bytes. Pipe material 3 bytes."Mas" denotes a mass calculation, "Vol" a volume 3 bytes. "Yes" or " No" for drainhole Vent As String * 3 60 bytes.Units conversion factor FS (1 To 15) As Single 80 bytes.( l -15)Calc Input data, 16) beta, GS(1 To 20) As Single (17)EdgeRad (18)Norm flow, (19)VentSize UnS( l To 15) As String * 8 120 bytes.Unit Name

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Data sheet info SdS( l To 7) As Single 28 bytes. AraS ( l To 16) As String * 25 400 bytes . Data sheet array selections Txtl (1 To 3) As String * 25 75 bytes.Data sheet service,line num, fluid Txt2( l To 3) As String * 60 180 bytes.Data sheet notes TXT3(1 To 7) As String * 10 70 bytes.Data sheet num,spec,rev,date,req,by,appr Record len= l 025 End Type

Common data all Elements

ElemMatlNom and PipeMatlNum If material number = 1 Then Material = "301 stainless steel " If material number 2 Then Material = "304 stainless steel" If material number = 3 Then Material = "310 stainless steel " If material number = 4 Then Material "316 stainless steel" If material number = 5 Then Material = "330 stainless steel " If material number = 6 Then Material = "347 stainless steel" If material number = 7 Then Material = "Aluminum bronze" If material number = 8 Then Material = "Beryllium copper" If material number - 9 Then Material = "Carbon steel" If material number = 10 Then Material = "Copper " If material number = 11 Then Material = "Cupronickel" If material number = 12 Then Material = "Hastelloy B" ~

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) 88

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YTSP = 359DJ. 3. Calculate Beta Ratio

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= 0.6991YTSP

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4. Calculate orifice bore

d = Po - D For complete details of all formula and techniques refer to the ISO 5167 and The Flow Measurement Engineering Handbook By R.W.Miller. These describe the development of the formulas, the application limitations and installation requirements for predictable results as well as a large amount of other valuable information. Nomenclature

H

Flowrate upper range variable

Ib/h

Flowrate normal flow

Ib/h inches of water

Differential upper range variable Differential normal

inches of water

Orifice sizing factor

Orifice inside diameter

dimensionless inches inches

Density at flow conditions

Ib/ft3

Absolute Viscosity

centipoise

D

Reynolds Number

dimensionless

Beta Ratio Orifice discharge coefficient


Orifice discharge coefficient for infinite Reynolds Number Gas expansion factor


Upstream pressure Ratio of specific heats

psia dimensionless

Thermal expansion factor

dimensionless

Downstream pressure for sonic velocity

psia

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pjpe inside diameter at flowing temperature

C C INF

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ISO Flow Element Calculation Routines Routines are similar all devices except that the discharge coefficient formulas vary. The gas restriction orifice is checked for critical flow, see RO Sonic Gas Routine. Set initial values. C=0.6:Y=1

1. Calculate the Normal Differential Range f

HN = HM.

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2 Calculate the SM Factor

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SM = 358.9628.D 2N. . . FA VYn HN

3 . Calculate Reynolds Number D

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4. Calculate the beta ratio -0.25

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5. Calculate the discharge coefficient at infinite Reynolds Number Typical for comer taps

C1NF = 0.5959 + 0.3121PQ

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6. Calculate the true discharge coefficient ;

C - C|NF +

b

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Where typically 2.5 b = 91. 71PO

and n = 0.75 for corner taps 7. If the fluid is gas then calculate the expansion factor f

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f 27.73KPfJ ' 8. Repeat from step 4 until the value of the beta ratio changes less than 0.000001 ü

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R. O. Sonic Gas Routine 1. Check for sonic velocity

PSONIC = Pf

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k +1

2 . If the discharge pressure is more than -

p * SONIC

then use pipe tap calculation Else

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Select Options

Clears all checks on the form Clear checks Clears all other data on the form Clear Other Data Make new field selections Each field has four boxes A check box to select the field A box to specify the field width A box to enter data to compare A box to specify the compare method (Double click for data) Select data relationship And or or using Windows Print Manager Click Print to print

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File Options Save print options Saves a standard printout Go to Program Menu Form Returns to program menu for further work on this module Exit Returns to the Windows Program Manager

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Procedure for a standard printout Select Options Recall saved options Print Procedure to print all fields

Select Options Check all Print

Other Options Select font

Windows font selection procedure Select Printer Windows Print manager 85

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If material number = 13 Then Material = "Hastelloy C" If material number = 14 Then Material = "Haynes Stellite 25" If material number = 15 Then Material = "Inconel X" If material number = 16 Then Material = "K - Monel" If material number = 17 Then Material = "Nickel " If material number = 18 Then Material = "Pyrex glass" If material number = 19 Then Material = "Tantalum " If material number 20 Then Material = "Titanium" FloBasis "Mas" denotes a mass calculation, "Vol " a volume Vent "Yes" or "No" for drainhole

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Liquid calculations

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If ProgNum = 1 Then Program = "Concentric Orifice Plate - FlangeTaps - ISO Liquid" If ProgNum = 2 Then Program = "Concentric Orifice Plate - D and D/2 taps - ISO Liquid" If ProgNum = 3 Then Program = "Concentric Orifice Plate - Comer taps - ISO Liquid" If ProgNum = 4 Then Program = "Concentric Orifice Plate - Pipe taps - ISO - Liquid " If ProgNum = 5 Then Program = "Eccentric Orifice Plate - Flange side taps - ISO Liquid " If ProgNum = 6 Then Program = "Segmental Orifice Plate - Flange taps - ISO Liquid" If ProgNum = 7 Then Program = "Quadrant Edge Orifice Plate - Comer taps - ISO Liquid" If ProgNum = 8 Then Program = "Conic Orifice Plate - Comer taps - ISO - Liquid " If ProgNum = 9 Then Program = "Venturi-Machined Inlet - ISO - Liquid " If ProgNum = 10 Then Program = "Venturi-Cast Inlet - ISO - Liquid" If ProgNum = 11 Then Program = "Venturi-Welded Inlet - ISO - Liquid " If ProgNum = 12 Then Program = "Universal Venturi - ISO - Liquid" If ProgNum = 13 Then Program = "Lo-Loss tube - ISO - Liquid" If ProgNum = 14 Then Program = "Flow nozzle-ASME long radius - ISO - Liquid " If ProgNum = 15 Then Program = "Flow nozzle-ISA - ISO - Liquid " If ProgNum = 16 Then Program = "Flow nozzle-Venturi - ISO - Liquid "

All liquid flow elements GS(1) = Maximum flow FS(1) ( ) GS 2 = Flow temperature GS(3) = Inlet pressure FS(3) GS (4) = Differential range FS (4) GS (5) = Specific gravity at flow conditions GS(6) = Specific gravity at standard conditions GS (7) = Viscosity FS(7) GS(8) = Pipe inside diameter FS(8)

UnS( l ) UnS (2) UnS(3) UnS (4) A

UnS(7) UnS(8) !

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FS(12) UnS(12) FS (1) UnS( l ) FS(12) UnS(12) FS(4) UnS(4) FS(12) UnS(12)

GS (12) = Orifice size GS(18) = Normal flow GS (19) - Drain hole size SDS( l ) = Normal flow differential SDS(3) = Plate thickness SDS(4) = Beta ratio SDS (5) = Chart multiplier

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If ProgNum = 17 Then Program ="Concentric Restriction Orifice Plate -

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Liquid"

Liquid RO data FS(1 ) GS(1) = Maximum flow GS(2) = Flow temperature FS (3) GS(3) = Inlet pressure gravity conditions at flow GS (5) = Specific GS (6) = Specific gravity at standard conditions FS(7) GS(7) = Viscosity (8) FS inside diameter GS(8) = Pipe

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UnS( l ) UnS(2) UnS(3)

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UnS (7) UnS(8) FS(10) UnS( lO) FS(12) UnS(12) FS(3) UnS(3) FS (12) UnS(12) FS (12) UnS (12)

GS(10) = Vapor pressure GS(12) = Orifice size GS(16) = Discharge pressure GS(19) = Drain hole SDS (3) = Plate thickness SDS(4) = Beta ratio

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Gas calculations

If ProgNum = 21 Then Program - "Concentric Orifice Plate - FlangeTaps - ISO Gas" If ProgNum = 22 Then Program = "Concentric Orifice Plate - D and D/2 taps - ISO Gas" If ProgNum = 23 Then Program = "Concentric Orifice Plate - Comer taps - ISO Gas" If ProgNum = 24 Then Program = "Concentric Orifice Plate - Pipe taps - ISO - Gas" If ProgNum = 25 Then Program = "Eccentric Orifice Plate - Flange side taps - ISO Gas" If ProgNum = 26 Then Program = "Segmental Orifice Plate - Flange taps - ISO Gas" If ProgNum = 27 Then Program = "Quadrant Edge Orifice Plate - Comer taps - ISO Gas" If ProgNum = 28 Then Program = "Conic Orifice Plate - Comer taps ISO - Gas" If ProgNum = 29 Then Program = "Venturi-Machined Inlet - ISO - Gas" If ProgNum = 30 Then Program = " Venturi-Cast Inlet - ISO - Gas" If ProgNum = 31 Then Program = "Venturi-Welded Inlet - ISO - Gas" If ProgNum = 32 Then Program = "Universal Venturi - ISO - Gas "

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If ProgNum = 33 Then Program = "Lo-Loss tube - ISO - Gas" If ProgNum = 34 Then Program = "Flow nozzle-ASME long radius - ISO - Gas " If ProgNum = 35 Then Program = "Flow nozzle- ISA - ISO - Gas " If ProgNum = 36 Then Program = "Flow nozzle-Venturi - ISO - Gas"

All gas flow elements GS(1) = Maximum flow

.

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FS(1) UnS( l ) UnS(2) FS(3) UnS(3) FS(4) UnS(4)

GS (2) = Flow temperature GS (3) = Inlet pressure GS(4) = Differential range GS(5) = Molecular weight GS(6) = Ratio of specific heats FS(7) UnS(7) GS(7) Viscosity FS(8) UnS(8) GS(8) - Pipe inside diameter FS(9) UnS(9) factor Compressibility GS(9) = FS (10) UnS( lO) GS (10) = Critical pressure UnS( ll ) GS (11) = Critical temperature ) UnS(12) FS ( 12 size ) Orifice GS (12 = ) (13) UnS FS 13 ( GS(13) = Base pressure UnS(14) GS (14) = Base temperature ) (15) ( UnS FS 15 pressure ) Barometric ( GS 15 = FS ( 12) GS (17) = Quadrant edge radius or Segment diameter FS(1) UnS(l ) GS(18) = Normal flow FS( I 2) UnS(12) GS(19) = Drain hole size FS(4) UnS (4) SDS ( l ) = Normal flow differential FS(12) UnS (12) SDS(3) = Plate thickness SDS(4) - Beta ratio SDS(5) = Chart multiplier

S

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UnS (12)

If ProgNum = 37 Then Program = " Concentric Restriction Orifice Plate -

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Gas"

Gas RO data

)

FS (1) UnS( l ) UnS(2) FS (3) UnS(3)

GS(1) - Maximum flow GS(2) = Flow temperature GS (3) = Inlet pressure GS(5) = Molecular weight GS (6) = Ratio of specific heats GS(7) = Viscosity GS(8) = Pipe inside diameter GS(9) = Compressibility factor GS(10) = Critical pressure GS(11) = Critical temperature GS (12) = Orifice size

FS(7) UnS(7) FS(8) UnS(8) FS(9) UnS (9) FS(10) UnS( lO) UnS( ll ) FS(12) UnS(12)

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FS(13) UnS (13) UnS(14) FS (14) UnS(14) FS(3) UnS (3) FS(12) UnS (12) FS(12) UnS(12)

GS (13) Base pressure GS (14) = Base temperature GS(15) = Barometric pressure GS (16) = Discharge pressure GS (19) = Drain hole size SDS(3) = Plate thickness SDS(4) = Beta ratio

Miscellaneous Files ISODAT.UNS ISODAT.STP ISOSPEC.TXT HEADINGS.DAT ISOSUM.DAT

ISOCALC.DRV ISOCALC.COL


ISO Import Process Data To Import process data into a calculation: Make a sequential file for each calculation. Files to have a filename(Suggest the tag number) with no extension (i.e. FE-100). After INSTRUCALC reads the file it will rename the file to "FILENAME.OK". This will divide the files into two lists, those which have been processed and those which have not. To read a file: 1 . Go to the required calculation and select the required units. 2. Take the Import data menu option. 3. Find the required file. (Using standard Windows procedures) 4. Select the file and the data will be loaded. 5. Proceed with the calculation and save the data. (Now in the INSTRUCALC file) 6. The sequential file will be assigned the extension ".OK", and will disappear from the list. 7. If a review is required, use the Windows file procedures for files with an extension

8. Revised process data should be provided without extensions. The Instrument engineer will then have an instant review of work not yet performed.

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Data input sequential file requirements : (In input order)

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Gas Flow elements

name 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Tag number Fluid name Maximum flow Normal flow Temperature Inlet pressure Barometric pressure Differential range

MW /Cv Viscosity Pipe size Density Critical pressure Critical temperature Line number Service

!

Gas restriction orifice

Variable

'

Tag number Fluid name Normal flow Temperature Inlet pressure Barometric pressure Discharge pressure MW /Cv Viscosity Pipe size Density Critical pressure Critical temperature Line number Service

(Seq file) Txtl (3) G( l ) G(18) G(2) G(3) G(15) G(4) G(5) G(6) G(7) G(8) G(9) G(10) G(11) Txtl (2) Txtl (l )

(Seq file) Txtl (3) G( l ) G(2) G(3) G(15 G(4) G(5) G(6) G(7) G(8 ) G(9) G(10) G( ll ) TxtTl (2) Txtl ( l )

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Liquid restriction orifice

Liquid flow elements 1 Tag number 2 Fluid name 3 Maximum flow 4 Normal flow 5 Temperature 6 Inlet pressure 7 Barometric pressure 8 Differential range 9 SG @ FTP 10 SG@ Base 11 Viscosity 12 Pipe size 13 Line number 14 Service

(Seq file) Txtl (3) G( l ) G(2) G(3) G(4) Barometric pressure G(15) G(10) Vapor pressure G(5) SG @ FTP G(6) SG @ base G(7) Viscosity (8) G Pipe size Txtl (2) Line number Txtl ( l ) Service

Tag number Fluid name Normal flow Temperature Inlet pressure Discharge pressure

(Seq file) Txtl (3) G( l ) G(18) G(2) G(3) G(15) G(4) G(5) G(6) G(7) G(8) Txtl (2) Txtl ( l )

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93

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ISO Pipe Inside Diameter The orifice pipe run is the straight sections of pipe, upstream and downstream of the orifice plate, as specified in ISO 5167 and AGA3 and ANSI 2530. The ISO pipe inside diameter is the average of 12 measurements of the upstream section of the meter measured at a room temperature.

?

Initially, in most cases, the orifice pipe run is not available and the standard size is used. This is available in a program look-up table. To find the size, select the meter run size button to display the pipe size screen, enter the nominal size of the pipe and select the search button. The available wall thickness and the corresponding inside diameters for the nominal size are displayed. Select the required size and it will be transferred to the calculation. When the meter tube becomes available, measure the inside diameter and back calculate either the amended flow rate or differential

[ Ï

pressure. Metric dimensions are in millimeters and nominal sizes are based on 25 mm per nominal inch. If Units other than inches or millimeters are used , the data transferred back to the calculation will be converted to the calculation units.

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Chapter 3

RELIEF VALVES \!

T

Relief Valve Programs Liquid Relief - Known Flow Gas Relief - Known Flow Steam Relief - Known Flow Heat Exchanger - Entrapped Liquid Heat Exchanger - Tube Failure Pipeline - Entrapped Liquid Fire Size - Liqidd Vaporization Fire Size - Gas Expansion Î

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RELIEF VALVES Program Overview

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Most instrument engineers do not consider pressure relief valves as instruments. ISA publishes a specification sheet for them, yet very rarely does ISA mention them again. Engineering contractors generally delegate them to their Instrument Department, yet operating companies rarely do. They are vital to the safe operation of the plant, and the person responsible for them must be familiar with API 520 parts 1 and 2, NFPA #30, the ASME pressure vessel code and any other authoritative body. Every ASME coded vessel must be protected with an ASME certified relief valve. The manufacturers are a valuable source of information for much of the sizing data.

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To size a relief valve, plant operations must be thoroughly understood, an analysis of all possible contingencies must be made and the worst case selected (typical cases are shown in Table 4-1). It is not normal to consider double contingencies such as an external fire and, at the same time, an operations error, unless there is a real possibility of it happening. Good engineering judgment is called for. The valves are inexpensive insurance for the plant, and the underinsurance can be an unmitigated disaster. ASME and other governing authorities require pressure relief valves to be installed on all equipment that can be blocked in, and are rated at 15 psig or more, although it is pennissible to have a block valve car sealed open. Rupture discs are sometimes installed under a relief valve where bubble- tight shutoff is required or where corrosive or dirty service conditions exist. In such cases a pressure gauge should be installed between the two so that rupture disc failures can be detected. The relief valve capacity must be decreased by 25% of the rated capacity if used with a rupture disc, unless the capacity of the combination has been established in accordance with the appropriate paragraphs of UG-132 of ASME Code Section 8. Dual valves, with a special three-way valve that ensures full relief area is always available, can be installed where servicing may be required between unit shutdowns.

When sizing pressure relief valves, that they are basically differential pressure devices. They open when the inlet pressure minus the back pressure equals the set pressure. Most valves relieve into a relief header which is tied into the flare. If the relief header already has some valves discharging into it, a higher backpressure will be exerted on those valves not yet open, and a higher inlet pressure will be required to open them. The installation of the valve can significantly affect its performance and selection. If the inlet piping has too much friction pressure loss, the valve will open at its correct set pressure but may start to close as the pressure drops, only to open again as the pressure builds up again. The inlet piping pressure loss due to friction should not exceed 3% of the set pressure, based on the valve capacity flow, not the flow used in the sizing calculation.

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l! Since most valves are set at the maximum allowable working pressure of the vessel, and since the ASME codes allow the pressure to exceed this by 10% (or up to 21% for external fire sizing), any downstream piping should be sized to limit the built up backpressure to 10% of the lowest set point if standard valves are to be used. There are essentially three types of valves - standard valves, bellows valves and pilot operated valves (some typical valves are shown on the next page). The bellows valve has a bellows installed over the seat mechanism to keep the backpressure at atmospheric pressure. The pilot operated valve operates with more precision and flexibility than the others.

Standard valves are usually selected for cases where the backpressure is likely to be nearly constant. (This is not necessarily atmospheric pressure.) The spring is adjusted to give the desired opening pressure. A variable backpressure of 10% of set pressure is usually allowed, for a valve is usually sized on the basis of critical flow. Therefore, a 10% overpressure would only delay the valve opening; it would not affect flowrate or accumulation (accumulation being defined as the allowable increase in pressure during discharge through the relief valve).

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Where backpressure variations exceed 10% of the set pressure, a pilot operated or balanced bellows valve is normally chosen. The bellows must be vented to the atmosphere. These valves inherently require more maintenance than standard valves. Failure of the bellows by corrosion, rupture, or plugging of the vent converts them to standard valves. The bellows valves have backpressure and size limitations and, where the backpressure is sufficiently high to prevent sonic velocity through the valve, they usually have a smaller capacity than the standard valve.

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The set pressure is the pressure at which a liquid valve starts to lift and a gas or vapor valve pops open. Maximum flow is achieved at a slightly higher pressure called accumulation. ASME has very definite limits as to the accumulation rise if the set pressure is also the maximum allowable working pressure. Accumulation is defined as: (set pressure psig x over pressure factor + 14.7) psia. The backpressure required for the calculation is the total backpressure. This is the sum of the superimposed backpressure and the built up backpressure. The superimposed backpressure is the pressure imposed on the valve before it opens. It affects the set pressure of the valve. The built up backpressure is the increase in the outlet pressure caused by the friction loss in the discharge piping during relief flow through the valve. This will not affect the set pressure. For liquids, the total backpressure will always affect the capacity of the valve, for gases it will not affect the capacity unless the backpressure increases to the point where sonic flow no longer exists through the valve. Sonic velocity occurs when the pressure drop across the valve is approximately 50% of the absolute inlet pressure. Because of the ASME limitation of 10% most valves will have sonic velocity through them. The API RP-

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520 formula include a method of predicting subsonic flow and compensating for it. The program always checks for this and makes an allowance for backpressure when it is necessary.

The backpressures are largely determined by the discharge piping. The ASME suggested maximum piping pressure loss for a standard valve is 10%, a bellows 30% and a pilot operated valve, 50% of the set pressure. The ASME inlet piping pressure loss must not exceed 3%: It is suggested that after a calculation is made and the maximum flow capacity and size is known that the line pressure loss program in chapter five is run to determine the minimum pipe sizes and the maximum equivalent line lengths for the inlet and outlet sizes. Sonic velocity should be avoided in the lines. Use this data to design the piping. You may be surprised to find that even with close coupled valves that a larger line is sometimes required in order to stay below the 3% figure.

Accuracy of the Calculations The formulas used have been accepted over the years. The ASME gas formulas apply only to pressures exceeding 15psig. All formulas are empirical by nature and generally adequate over the range of normal circumstances, the challenge is to recognize what are not normal circumstances. The fire sizing calculations have options to use either the API 520 or NFPA #30 method to determine relieving flowrate. The program places limits on the input data to reject obvious errors, such as negative flowrates. Relief valve sizing, particularly fire sizing, is not an exact science, the is wise to be cautious and conservative. It is entirely possible to enter impossible data and still get an answer. The programs are an aid to engineering not a replacement of. The principles of GIGO apply. The results should be interpreted by a competent person.

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Most of these data are based on ASME Section 8: Pressure Vessel Code, ASME Section 1, Power Boiler Code, API RP520, The Recommended Practice for the Design and Installation of Pressure Relieving Systems in Refineries, API 2000, Venting Atmospheric and Low Pressure Storage Tanks and The National Fire Protection Agency #30. It is recommended that copies be obtained for reference purposes. Either the ASME or the API 520 formula can be selected for liquid sizing. It should be noted that for ASME coded vessels built after 1985, the ASME formula applies. Be careful to specify the ASME certified liquid trim valves for these.

Program Options Standard or balanced bellows Rupture disk allowance Selecting orifice designation

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ASME or API liquid calculations (New ASME approved vessels require the ASME formula, vessels designed prior to the adoption of the ASME formula may still use the API formula) Calculate the inlet and outlet pipe losses ASME limits the inlet losses to 3% and the outlet losses to 10%

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Sizing Considerations Relief valve sizing, particularly fire sizing is not an exact science. There are many contingencies, such as loss of coolant, loss of power, blockage of lines, equipment failure, operator error. The one requiring the largest valve is the one required. It is not normal to consider double contingencies unless there is a real possibility of it happening. Good conservative engineering judgment is called for. The valves are inexpensive insurance for the safety of the plant. Under insurance can be an unmitigated disaster.

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ASME and other governing bodies require relief valves to be installed on all pressure equipment that is rated at 15 psig or more and can be blocked in by valves which are not car sealed open. •

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Rupture disks are sometimes installed under a valve where bubbletight shutoff is required or where corrosive or dirty service conditions exist. In such cases a pressure gage should be installed between the two so that rupture disk failures can be detected. The relief valve capacity must be reduced to 90% of its capacity if used with a rupture disk, unless the capacity of both have been established in accordance with the appropriate paragraphs of UG-132 of ASME Code Section 8. \

Dual valves, with a special three way valve which ensures full relief area is always available, can be installed where servicing is required without a plant shutdown.

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The set pressure is the pressure at which a liquid valve starts to lift and a gas or vapor valve pops open. Maximum flow is achieved at a slightly higher pressure called accumulation. If the set pressure is also the maximum allowable working pressure of the vessel (which it normally is) then ASME allows:

Section 1 fired pressure vessel Accumulation = Set pressure + 3 % + 14.7 psig Section 8 unfired pressure vessel Accumulation = Set pressure + 10% + 14.7 psig Section 8 pressure vessel fire sizing Accumulation = Set pressure + 21 %.+ 14.7 psig The back pressure required in the calculations is the total back pressure. This is the sum of the superimposed back pressure plus the built-up back pressure. The superimposed back pressure is the pressure imposed on the valve before it opens. It affects the set pressure. The built-up back pressure is the increase in pressure caused by the friction loss in the discharge piping during relief flow through the valve. This 99

does not affect the set pressure of the valve. For liquids, the total back pressure will always affects the capacity of the valve. For gases it will not affect the capacity unless the back pressure rises to the point where sonic flow no longer exists though the valve. Sonic flow occurs when the pressure drop is approximately 50% of the absolute inlet pressure. Since the ASME limitation is 10% then sonic flow will always exist.

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Standard valves Bellows valves

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If back pressure is relatively constant (not necessarily atmospheric) a standard valve is normally used. The spring is adjusted for the back pressure. If the valves discharge into a common header and have different set-pressures, then standard valves may not be suitable for the low set pressure valves because the 10% back pressure of the high set pressure valves will exceed the 10% of the low pressure valve. If the pressure rise is less than 30% of a valve set pressure then a bellows valve may be the option. If it is less than 50% then a pilot valve is an option.

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RELIEF VALVE Program Features Perform sizing calculations

Calculate either.— ASME single, ASME multi, or API method Calculate fire sizes and vessel wetted areas Calculate liquid thermal expansion sizes Calculate inlet and outlet pipe losses Supply fluid properties at flow conditions Supply steam data Supply pipe sizes Use English or SI engineering units in any mixture Use mass or volume flow units Import process data Print a calculation sheet using the Windows Print Manager 100

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WYSIWYG style Initially general-sheets for bid purposes Supply database of standard specification items After vendor selection, revise for permanent records Print a data sheet using the Windows Print Manager Save the data

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Print all records Print selected records Print only records having required characteristics

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This is a program for calculating the size of relief valves for: Known Flow Known Flow Known Flow Entrapped Liquid Tube Failure Entrapped Liquid Liquid Vaporization Gas Expansion

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The Liquid Relief - Known flow calculation has options to use the API or the ASME formula. The Gas Relief - Known flow calculation uses the ASME formula. It has options for section 1, section 8 or the fire code. The reaction force and the noise level are calculated. The Steam Relief - Known flow calculation is an ASME calculation, it also has options for Section 1 , section 8 and the fire code and calculates the reaction force and noise level. The Heat Exchanger - Entrapped liquid calculation is for a blocked in liquid filled exchanger which has the heat turned on. It calculates the flow caused by the liquid expansion and is either an ASME or API calculation.

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The Heat Exchanger - Tube failure calculation is for tube rupture where the tube pressure is 50% greater than the shell pressure. It assumes no vaporization of the shell side product. It is either an ASME or API calculation. The Pipeline - Entrapped liquid calculation is for liquid expansion in long, blocked in, pipelines on a hot day. It usually only takes a very small relief valve to avoid blowing the gaskets. The calculation can be either ASME or API. The Fire size - Liquid vaporization is the most complex calculation . It gathers the flame wetted area of up to 15 liquid containing vessels. The heat input is calculated either by The API 520 or the National Fire Protection Association NFPA #30, method and a relieving flow rate is determined. The ASME formula determines the valve size. The reaction force and relieving noise level are also calculated. The Fire size - Gas expansion also gathers the flame wetted area, this time of up to 15 gas containing vessels. The required size is determined by the API 520 formula.

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The maximum flow is then back calculated from the valve size. The reaction force and relieving noise level are then calculated.

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RELIEF VALVE Program Menu Options New calculation

Select the required calculation option and the fluid option, then select OK (or double- click if at least one of the options is already selected) File

Default files Recalls file data using the files in the default drives and paths . .

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Other files Recalls file data using the Windows file selection procedure. Data file maintenance Edit Tag Numbers Provides the facility to change the Tag Numbers on file. Or delete records from file. Sort data file Rearrange the Tag Numbers in ascending order. Delete the items marked if the edit was saved . Data files path Path for the default calculation data files. unit file path Path for the default engineering units file. Printout headings file path Path for the printout headings file. 103

There are three paths. If a Drive and Path different from the Default Path and Drive provided in the initial Set Up Procedure was used, the program will update them to the Drive and Path which was installed . They are saved in sequential file RVWCALC.DRV which resides with the programs. To check or change the paths, either call up the Drive and Path for edit or use a text editor to or change the file contents.

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Convert V3 file stage 2 Instrucalc version 3 file conversion to Windows format. Exit Exits from Instrucalc to Windows Program Manager. Color

Provides color options for Instrucalc displays, using the Windows palette. Edit Tables

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InstruCalc uses Data Tables for Gas, Liquid, Pipe Size and Material properties, these contain data from which exact properties for the flow conditions are calculated. It also has tables for equipment data. These option provides an easy means of customizing them. Items can be added, inserted, deleted and changed.

Each program can edit the tables used in the program . Take note that some, such as the Gas, Liquid and Pipe Size are used by other programs and may include data required only by them. Editing is performed by either clicking the appropriate line in the Grid or entering the line number in Row to Edit and clicking Recall Row. Edit the data and Load Row to the Grid. When a box in the edit line is clicked, information on the data required is displayed above. Save Grid overwrites the old file. A backup file is recommended before you start. The file name is in the heading of the Edit Form and the files are in

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Note that data cannot be edited directly in the grid. Print Summary Goes to the print summary program.

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RELIEF VALVE Program Lead Sheet The program will only stop at the Lead Sheet if it fails to find the default paths file. To continue, type in the paths and save the file. The Data Files are specific to a project and an instrument type The Units File may be common for all projects and specific for an instrument type The Headings File may be specific for a project and common for all instruments

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For Bellows Valves, the back pressure characteristic varies between manufacturers, the program follows the curve in API 520. The manufacturers data should be used when available. Engineering Units There are four standard unit sets and one selected set available:

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Mass Flow - English Units. Volume Flow ~ English Units . Mass Flow - SI Units. Volume Flow - SI Units. Units .

Pounds per hour and degrees Fahrenheit US gallons per minute and degrees Fahrenheit Kilograms per second and degrees Centigrade Litres per second and degrees Centigrade A set of units selected horn the Liquid Flow Engineering Unit screen

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To make or change a Unit set select the option Review units. The Liquid Flow Engineering Unit screen will be displayed . It shows the available options and the current unit selection. Select the required units and save the file.

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Unit Selection


The Unit Selection can be made at any time. The input data will be converted to the new units . If a volumetric flow unit set is selected and the specific gravity is not available the flow is set to zero. Units for any individual input entry can be changed by selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen.

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Fluid Properties


For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered. For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select

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Sizing Code

In the Summer 1984 Addenda to the Pressure Vessel Code, ASME published a formula for liquid sizing. All vessels ed after 1984 must be sized with the ASME formula and use special liquid trim valves with capacity approved by ASME for liquid service and stamped accordingly. Vessels built before this may still use the API formula and the old valves. Valve Type

If the relief is to discharge into a relief header and be subject to varying back pressure, a bellows valve may be required, otherwise select a standard valve. Rupture disk A rupture disk is sometimes installed under the valve for bubble-tight or corrosive service, otherwise select No.

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Input Data The enabled input boxes define the data required for the calculation. When selecting the options the standard factors are entered Overwrite the factors with the manufacturers, if desired. Calculate

Click the Calculate button. The program will validate the input data. It will select the valve area and valve orifice designation. Calculate the output data Display the results Editing Data

The output data should be examined for adequacy. If a different valve area is required then overwrite the data. Change data as required and recalculate. When the selection is final then take the pipe losses option . The inlet losses should not exceed 3% and the discharge losses should be less than 10%.

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The options in the File menu are: Program menu Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet fonn for the calculated item. New record - Clears the screen for a new calculation. Save Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New. .Using the default path, it saves an existing record as a new record (Used to duplicate similar items i .e. Recall an existing record. Edit as required and Save New) Save As.... Uses the Windows file access system. Saves to a file anywhere. Import data Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records The default paths are: The Data Files. (RVDDAT.TAG and RVDDAT.DAT). The Unit Files. (RVDDAT . UNS ) The Printout Headings File (HEADINGS . DAT) Print calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit Leaves the program and returns to the Windows Program Manager

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The ASME valve discharge coefficient is 0.62, for API it is 0.64. They will allow a different value for tested and approved valves. This data is available in the relief valve manufacturers catalogs.

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The rupture disk derating factor is 1 for no rupture disk, the ASME derating factor is 0.9, they will allow the use of a different factor for tested and approved assemblies. This data will be in the rupture disk manufacturers catalogs . For Bellows Valves, the back pressure characteristic varies between manufacturers, the program follows the curve in API 520. The manufacturers data should be used when available.

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Engineering Units There are four standard unit sets and one selected set available Pounds per hour and degrees Fahrenheit Mass Flow - English Units. US gallons per minute and degrees . Volume Flow - English Units Fahrenheit Kilograms per second and degrees Mass Flow - SI Units. Centigrade Litres per second and degrees Centigrade Volume Flow - SI Units . A set of units selected from the Liquid Units . Flow Engineering Unit screen

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To make or change a Unit set select the option Review units . The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file. f

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The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen.

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Fluid Properties




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Sizing Code

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In the Summer 1984 Addenda to the Pressure Vessel Code, ASME published a formula for liquid sizing. All vessels ed after 1984 must be sized with the ASME formula and use special liquid trim valves with capacity approved by ASME the for liquid service and stamped accordingly. Vessels built before this may still use API formula and the old valves. Valve Type

If the relief is to discharge into a relief header and be subject to varying back pressure a bellows valve may be required, otherwise select a standard valve. Rupture disk

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A rupture disk is sometimes installed under the valve for bubble-tight or corrosiv service, otherwise select No .

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The enabled input boxes define the data required for the calculation. When selecting the options the standard factors are entered Overwrite the factors with the manufacturers if desired.

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Click the Calculate button. The program will validate the input data. It will select the valve area and valve orifice designation. Calculate the output data Display the results

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Editing Data

The output data should be examined for adequacy. If a different valve area is required then overwrite the data. Change data as required and recalculate. When the selection is final then take the pipe losses option. The inlet losses should not exceed 3% and the discharge losses should be less than 10%. Filing and Moving On The options in the File menu are: Program menu Clears the calculation and returns to the main menu.

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Prepare data sheet Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item . New record Clears the screen for a new calculation. Save Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New. .Using the default path, it saves an existing record as a new record (Used to duplicate similar items, i.e. Recall an existing record . Edit as required and Save New) Save As .. .. Uses the Windows file access system . Saves to a file anywhere. Import data Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records The default paths are The Data Files . (RVDDAT.TAG and RVDDAT.DAT). The Unit Files. (RVDDAT. UNS) The Printout Headings File (HEADINGS.DAT) Print calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager

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The rupture disk derating factor is 1 for no rupture disk, the ASME derating factor is 0.9, they will allow the use of a different factor for tested and approved assemblies. This data will be in the rupture disk manufacturers catalogs.

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For Bellows Valves, the back pressure characteristics varies between manufacturers, the program follows the curve in API 520 the manufacturers data should be used when available.

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Engineering Units There are four standard unit sets and one selected set available: Pounds per hour and degrees Fahrenheit Mass Flow - English Units. US gallons per minute and degrees Volume Flow - English Units . Fahrenheit Kilograms per second and degrees Mass Flow - SI Units . Centigrade Litres per second and degrees Centigrade Volume Flow - SI Units. A set of imits selected from the Liquid Units. Flow Engineering Unit screen

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The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file. Unit Selection A new calculation defaults to Mass English units.


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Fluid Properties

The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply. :

For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered. For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is updateable.

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Sizing Code

In the Summer 1984 Addenda to the Pressure Vessel Code, ASME published a formula for liquid sizing. All vessels ed after 1984 must be sized with the ASME formula and use special liquid trim valves with capacity approved by ASME for liquid service and stamped accordingly. Vessels built before this may still use the API formula and the old valves.

Valve Type If the relief is to discharge into a relief header and be subject to varying back pressure a bellows valve may be required, otherwise select a standard valve. Rupture disk

A rupture disk is sometimes installed under the valve for bubble-tight or corrosive service, otherwise select No.

Input Data

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The enabled input boxes define the data required for the calculation. When selecting the options the standard factors are entered Overwrite the factors with the manufacturers if desired. Calculate

Click the Calculate button. The program will validate the input data. It will select the valve area and valve orifice designation. Calculate the output data Display the results Editing Data The output data should be examined for adequacy. If a different valve area is required then overwrite the data. Change data as required and recalculate. When the selection is final then take the pipe losses option .Tire inlet losses should not exceed 3% and the discharge losses should be less than 10%.


The options in the File menu are: 115

Program menu - Clears the calculation and returns to the main menu. Prepare data sheet -Is enabled after a calculation is made, it displays the screen prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New.-.Using the default path, it saves an existing record as a new record (used to duplicate similar items, i.e. recall an existing record. Edit as required and Save New). Save As.... Uses the Windows file access system. Saves to a file anywhere. Import data Select the units and read Input data supplied in sequential files . File default path Changes the default paths for the calculation records The default paths are The Data Files . (RVDDAT.TAG and RVDDAT.DAT). The Unit Files. ( RVDDAT.UNS) The Printout Headings File (HEADINGS . DAT) Print calculation Is enabled after a calculation is made. It displays the screen to print a calculation. Exit Leaves the program and returns to the Windows Program Manager

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Relief Valve Size - Heat Exchanger Tube Rupture Calculation

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The program determines the relief valve size if a tube ruptures. It calculates a relief area based on the tube inside diameter and the difference in the tube and shell pressure ratings.

The ASME valve discharge coefficient is 0.62, for API it is 0.64. They will allow a different value for tested and approved valves. This data is available in the relief valve manufacturers catalogs. The rupture disk derating factor is 1 for no rupture disk, the ASME derating factor is 0.9, they will allow the use of a different factor for tested and approved assemblies. This data will be in the rupture disk manufacturers catalogs .

For Bellows Valves, the back pressure characteristic varies between manufacturers, the program follows the curve in API 520. The manufacturers data should be used when available.

Engineering Units

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There are four standard unit sets and one selected set available Mass Flow - English Units . Pounds per hour and degrees Fahrenheit US gallons per minute and degrees Volume Flow - English Units . Fahrenheit Kilograms per second and degrees Mass Flow - SI Units. Centigrade

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Volume Flow - SI Units. Units.

Litres per second and degrees Centigrade A set of units selected from the Liquid Flow Engineering Unit screen

To make or change a Unit set select the option Review units . The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection . Select the required units and save the file.

Unit Selection

i

A new calculation defaults to Mass English units. The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity is not available the flow is set to zero. Units for any individual input entry can be changed by selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen. Sizing Code

In the Summer 1984 Addenda to the Pressure Vessel Code, ASME published a formula for liquid sizing. All vessels ed after 1984 must be sized with the ASME formula and use special liquid trim valves with capacity approved by ASME for liquid service and stamped accordingly. Vessels built before this may still use the API formula and the old valves. Valve Type

If the relief is to discharge into a relief header and be subject to varying back pressure a bellows valve may be required, otherwise select a standard valve. Rupture disk A rupture disk is sometimes installed under the valve for bubble-tight or corrosive service, otherwise select No .

Input Data

The enabled input boxes define the data required for the calculation. When selecting the options the standard factors are entered Overwrite the factors with the manufacturers if desired.

118

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Calculate


The output data should be examined for adequacy. If a different valve area is required then overwrite the data. Change data as required and recalculate.


The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New Clears the screen for a new calculation. Save Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New.-.Using the default path, it saves an existing record as a new record (Used to duplicate similar items, i.e. recall an existing record. Edit as required and Save New) Save As. . Uses the Windows file access system. Saves to a file

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anywhere. Import data - Select the units and read Input data supplied in sequential files. File default path Changes the default paths for the calculation records

-

The default paths are The Data Files . (RVDDAT.TAG and RVDDAT.DAT). The Unit Files. ( RVDDAT.UNS) The Printout Headings File (HEADINGS.DAT) Print calculation Is enabled after a calculation is made. It displays the screen to print a calculation . Exit - Leaves the program and returns to the Windows Program Manager

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The screen shows the process variables used in a liquid calculation and list the available options. To assure full coverage each (Except Flow Time Base) has an “ Other” option. This is a defined unit . Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list.

The screen shows the current selection. Any unit may be selected and will be used in the calculation if OK is selected . To create a File for the File Unit option in the calculation, select the desired units and click the save button. A double click on any unit option selects that option and returns to the calculation.

Data conversion !

For all items except flow the unit change represents only a multiplier to convert the input data and the data is always converted. The Flow Quantity option has Mass and Volume options. The relationship between mass flow and volume flow is a multiplier and the specific gravity of the fluid. If the flow units are changed from

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bara = bars absolute kg/ cm2a = kilograms per square centimetre absolute Other = defined absolute pressure unit Temperature : degF = degrees Fahrenheit degF = degrees Centigrade degR = degrees Rankine degK = degrees Kelvin Other = defined temperature unit Velocity fl/s = feet per second m/s = metres per second Other = defined velocity Viscosity : = centipoises Pa.s = Pascal seconds cs = centistokes kPa.s = kiloPascal seconds Other = defined viscosity unit Pipe diameter : in = inches mm = millimeters cm = centimeters ft - feet m = metres Other = defined size Valve area : in2 = square inches mm2 = square millimeter cm2 - square centimeters ft2 = square feet m2 square metres Other = defined area Length and elevation : ft = feet m = metres Other = defined dimension Specific heat : btu/lb/ degF = British thermal units per pound per degree Fahrenheit btu/lb/degC = British thermal units per pound per degree Centigrade kJ/kg/degC = kilojoules per kilogram per degree Centigrade kcal/kg/degC = kilocalories per kilogram per degree Centigrade Other = defined specific heat

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Calculation options

Select the Pipe Material. Select the Pipe Condition.

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Input Data ;

The enabled input boxes define the data required for the calculation. Enter the piping configuration and the pipe lengths and elevation change. Enter the process data not ed down from the valve calculation. Calculate Click the Calculate button. The program will validate the input data, Calculate the output data Display the results

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The output data should be examined for adequacy. Are the ASME limits met? Change data as required and recalculate If satisfactory transfer the back pressure to the valve calculation by clicking Transfer.

RELIEF VALVE Calculation Data Printout This program will print the input and output calculation data and one associated comment. The conunent is included in the data sheet for reference purposes. It also creates the default printout headings. The headings are printed at the top of all printouts. They are saved in the HEADINGS .DAT file. This is the third default 124

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Cancel. Returns to the calculation form without printing OK. Prints the headings and calculation using the Windows Print Manager, then returns to the calculation form

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Relief Valve Data Sheet

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Octagon Enginering Corporation Liauid relief Known flow Spec. Project 2314 Req. By

-

Plant Conversion 2001 Update

Sheet

Rev. Date Appr

11/ 18 /01

Tag Number RV- 100

Valve Design

Flange Data

Material

Accessories

Nozzle design: Valve design & type Bonnet type | Inlet Size f Outlet | Outlet 5) Connections | Inlet [ Outlet [ Inlet 6) Rating [ Bonnet 7) Body | Disk 8) Seat 9) Resilient seat seal | Rings 10) Guide 11) Spring 12 ) Bellows 13) Cap type 14) Lever I) 2) 3) 4)

15) Gag 16) Rupture disk

Selection basis Service Conditions

Valve data

-

17) 18) Code 19) Fire 20) 21) Service 22 ) Line number 23) Fluid name 24) Fluid state 25) Required capacity 26) Specific gravity @ FTP 27) Viscosity @ FTP | Set | Operating 28) Pressure 29) Temperature | Operating | Relief 30) Constant back pressure 31) 43 uiU up back pressure 32) Differential set pressure 33) Allowable overpressure % 34) Compressibility factor 35) 36) Calculated area 37) Selected area 38) Orifice designation 39) Manufacturer 40) Model

Standard 2 in

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Carbon steel

Not required

Not required •

ASME Section 8

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Notes:


The relevant data from the calculation is automatically displayed. Minor editing, such as rounding can be performed. Major editing should be done in the calculation

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126

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routine in order to preserve the integrity of the calculation. defined database is available to enter data for those inputs which have a limited number of options. To activate this, double click the input box, the data on file is displayed. Double click the required option and the data is transferred to the data sheet form. The database should be customized for the project requirements. To edit the data; click the selected item. Edit the data in the active top line, select Replace, continue with the edit and Save on completion. The Input data menu option has option to enter either the first or the second item in the list for all items. If the database is constructed so that the first item is the first standard selection and the second item is the second standard selection then two standard data sheets are available for a single keystroke. This feature only enters data into empty input boxes. Some input boxes require unique data which is typed in. Space is provided to enter information for nonstandard options. Enter the title and data, it will be saved with the other data.

Three lines of notes of special instructions are available at the bottom of the data sheet. The input data is limited to 25 characters and 60 characters for each of the

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File options

)

Print data sheet - Prints the data sheet using the Windows Print Manager. Refer to Windows Help. Go to calculation - Returns to the calculation form using the same record

Update headings - Overwrites the headings with the current default set

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) 128

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Mass Flow - SI Units. Volume Flow - SI Units Units.


To make or change a Unit set select the option Review units .

The Gas Flow Engineering Unit screen will be displayed . It shows the available options and the current unit selection. Select the required units and save the file.

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Unit Selection i

A new calculation defaults to Mass English units. The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Gas Flow Engineering Unit screen. I

Fluid Properties

The Fluid properties option is enabled when the pressure and temperature are entered . The properties required for a calculation are available for pure gases and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply.

For a pure gas find the name and select (or double-click) the name, the fluid properties will be entered. :

For a mixture select the first component . In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values . The fluid properties database is updateable Sizing Code.

The overpressure ratings are available in the pressure vessel code: Section 1. Fired pressure vessels 3% 10% Section 8. Unfired pressure vessels 21 % External fire sizing.

129

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Valve Type

If the relief is to discharge into a relief header and be subject to varying back pressure a bellows valve may be required, otherwise select a standard valve. Rupture disk •

i

A rupture disk is sometimes installed under the valve for bubble-tight or corrosive service, otherwise select No Input Data.

1 I i

The enabled input boxes define the data required for the calculation. When selecting the options the standard factors are entered. Overwrite the factors with the manufacturers if desired.

i

Calculate

j

Click the Calculate button. The program will validate the input data. It will select the valve area and valve orifice designation. Calculate the output data Display the results

(

)

Editing Data

The output data should be examined for adequacy. If a different valve area is required then overwrite the data. Change data as required and recalculate. When the selection is final then take the pipe losses option. The inlet losses should not exceed 3% and the discharge losses should be less than 10%.

•



Program menu - Clears the calculation and returns to the main menu. Prepare data sheet Is enabled after a calculation is made, it displays the screen to prepare a data sheet fonn for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New - Using the default path, it saves an existing record as a new record (used to duplicate similar items, i.e. recall an existing record. Edit as required and Save New)

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130

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Save As.... Uses the Windows file access system. Saves to a file anywhere. Import data Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records. The default paths are The Data Files. (RVDDAT.TAG and RVDDAT.DAT) . The Unit Files. (RVDDAT.UNS) The Printout Headings File (HEADINGS.DAT) Print calculation Is enabled after a calculation is made. It displays the screen to print a calculation. Exit Leaves the program and returns to the Windows Program Manager

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The rupture disk derating factor is 1 for no rupture disk, the ASME derating factor is 0.9, they will allow the use of a different factor for tested and approved assemblies. This data will be in the rupture disk manufacturers catalogs. For Bellows Valves, the back pressure characteristic varies between manufacturers, the program follows the curve in API 520. The manufacturers data should be used when available.

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Engineering Units

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Mass Flow - English Units . Volume Flow - English Units. Mass Flow - SI Units . Volume Flow - SI Units Units.


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The Gas Flow Engineering Unit screen will be displayed . It shows the available options and the current unit selection. Select the required units and save the file. Unit Selection A new calculation defaults to Mass English units.

The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Gas Flow Engineering Unit screen. Sizing Code

The overpressure ratings are available in the pressure vessel code:

3% 10% 21%

Section 1. Fired pressure vessels Section 8. Unfired pressure vessels External fire sizing.

> 132

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Valve Type


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A rupture disk is sometimes installed under the valve for bubble-tight or corrosive service, otherwise select No.

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Input Data The enabled input boxes define the data required for the calculation. When selecting the options the standard factors are entered Overwrite the factors with the manufacturers if desired.

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The output data should be examined for adequacy. If a different valve area is required then overwrite the data. Change data as required and recalculate. When the selection is final then take the pipe losses option. The inlet losses should not exceed 3 % and the discharge losses should be less than 10% . Filing and Moving On

The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet -Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New.-.Using the default path, it saves an existing record as a new record (used to duplicate similar items, i.e. recall an existing record . Edit as required and Save New)

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records. The default paths are The Data Files. (RVDDAT.TAG and RVDDAT. DAT) . The Unit Files. (RVDDAT.UNS) The Printout Headings File (HEADINGS . DAT) Print calculation Is enabled after a calculation is made. It displays the screen to print a calculation. Exit Leaves the program and returns to the Windows Program Manager

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A fire zone is first established from the plot plan. It may be designed into the plant or it may be determined by natural barriers and/or elevations. The vessels in the zone must be connected with lines sufficiently large to carry the flow which cannot be blocked in. For the vessels in the zone, the area of metal wetted by both fire and internal liquid is determined . API suggests that a normal inventory of liquid be assumed and an allowance be made for at least 25 feet above the level on which a reasonable fire could be sustained. Spheres should be considered at least up to their maximum diameter.

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NFPA #30 allowable environmental credits are:

No credit Approved drainage Water spray NFPA 15 Approved insulation Fixed water spray plus approved insulation

Environment factor 1 Environment factor 0.5 Environment factor 0.3 Environment factor 0.3 Environment factor 0.15

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Only one factor can be used . Credit for the insulation requires that it be noncombustible, nonabsorbent and strong enough to resist being dislodged by fire hoses .

A thorough study of API 520 and NFPA #30 is recommended fully understand the options and requirements. The program will accept data for 15 vessel, calculate the wetted area and either using the API method or the NFPA-30 method, determine the flowrate generated by the external fire. The pipe loss option will determine the inlet and outlet losses as well as the total back pressure. The ASME valve discharge coefficient is 0.975 for gas flow. They will allow a different value for tested and approved valves . This data is available in the relief valve manufacturers catalogs. The rupture disk derating factor is 1 for no rupture disk, the ASME derating factor is 0.9, they will allow the use of a different factor for tested and approved assemblies. This data will be in the rupture disk manufacturers catalogs.

For Bellows Valves, the back pressure characteristic varies between manufacturers, the program follows the curve in API 520. The manufacturers data should be used when available.

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Engineering Units :•

There are four standard unit sets and one selected set available: Mass Flow - English Units . Volume Flow - English Units.

Mass Flow - SI Units . Volume Flow - SI Units Units.


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To make or change a Unit set select the option Review units. The Gas Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file.

1: l

Unit Selection A new calculation defaults to Mass English units . 136

The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity is not available the flow is set to zero. Units for any individual input entry can be changed by selecting the Review Units option and choosing from the Gas Flow Engineering Unit screen . Fluid Properties

The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure gases and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply.

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For a pure gas , find the name and select (or double-click) the name, the fluid properties will be entered . For a mixture, select the first component . In the component box, enter the percentage.

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Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is updateable.

Sizing Code An overpressure of 21 % is used.

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Valve Type

If the relief is to discharge into a relief header and be subject to varying back pressure a bellows valve may be required, otherwise select a standard valve.

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Rupture disk A rupture disk is sometimes installed under the valve for bubble-tight or corrosive service, otherwise select No

Input Data

The enabled input boxes define the data required for the calculation. When selecting the options the standard factors are entered Double click the Maximum metal temperature text box for typical data. Overwrite the factors with the manufacturers if desired. ) 137

Calculate


The output data should be examined for adequacy. Fire sizing is not an exact science, it warrants a serious study of the options. If a different valve area is required then overwrite the data. Change data as required and recalculate. When the selection is final then take the pipe losses option .The inlet losses should not exceed 3% and the discharge losses should be less than 10 %. Filing and Moving On

The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item . New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record . Save New.-.Using the default path, it saves an existing record as a new record (used to duplicate similar items, i.e. recall an existing record . Edit as required and Save New) Save As.. .. - Uses the Windows file access system. Saves to a file anywhere. Import data Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation

-

-

records The default paths are The Data Files. (RVDDAT.TAG and RVDDAT.DAT). The Unit Files . (RVDDAT. UNS ) The Printout Headings File (HEADINGS.DAT) Print calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit Leaves the program and returns to the Windows Program Manager

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Relief Valve Fire Size Gas Expansion x f

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A fire zone is first established from the plot plan. It may be designed into the plant or it maybe determined by natural barriers and/or elevations. i

The vessels in the zone must be connected with lines sufficiently large to carry the flow which cannot be blocked in. For the vessels in the zone, the area of metal wetted by the fire is determined. Allowance should be made for at least 25 feet above the level on which a reasonable fire could be sustained. Spheres shouldbe considered at least up to their maximum diameter. A thorough study of API 520 is recommended to fully understand the options and requirements. The program will accept data for 15 vessel, calculate the wetted area

139

;s

and either using the API method or the NFPA-30 method, detemiine the flowrate generated by the external fire. The pipe loss option will determine the inlet and outlet losses as well as the total back pressure. The ASME valve discharge coefficient is 0.975 for gas flow. They will allow a different value for tested and approved valves. This data is available in the relief valve manufacturers catalogs.

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For Bellows Valves, the back pressure characteristic varies between manufacturers, the program follows the curve in API 520. The manufacturers data should be used when available. r

Engineering Units There are four standard unit sets and one selected set available:


Mass Flow - SI Units . Volume Flow - SI Units Units.


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To make or change a Unit set select the option Review units . The Gas Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file.

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Unit Selection V

A new calculation defaults to Mass English units. The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Gas Flow Engineering Unit screen.

) ’

140 :

Fluid Properties I !

The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure gases and mixtures and are provided in the selected units . Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply.

For a pure gas , find the name and select (or double-click) the name, the fluid properties will be entered.

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For a mixture, select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is updateable. Sizing Code An overpressure of 21 % is used. :

Valve Type )


A rupture disk is sometimes installed under the valve for bubble-tight or corrosive sendee, otherwise select No.

Input Data The enabled input boxes define the data required for the calculation. When selecting the options the standard factors are entered Overwrite the factors with the manufacturers if desired.

Calculate

Click the Calculate button. The program will validate the input data. It will select the valve area and valve orifice designation . Calculate the output data. Display the results.

:

) 141

J

Editing Data

The output data should be examined for adequacy. Fire sizing is not an exact science, it warrants a serious study of the options. If a different valve area is required then overwrite the data. Change data as required and recalculate. When the selection is final then take the pipe losses option. The inlet losses should not exceed 3% and the discharge losses should be less than 10%.

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Filing and Moving On \

The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New.-.Using the default path, it saves an existing record as a new record (used to duplicate similar items, i.e. recall an existing record. Edit as required and Save New) Save As.... - Uses the Windows file access system. Saves to a file anywhere. Import data Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records The default paths are The Data Files. (RVDDAT. TAG and RVDDAT. DAT) . The Unit FUes . (RVDDAT . UNS) The Printout Headings File (HEADINGS.DAT) Print calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager

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142

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RELIEF VALVE Gas Engineering Units

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The screen shows the process variables used in a liquid calculation and lists the available options. To assure full coverage each (except Flow Time Base) has an “ Other” option. This is a defined unit. Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list.

The screen shows the current selection. Any unit may be selected and will be used in the calculation if OK is selected. To create a File for the File Unit option in the calculation, select the desired units and click the save button. A double click on any unit option selects that option and returns to the calculation.

Data Conversion

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For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted. The Flow Quantity option has Mass and Volume options . The relationship between mass flow and volume flow is a multiplier and the molecular weight of the gas, conversion can only be made when the molecular weight has been entered. 143

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Definition of units

Mass flow units : lb = pounds kg = kilograms tonne = 1000 kg = 1 Mg g = gram UKton = 2240 lb USton = 2000 lb Other = defined mass unit

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Volume flow units : sft3 = standard cubic feet sdm3 = standard cubic decimeters sm3 = standard cubic metres Msft3 = million standard cubic feet Other = defined volume unit

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Time base : /s = per second /m = per minute /h = per hour /d = per day

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Gauge pressure :

psig = pounds per square inch gauge kPag = kiloPascals gauge atg = atmospheres gauge inhgg inches of mercury gauge MPag = megaPascals gauge inH20g = inches of water gauge mmhgg = millimetres of mercury gauge barg = bars gauge kg/cm 2g = kilograms per square centimetre gauge Other = defined gauge pressure unit

—

Absolute pressure : psia = pounds per square inch absolute kPaa = kiloPascals absolute ata = atmospheres absolute inhga = inches of mercury absolute MPaa = megaPascals absolute inH20a = inches of water absolute mmhga = millimetres of mercury absolute bara = bars absolute kg/cm2a = kilograms per square centimetre absolute Other = defined absolute pressure unit 144

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Temperature : degF = degrees Fahrenheit degF = degrees Centigrade degR = degrees Rankine degK - degrees Kelvin Other = defined temperature unit Velocity ft/s = feet per second m/s = metres per second Other = defined velocity

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Viscosity : = centipoises Pa.s = Pascal seconds cs = centistokes kPa.s = kiloPascal seconds Other = defined viscosity unit

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Pipe diameter : in = inches mm = millimeters cm = centimeters ft = feet m = metres Other = defined size

Relief area : in2 = square inches mm2 = square millimeters cm2 = square centimeters ft2 = square feet m2 = square metres Other = defined area j

Length and Height : ft = feet m = metres Other = defined length

Latent Heat : btu /lb = British thermal units per pound kJ/lb = kilojoules per pound Other = defined latent heat

) 145

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Force :

.

lb = pound kg = kilogram Other = defined force unit Density lb/ft3 = pounds per cubic foot kg/m 3 = kilograms per cubic metre g/ cm3 = grams per cubic centimeter lb/in3 = pounds per cubic inch Other = defined density unit

Print (RELIEF VALVE) Summary The program will provide a printout summary of data sheet records on file. This is accessed form the main Relief Valve Sizing Programs menu screen. It can provide a printout of either: All fields Selected fields Fields equal to Fields not equal to Fields equal to or less than Fields equal to or greater than Fields less than Fields more than

Procedure for a new Summary Select Options

Clears all check on the form Clear checks Clears all other data on the form Clear Other Data Make new field selections Each field has four boxes A check box to select the field A box to specify the field width A box to enter data to compare A box to specify the compare method (Double click for data) Select data relationship And or or Click Print to print using Windows Print Manager

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146

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File Options :

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Save print options Saves a standard printout Go to Program Menu Form Returns to program menu for further work on this module Exit Returns to the Windows Program Manager

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Procedure for a standard printout Select Options Recall saved options Print

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Procedure to print all fields

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Other Options Select font

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Windows font selection procedure Select Printer Windows Print manager

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147

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Relief Valve Calculation Routines Liquid Relief Known f!ow 1. Calculate the back pressure factor Standard valves Kw =1 Bellows valves.f

PIN

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2. Calculate the relief area -

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}

'' POUT'

. until A equals the selected valve area Increment POUT Gas Relief Known Flow

1. Calculate the pressure ratio -

148

P r= >

,

P

Limited to a minimum of k

2

\ k -1

vk + V 2. Calculate the specific heat ratio coefficient k +1 -1

C = 520

:

3. Calculate the back pressure correction factor Standard valves

.

K =

735R2 C

-

I

VT^r

Where / 2

k

1- r

r*

k -1

kz1^ k

1- r \

Bellows valves

J

(Typical) -

Kb

- 04 = 1.6 - 0.3 e - Pw - 1.18r

(

°

4. Calculate the required area -

v

W.

A=

KdiKb *

2

60 + OV\ RIN 70 j

^

)(

;

M

square inches pressure back allowable maximum . 5 Calculate A _ CALC y V

Kbu«

“

^ T M

Kb

;

VALVE

:•

Standard valves iterate to find r pressure back Maximum

, - 14.7

= rP

:•

psig

Bellows valves Maximum back pressure \

/

PIN

PIN(1.6 - 0.3E-°^) - KW 2 -i- ov reo 118 \

70

psig (Typical)

Steam Relief Known Flow 1. Calculate the pressure ratio -

i

f. I

\

149

Limited to a minimum of k k -1

r 2 \

)

k + 1y

2 . Calculate the superheat correction factor - 0.00012 TSHLogPt = 1+ 0.00Û04 3. Calculate the back pressure correction factor Standard valves

KSH

TSH

? 35 fi C

Kb = Where -

4

^

k -1

Bellows valves

l 1- r k k rk = kk - lJ 1- r

1

-

I

>

i

y

\

^

Kb = (l.6 - 0.3S ° MPN - 1.18r) '

'

4. Calculate the required area

à=

i !

i:

/

r2

|

r

A

f

w

m

,

60 + OVN

70

/

2

PIN

;

(Typical)

i

5 i 5K àP KSHKb square inches

:

5. Calculate the maximum allowable back pressure factor

«bMAX A^ -

A

;

:

CALC b

,

‘VALVE

Standard valves Iterate to find r Maximum back pressure

:

•

= rP1 - 14.7 psig

-

Bellows valves Maximum back pressure y

, PIN

\

,(

P H l.6 - 0.3e - -

"“ “ ) - Kw p

i

2

/

60 + OV 1.18 70

J

.

psig (Typical)

6 Calculate gas valve reaction force in pounds force

1.61, AVALVE.P\.C

^°

>

(T + 460

'

.

7. Calculate the gas valve sound pressure level ( dBA @ 3 feet )

f \—

85 + 1 QLQG10

1

k T| + 46 3.42.M

)

Fluid Properties \

;

150

}

SI ij

'

)

These are calculated using common chemical formulae with each item corrected for pressure and temperature. Some fluids show deviations from the formulae, the should check typical calculated values against known values. In all cases if accurate laboratory information is available it should be used. Density uses the Redlich- Kwong Equation. Nomenclature A Relief area

square inches

dimensionless

Specific gravity at flowing temperature

5

Kd

Coefficient of discharge

K t>

Gas back pressure correction factor

k

Ratio of specific heats


Kp

Overpressure correction factor

dimensionless

^

SH

Superheat correction factor

dimensionless

w

Liquid back pressure correction factor

dimensionless

Viscosity correction factor % overpressure Molecular weight

dimensionless dimensionless diménsionless

Maximum back pressure factor

dimensionless

Set pressure

psig

1

Back pressure

psig

ü

Relieving pressure

psia

Back pressure Pressure ratio

psia dimensionless

Relief temperature

degR

i

sh

Superheat

degF

I

°

Reynolds number

dimensionless

!

Flow rate

Ib/h

Compressibility factor

dimensionless

Absolute viscosity

centipoises

K

OV M pb

**

p

)

II

PoLd p 1

p

2

f

T

f

T

Z

^

•

dimensionless

! Ii jj

! Ü

i

1

i

!

151

!

\

Relief Valve Calculation Routines Entrapped liquid - heat exchanger 1 Calculate the flow rate -

Wm =

! :j

-

_

/

BH

c

!b /h

Entrapped liquid - pipeline 1. Calculate the flow rate. -

-

Wm = 13.62D 2 LBGf

|b/h

t

(for a temperature rise of 5 degF per hour) Both are common from here 2 Calculate the back pressure factor -

li

U

\\

-

Standard valves

fi

Kw - 1 Bellows valves

-

i-P,1 KwW = 1.17 -l

IN i

OUT

3 Calculate the relief area

A=

-

W.m

i

, ,

19008.4KaKfKwV/ G (P

4 Calculate viscosity correction factor D

" 'D —

Kv -

i ^

-

-

I

Pour ) square inches

•

5.6 W.rri

.*

HopVA

:

;

1.892 In. In. In. RD - R -0.6

!

'

0.047

RS

If the Reynolds Number is greater than 50000 then =1

-

Kv

If the Reynolds Number is less than 100 then -

Kv = 0.26.Ln. RD - 0.6

If the Reynolds Number is. less than 15 then -

Ky = RD

;

15

5. Calculate the viscosity corrected area

A=

-

A

Kv

6 Calculate the maximum allowable back pressure Standard valves

-

/

w

\ 2

m

\

PfW PIN ~

19008.4KdKpKwKvAj

Or V

Bellows valves

psig

-

4

152

I Calculate

)

Kw - 1.17 -

f P, IN

\

n

^ Pour'

i!

Calculate A in formula 3 P Increment OUT until A equals the selected valve area

H.

l\

Heat Exchanger Tube Failure -

A-

Â .

-n oc nJBE

Kd

PTUBE

(PSHELL Pb^ )

- 1.5

f

1.85P,SHEU-

I!

square inches

The tube pressure must be greater than 150% of the she!) pressure. The ruptured tube is the assumed to provide a flow area of one tube and a flow coefficient of 0.62. The is no allowance in formula for flashing or thermal expansion. 10 %.

K

is 1 for 25% overpressure, 0.82 for 16 % and 0.62 for

i!

These are calculated using common chemical formulae with each item corrected for pressure and temperature. Some fluids show deviations from the formulae , the should check typical calculated be values against known values. In all cases if accurate laboratory information is available it should

used.

Density uses the Redlich-Kwong Equation.

A A TUBE B C

Relief area

square inches

Tube cross section area Liquid cubical expansion at flow temp Liquid specific heat

square inches per degF BTU/lb/degF

Gf H

Specific gravity at flowing temperature Total heat transfer

dimensionless BTU/hour

Kd


dimensionless

KP


dimensionless

Liquid back pressure correction factor


M

Viscosity correction factor % overpressure Molecular weight


Pmx

Maximum back pressure

psig

**

)

li ti

ïi! ;

Nomenclature

OV

!i |i

Fluid Properties

Kw Kv

i

!! i

PSHELL shell maximum allowable working pressure P TUBE Tube maximum allowable working pressure Pin Set pressure

psig

P

Back pressure

f

Pressure ratio

psig dimensionless

psig

! ;• !

ii :

!I i

:

:

psig

t

153

I

T

f

RD

M'

Relief temperature

degR

Reynolds number

dimensionless

Flow rate

lb/h

Absolute viscosity

centipoise

)

f

V

L.

154

T ï :

!

;

-

/

î

°“ ~ ) - Kb„

l.6 - 0.3S -

PIN(

pIN

;

'N

reo + ovV

1.18

70

\

\

Fire size Gas Expansion 1. Calculate the wetted area

y

psig (Typical)

-

: :

Aw — EXnDv (Dv + LV ) square feet 2. Calculate pressure ratio -

;

p2

r = -±-

Pi

Limited to a minimum of

t

[

k

=

2 ") k i

f

Vk + v

3. Calculate the specific heat ratio coefficient -

c = 520

f ( khT

7+7

I

1

r


.^

K = Where

-

C

/

.

. PS -r k -1

F2

!

7

*

:

k -i > k

:

1- r 1- r

:•

j

\

Bellows valves

Kb

= (l.6 - 0.3 s

MP» '

°

~

(

- 1.18r) V

60 + OV

70

2

I ;

PIN (Typical)

5. Calculate the relief temperature 3 (v T + 460) Tff = — -14.7 " Pn + 6. Calculate the relief valve factor 1.25 N r 0.1406 (Tw - T,)

’

fl

=

Kdc

^

T;0.6506

'

•»

F Aw A=

47

8 . Calculate the flow rate

-

degR

7

7 Calculate the required area ,

i

square inches

L

I.

155

:

Relief Valve Calculation Routines Fire size Liquid Vaporization 1. Calculate the wetted area -

)

Aw - EXnDv (Dv + LV ) square feet

2. Calculate vaporized liquid -

w

21000FA

=

2

LHV

3 . Calculate the pressure ratio

lb/h

-

t

)

t

,

p

Limited to a minimum of k

f

\k 1 -i

^

W-+ v

4. Calculate the specific heat ratio coefficient k +T ( 2 MM C = 520, k vk +1


Kb

=

Where -

p V^7

^

F2 =

-

r

k

k k -1

2

1- r

rk

k -l \ k

1- r \

y

Bellows valves

Kb = (1.6 - 0.3 B

"^ - 1.18r)

-0

6. Calculate the required area

A=

W.m /V KdiKj, V M squgre

60 + OVV PIN 70 (Typical)

J

jnches

7. Calculate maximum allowable back pressure _ rA CALC V

'

-

A VALVE

^

IX Kb

Standard valves Iterate to find r Maximum back pressure -

= rP1 - 14.7 psig Bellows valves Maximum back pressure

-

i

| :•

i

i-

156 :

!

'

)

W„= KdA

M

» lf Ib/h 9 . Calculate maximum allowable back pressure -

Kb

-

_ 'A CALC

A VALVE Standard valves -

Kb

Iterate to find r Maximum back pressure = rP - 14.7 psig

^

Bellows valves Maximum back pressure -

\

/

) - K,Vl,

„

P (l6 - 0.38^

, PIN

18

:

2

76O + OV

70 psig (Typical) ^ force pounds in force Calculate gas valve reaction y

V

10 ,

i

1.61. AVALVE.PV C

(T, + 460 ).

)

:

M J-28.97

11. Calculate the gas valve sound pressure level ( dBA @ 3 feet) WM. k. (T + 460

,

85 + 10LOG10

\

y

3.42. M

Fluid Properties

These are calculated using common chemical formulae with each item corrected for pressure and temperature. Some fluids show deviations from the formulae, the should check typical calculated values against known values. In all cases if accurate laboratory information is available it should be

used. Density uses the Redlich-Kwong Equation. Nomenclature A Relief area

Aw

. !

:•

C

square feet dimensionless

Dv

Vessel diameter

feet

Relief valve factor

dimensionless

'

)

square inches

Wetted area Specific heat ratio coefficient

F

\

;

:

:

Kd Kb


dimensionless

Gas back pressure correction factor

k

Ratio of specific heats


Kp


dimensionless

l- HV

Latent heat of vaporization at flow temp.

Btu per pound

t

\

157

*- v ov M

Vessel length, tangent to tangent % overpressure Molecular weight


Pbm„

Maximum back pressure factor

dimensionless

feet

Pln

Set pressure

p„

psig

Operating pressure

psig

pi

Relieving pressure

psia

r T

^ ,

Back pressure Pressure ratio

psia dimensionless

Relief temperature

degR

Tn

Operating temperature

degF

Flow rate

Ib/h

Vessel wetted portion Compressibility factor


2

wm ,

X

z

158

Relief Valve Data Files

: i ;

INSTRUCALC V5 Random access file specification for relief valves RVWDAT.Dat. Tag Numbers are stored in sequential file RVWDAT.TAG. Its number in the file is the record number in the random access file. Type FileData ProgNum As Integer Code As String * 3 RupDisk As String * 3 Bellows As String * 3 PipeCond As Integer PipeMatl As Integer FloBasis As String * 3 FS(0 To 23) As Single GS (0 To 23) As Single UnS(0 To 23) As String * 8 PDSS(1 To 6) As Single PDIS( I To 14) As Integer PDCS( I To 6) As Single SdS( l To 7) As Single

2 bytes .Program number 3 Bytes ASME or API Liq sizing.’ T " ” 8" or "Fre" for gas 3 bytes "Yes" or "No ” 3 bytes "Yes" or "No" 2 bytes.0% 20% or 50%

!

2 bytes Pipe material 3 bytes . FloBasis = Liqbasis or GasBasis 96 bytes.Units conversion factor 96 bytes. 192 bytes. Unit Name 24 pipe loss pipe dims 28 Pipe elements 24 Pipe loss variable data 28 bytes.Spec inputs CalcArea, Const BP,Built upBP,Oper press,Oper temp Aras( l To 33) As String * 25 825 bytes.Data sheet array selections Txtl ( l To 3) As String * 25 75 bytes.Data sheet service,line num, F1D$ Txt2( l To 3) As String * 60 180 bytes.Data sheet notes TXT3 (1 To 7) As String * 10 70 bytes.Data sheet num,spec,rev,req,date,by,appr Record len = 1656 End Type

i

f

>

Prognum = 1 Program = "Liquid relief - Known flow " Code = " API" API 520 sizing ASME Section 8 sizing Code = "ASM" RupDisk = "Yes" or "No" for rupture disk Bellows = "No" or "Yes " for bellows type valve PipeCond See pipe loss program ditto PipeMatl FloBasis - "Mas" for mass flow,or "Vol " for volumetric flow FS(1) UnS( l ) GS(1) = Normal flow FS(2) UnS(2) GS (2) = Relief temperature FS(3) UnS(3) GS(3) = Valve set pressure FS (4) UnS(4) GS(4) = Total back pressure GS (5) = Specific gravity at flow conditions FS(7) UnS(7) GS(7) = Viscosity at flow conditions

j

Î"

i 159

FS(13) UnS(13) GS(13) = Selected valve area GS (14) = Percent overpressure GS (15) = Valve discharge coefficient GS ( 16) = Rupture disk derating factor Un(5) is used for the valve orifice designation ( G(5) Specific gravity has no units) PDSS(1 to 6) See pipe loss program PDIS (1 To 14)- ditto PDCS(1 To 6) - ditto FS (13) UnS (13) SDS( l ) = Calculated valve area FS (4) UnS(4) SDS (2) = Constant back pressure (4) UnS(4) FS pressure SDS(3) = Built up back FS(3) UnS(3 ) SDS(4) = Operating pressure FS(2) UnS(2) SDS(5) = Operating temperature selections array sheet Aras( l To 33) Data Txtl ( l To 3 ) 75 bytes.Data sheet service, line num, Fluid name Txt2( l To 3) Data sheet notes Txt3 ( l To 7) Data sheet num ,spec,rev,req,date,by,appr

——

Prognum = 2 Program = "Gas relief - Known flow " Code = "AS1 " ASME Section 1 sizing Code = "AS8" ASME Section 8 sizing Code = "Fre" ASME Section 8 fire sizing RupDisk = "Yes" or "No" for rupture disk Bellows = "No " or "Yes " for bellows type valve See pipe loss program PipeCond ditto PipeMatl mass flow,or "Vol " for volumetric flow for Mas " " FloBasis = FS(1) UnS( l ) GS(1) = Normal flow FS(2) UnS (2) GS(2) = Relief temperature FS(3) UnS(3) GS(3) = Valve set pressure FS(4) UnS(4) GS(4) = Total back pressure GS(6) = Molecular weight GS(9) = Density GS(10) = Ratio of specific heats FS (11) UnS( l 1 ) GS(11) = Critical pressure UnS(12) temperature GS (12) = Critical (13) ) UnS 13 FS ( GS(13) = Selected valve area GS(14) = Percent overpressure GS( 15) = Valve discharge coefficient GS(16) = Rupture disk derating factor Un(5) is used for the valve orifice designation (G(5) Specific gravity has no units) PDSS(1 to 6) See pipe loss program PDIS(1 To 14)- ditto ditto PDCS(1 To 6)

—

160

FS(13) UnS ( 13) SDS( l ) = Calculated valve area FS (4) UnS (4) SDS(2) = Constant back pressure FS (4) UnS(4) SDS(3) = Built up back pressure FS(3) UnS(3) SDS(4) = Operating pressure UnS (2) SDS(5) = Operating temperature Aras( l To 33) Data sheet array selections Txtl ( l To 3) 75 bytes. Data sheet service,line num, Fluid name Txt2( l To 3) Data sheet notes Txt3( l To 7) Data sheet num,spec,rev,req,date,by, appr

If ProgNum = 3 Then Program = "Steam relief - Known flow" Code = "AS1" ASME Section 1 sizing Code = "AS8 " ASME Section 8 sizing Code = "Fre" ASME Section 8 fire sizing RupDisk = "Yes " or "No " for rupture disk Bellows = "No " or "Yes " for bellows type valve See pipe loss program PipeCond PipeMatl ditto FloBasis = "Mas" for mass flow,or "Vol" for volumetric flow FS(1) UnS( l ) GS (1) = Normal flow UnS (2) GS (2) = Relief temperature ( ) UnS (3) FS set 3 3 pressure GS( ) = Valve GS(4) = Total back pressure FS (4) UnS (4) GS (9) = Degress superheat FS(2) UnS(2) ( ) FS(13) UnS(13) GS 13 Selected valve area GS (14) = Percent overpressure GS(15) = Valve discharge coefficient GS(16) = Rupture disk derating factor Un(5) is used for the valve orifice designation (G(5) Specific gravity has no units) PDSS(1 to 6) See pipe loss program PDIS(1 To 14)- ditto PDCS(1 To 6) - ditto FS(13) UnS ( 13) SDS( l ) = Calculated valve area FS(4) UnS (4) SDS(2) = Constant back pressure FS(4) UnS(4) SDS(3) = Built up back pressure FS(3) UnS (3) SDS(4) - Operating pressure UnS(2) SDS(5) = Operating temperature Aras( l To 33) Data sheet array selections Txtl ( l To 3 ) 75 bytes.Data sheet service,line num, Fluid name Txt2( l To 3) Data sheet notes Txt3 ( l To 7) Data sheet num,spec,rev,req ,date,by,appr

——

161

:

If ProgNum = 4 Then Program = "Heat exchanger - Entrapped liquid " Code = "API " ASME Section 1 sizing Code = " ASM" ASME Section 8 sizing RupDisk = "Yes " or "No " for rupture disk Bellows = "No " or "Yes" for bellows type valve PipeCond See pipe loss program PipeMatl ditto FloBasis = "Mas " for mass flow,or "Vol " for volumetric flow GS(1 ) = Normal flow FS (1) UnS ( l ) GS (2) = Relief temperature UnS(2) GS(3) = Valve set pressure FS(3) UnS(3) GS(4) = Total back pressure FS(4) UnS (4) GS(5) = Specific gravity GS(6) = Cubical expansion UnS (2) GS(7) = Viscosity FS(7) UnS (7) GS (13) = Selected valve area FS(13) UnS(13) GS(14) = Percent overpressure GS (15) = Valve discharge coefficient GS(16) = Rupture disk derating factor G8(21) = Specific heat FS(21) UnS(21) GS(22) = Heat input FS(22) UnS (22) Un(5) is used for the valve orifice designation (G(5) Specific gravity has no units) PDSS ( 1 to 6) See pipe loss program PDIS(1 To 14)- ditto PDCS(1 To 6) - ditto SDS( l ) = Calculated valve area FS (13) UnS (13) SDS (2) = Constant back pressure FS(4) UnS(4) SDS(3) = Built up back pressure FS(4) UnS(4) SDS (4) = Operating pressure FS(3) UnS(3) SDS(5) = Operating temperature UnS(2) Aras( l To 33) Data sheet array selections Txtl ( l To 3 ) 75 bytes.Data sheet service,line num , Fluid name Txt2( l To 3) Data sheet notes Txt3( l To 7) Data sheet num,spec,rev,req, date,by,appr

(

:

r

) /

i

:

— —

If ProgNum = 5 Then Program = "Pipeline - Entrapped liquid" Code = "API " API Section 1 sizing Code = "ASM" ASME Section 8 sizing RupDisk = "Yes " or " No" for rupture disk Bellows = "No " or "Yes " for bellows type valve PipeCond See pipe loss program PipeMatl ditto FloBasis = "Mas" for mass flow,or "Vol " for volumetric flow

162

)

•

FS(1) UnS( l ) GS (1) = Nonrial flow UnS (2) GS(2) = Relief temperature UnS(3) 3 ( ) FS GS (3) - Valve set pressure FS(4) UnS(4) GS (4) = Total back pressure GS(5) = Specific gravity UnS (2) GS (6) = Cubical expansion FS(7) UnS (7) GS (7) = Viscosity FS(13) UnS (13) GS(13) = Selected valve area GS(14) = Percent overpressure GS(15) = Valve discharge coefficient GS (16) = Rupture disk derating factor FS (17) UnS ( 17) GS (17) = Line diameter FS(18) UnS (18) GS(18) = Line length Un(5) is used for the valve orifice designation (G(5) Specific gravity has no units) PDSS(1 to 6) See pipe loss program PDIS(1 To 14)- ditto PDCS (1 To 6) - ditto FS(13) UnS(13) SDS( l ) = Calculated valve area FS (4) UnS (4) SDS(2) = Constant back pressure FS (4) UnS(4) SDS(3) = Built up back pressure FS(3) UnS(3) SDS(4) = Operating pressure UnS(2) SDS(5) = Operating temperature Aras( l To 33) Data sheet array selections Txtl ( l To 3) 75 bytes.Data sheet service,line num, Fluid name Txt2( l To 3) Data sheet notes Txt3( l To 7) Data sheet num,spec,rev,req,date,by,appr

——

If ProgNum = 6 Then Program = "Fire size - Liquid vaporization" Code = "API" API fire sizing Code = "NFP " National Fire Protection Association sizing Code = "Oth " Other fire sizing system RupDisk = "Yes " or "No" for rupture disk Bellows - "No " or "Yes " for bellows type valve See pipe loss program PipeCond ditto PipeMatl FloBasis = "Mas" for mass flow,or "Vol" for volumetric flow FS(1) UnS( l ) GS(1) = Normal flow UnS (2) GS (2) = Relief temperature FS(3) UnS(3) GS (3) = Valve set pressure FS(4) UnS (4) GS (4) = Total back pressure GS (5) = Environment factor GS(6) = Molecular weight GS(9) = Compressibility factor

163

GS (10) = Ratio of specific heats FS(11) UnS( l 1) GS( ll ) = Critical pressure FS (12) UnS(12) temperature 12 Critical ( ) GS = FS ( 13) UnS (13) GS (13) = Selected valve area GS (14) = Percent overpressure GS (15) = Valve discharge coefficient GS(16) = Rupture disk derating factor FS (23) UnS(23) GS(23) = Latent heat of vaporization Specific gravity has no units) ) ( ( G 5 designation Un(5) is used for the valve orifice PDSS(1 to 6) See pipe loss program PDIS(1 To 14)- dittoditto PDCS( 1 To 6) FS(13) UnS(13) SDS( l ) = Calculated valve area FS(4) UnS(4) SDS(2) = Constant back pressure FS(4) UnS (4) SDS(3) = Built up back pressure FS(3) UnS(3) SDS(4) = Operating pressure UnS (2) SDS(5) = Operating temperature selections array Aras( l To 33) Data sheet Txtl ( l To 3) 75 bytes. Data sheet service,line num, Fluid name Txt2( l To 3) Data sheet notes Txt3( l To 7) Data sheet num,spec,rev,req,date,by,appr Vessel data is stored in sequential file RVWF. FLE

—

:

! !

I i

;

:

I

If ProgNum = 7 Then Program = "Fire size - Gas expansion " RupDisk = "Yes " or "No " for rupture disk Bellows = "No" or "Yes" for bellows type valve See pipe loss program PipeCond ditto PipeMatl FloBasis = "Mas" for mass flow,or "Vol" for volumetric flow FS (1) UnS( l ) GS(1) = Normal flow FS (3) UnS(3) pressure 3 Valve set GS( ) FS (4) UnS(4) GS(4) = Total back pressure GS(6) = Molecular weight FS (3) UnS(3) GS(8) = Operating pressure GS(10) = Ratio of specific heats FS(13) UnS (13) GS(13) = Selected valve area GS(14) = Percent overpressure GS (15) - Valve discharge coefficient GS(16) = Rupture disk derating factor UnS(2) GS(22) = Operating temperature UnS (2) GS(23) = Maximum metal temperature G gravity has no units) Specific 5 ( ( ) designation orifice valve the used ) for Un(5 is PDSS (1 to 6) See pipe loss program ditto — PDIS(1 To 14) ditto PDCS(1 To 6)

——

—

?

i

164 i

!

; i

FS(13) UnS (13) SDS( l ) = Calculated valve area FS(4) UnS (4) SDS (2) = Constant back pressure FS(4) UnS(4) SDS (3) = Built up back pressure Aras( l To 33) Data sheet array selections Txtl ( l To 3) 75 bytes.Data sheet service,line num, Fluid name Txt2( l To 3) Data sheet notes Txt3( l To 7) Data sheet num,spec,rev, req,date,by,appr Vessel data is stored in sequential file RVWF.FLE -

If ProgNum = 11 Then Program = "Heat exchanger - Tube rupture- No heat gain"

-

Code = "API" API sizing ASME sizing Code "ASM" RupDisk = "Yes" or "No" for rupture disk Bellows = " No" or "Yes " for bellows type valve See pipe loss program PipeCond ditto PipeMatl FloBasis = "Mas" for mass flow,or " Vol " for volumetric flow FS(3) UnS(3) GS (3) = Valve set pressure FS(4) UnS (4) GS (4) = Total back pressure FS(3) UnS(3) GS (8) = Exchanger tube rating FS(13) UnS(13) GS(13) = Selected valve area GS ( 16) = Rupture disk derating factor FS(17) UnS (17) GS (17) = Exchanger tube inside diameter Un(5) is used for the valve orifice designation (G(5) Specific gravity has no units) PDSS (1 to 6) See pipe loss program PDIS(1 To 14) ditto PDCS(1 To 6) ditto SDS ( l ) = Calculated valve area (From calculation program) SDS (2) = Constant back pressure (From pipe loss program) SDS (3) = Built up back pressure (From pipe loss program) SDS(4) = Operating pressure (From data sheet program) SDS ( 5) = Operating temperature (From data sheet program) Aras( l To 33) Data sheet array selections Txtl (1 To 3) 75 bytes.Data sheet service,line num, Fluid name Txt2( l To 3) Data sheet notes Txt3 ( l To 7) Data sheet num,spec,rev,req,date,by,appr

f-

t

:

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Pipe loss sub-progam (accessed from all programs)

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PipeCond PipeMatl = 1 PipeMatl = 2 PipeMatl = 3 PipeMatl = 4

Percentage increase in friction factor, 0,20 or 50 Commercial steel Drawn tubing Cast Iron :

Galvanized Iron 165

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PipeMatl = 5 Asphalt lined PipeMatl = 6 Concrete PipeMatl = 7 Wood stave PDS( l ) = Pipe length PDS(2) - Inlet pipe inside diameter PDS(3) = Pipe elevation PDS (4) = Outlet pipe length PDS(5) = Outlet pipe inside diameter PDS(6) = Outlet pipe elevation PDI( l ) = Number of Inlet gate valves PDI(2) = Number of Inlet globe valves PDI(3) = Number of Inlet check valves PDI(4) Number of Inlet 90deg elbows PDI(5) = Number of Inlet 45deg elbows PDI(6) = Number of Inlet thru tees PDI(7) = Number of Inlet branch tees PDI(8) = Number of Outlet gate valves PDI( 9) = Number of Outlet globe valves PDI( IO) = Number of Outlet check valves PDI(11) = Number of Outlet 90deg elbows PDI(12) = Number of Outlet 45deg elbows PDI(13) = Number of Outlet thru tees PDI(14) = Number of Outlet branch tees PDC( I ) = Flow PDC(3) = Source pressure PDC(4) = Viscosity PDC(5) = Temperature PDC(6) - Destination pressure

FS (18) UnS (18) FS(17) UnS(17) FS(18) UnS(18) FS(18) UnS(18) FS(17) UnS(17) FS(18) UnS (18)

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Miscellaneous Files RVWDAT.UNS RVWDAT.STP. RVWSPEC.TXT HEADINGS . DAT RVWSUM.DAT RVWCALC.DRV

RVWCALC.COL

FS(1) UnS( l ) FS(3) UnS(3) FS (7) UnS (7) UnS(2) ( ) FS 3 UnS(3)


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Relief Valve Import Process Data To Import process data into a calculation: Make a sequential file for each calculation . Files to have a filename (Suggest the tag number) with no extension (ie RV-100.). After INSTRUCALC reads the file it will rename the file to " FILENAME.OK" . This will divide the files into two lists, those which have been processed and those which have not. To read a file. 1. Go to the required calculation and select the required units. 2. Take the Import data menu option. 3. Find the required file. (Using standard Windows procedures) 4. Select the file and the data will be loaded. 5. Proceed with the calculation and save the data. (Now in the INSTRUCALC file) 6. The sequential file will be assigned the extension ".OK " , and will disappear from the list. 7. If a review is required , use the Windows file procedures for files with an extension ".OK" 8. Revised process data should be provided without extensions. The Instmment engineer will then have an instant review of work not yet perfonned .

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Data input sequential file requirements (in input order) i

RV gas known flow 1 Tag number 2 Fluid name 3 Relief temperature 4 Set pressure 5 Required flow 6 Total back pressure 7 Molecular weight 8 Ratio of specific heat 9 Compressibility factor 10 Operating pressure 11 Operating temperature 12 Constant back pressure 13 Built up back pressure 14 Line number 15 Service

Variable name Seq file) xtl (3) (2) G(3) (1) (4) G(6) G(10) G(9) SD(4) SD(5) SD(2) SD(3) Txtl (2) Txtl ( l )

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RV fire liquid vaporization 1 Tag number 2 Fluid name 3 Relief temperature 4 Set pressure 5 Required flow 6 Total back pressure 7 Molecular weight 8 Ratio of specific heat 9 Environment factor 10 Compressibility factor 11 Latent heat of vaporization 12 Operating pressure 13 Operating temperature 14 Constant back pressure 15 Built up back pressure 16 Line number 17 Service

Variable name (Seq file) Txtl (3) G(2) G(3) G( l ) G(4) G(6) G(10) G(5) G (9) G(23) SD(4 ) SD(5) SD(2) SD(3) Txtl (2) Txtl ( l )

RV fire gas expansion 1 Tag number 2 Fluid name 3 Operating temperature 4 Set pressure 5 Operating pressure 6 Total back pressure 7 Molecular weight 8 Ratio of specific heat 9 Maximum metal temperature 10 Constant back pressure 11 Built up back pressure 12 Line number 13 Service

Variable name (Seq file) Txtl (3) SD(5) G(3) SD(4) G(4) G(6) G(10) G(23) SD(2) SD(3) Txtl (2) Txtl ( l )

RV liquid known flow 1 Tag number 2 Fluid name 3 Relief temperature 4 Set pressure 5 Required flow 6 Total b ack pressure 7 SG @ flow conditions 8 Viscosity @ flow conditions 9 Operating pressure 10 Operating temperature

Variable name (Seq file) Txtl (3) G(2) G(3) 0(1) G(4) G(5) G(7) SD(4) SD(5) 168

Il Constant back pressure 12 Built up back pressure 13 Line number 14 Service

SD(2) SD(3) Txtl (2) Txtl ( l ) !

Variable name RV liquid pipeline thermal expansion (Seq file) 1 Tag number Txtl (3) 2 Fluid name G 2 temperature ( ) 3 Relief G(3) 4 Set pressure G(4) 5 Total back pressure G(17) 6 Line diameter G(18) 7 Line length G(6) 8 Cubical expansion (5) SG G flow conditions @ 9 G(7) 10 Viscosity @ flow conditions SD(4) 11 Operating pressure SD(5) 12 Operating temperature SD(2) 13 Constant back pressure SD(3) 14 Built up back pressure Txtl (2) 15 Line number Txtl ( l ) 16 Sendee

RV liquid heat exchanger thermal expansion (Seq file) 1 Tag number ' l xil (3) 2 Fluid name G(2) 3 Relief temperature G(3) 4 Set pressure G(4) 5 Total back pressure G(6) 6 Cubical expansion G(22) 7 Heat input G(21) 8 Specific heat G(5) 9 SG @ flow conditions G(7) 10 Viscosity @ flow conditions SD(4) 11 Operating pressure SD(5) 12 Operating temperature SD(2) 13 Constant back pressure SD(3) 14 Built up back pressure (2) Txtl 15 Line number Txtl ( l ) 16 Service '

RV steam known flow 1 Tag number 2 Fluid name 3 Degrees superheat

(Seq file) Txtl (3) G(9) 169

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Set pressure Total back pressure Required flow Operating pressure Operating temperature Constant back pressure Built up back pressure Line number Service

0(3) 0(4) 0(1) SD(4) SD(5) SD(2) SD(3) Txtl (2) Txtl ( l )

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RV heat exchanger tube rupture 1 Tag number 2 Fluid name 3 Set pressure 4 Tube inside diameter 5 Tube pressure rating 6 Total back pressure 8 Operating pressure 9 Operating temperature 10 Constant back pressure 11 Built up back pressure 12 Line number 13 Service

(Seq file) Txtl (3) 0(3) 0(17) 0(8) 0(4) SD(4) SD(5) SD(2) SD(3) Txtl (2) Txtl ( l )

Relief Valve Program Pipe Dimensions The pipe sizes are available in a program look-up table. To find the size, select the Pipe ID button to display the pipe size screen, enter the nominal size of the pipe and select the search button . The available wall thickness and the corresponding inside diameters for the nominal size are displayed. Select the required size and the data will be ed to the calculation. Metric dimensions are in millimeters and nominal sizes are based on 25 mm per nominal inch. If units other than inches or millimeters are used, the data transferred back to the calculation will be converted to the calculation units.

170

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Chapter 4

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RELIEF DEVICES Rupture Disks and Tank Vents

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Pressure Relieving Devices

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Rupture Disk Liquid Flow Rupture Disk - Gas Flow Tank Vent - Gas Relief

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The rupture disk programs are based on the ASME pressure vessel code. The tank vents are based on NFPA and API 2000 .

Rupture Disks A Rupture Disk is a non reclosing pressure relieving device which bursts at the set pressure. It is a reliable, low cost and accurate method of preventing overpressure. It can either be used as a stand alone device or in combination with a relief valve when corrosive or bubble-tight shutoff is required during normal operations and some resealing capability is required after over pressure has occurred . 171

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A safety head assembly is recommended to ensure proper alignment, proper seating and a reduced possibility of damage during handling and installation.

Rupture disks must meet the ASME code for sizing, manufacturing and testing, the same back pressure and overpressure limitations as relief valves apply. :

Being a non reclosing device, caution is advised if you have a superimposed back pressure. If you subtract it from the set pressure to ensure that the allowable overpressure is not exceeded , you may have unexpected shutdowns - not because the internal pressure went too high, but because the external down stream pressure went too low.

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The minimum rupture disk diameter calculated is the inside diameter of the mounting flanges. The inlet and outlet piping is limited to the same losses (3% and 10%) as the relief valve. This can be checked with the pipe losses option.

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Tank Vents

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Venting must be provided for normal operational inbreathing and outbreathing requirements and emergency pressure relief for fire conditions. Tanks are normally designed to API 650 or API 620 and vented according to API 2000 and NFPA 30. Emergency pressure relief for API 650 is usually provided in the tank design by the frangible characteristic of the shell to roof seam. API 620 usually requires a vent of sufficient size. This size is usually too large for satisfactory normal operations and is a separate device with Tanks designed to API are limited to a maximum pressure of 15 psig. Above this they become pressure vessels governed by ASME. The tank pressure is largely determined by the thickness of the roof material. The minimum thickness for products of low volatility is 3/16 inch steel, which weighs 0.84 ounces per square inch. The roof is usually ed by an inside frame and is usually stronger under vacuum than pressure. A limit of 0.5 ounces per square for both pressure and vacuum is common for a 3/16 inch thick steel roof.

Under pressure can cause the tank walls to buckle, which is more difficult to repair than a weak seam splitting because of overpressure. Under pressure may typically be caused by a thunderstorm on a hot day, sometimes causing a temperature drop of 40°. The API code states that free vents shall not be used when the contents have a flashpoint below 100°, only breather valves are acceptable. Flame arrestors should be used when the product flashpoint is below 100° or when the bulk of the contents can be heated to the flashpoint under operating conditions .

The size of the assembly is selected so that both the pressure flow and vacuum flow keep the vessel within the prescribed limits. Maximum flow is usually reached when the overpressure is twice the set pressure. 172

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The API 2000 calculation is based on the hexane worst case formula. This is a conservative value but does not increase the size significantly, It has the advantage that if the contents are changed either deliberately or accidentally, then the venting will most likely still be adequate. General

If changes are made to data recalled from file, the data will be displayed in the color selected for changed data . This will assist in recognising the affect the changes make to other calculations and the data sheet.

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RELIEF DEVICE Program Features Perform sizing calculations

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Calculate either. ASME single, ASME multi or API formulas Calculate inlet and outlet pipe losses Supply fluid properties at flow conditions Supply steam data Supply pipe sizes Use English or SI engineering units in any mixture Use mass or volume flow units Import process data Print a calculation sheet using the Windows Print Manager Save the data

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Prepare instrument data sheets WYSIWYG style Initially general- sheets for bid purposes Supply database of standard specification items After vendor selection, revise for permanent records Print a data sheet using the Windows Print Manager Save the data

Print a summary of saved records Print all records Print selected records Print only records having required characteristics

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This is a program for calculating the size of Rupture Disks and Tank Vents . The available options are: Rupture disk - Liquid flow Rupture disk - Gas flow Tank vents - Gas relief

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RELIEF DEVICE Program Menu Options New calculation

Select the required calculation option and the fluid option, then select OK (or doubleclick if at least one of the options is already selected). File

Default files. Recalls file data using the files in the default drives and paths. Other files . Recalls file data using the Windows file selection procedure. Data file maintenance. Edit Tag Numbers . Provides the facility to change the Tag Numbers on file. Or delete records from file. Sort data file. Rearrange the Tag Numbers in ascending order. 174

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Delete the items marked if the edit was saved. Data files path Path for the default calculation data files. unit file path Path for the defaults engineering units file. Printout headings file path Path for the printout headings file. Ii

There are three paths. If a Drive and Path different from the Default Path and Drive provided in the initial Set Up Procedure was used, the program will update them to . . • the Drive and Path which was installed . They are saved in sequential file RDWCALC.DRV which resides with the programs. To check or change the paths, either call up the Drive and Path for edit or use a text editor to or change the file

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contents. Convert V3 file stage 2 Instmcalc version 3 file conversion to Windows format. |

Exit

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Exits from Instrucalc to Windows Program Manager.

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\ Edit Tables

(Version 5.1)

InstruCalc uses Data Tables for Gas, Liquid, Pipe Size and Material properties, these contain data from which exact properties for the flow conditions are calculated. It also has tables for equipment data. These option provides an easy means of customizing them. Items can be added, inserted, deleted and changed.

Each program can edit the tables used in the program. Take note that some, such as the Gas, Liquid and Pipe Size are used by other programs and may include data required. only by them. '

Editing is performed by either clicking the appropriate line in the Grid or entering the line number in Row to Edit and clicking Recall Row. Edit the data and Load Row to the Grid. When a box in the edit line is clicked, information on the data required for that box is displayed above. Save Grid overwrites the old file. A backup file is recommended before you start. The file name is in the heading of the Edit Form and the files are in the program directory.

Note that data cannot be edited directly in the grid.

175

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RELIEF DEVICE Program Lead Sheet

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The program will only stop at the Lead Sheet if it fails to find the default paths file. To continue, type in the paths and save the file.

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The Data Files are specific to a project and an instrument type The Units File may be common for all projects and specific for an instrument type The Headings File may be specific for a project and common for all instruments

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Mass Flow - SI Units. Volume Flow - SI Units . Units .

Kilograms per second and degrees Centigrade Litres per second and degrees Centigrade A set of units selected from the Liquid Flow Engineering Unit screen

To make or change a Unit set select the option Review units. The Liquid Flow Engineering Unit screen will be displayed . It shows the available options and the current unit selection. Select the required units and save the file. Unit Selection

A new calculation defaults to Mass English units. The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero . Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen. Fluid Properties The Fluid properties option is enabled when the pressure and temperature are entered . The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply.


Sizing Code

In the Summer 1984 Addenda to the Pressure Vessel Code, ASME published a formula for liquid sizing. All vessels ed after 1984 must be sized with the ASME formula. Vessels built before this may still use the API formula.

177

Input Data The enabled input boxes define the data required for the calculation . The maximum ASME overpressure is 10%, API 25%.

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Calculate

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Click the Calculate button. The program will validate the input data, Calculate the output data Display the results The selected disk diameter is the flange inside diameter

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The output data should be examined for adequacy. Change data as required and recalculate

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Filing and Moving On The options in the File menu are: Program menu - Clears the calculation and returns to the main menu . Prepare data sheet Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New.-.Using the default path, it saves an existing record as a new record (used to duplicate similar items, i . e. recall an existing record . Edit as required and Save New) Save As.... - Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation

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records The default paths are The Data Files. (RVDDAT.TAG and RVDDAT.DAT). The Unit Files . (RVDDAT.UNS) The Printout Headings File (HEADINGS.DAT) calculation Print - Is enabled after a calculation is made. It displays the screen to print a calculation.

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Exit - Leaves the program and returns to the Windows Program Manager

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The screen shows the process variables used in a liquid calculation and list the available options. To assure fall coverage each (Except Flow Time Base) has an “ Other” option. This is a defined unit. Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list . The screen shows the current selection. Any unit may be selected and will be used in the calculation if OK is selected .

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To create a File for the File Unit option in the calculation, select the desired units and click the save button. A double click on any unit option selects that option and returns to the calculation. X

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Data conversion

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For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted. The Flow Quantity option has Mass and Volume options. The relationship between mass flow and volume flow is a multiplier and the specific gravity of the fluid. If the flow units are changed from mass to volume, or volume to mass and the specific gravity is not available the flow rate is set to zero .

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RELIEF DEVICE Inlet and Outlet Pressure Loss Calculation

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The Superimposed back pressure is the pressure in the discharge header before the valve opens. The program adds any head pressure to the source pressure.

The Built-up back pressure is the pressure built up in the discharge as the result of flow. The Total back pressure is the sum of the two. It always affects the flow capacity of a liquid device and rarely affects a gas device flow capacity because the large pressure drop across the device usually causes critical flow conditions.

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Calculation options.

Select the Pipe Material. Select the Pipe Condition.

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Input Data

The enabled input boxes define the data required for the calculation. Enter the piping configuration and the pipe lengths and elevation change. Enter the process data not ed down from the valve calculation.

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Calculate

Click the Calculate button. The program will validate the input data, Calculate the output data Display the results

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Editing Data

The output data should be examined for adequacy. Are the ASME limits met? Change data as required and recalculate If satisfactory transfer the back pressure to the device calculation by clicking Transfer.

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RELIEF DEVICE Calculation Data Printout This program will print the input and output calculation data and one associated comment. The comment is included in the data sheet for reference purposes. 181

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It also creates the default printout headings. The headings are printed at the top of all printouts . They are saved in the HEADINGS .DAT file. This is the third default path. If all programs are set to the same path, this becomes the default headings for all program printouts.

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182

RELIEF DEVICE Data Sheet Octogon Enginering Corporation Rupture disk Liquid flow Spec.

-

Plant Conversion 2001 Update

Disk

Vacuum Flanges

Accessories Selection basis Service conditions

Req.

By Tag Number: RD- 100 1 ) Size 2) Material j Inlet 3) Coating 1 Outlet 4) Quantity per assembly 5) 6) Model 7) Material 8) Quantity per assembly 9) Attached to disk 10) Assembly number 11) Material [ Base | Holddown 12) Piping inside diameter 13) Flange rating and facing 14) Jack screws in holddown flange 15 ) Studs , nuts | Preassembly screws 16 ) Pressure gage j Excess flow valve

17) 18) Code 19) Fire

Sheet Rev. 11/18/01

Appr

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ASME Section 8

20) 21 ) Service 22) Vessel or Line number 23) Fluid name 24) Fluid state

Disk data

Project 2314 Date

25 ) Required capacity 26 ) Specific gravity @ FTP 27) 28) Pressure | Operating | Bursting 29) Temperature | Operating j Relief 30) Constant back pressure 31) Static or pulsating pressure 32) Coirosive agents 33) Allowable overpressure % 34) Coinpress ibility factor 35 ) 36 ) Calculated diameter 37) Selected diameter 38) Manufacturer 39) Model

Liquid 25 Lb/ h

.63 1 Psig DegF psig

! 24 psig | 23 degF

10

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.008518 in 0 in

Notes:


The relevant data from the calculation is automatically displayed . Minor editing, such as rounding can be performed. Major editing should be done in the calculation routine in order to preserve the integrity of the calculation. A defined database is available to enter data for those inputs which have a limited number of options. To activate this, double click the input box, the data on

183

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file is displayed. Double click the required option and the data is transferred to the data sheet form. The database should be customized for the project requirements. To edit the data; click the selected item. Edit the data in the active top line, select Replace, continue with the edit and Save on completion. The Input data menu option has an option to enter either the first or the second item in the list for all items. If the database is constructed so that the first item is the first standard selection and the second item is the second standard selection then two standard data sheets are available for a single keystroke. This feature only enters data into empty input boxes.

Some input boxes require unique data which is typed in. Space is provided to enter information for non standard options. Enter the title and data, it will be saved with the other data. Three lines of notes of special instructions are available at the bottom of the data sheet. The input data is limited to 25 characters and 60 characters for each of the notes.

File options

Print data sheet Prints the data sheet using the Windows Print Manager. Refer to Windows Help Go to calculation. Returns to the calculation form using the same record

Update headings set

Overwrites the headings with the current default

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Rupture Disk Size - Gas Calculation i

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Mass Flow - English Units . Volume Flow - English Units . Mass Flow - SI Units . Volume Flow - SI Units .

Pounds per hour and degrees Fahrenheit Standard cubic feet per minute and degrees Fahrenheit Kilograms per second and degrees Centigrade Standard cubic decimeters per second and degrees Centigrade

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Units .

A set of units selected from the Gas Flow Engineering Unit screen


The Gas Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file.

Unit Selection A new calculation defaults to Mass English units . 185

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The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Gas Flow Engineering Unit screen. Sizing Code

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New vessels must use the ASME code, Old vessels (Before 1985) may still use the old API formula.

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The enabled input boxes define the data required for the calculation. The maximum ASME overpressure is 10%, API 25%

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Click the Calculate button. The program will validate the input data, Calculate the output data Display the results The selected disk diameter is the flange inside diameter

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Editing Data |

The output data should be examined for adequacy. Change data as required and recalculate i

Filing and Moving On The options in the File menu are: Program menu Clears the calculation and returns to the main menu. Prepare data sheet --Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path,, it saves a new record if not previously saved or saves changes to an existing record. Save New.-.Using the default path, it saves an existing record as a new record (used to duplicate similar items, i .e. recall an existing record. Edit as required and Save New) Save As.... - Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files.

—

186

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File default path - Changes the default paths for the calculation records The default paths are The Data Files. (AGADAT.TAGandAGADAT.DAT). The Unit Files . (AGADAT.UNS) The Printout Headings File ( HEADINGS . DAT) Print calculation Is enabled after a calculation is made. It displays the screen print a calculation. Exit Leaves the program and returns to the Windows Program Manager

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Venting must he provided for normal operational inbreathing and outbreathing requirements and emergency pressure relief for fire conditions. Tanks are normally designed to API 650 or API 620 and vented according to API 2000 and NFPÀ 30. Emergency pressure relief for API 650 is usually provided in the tank design by the frangible characteristic of the shell to roof seam . API 620 usually requires a vent of sufficient size. Its size is usually too large for satisfactory normal operations and is a separate device with a higher set pressure.

187


Mass Flow - English Units . Volume Flow - English Units. Mass Flow’ - SI Units . Volume Flow - SI Units. Units .


To make or change a Unit set select the option Review units . The Gas Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file. Unit Selection

A new calculation defaults to Mass English units.

The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Gas Flow Engineering Unit screen. Fire Emergencies

Pressure can be relieved by either a weak seam or by an emergency vent. When sizing the vent for stable liquids, the National Fire Protection Association Standard NFPA 30 (ANSI Approved) allows the use of an environment factor with the options.

No credit Approved drainage Water spray NFPA 15 Approved insulation Fixed water spray plus approved insulation

Environment factor 1 Environment factor 0.5 Environment factor 0.3 Environment factor 0.3 Environment factor 0.15

Only one factor can be used for any one tank.

188

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Input Data The enabled input boxes define the data required for the calculation.

Calculate Click the Calculate button. The program will validate the input data, Calculate the output data Display the capacity for the operational and emergency vent Editing Data

The output data should be examined for adequacy. Change data as required and recalculate Filing and Moving On

——

The options in the File menu are: Program menu Clears the calculation and returns to the main menu. Prepare data sheet Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New.-.Using the default path, it saves an existing record as a new record (used to duplicate similar items, i.e. recall an existing record. Edit as required and Save New) Save As.... Uses the Windows file access system . Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files. File default path Changes the default paths for the calculation records The default paths are The Data Files. (AGADAT.TAG and AGADAT.DAT). The Unit Files. (AGADAT.UNS) The Printout Headings File (HEADINGS.DAT) Print calculation Is enabled after a calculation is made. It displays the screen to print a calculation. Exit Leaves the program and returns to the Windows Program Manager

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189

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The screen shows the process variables used in a liquid calculation and list the available options. To assure full coverage each (except Flow Time Base) has an Other option. This is a defined unit . Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list. The screen shows the current selection. Any unit may be selected and will be used in the calculation if OK is selected. To create a File for the File Unit option in the calculation, select the desired units and click the save button. A double click on any unit option selects that option and returns to the calculation. Data Conversion For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted . The Flow Quantity option has Mass and Volume options. The relationship between mass flow and volume flow is a multiplier and the molecular weight of the gas, conversion can only be made when the molecular weight has been entered.

190

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kg = kilograms tonne = 1000 kg = lMg g = gram UKton = 2240 lb USton = 2000 lb Other = defined mass unit Volume flow units : sft3 = standard cubic feet sdm3 = standard cubic decimetres sm3 = standard cubic metres Msft3 = million standard cubic feet Other = defined volume unit Time base : / s = per second /m = per minute /h = per hour /d = per day Gauge pressure : psig = pounds per square inch gauge kPag = kiloPascals gauge atg = atmospheres gauge inhgg = inches of mercury gauge MPag = megaPascals gauge inH20g = inches of water gauge mmhgg = millimetres of mercury gauge barg ~ bars gauge kg/ cm 2 g = kilograms per square centimetre gauge Other defined gauge pressure unit Absolute pressure : psia = pounds per square inch absolute kPaa = kiloPascals absolute ata - atmospheres absolute inhga = inches of mercury absolute MPaa = megaPascals absolute inH20a = inches of water absolute mmhga millimetres of mercury absolute bara = bars absolute kg/cm2a = kilograms per square centimetre absolute Other = defined absolute pressure unit Temperature : degF = degrees Fahrenheit degF = degrees Centigrade degR = degrees Rankine degK = degrees Kelvin Other = defined temperature unit

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191

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Velocity ft/s = feet per second m/s - metres per second Other - defined velocity Viscosity : = centipoises Pa.s = Pascal seconds cs = centistokes kPa.s = kiloPascal seconds Other = defined viscosity unit Pipe and disk diameter : in = inches mm = millimetres cm = centimetres ft = feet m = metres Other = defined size Relief area : in 2 = square inches mm2 = square millimetres cm2 = square centimetres ft2 = square feet m2 = square metres Other = defined area Length and Height : ft = feet m = metres Other = defined length Latent Heat : btu/lb = British thermal units per pound kJ /lb = kilojoules per pound Other = defined latent heat Force : lb = pound kg = kilogram Other defined force units

—

Print (RELIEF DEVICE) Summary The program will provide a printout summary of data sheet records on file. The Print Summary is accessed from the Relief Device Sizing Programs menu . It is available for Rupture Disks and / or Tank Vents

192

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It can provide a printout of either: All fields Selected fields Fields equal to Fields not equal to Fields equal to or less than Fields equal to or greater than Fields less than Fields more than

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Procedure for a new Summary Select Options Clear checks Clears all checks on the form Clear Other Data Clears all other data on the form Make new field selections Each field has four boxes A check box to select the field A box to specify the field width A box to enter data to compare A box to specify the compare method (Double click for data) Select data relationship And or or Click Print to print using Windows Print Manager

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File Options Save print options Saves a standard printout Go to Program Menu Form Returns to program menu for further work on this module Exit Returns to the Windows Program Manager

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Procedure for a standard printout Select Options Recall saved options Print

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Procedure to print all fields Select Options Check all Print i

Other Options

Select font Windows font selection procedure Select Printer Windows Print Manager

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194

Relief Device Calculation Routines Rupture Disk-Liquid Size

Calculate required diameter -

Wm

D=

90711/G (P

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(

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Rupture Disk Gas Size 1. Calculate if sonic flow If

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Nomenclature

D

Required rupture disk diameter for flow conditions

inches

Liquid specific gravity at flow conditions

M P.1

Ratio of specific heats Gas molecular weight

dimensionless dimensionless dimensionless

Relief pressure

psia

P2

Back pressure

psia

Tf

Gas flowing temperature

degR

Wm,

Relief flow

Ib/h

Of k

Tank Vents 1 Vent for normal operations 1. Calculate normal venting requirements for product movement Product flow in If the liquid flashpoint is more than 100 degF -

V]N = ( 6 X barrels per hour ) CFH of free air. If it is less than 100 degF -

-

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: 195

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VIN = ( 12 X barrels per hour ) CFH of free air. Product flow out i

^

OUT

2. Thermal breathing -

Tank size less than 20000 barrels.R IN = ( Tank size in barrels ) CFH of free air.

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Tank size more than 20000 barrels.D D

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CFH of free air

-| l

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If the liquid flash point is more than 100 degF then B N = 0.6BN CFHoffreeair

,

3. Calculate the vent pressure flow requirement.- Pump in rate + thermal outbreathing

=

VIN

-4- R OUT

cubic feet of air per hour 4. Calculate the vent vacuum flow requirement.= Pump out rate + thermal inbreathing -f R V IN cubic feet of free air per hour = OUT

2 . Emergency Vent 1. Calculate the vessel iiquid/ flame wetted area 2 = 7iDH + D squarefeet

Aw

0

N:

2. Calculate the emergency pressure venting requirements -

If

Aw

is less then 200 then -

Ev = 1048FA °° isbetween 200 to 1000 then -

If

^

1

EV = 10517FA

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is between 1000 to 2800 then -

If

Ev = 50673FA if

Aw

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Ev If

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A w is greater than 2800 and the tank design pressure is greater than 1 psig then -

Ev = 1107FA Nomenclature

82

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Aw

Wetted area

square feet

R lN

Thermal inbreathing rate

cubic feet of free air per hour

R DOUT

Thermal outbreathing rate


D

Tank diameter

feet

196

r

Fv

Emergency outbreathing rate


Environment factor Tank height

dimensionless feet

IN

Venting for pump in rate


OUT

Venting for pump in rate


F H

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Reference API 2000 Venting Atmospheric and low pressure storage tanks API 620 Design of large steel tank for oil storage API 650 Welded tanks for oil storage tanks American Petroleum Institute Washington DC 20005 National Fire Protection Association NFPA #30

197

Data Files

;

/

INSTRUCALC V 5 Random access file specification for relief valves RDWDat.Dat. Tag Numbers are stored in sequential file RDWDAT.TAG. Its number in the file is the record number in the random access file.

Type FileData 2 bytes.Program number ProgNum As Integer Bytes 3 String As 3 Code * 3 bytes "Yes" or "No" RupDisk As String * 3 3 bytes "Yes" or"No " Bellows As String * 3 bytes.0% 20% or 50% 2 Integer PipeCond As 2 bytes Pipe material PipeMatl As Integer 3 bytes.FloBasis = Liqbasis or GasBasis FloBasis As String * 3 .Units conversion factor bytes 96 Single As 23 FS (0 To ) 96 bytes. GS(0 To 23) As Single UnS(0 To 23) As String * 8 192 bytes.Unit Name 24 pipe loss pipe- dims PDSS(1 To 6) As Single 28 Pipe elements PDIS(1 To 14) As Integer 24 Pipe loss variable data PDCS(1 To 6) As Single 28 bytes.Spec inputs CalcArea,Const BP,Built SdS( l To 7) As Single upBP, Oper press,Oper temp Aras( l To 34) As String * 25 850 bytes . Data sheet array selections Txtl ( l To 3) As String * 25 75 bytes.Data sheet service,line num,Fluid name Txt2( l To 3) As String * 60 180 bytes.Data sheet notes TXT3(1 To 7) As String * 10 70 bytes.Data sheet num,spec,rev,req,date,by,appr Record len = 1681 End Type

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Prognum = 8 Program = ’ ’ Rupture Disk - Liquid flow ” Code = " API" API 520 sizing Code = "ASM ASME Section 8 sizing Seepipeloss program PipeCond ditto PipeMatl FloBasis = "Mas" for mass flow,or " Vol " for volumetric flow FS(1) UnS( l ) GS (1) = Required capacity UnS (2) temperature Relief 2 GS( ) = FS (3) UnS(3) GS(3) = Bursting pressure FS(4) UnS(4) GS(4) = Total back pressure GS(5) = Specific gravity at flow conditions GS (14) = Percent overpressure GS (15) = Disk discharge coefficient FS(17) UnS( l 7) GS (17) = Selected disk diameter PDSS(1 to 6) See pipe loss program

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PDIS(1 To 14)- ditto PDCS(1 To 6) - ditto FS (17) UnS(17) SDS( l ) = Calculated diameter (4) UnS(4) FS SDS(2) = Constant back pressure FS (4) UnS(4) SDS (3) = Built up back pressure FS (3) UnS (3) SDS (4) = Operating pressure UnS (2) SDS (5) - Operating temperature Aras( l To 34) Data sheet array selections Txtl ( l To 3) 75 bytes.Data sheet service,line num, Fluid name Txt2( l To 3) Data sheet notes Txt3 ( l To 7) Data sheet num,spec,rev,req,date,by,appr

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Prognum = 9 Program = "Rupture Disk - Gas flow"

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If ProgNum = 10 Then Program = "Tank Vent " API weak seam design for emergency venting Code = " WKS " Emergency vent NFPA sizing no credits Code = "EVN" Emergency vent NFPA sizing credit for drainage Code = "EVD " Emergency vent NFPA sizing credit for insulation Code = "EVT Emergency vent NFPA sizing credit for water spray Code = "EVW" Emergency vent NFPA sizing credit for water spray and Code = "EVS " insulation See pipe loss program PipeCond ditto PipeMatl FloBasis = "Mas" for mass flow,or "Vol" for volumetric flow FS(1) UnS( l ) GS(1) = Fill rate UnS(2) GS(2) - Liquid flash point FS(3) UnS(3) pressure design GS (3) = Tank FS(1) UnS ( l ) GS(4) = Empty rate GS (5) = Liquid specific gravity GS (14) = Pad gas valve failure flow GS (15) = Environment factor FS (18) UnS(18) GS(17) = Tank height FS (18) UnS(18) diameter Tank GS(18) = PDSS (1 to 6) See pipe loss program PDIS(1 To 14)- ditto PDCS(1 To 6) - ditto SDS (2) = Pressure vent capacity scfh SDS(3) = Vacuum vent capacity scfh SDS(4) = Emergency capacity scfh Aras( l To 34) Data sheet array selections Txtl ( l To 3) 75 bytes.Data sheet service,line num, Fluid name Txt2(l To 3) Data sheet notes Txt3( l To 7) Data sheet num,spec,rev,req,date,by,appr

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Pipe loss stib-progam ( accessed from all programs) Percentage increase in friction factor, 0,20 or 50 PipeCond PipeMatl = 1 Commercial steel PipeMatl = 2 Drawn tubing PipeMatl = 3 Cast Iron PipeMatl = 4 Galvanized Iron PipeMatl = 5 Asphalt lined PipeMatl = 6 Concrete PipeMatl = 7 Wood stave FS (18) UnS (18) PDS ( l ) = Pipe length FS(17) UnS (17) PDS (2) = Inlet pipe inside diameter FS(18) UnS ( I 8) PDS (3) = Pipe elevation FS ( 18) UnS(18) length Outlet pipe PDS (4) =

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PDS (5) = Outlet pipe inside diameter PDS (6) = Outlet pipe elevation PDI( l ) = Number of Inlet gate valves PDI(2) = Number of Inlet globe valves PD1(3) = Number of Inlet check valves PDI(4) = Number of Inlet 90deg elbows PDI(5) = Number of Inlet 45deg elbows PDI(6) = Number of Inlet thru tees PDI(7) = Number of Inlet branch tees PDI(8) = Number of Outlet gate valves PDI(9 ) = Number of Outlet globe valves PDI(10) = Number of Outlet check valves PDI(11) = Number of Outlet 90deg elbows PDI(12) = Number of Outlet 45deg elbows PDI(13) = Number of Outlet thru tees PDI(14) = Number of Outlet branch tees PDC(l ) = Flow PDC(3) = Source pressure PDC(4) = Viscosity PDC(5) = Temperature PDC(6) = Destination pressure

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Miscellaneous Files RDWDAT. UNS RDWDAT.STP RDWSPEC .TXT HEADINGS.DAT

RDWSUM. DAT RDWCALC.DRV RDWCALC.COL


RELIEF DEVICE Import Process Data To Import process data into a calculation. Make a sequential file for each calculation. Files to have a filename (Suggest the tag number) with no extension (i.e. RD-100.). After INSTRUCALC reads the file it will rename the file to "FILENAME.OK". This will divide the files into two lists, those which have been processed and those which have not.

To read a file. 1. Go to the required calculation and select the required units. 2. Take the Import data menu option. 3. Find the required file. (Using standard Windows procedures) 201

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4. Select the file and the data will be loaded . 5. Proceed with the calculation and save the data. ( Now in the INSTRUCALC file) 6. The sequential file will be assigned the extension ".OK ” and will disappear from the list. 7. If a review is required, use the Windows file procedures for files with an extension "OK ” 8. Revised process data should be provided without extensions. The Instrument engineer will then have an instant review of work not yet performed. ,

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Data input sequential file requirements: (In order of input)

Tank Vent 1 Tag number 2 Fluid name 3 Tank design pressure 4 Tank diameter 5 Tank height 6 Liquid flash point 7 Fill rate 8 Empty rate 9 Liquid SG 10 Environment factor 11 Pad gas valve failure 12 Line number 13 Service

Variable name (Seq file) Txtl (3) G(3) G(18) G(17) G(2) G( l ) G(4) G(5) G(15) G(14) Txtl (2) Txtl ( l )

Rupture disk liquid flow 1 Tag number 2 Fluid name 3 Relief temperature 4 Bursting pressure 5 Total backpressure 6 Required capacity 7 Operating temperature 8 Operating pressure 9 Constant back pressure 10 SG @ flow conditions 11 Line number 12 Service

Variable name (Seq file) Txtl (3) G(2) G(3) G(4) G( l ) SD(5) SD(4) SD(2) G(5) Txtl (2) Txtl ( l ) :

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Variable name (Seq file) Txtl (3) G(2) G(3) G (4) G( l ) SD(5) SD(4) SD(2) G (6) G(10) G(9) Txtl (2) Txtl ( l )

Rupture disk gas flow 1 Tag number 2 Fluid name 3 Relief temperature 4 Bursting pressure 5 Total backpressure 6 Required capacity 7 Operating temperature 8 Operating pressure 9 Constant back pressure 10 Molecular weight 11 Ratio of specific heats 12 Compressibility factor 13 Line number 14 Service

RELIEF DEVICE Pipe Dimensions The pipe sizes are available in a program look-up table. To find the size, select the Pipe ID button to display the pipe size screen, enter the nominal size of the pipe and select the search button. The available wall thickness and the corresponding inside diameters for the nominal size are displayed . Select the required size and the data will be ed to the calculation. Metric dimensions are in millimeters and nominal sizes are base on 25 mm per nominal inch. If units other than inches or millimeters are used, the data transferred back to the calculation will be converted to the calculation units.

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Chapter 5

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Auxiliary Programs .j :• :

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Liquid Line Friction Pressure Loss. Gas Line Friction Pressure Loss. Water Hammer Liquid Flow. Process Liquid Data Process Gas Data. j i

Program Overview These programs are general chemical engineering programs. They are included in the Instalment Engineering package because they produce difficult-to-find data which is needed to solve many instrumentation problems. Some of these programs are used as subroutines condition some of the data before using in the instrument programs. Be aware that the instrument programs them, so if you are using these programs in conjunction with them, be careful to use the same values. For example, when used in the relief valve programs, the pressure value used is the set pressure plus overpressure.

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The programs will supply satisfactory accuracy for pure hydrocarbon fluids, most hydrocarbon mixtures and many other fluids. A test of known values is suggested to confirm their applicability to a particular fluid.

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The Pressure Loss Programs, knowing the source pressure will calculate the destination pressure. They have pipe material options for :

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Commercial Steel Pipe. Drawn Tubing. Cast Iron Pipe. Galvanized Iron Pipe. Asphalted Iron Pipe. Concrete Pipe. Wood Stave Pipe.

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Each have pipe conditions for: i

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(Normal friction factor). ( Normal friction factor plus 20%). (Normal friction factor plus 50%).

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They have options for a sudden contraction inlet, a sudden expansion outlet, number of, gate, globe and check valves, number of 90deg, 45deg, through tee and branch tee. They will compensate for elevation changes and include an input for equipment losses .

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The output data is the destination pressure, the velocity, the equivalent line length, the pressure drop per 100ft, The liquid program displays the Reynolds Number and the gas program displays the sonic velocity. |

The gas program divides the equivalent line length into 20 parts, it recalculates the density for each increment of length, sums the pressure loss, and checks for sonic velocity. Î

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The Water Hammer program is for determining closing times for valves in long liquid filled lines. When a flow of liquid is suddenly stopped a pounding of the line is sometimes produced which can be large enough to damage equipment and pipe s . The worst conditions are at the critical time or less . The critical time being the time it takes for the pressure wave to travel the length of the pipe and return.

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The program will calculate the critical time, the pressure wave velocity, the pressure wave magnitude, the pipe force and the minimum closing time to avoid over pressure. For a selected closing time it will calculate the magnitude of the pressure wave and the pipe force.

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The Process Data programs are for liquid and gas. They will provide process data from the data bank at the pressure and temperature entered in the program. The data is for pure fluids or mixtures. The available datais: Molecular weight . Specific gravity at pressure and temperature. Specific gravity at base conditions. Viscosity at pressure and temperature Vapor pressure. Density at pressure and temperature. Critical pressure. Critical temperature. Normal boiling point . Liquid bulk modulus. Liquid flash point. Ratio of specific heats. Compressibility factor. Latent heat of vaporization.

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Density at pressure and temperature Compressibility factor at pressure and temperature. Vapor pressure. Vapor temperature. Latent heat of vaporization . *

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If changes are made to data recalled from file, the data will be displayed in the color selected for changed data. This will assist in recognizing the affect the changes make to other calculations and the data sheet.

This set of programs provide for the following calculations:

Liquid Line Friction Pressure Loss Gas Line Friction Pressure Loss Water Hammer Liquid Flow Process Liquid Data Process Gas Data

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AUXILIARY PROGRAM Features Perform calculations

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Calculate pressure loss due to flow Calculate waterhammer critical time Calculate fluid properties at flow conditions Calculate steam data Supply pipe sizes Use English or SI engineering units in any mixture Use mass or volume flow units

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Import process data Print a calculation sheet using the Windows Print Manager Save the data

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Print a summary of saved records


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This is a program for calculating pressure loss in pipe, waterhammer and process data. The available program options are: Line Loss - Liquid Flow Line Loss - Gas Flow Water Hammer - Liquid Flow Process Liquid Data

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AUXILIARY PROGRAM Menu Options New calculation Select the required calculation option and the fluid option, then select OK (or doubleclick if at least one of the options is already selected ).

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Default files Recalls file data using the files in the default drives and paths. Other files Recalls file data using the Windows file selection procedure. 209

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Data file maintenance Edit Tag Numbers Provides the facility to change the Tag Numbers on file. Or delete records from file. Sort data file Rearrange the Tag Numbers in ascending order. Delete the items marked if the edit was saved . Data files path Path for the default calculation data files. unit file path Path for the default engineering units.

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There are three paths. If a Drive and Path different from the Default Path and Drive provided in the initial Set Up Procedure was used, the program will update them to the Drive and Path which was installed. They are saved in sequential file AUXCALC.DRV which resides with the programs. To check or change the paths, either call up the Drive and Path for edit or use a text editor to or change the file contents ‘

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Provides color options for Instrucalc displays, using the Windows palette. t

Edit Tables

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InstruCalc uses Data Tables for Gas, Liquid ,Pipe Size and Material properties, these contain data from which exact properties for the flow conditions are calculated. This option provides an easy means of customizing them. Items can be added, inserted, deleted and changed. Editing is performed by either clicking the appropriate line in the Grid or entering the line number in Row to Edit and clicking Recall Row. Edit the data and Load Row to the Grid. When a box in the edit line is clicked, information on the data required is displayed above. Save Grid overwrites the old file. A backup file is recommended before you start. The file name is in the heading of the Edit Form and the files are in the program directory. i

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AUXILIARY PROGRAM Lead Sheet The program will only stop at the Lead Sheet if it fails to find the default paths file. To continue, type in the paths and save the file.

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The Data Files are specific to a project and an instrument type The Units File may be common for all projects and specific for an instrument type. The Headings File maybe specific for a project and common for all instruments .

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Auxiliary Program Liquid Pipe Loss Calculation

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To make or change a Unit set select the option Review units. The Liquid Flow Engineering Unit screen will be displayed . It shows the available options and the current unit selection . Select the required units and save the file. Unit Selection

A new calculation defaults to Mass English units. The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen.

Base Conditions

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The Base Conditions option will display the current values of base pressure, base temperature and barometric pressure. They should be checked and modified and saved to suit the operating conditions. AGA specifies a base pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60 degF. The ISO standard is 14.696 psia and 59 degF. Fluid Properties


For apure liquid find the name and select (or double-click) the name, the fluid properties will be entered. For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is upgradable.

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Select the Pipe Material. Select the Pipe Condition. Check the Entrance if it is a large contraction Check the Exit if it is a large expansion Input Data Three cases are available, use only what is needed. The enabled input boxes define the data required for the calculation. Enter the piping configuration and the pipe lengths and elevation change. Enter the process data.

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The output data should be examined for adequacy. A reasonable velocity for orifice plates is 2 to 10 feet per second Or 2 to 25 feet per second for other devices. Change data as required and recalculate

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Filing and Moving On The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New. .Using the default path, it saves an existing record as a new record (used to duplicate similar items, i.e. recall an existing record. Edit as required and Save New) Save As.... - Uses the Windows file access system. Saves to a file anywhere. Import case data (1, 2 or 3) - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records The default paths are

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The Data Files . (AUXDAT.TAG and AUXDAT.DAT). The Unit Files . (AUXDAT.UNS) The Printout Headings File (HEADINGS.DAT) Print calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager

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AUXILIARY PROGRAM Liquid Data Calculation This program provides various process data which is required for many instrument calculations. It is integral with INSTRUCALC and is provided here for other calculations •

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The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen.

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For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered. For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database can be upgraded.

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atmosphere, and a base temperature of 60 degF. The ISO standard is 14.696 psia and 59 degF.

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Recall File Data Density Vapor pressure Vapor temperature

Recalls data from the database. Calculates with input data. Calculates with input data. Calculates with input data.

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The Calculating Options selected enable the input boxes of the data required for the calculation and disable the input boxes for the calculated outputs and the data not required. Three cases are available, use as many as required. Recall File Data Option Enter the pressure and temperature conditions for the output data. From the Input Data Option select the Case Properties. Select either Pure Liquid or Liquid Mixture For Pure Liquid select the liquid For Liquid Mixtures select the components until remaining % is zero. Select Calculate

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The available data is displayed. Density Option Enter Specific gravity. Select Case button to calculate. Display the Density. Vapor Pressure Option Enter the temperature, critical pressure, critical temperature and normal boiling point. Select the Case button to calculate Display the vapor pressure. Vapor Temperature Option Enter the vapor pressure, critical pressure, critical temperature and normal boiling point. Select the Case button to calculate. Display the vapor temperature :

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Calculation Results The output data should be examined for adequacy. Be sure that the mixture law applies to your mixture. Change data as required and recalculate. Filing and Moving On The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. New record Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save Nevv. .Using the default path, it saves an existing record as a new record (used to duplicate similar items, i.e. recall an existing record. Edit as required and Save New) Save As.... Uses the Windows file access system . Saves to a file anywhere. File default path - Changes the default paths for the calculation records The default paths are The Data Files . (AUXDAT.TAG and AUXDAT.DAT). The Unit Files . (AUXDAT.UNS) The Printout Headings File (HEADINGS . DAT) Print calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager

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AUXILIARY PROGRAM Water Hammer - Liquid Flow

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This program is for determining the closing time of valves to prevent water hammer

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There are four standard unit sets and one selected set available -

Mass Flow - English units . Volume Flow - English Units. Mass Flow - SI Units. Volume Flow - SI Units . Units .

Pounds per hour and degrees Fahrenheit US gallons per minute and degrees Fahrenheit Kilograms per second and degrees Centigrade Litres per second and degrees Centigrade A set of units selected from the Liquid Flow Engineering Unit screen

To make or change a Unit set select the option Review units.

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The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file. : ;

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Unit Selection A new calculation defaults to Mass English units.


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i Fluid and Pipe Properties The Fluid and Pipe Properties option is enabled when the pressure and temperature are entered.

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Fluid Properties The fluid properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply. For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered . For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties data base is upgradable.

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Pipe Properties The pipe properties required for a calculation are available by clicking on the pipe elastic modulus option. Select the appropriate pipe property for this calculation.

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Input Data The enabled input boxes define the data required for the calculation. Enter the data and select the Pipe inside diameter . Pipe inside diameter Click on the Pipe inside diameter button to access the Pipe Sizes menu.

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Calculate

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Click the Calculate button. The program will validate the input data , Calculate the Critical closing time conditions, the closing time for the allowable pressure and enable the selected time input box . Enter the Selected closing time. Calculate to display the selected time conditions. Editing Data The output data should be examined for adequacy. Is the closing time conservative enough? Change data as required and recalculate


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The options in the File menu are Program menu Clears the calculation and returns to the main menu. New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record.

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Save New .-.Using the default path, it saves an existing record as a new record ( Used to duplicate similar items i.e. Recall an existing record . Edit as required and Save New) Save As . . .. - Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records The default paths are The Data Files. (AUXDAT.TAG and AUXDAT.DAT). The Unit Files. (AUXDAT.UNS) The Printout Headings File (HEADINGS.DAT) ,

Print calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit — Leaves the program and returns to the Windows Program Manager

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The screen shows the process variables used in a liquid calculation and list the available options . To assure full coverage each (Except Flow Time Base) has an Other option. This is a defined unit. Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list. 221

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For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted. The Flow Quantity option has Mass and Volume options. The relationship between mass flow and volume flow is a multiplier and the specific gravity of the fluid. If the flow units are changed from mass to volume, or volume to mass and the specific gravity is not available the flow rate is set to zero

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Mass flow units : lb = pounds kg = kilograms tonne = 1000 kg = lMg g = gram UKton = 2240 lb USton = 2000 lb Other defined mass unit Volume flow units : US gal = US gallons litre = litres ft3 - cubic feet UKgal = UK gallons m3 = cubic metres bbl = barrels (42 US gallons) cm3 = cubic centimetres Other = defined volumetric unit Flow time base : /s = per second /m - per minute / h = per hour

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Pipe size : in = inches mm = millimetres cm = centimetres ft = feet m = metres Other = defined size Valve size : in = inches mm = millimetres cm = centimetres ft = feet m = metres Other = defined size Length and elevation : ft - feet m = metres Other = defined length Bulk Modulus & Modulus of elasticity) psi = pounds per square inch kPa = kiloPascals Other = defined unit

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AUXILIARY PROGRAM Calculation Data Printout This program will print the input and output calculation data and one associated comment . The comment is included in the data sheet for reference purposes.

It also creates the default printout headings. The headings are printed at the top of all printouts. They are saved in the HEADINGS.DAT file. This is the third default path. If all programs are set to the same path, this becomes the default headings for all program printouts.

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AUXILIARY PROGRAM Gas Pipe Pressure Loss Calculation ..

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The Base Conditions option will display the current values of base pressure, base temperature and the barometric pressure. They should be checked and modified and saved to suit the operating conditions. AGA specifies a base pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60 degF. The ISO standard is 14.696 psia and 59 degF. j

Fluid Properties The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure gases and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply.

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For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database can be maintained Calculation options. Select the Pipe Material . Select the Pipe Condition. Check the Entrance if it is a large contraction Check the Exit if it is a large expansion Input Data

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The enabled input boxes define the data required for the calculation. Enter the piping configuration and the pipe lengths and elevation change. Enter the process data

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Editing Data The output data should be examined for adequacy. A reasonable velocity for orifice plates is 20 to 150 feet per second Or 20 to 250 feet per second for other devices. Change data as required and recalculate


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The options in the File menu are: Program menu Clears the calculation and returns to the main menu. New record Clears the screen for a new calculation. Save Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New. .Using the default path, it saves an existing record as a new record (used to duplicate similar items, i.e. recall an existing record. Edit as required and Save New) Save As.... - Uses the Windows file access system . Saves to a file anywhere. Import case data (1 , 2, or 3) - Select the units and read Input data supplied in

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sequential files. File default path Changes the default paths for the calculation records The default paths are The Data Files. (AUXDAT.TAG and AUXDAT.DAT). The Unit Files. (AUXDAT.UNS) The Printout Headings File (HEADINGS.DAT) Print calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager

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AUXILIARY PROGRAM Gas Data Calculation

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This program provides various process data which is required for many instrument calculations. It is integral with INSTRUCALC and is provided here for other calculations .

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A new calculation defaults to Mass English units. The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the molecular weight is not available the flow is set to zero. Units for any individual input entry can be changed by selecting the Review Units option and choosing from the Gas Flow Engineering Unit screen.

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Base Conditions The Base Conditions option will display the current values of base pressure, base temperature and barometric pressure. They should be checked and modified and saved to suit the operating conditions. AGA specifies a base pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60 degF. The ISO standard is 14.696 psia and 59 degF.

Fluid Properties

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The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure gases and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply.

For a pure gas find the name and select (or double-click) the name, the fluid properties will be entered.

For a mixture select the first component . In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database can be upgraded. Calculation Options

Recalls data from the database. Calculates with input data. Calculates with input data Calculates with input data. Calculates with input data. Calculates with input data

Recall File Data Density Compressibility Factor Vapor Pressure Vapor Temperature Latent Heat of Vaporization

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Input Data The Calculating Options selected enable the input boxes of the data required for the calculation and disable the input boxes for the calculated outputs and the data not required . Three cases are available, use as many as required.

Recall File Data Option Enter the pressure and temperature conditions for the output data. From the Input Data Option select the Case Properties . Select either Pure Gas or Gas Mixture For Pure Gas select the liquid For Gas Mixtures select the components until remaining % is zero. Select Calculate The available data is displayed. •'

Density Enter temperature, pressure, molecular weight, critical pressure, critical temperature,. Select Case button to calculate. Display the Density.@ TP

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Vapor Pressure Enter the temperature, critical pressure, critical temperature and normal boiling point. Select the Case button to calculate. Display the vapor pressure. ;

Vapor Temperature Enter the vapor pressure, critical pressure, critical temperature and normal boiling point. Select the Case button to calculate. Display the vapor temperature.

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Latent Heat of Vaporation Enter the required latent heat temperature, critical temperature, known value of latent heat of vaporization, temperature at known latent heat of vaporization. i 231

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Calculation Results

The output data should be examined for adequacy. Be sure that the mixture law applies to your mixture. Change data as required and recalculate.

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The options in the File menu are: Program menu Clears the calculation and returns to the main menu. New record - Clears the screen for a new calculation. Save Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New -.Using the default path, it saves an existing record as a new record (used to duplicate similar items, i.e. recall an existing record. Edit as required and Save New) Save As.... - Uses the Windows file access system. Saves to a file anywhere. File default path - Changes the default paths for the calculation records The default paths are The Data FUes. (AUXDAT.TAG and AUXDAT.DAT). The Unit Files . ( AUXDAT.UNS) The Printout Headings File ( HEADINGS.DAT) Print calculation Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager

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The screen shows the process variables used in a liquid calculation and list the available options. To assure full coverage each (Except Flow Time Base) has an ’’Other” option . This is a defined unit. Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list. The screen shows the current selection. Any unit may be selected and will be used in the calculation if OK is selected.


Data Conversion

For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted. The Flow Quantity option has Mass and Volume options . The relationship between mass flow and volume flow is a multiplier and the molecular weight of the gas, conversion can only be made when the molecular weight has been entered . 233

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Definition of units

Mass flow units : lb = pounds kg = kilograms tonne = 1000 kg = lMg g = gram UKton = 2240 lb USton = 2000 lb Other = defined mass unit Volume flow units : sft3 = standard cubic feet sdm3 = standard cubic decimetres sm3 = standard cubic metres Msft3 = million standard cubic feet Other = defined volume unit Flow time base : /s = per second !m = per minute /h = per hour /d = per day Gauge pressure : psig - pounds per square inch gauge kPag = kiloPascals gauge atg = atmospheres gauge inhgg = inches of mercury gauge MPag = megaPascals gauge inH20g = inches of water gauge mrnhgg = millimetres of mercury gauge barg = bars gauge kg/cm2g = kilograms per square centimetre gauge Other = defined gauge pressure unit Pressure drop : psi = pounds per square inch kPa = kiloPascals at = atmospheres inhg - inches of mercury MPa = megaPascals inH 20 - inches of water mmhg = millimetres of mercury bar = bars kg/ cm2 = kilograms per square centimetre Other = defined pressure drop unit

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Absolute pressure : psia = pounds per square inch absolute kPaa = kiloPascals absolute ata = atmospheres absolute inhga = inches of mercury absolute MPaa = megaPascals absolute inH20a - inches of water absolute mmhga = millimetres of mercury absolute bara bars absolute kg/ cm2 a = kilograms per square centimetre absolute Other = defined absolute pressure unit Temperature : degF = degrees Fahrenheit degF = degrees Centigrade degR = degrees Rankine degK = degrees Kelvin Other = defined temperature unit Velocity ft/s = feet per second m/s = metres per second Other = defined velocity Viscosity : = centipoises Pa.s = Pascal seconds cs = centistokes kPa.s = kiloPascal seconds Other = defined viscosity unit Pipe size : in = inches mm = millimetres cm = centimetres ft = feet m = metres Other = defined size Length and elevation : ft = feet m = metres Other = defined length Density lb/ft3 - pounds per cubic foot kg/m3 = kilograms per cubic metre g/ cm3 = grams per cubic centimetre lb/in3 - pounds per cubic inch Other = defined density unit

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Latent Heat : btu/lb = British thermal units per pound kJ/lb = kilojoules per pound Other = defined latent heatMass flow units :

AUXILIARY PROGRAM Calculation Data Printout

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This program will print the input and output calculation data and one associated comment. The comment is included in the data sheet for reference purposes. It also creates the default printout headings. The headings me printed at the top of all printouts. They are saved in the HEADINGS.DAT file. This is the third default path. If all programs are set to the same path, this becomes the default headings for all program printouts.

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Auxiliary programs Pipe pressure loss calculation 1. Calculate the Reynolds Number -

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Reference The Crane Company Technical Paper No 41OC Nomenclature W Ib/h Rate of flow D inches Pipe inside diameter f dimensionless Friction factor

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Specific gravity at flow conditions

dimensionless

Bulk modulus of elasticity of the fluid

psi inches

pipe inside diameter

psi

Modulus of elasticity of the pipe material

Pipe wall thickness Normal flow velocity

inches feet per second

Critical time

seconds

Pipe length

feet

Closing time for safety valve set pressure

seconds

Pressure rise for critical time

psi

Safety Valve set pressure

psi

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Operating pressure

psig

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Selected time for closing

seconds

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AUXILIARY PROGRAM Data Files :

INSTRUCALC V5 Random access file specification for Auxiliary programs AUXDAT. Dat.Tag Numbers are stored in the sequential file AUXDAT.TAG. Its number in the file is the record number in the random access file.

1 :

Type FileData ProgNums As Integer 2 bytes 2 bytes PipeConds As Integer 2 bytes PipeMatls As Integer 3 bytes GasBasiss As String * 3 3 bytes. LiqBasiss As String * 3 112 bytes.Units conversion factor FS(0 To 27) As Single 112 bytes. GS 0(O To 27) As Single 112 bytes. GS1(0 To 27) As Single 112 bytes. GS2(0 To 27) As Single 24 bytes.Unit Name UnS(0 To 27) As String * 8 2 24 bytes. PDSs( l To 6) As Single 28 bytes. PDIs ( l To 14) As Integer 125 bytes.Data sheet service,Date, Services( l To 5) As String * 25 By,Fluid,,PipeMatl 60 bytes.Data sheet notes Notess As String * 60 Record len=921 End Type

GasBasiss LiqBasiss

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"Mas" for a gas mass calculation, "Vol" a volume "Mas " for a liquid mass calc, " VoT a volume

If ProgNum = 1 Then Program = "Line Loss - Liquid flow" If ProgNum = 2 Then Program = "Line Loss - Gas Flow" Common data Percentage increase in friction factor, 0,20 or 50 PipeCond PipeMatl = 1 Commercial steel PipeMatl = 2 Drawn tubing PipeMatl = 3 Cast Iron PipeMatl = 4 Galvanised Iron PipeMatl = 5 Asphalt lined PipeMatl = 6 Concrete PipeMatl = 7 Wood stave UnS(25) F8(25) PDS( i ) = Pipe length UnS (18) ( ) FS 18 PDS(2) = Pipe inside diameter UnS (25) FS (25) PDS(3) = Pipe elevation PDS(4) = Entrance type PDS(5) = Exit type PDI( l ) = Number of gate valves 239

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Liquid data GSx( l ) = Flow rate FS(1) GSx(2) = Temperature FS(3) GSx (3) = Pressure GSx (4) = Equipment pressure loss FS(4) GSx (6) = Specific gravity at flow conditions GSx(7) ~ Viscosity at flow conditions FS(7) Gas data GSx (O) = Flow rate GSx(2) — Temperature GSx(3) = Pressure GSx(4) = Equipment pressure loss GSx(5) = Molecular weight GSx(7) = Viscosity GSx( lO) = Ratio of specific heats GSx( l 1) = Critical pressure GSx( 12) = Critical temperature

FS (0)

UnS ( l ) UnS (2) UnS(3) UnS(4) UnS (7)

FS(3) FS (4)

UnS(O) UnS(2) UnS(3) UnS(4)

FS(7)

UnS(7)

FS( ll ) FS (12)

UnS ( ll ) UnS (12)

FS(1) FS(3) FS (3)

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If ProgNum = 3 Then Program = "Water Hammer - Liquid flow" GS0(1) = Flow rate GS 0(2) = Temperature GS0(3) = Operating pressure GS1(3) = Allowable pressure GS0(6) = Specific gravity GS 0(27) = Bulk modulus GS1(27) = Line Elastic modulus GS0(25) = Line length GS0(18) - Pipe inside diameter GS2(18) = Pipe wall thickness GSO( IO) = Selected time secs

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FS(27) FS(27) FS (25) FS(18) FS (18)

UnS(27) UnS(27) UnS(25) UnS (18) UnS ( 18) |

If ProgNum = 4 Then Program = "Process Liquid Data" GSx(O) - Molecular weight UnS (2) GSx( l ) = Liquid flash point UnS (2) GSx(2) = Temperature UnS (3) FS(3) GSx(3) = Pressure 240

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UnS(2) GSx(4) - Normal boiling point conditions gravity GSx(5) = Specific at base GSx (6) = Specific gravity at flow conditions FS (7) UnS(7) GSx(7) = Viscosity FS(8) UnS(8) GSx(8) = Vapor pressure FS(9) UnS(9) GSx(9) Density FS( ll ) UnS( ll ) GSx( l 1) = Critical pressure UnS(12) GSx(12) = Critical temperature FS(27) UnS(27) GSx(27) = Bulk modulus

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If ProgNum = 5 Then Program = “ Process Gas Data ” GSx(O) = Compressibility factor UnS(2) GSx(2) = Temperature

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FS(3) UnS(3) GSx(3) - Pressure UnS(2) GSx(4) = Nonnal boiling point GSx(5) = Molecular weight FS (7) UnS(7) GSx(7) = Viscosity FS(8) UnS(8) GSx (8) = Vapor pressure FS (9) UnS(9) GSx(9) = Density GSx( lO) = Ratio of specific heats FS( ll ) UnS( ll ) GSx( l 1) = Critical pressure UnS(12) GSx(12) = Critical temperature GSx (13) = Required latent heat of vaporization FS(16) UnS (16) GSx( l 6 ) = Known latent heat of vaporization FS(16) UnS( l 6) UnS(2) GSx ( l 5) = Known latent heat temperature Miscellaneous files AUXDAT.UNS AUXDAT.STP HEADINGS.DAT AUXCALC.DRV AUXCALC.COL

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AUXILIARY PROGRAMS Import Process Data To Import process data into a calculation, make a sequential file for each calculation . Files to have a filename (Suggest the tag number) with no extension (ie AUX-100 , ). After INSTRUCALC reads the file it will rename the file to "FILENAME.OK". This will divide the files into two lists, those which have been processed and those which have not.

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I! To read a file. 1 . Go to the required calculation and select the required units. 2. Take the Import data menu option. 3 . Find the required file. (Using standard Windows procedures) 4 . Select the file and the data will be loaded. 5. Proceed with the calculation and save the data. ( Now in the INSTRUCALC file) 6. The sequential file will be assigned the extension ".OK " and will disappear from the list. 7. If a review is required , use the Windows file procedures for files with an extension ".OK " 8. Revised process data should be provided without extensions. The Instrument engineer will then have an instant review of work not yet performed.

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Data input sequential file requirements (In input order)

Water Hammer calculation 1 Tag number 2 Fluid name 3 Maximum flow 4 Maximum allowable pressure 5 Temperature 6 Operating pressure 7 SG @ flow conditions 8 Liquid bulk modulus 9 Pipe elastic modulus 10 Line length 11 Pipe inside diameter 12 Pipe wall thickness 13 Pipe material

Variable name (Seq file) Service(3) G(0,1) GO,3) G(0,2) G(0,3) G(0,6) G(0, 27) G( l ,27) G(0,25) G(0,18) G(2.18) Service(5)

Pressure loss calculation Liquid Flow 1 Tag number 2 Fluid name 3 Maximum flow 4 Temperature 5 Pressure 6 SG @ flow conditions 7 Viscosity 8 Pipe size

Variable name (Seq file) Service(3) G(Case, l ) G(Case,2) G(Case,3) G(Case,6) G(Case,7) PDS(2)

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242

Pressure loss calculation Gas Flow 1 Tag number 2 Gas name 3 Gas Flow 4 Temperature 5 Pressure 6 Barometric pressure 7 Gas MW 8 /Cv 9 Viscosity 10 Critical pressure 11 Critical temperature 12 Pipe inside diameter

Variable name (Seq file) Service(3) G(Case, 0) G(Case, 2) G(Case, 3) 0(0,23) G (Case, 5) G(Case, 10) G(Case,7) G(Case, 11) G(Case, 12) PDS(2)

AUXILIARY PROGRAM Pipe Dimensions

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The pipe sizes are available in a program look -up table. To find the size, select the Pipe ID button to display the pipe size screen, enter the nominal size of the pipe and select the search button. The available wall thickness and the corresponding inside diameters for the nominal size are displayed. Select the required size and the data will be ed to the calculation.

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Metric dimensions are in millimeters and nominal sizes are base on 25 mm per nominal inch. If units other than inches or millimeters are used the data transferred back to the calculation will be converted to the calculation units. ,

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Appendices Appendix A: Questions s Ask Most Appendix B: Sources of Version 5.1

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Appendix A Questions s Ask Most )

1. Are the CV, ORD, PIT, and REL calculations made at standard, maximum, or flowing conditions ? Yon should enter the maximum flow. 2 . What standards do the CV (ORE, PIT, and REL calculations conform to? See Appendix D for a list of the sources used in the calculations. Also the sequence of calculations for each routine, which follows the routine (or group of routines), lists the source of the routine.

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3. How do the base conditions affect the calculations ? Can these be changed? The base conditions are important only in the ORE calculations. You can change the base conditions in these calculations .

4.1 know the size of the bore and the size of the the orifice and the flowrate . Can I calculate a new differential pressure? Enter the known data and the best guess for the differential pressure. Then enter the orifice size in the selected orifice diameter line. Then run the calculation. Compare the calculated orifice to the selected orifice bore. If it is different, enter a new differential pressure and repeat until the sizes match. It takes less than one minute to figure things this way. Any unknown variable can be calculated this way.

246

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5 . I compared the results of an INSTRUCALC CV calculation with the results I got from doing the problem by hand (or with results from another program) and the results don't match . Why not? INSTRUCALC overestimated (underestimated) the size of this valve by more than X% . These calculations are wrong? There could be a variety of reasons why your results and those of INSTRUCALC do not match. Most 's first reaction is to figure there is a bug in the program. This certainly could be the reason, but it is not likely. The calculation programs have been used successfully for more than eight years and have been tested considerably. More likely, INSTRUCALC is taking some value into consideration that your hand calculation did not calculate. Review the sequence of calculations at the end of each routine to make sure you (or the other software program) have followed all the steps involved.

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Any of the following can have a significant effect on the calculated size of control valves and usually are forgotten when hand calculations are done: piping geometry, viscosity, critical flow, flashing, choked flow.

If after reviewing the calculation again, yon feel that the program is still giving you erroneous results, make a screen print of all your input (please give us screen prints, and not just the end printout) and note the areas of difference. Send this to us and we will review your results and let you know what the problem is. However, please be aware that deducing what the problem is can take some time, so please allow at least four days for an answer.

6. INSTRUCALC allows me to enter data that conflicts with known standards. For example, general guidelines for backpressure build up call for not more than 10% of set pressure. INSTRUCALC allowed me to have a backpressure of almost 92% of set pressure. Why ? INSTRUCALC should be used by knowleadgable professionals . Some entries axe for your information only and though they will affect your final decision, the calculation itself cannot for this information. You must be sure you understand what the calculation calculates and how. Review the sequence of calculations after the routine for this information. Also, review the infonnation at the beginning of the module chapter for general rules concerning the calculations. INSTRUCALC is a tool, but it cannot replace the engineers who use it. Be sure you understand what the results mean. 7. How do you change a tag number. When I try to edit it, nothing happens. The tag number is the key to the calculation . You can only change it if you save the tag as a new file. Otherwise the tag number will not change. You can also use the Edit Data Files option in the Utility Program to change and update the tag numbers . Each tag is not really saved as a separate file, but as a separate record in a file that contains all the tags.

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Appendix B Sources for Version 5.1 Control V alves ANSI/ISA-S 75.01, 1977 ISA Handbook for Control Valves- J.W. Hutchison Masoneilan noise prediction formula

Flow Element Sizing ISO 5167 Sizing Equation as described by R.W. Miller ISO 5168 Accuracy Standard ISO 5024 Volumetric Standards(14.69595 psia & 59 F) Principles and Practice of Flowmeter Engineering, L.K. Spink, The Foxboro Company. The Flow Meter Engineering Handbook, R. W. Miller, McGraw Hill, New York. ISO Flow Elements Annubar Flow Handbook, Dietrich Standard Corporation Annubar no longer requires viscocity correction for liquids less than 250 .

Pressure Relief Valves API RP-520, parts 1 and 2, 4th Ed ., 1976 AS ME Code Section 8, Pressure Vessel Code, UG-132 ASME Code Section 1 , Power Boiler Code Manufacturers API or NFPA 30 data for fire generated flowrate ASME for new liquid trim vlaves which is now mandatory for new work. 249

Option to use data published by National Fire Protection Association (NFPA 30) Heat Exchanger, Piping Entrapped Liquid ASME Code, Section 8, Pressure Vessel Code, Summer 1984 addenda API RP-520, 1976 ANSI B31

Tank Vents API 2000 API 620 API 650 Rupture Disks ASME Code, Sections I and VIII. Fike Metal Products Technical Bulletin, TB 8100-8102 Auxiliary Programs Line Pressure Drop- Crane Company Technical Paper, No. 410C Compressibility Factor- Redlich-Kwong Vapor Temperature- Lee and Kesler Latent heat of Vaporization- Watson

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AGA Orifice Plates Concentric-Flange Taps Concentric-Radius Taps Concentric-Corner Taps

Program Overview These programs are based on 1990 AGA Report No. 3. Orifice Metering of Natural Gas and Other Related Hydrocarbon Fluids. They are suitable for use with all gaseous and liquid fluids that are considered to be clean, single phase, homogeneous and Newtonian. All gases, most liquids and most dense phase fluids associated with the petroleum, petrochemical and natural gas industries are usually considered Newtonian . The should be familiar with the report in order to be aware of the design, application, installation and limitations required in order for the uncertainty percentage to be applicable. Prior to this report, AGA used the Buckingham equation and its associated data set. The new report is based on a new data set derived for oil, water, natural gas

and air using 11 different laboratories, 12 different meter tubes and more than 100 different orifice plates. The data set consisted of 5734 flange, 2298 comer and 2160 radius tap points. Data was collected from the United States, Europe, Canada, Norway and Japan. Its new equations use the Stolz linkage form and the Reader-Harris/Gallagher coefficient of discharge equation. AGA differs from the IS O/Miller technique because of the discharge coefficient equation, the requirement of using the meter tube inside diameter and orifice bore at the operating temperature instead of using the thermal expansion factor (Fa) and the calculation of the uncertainty % for the discharge coefficient.

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AGA sets limits of nominal pipe sizes larger than 2 inches, schedule 160, orifice bore sizes larger than 0.45 inches, beta ratios of 0.1 to 0.75 and pipe Reynolds Numbers greater than 4000, to achieve a standard deviation of 0.24% for the 10192 data points, compared to 0.68% for the previous AGA equations.

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Because of the worldwide participation, equations are available for sharp edge orifice plates using flange, comer and radius taps for both liquid and gas. Programs for each are included even though the AGA Report No.3 only recognizes flange taps. The uncertainty percentage is expressed as a plus and minus percentage of the overall flow measurement and is considered to be accurate nineteen times out of twenty. It is calculated using sensitivity coefficients for the empirical discharge coefficient, expansion factor, orifice diameter, pipe diameter, differential pressure, static pressure temperature and density.

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j The programs require the input of the meter tube and required orifice diameter at a temperature of 68° and the construction materials for both the meter tube and orifice plate. The program calculates the meter tube diameter at the flowing temperature. It uses this to calculate the meter tube Reynolds number, the beta ratio and then the orifice diameter. The calculated orifice diameter is compensated for 68° for display. Thus, there is no direct correlation between the displayed beta ratio and meter tube and orifice diameters. An orifice plate is a circular flat plate which is inserted between flanges to measure flow in pipelines. It has a precision bored hole in its center which causes a pressure drop. Bernoulli in 1738 determined that flow rate was proportional to the square root of pressure drop . These programs determine the relationship between the flow rate, the pressure drop and the size of the hole.

The programs are based on the American Gas Association 1990 Report Number 3. "Orifice Metering of Natural Gas and Other Related Hydrocarbon Fluids ". They are suitable for use with all gaseous and liquid fluids that are clean, single phase, homogenous and Newtonian. All gases, most liquids and most dense phase fluids 2

associated with the petroleum petrochemical and natural gas industries are Newtonian. The should be aware of the report’s design, application and limitations requirements in order for the uncertainty percentage calculation to be applicable. AGA sets the following limits for an approved calculation The pipe size must be greater then 2 inch schedule 160 The orifice bore must be larger than .45 inches The beta ratio must be between between 0.1 and 0.75 The pipe Reynolds Number must be greater than 4000

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The AGA report is extracted from a new database. This database contained new information for flange, radius and comer pressure taps. Programs are provided for all of the taps. Only the flange taps are recognized by AGA, the other programs will provide increased accuracy over the ISO programs.

_ Program Features

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Perform sizing calculations Calculate either - Orifice size, Flow rate or Differential range Calculate vent or drain hole size if required Calculate the minimum plate thickness Calculate permanent pressure and power loss Calculate accuracy uncertainty percentage Supply fluid properties at flow conditions Supply steam data Supply pipe sizes Provide material selection Use English or SI engineering units in any mixture Use mass or volume flow units Import process data Print a calculation sheet using the Windows Print Manager Save the data

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Prepare instrument data sheets WYSIWYG style Initially general- sheets for bid purposes Supply database of standard specification items After vendor selection, revise for permanent records Print a data sheet using the Windows Print Manager Save the data

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Print a summary of saved records

Print all records Print selected records 3

Print only records having required characteristics

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This is a program for calculating the size of orifice plates in accordance with AGA Report #3. The available options are: liquid or gas Concentric - Flange Taps liquid or gas Concentric - Radius Taps liquid or gas Taps Concentric Comer

©I AGA Report #3 Orifice P ate Sizing »rogç

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AGA Program Menu Options »

File

Default files Recalls file data using the files in the default drives and paths. Other files Recalls file data using the Windows file selection procedure. Flow calc, maintenance Edit Tag Numbers Provides the facility to change the Tag Numbers on file. Or delete records from file. Sort and delete calcelled records Rearrange the Tag Numbers in ascending order. 4

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Delete the items marked if the edit was saved . Pressure calc , maintenance Edit Tag Numbers Provides the facility to change the Tag Numbers on file. Or delete records from file. Sort and delete calcelled records Rearrange the Tag Numbers in ascending order. Delete the items marked if the edit was saved. Data files path Path for the default calculation data files. unit file path Path for the default engineering units. Printout headings file path Path for the printout headings. V Convert 3 file stage 2 Instrucalc version 3 file conversion to Windows format.

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Exit

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Exits from Instrucalc to Windows Program Manager.

Color Provides color options for Instrucalc displays, using the Windows palette. •

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Edit Tables

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InstruCalc uses Data Tables for Gas, Liquid, Pipe Size and Material properties, these contain data from which exact properties for the flow conditions are calculated. It also has tables for equipment data. These option provides an easy means of customizing them. Items can be added, inserted, deleted and changed. Restrictions are built into the Materials Coefficient of Expansion table on insertion and deletion because the row number is used to save data in the

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calculations. Each program can edit the tables used in the program. Take note that some, such as the Gas, Liquid and Pipe Size are used by other programs and may include data required only by them. "

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Editing is performed by either clicking the appropriate line in the Grid or entering the line number in Row to Edit and clicking Recall Row. Edit the data and Load Row to the Grid. When a box in the edit line is clicked, information on the data required for that box is displayed above. Save Grid overwrites the old file. A backup file is recommended before you start. The file name is in the heading of the Edit Form and the files are in the program directory. I. j

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AGA Program Lead Sheet

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The program will only stop at the Lead Sheet if it fails to find the default paths file To continue, type in the paths and save the file.

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The Data Files are specific to a project and an instrument type The Units File may be common for all projects and specific for an instrument type The Headings File maybe specific for a project and common for all instruments

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Kilograms per second and degrees Centigrade. Litres per second and degrees Centigrade. A set of units selected from the Liquid Flow Engineering Unit screen. i

To make or change a Unit set select the option Review units . The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file.

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Unit Selection .

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Base Conditions . The Base Conditions option will display the current values of base pressure, base temperature, barometric pressure and calibration temperature. They should be checked and modified and saved to suit the operating conditions. AGA specifies a base pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°.

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Fluid Properties .

The Fluid Properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply.

For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered .

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For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database can be maintained.

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Calculation options are: Orifice size. Flowrate. Differential Range .

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Vent/Drain Hole option. Options provide for the automatic selection of the recommended hole size or the input of a size. Either a vent hole, a drain hole, both or neither can be selected. Both are the same size. If the flowing liquid contains gas bubbles, a vent hole will enable them to the orifice plate. If the line needs to be drained a drain hole can be provided The hole size will be compensated for in the calculation .

Meter tube ID. To look up the pipe dimensions, click the meter tube button. The pipe sizes screen will be displayed. Enter the nominal pipe size. Click the Search button to display the available sizes. Select the required inside diameter(Double-click or click OK).

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Material Selection. Select the Element material to display the materials screen. On the materials screen, select the required material. Repeat for the Meter tube material.

Input Data

The options selected enable the input boxes of the data required for the calculation and disable the input boxes for the calculated outputs and the data not required . The maximum flow rate is the upper range value. The normal flow will be the point of greatest accuracy. Specific gravity at base conditions is only required for volumetric flow.

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Calculate Click the Calculate button. The program will validate the input data. If not valid it will display the unsatisfactory data. If valid it will Calculate the output data. Display the results. Enable the calculation printout. Enable the data sheet option. Calculation Results The output data should be examined for adequacy. Best accuracy is for beta ratio in the area of 0.55. Change data as required and recalculate. The plate thickness is the recommended minimum.

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The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New. .Using the default path, it saves an existing record as a new record ( Used to duplicate similar items i.e. Recall an existing record. Edit as required and Save New) Save As.... Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records The default paths are: The Data Files. (AGADAT.TAG and AGADAT.DAT). The Unit Files. (AGADAT.UNS). The Printout Headings File (HEADINGS .DAT). Print flow calculation Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager.

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To create a File for the File Unit option in the calculation, select the desired units and click the save button. A double click on any unit option selects that option and returns to the calculation. Data conversion For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted. The Flow Quantity option has Mass and Volume options. The relationship between mass flow and volume flow is a multiplier and the specific gravity of the fluid . It is conventional when 10

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measuring flow by volume that it be at a standard temperature (Usually 60 degrees Fahrenheit). Two specific gravity values are necessary for a volumetric flow calculation, mass flow cannot be converted to volume flow until the specific gravity at standard conditions is available.

Definition of units \

Mass flow units : lb — pounds kg = kilograms tonne - 1000 kg = 1Mg g = gram UKton = 2240 lb USton 2000 lb Other = defined mass unit Volume flow units : USgal = US gallons litre = litres ft3 = cubic feet UKgal = UK gallons m3 = cubic metres bbl = barrels (42 US gallons) cm3 = cubic centimetres Other = defined volumetric unit Flow time base : /s per second /m = per minute /h = per hour /d = per day Gauge pressure : psig = pounds per square inch gauge kPag kiloPascals gauge atg = atmospheres gauge inhgg ~ inches of mercury gauge MPag = megaPascals gauge inH20g = inches of water gauge mmhgg = millimetres of mercury gauge barg = bars gauge kg/ cm2g = kilograms per square centimetre gauge Other = defined gauge pressure unit Absolute pressure : psia = pounds per square inch absolute kPaa = kiloPascals absolute inhga = inches of mercury absolute mmhga = millimetres of mercury absolute

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Other = defined absolute pressure unit Temperature : degF = degrees Fahrenheit degF = degrees Centigrade degR = degrees Rankine degK = degrees Kelvin Other = defined temperature unit Viscosity : = centipoises kPa.s = kiloPascal seconds Other - defined viscosity unit Differential pressure : inH20 = inches of water kPa = kiloPascals inhg = inches of mercury mmH20 -- millimetres of water mBar = millibars Other = defined differential Pipe and orifice diameter : in = inches mm = millimetres cm = centimetres ft = feet

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Other = defined size

AGA Material Selection The sheet displays the material options and the current selection. The temperature thennal expansion coefficients are selected with the material. AGA requires a thermal correction for both pipe and orifice plate. Either make a new selection (Double click or click then click OK), or click Cancel to return with no change. The program will return to the calculation.

AGA Calculation Data Printout This program will print the input and output calculation data and one associated comment. The comment is included in the data sheet for reference purposes. It also creates the default printout headings. The headings are printed at the top of all printouts. They are saved in the HEADINGS .DAT file. This is the third 12

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default path. If all programs are set to the same path, this becomes the default headings for all program printouts.

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AGA Flow Element Data Sheet The first use of the data sheet is to obtain competitive bids. It should initially emphasize the engineering requirements and be fairly general regarding the details. When a vendor is selected it should be updated to the exact details so that the data sheet is a record of the instrument purchased. The relevant data from the calculation is automatically displayed. Minor editing , such as rounding can be performed. Major editing should be done in the calculation routine in order to preserve the integrity of the calculation .

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A defined database is available to enter data for those inputs which have a limited number of options . To activate this, double click the input box, the data

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on file is displayed . Double click the required option and the data is transferred to the data sheet form .

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The database should be customized for the project requirements. To edit the data; click the selected item. Edit the data in the active top line, select Replace, continue with the edit and Save on completion. The Input data menu option has option to enter either the first or the second item in the list for all items. If the database is constructed so that the first item is the first standard selection and the second item is the second standard selection then two standard data sheets are available for a single keystroke. This feature only enters data into empty input boxes .

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Some input boxes require unique data which is typed in. Space is provided to enter information for non standard options. Enter the title and data , it will be saved with the other data. Three lines of notes of special instructions are available at the bottom of the data sheet. The input data is limited to 25 characters and 60 characters for each of the notes. File options

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Print data sheet - Prints the data sheet using the Windows Print Manager. Refer to Windows Help Go to calculation. - Returns to the calculation form using the same record Update headings - Overwrites the headings with the current default set

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There are four standard unit sets and one selected set available Pounds per hour and degrees Fahrenheit. Mass Flow - English Units. US gallons per minute and degrees Volume Flow - English Units.

Fahrenheit. Mass Flow - SI Units . Volume Flow - SI Units. Units.

Kilograms per second and degrees Centigrade. Litres per second and degrees Centigrade. A set of units selected from the Liquid Flow Engineering Unit screen.

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To make or change a Unit set select the option Review units . The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. :

Select the required units and save the file. 15

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Unit Selection.

A new calculation defaults to Mass English Units. The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen.

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Base Conditions. The Base Conditions option will display the current values of base pressure, base temperature, barometric pressure and calibration temperature. They should be checked and modified and saved to suit the operating conditions. AGA specifies a base pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°. Fluid Properties. The Fluid Properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply.

For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered . For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database can be maintained .

Calculation options are: Orifice size. Flowrate. Differential Range.

Select the calculation option and the necessary input data is enabled. The required variable will be disabled and will receive the calculated value. 16

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Vent/Drain Hole option .

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Options provide for the automatic selection of the recommended hole size or the input of a size. Either a vent hole, a drain hole, both or neither can be selected. Both are the same size. If the flowing liquid contains gas bubbles, a vent hole will enable them to the orifice plate. If the line needs to be drained a drain hole can be provided The hole size will be compensated for in the calculation.

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Meter tube ID To look up the pipe dimensions, click the meter tube button The pipe sizes screen will be displayed Enter the nominal pipe size Click the Search button to display the available sizes Select the required inside diameter(Double-click or click OK)

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Material Selection Select the Element material to display the materials screen On the materials screen, select the required material. Repeat for the Meter tube material.

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Input Data \

The options selected enable the input boxes of the data required for the calculation and disable the input boxes for the calculated outputs and the data not required. The maximum flow rate is the upper range value. The normal flow will be the point of greatest accuracy. j

Calculate Click the Calculate button. The program will validate the input data. If not valid it will display the unsatisfactory data. If valid it will - Calculate the output data. Display the results. Enable the calculation printout. Enable the data sheet option. Calculation Results The output data should be examined for adequacy. Best accuracy is for beta ratio in the area of 0.55. Change data as required and recalculate. The plate thickness is the recommended minimum.

17

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The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record Clears the screen for a new calculation. Save Using the default path, it saves a new record if not previously saved or saves changes to an existing record . Save New.-. Using the default path, it saves an existing record as a new record ( Used to duplicate similar items i.e. Recall an existing record. Edit as required and Save New) Save As.... - Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records The default paths are: The Data Files . (AGADAT.TAG and AGADAT.DAT) . The Unit Files. (AGADAT.UNS). The Printout Headings File (HEADINGS.DAT) . Print flow calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager.

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Print (AGA Flow Element) Summary The program will provide a printout summary of data sheet records on file. Access to this is from the AGA Sizing Programs menu It can provide a printout of either All fields

Selected fields Fields equal to Fields not equal to Fields equal to or less than Fields equal to or greater than Fields less than Fields more than

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Select Options Clears all check on the form Clear checks Clears all other data on the form Clear Other Data Make new field selections Each field has four boxes A check box to select the field A box to specify the field width A box to enter data to compare A box to specify the compare method (Double click for data) Select data relationship And or or Click Print to print using Windows Print Manager

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Save print options Saves a standard printout Go to Program Menu Form Returns to program menu for further work on this module Exit Returns to the Windows Program Manager i

Procedure for a standard printout Select Options

Recall saved options Print !

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The screen shows the process variables used in a liquid calculation and list the available options. To assure full coverage each (Except Flow Time Base) has an "Other" option. This is a defined unit. Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list. The screen shows the current selection. Any unit maybe selected and will be used in the calculation if OK is selected. To create a File for the File Unit option in the calculation, select the desired units and click the save button. A double click on any unit option selects that option and returns to the calculation. Data Conversion

For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted . The Flow Quantity option has Mass and Volume options. The relationship between mass flow and volume flow is a multiplier and the molecular weight of the gas, conversion can only be made when the molecular weight has been entered .

20

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Definition of units

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Mass flow units : lb = pounds kg = kilograms tonne = 1000 kg = 1 Mg g = gram UKton = 2240 lb USton = 2000 lb Other = defined mass unit Volume flow units : sft3 = standard cubic feet sdm3 = standard cubic decimetres sm3 - standard cubic metres Msft3 = million standard cubic feet Other = defined volume unit Time base : /s - per second /m = per minute /h = per hour /d - per day Gauge pressure : psig = pounds per square inch gauge kPag = kiloPascals gauge atg = atmospheres gauge inhgg = inches of mercury gauge MPag = megaPascals gauge inH20g = inches of water gauge mmhgg = millimetres of mercury gauge barg = bars gage kg/cm2g = kilograms per square centimetre gauge Other = defined gauge pressure unit Absolute pressure : psia = pounds per square inch absolute kPaa = kiloPascals absolute ata = atmospheres absolute bara = bars absolute Mpaa = megaPascals absolute kg/cm2a = kilograms per square centimetre absolute inhga = inches of mercury absolute mmhga = millimetres of mercury absolute Other = defined absolute pressure unit Temperature : degF = degrees Fahrenheit degF = degrees Centigrade

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degR = degrees Rankine degK = degrees Kelvin Other = defined temperature unit Viscosity : = centipoises Pa.s = Pascal seconds cs = centistokes kPa.s = kiloPascal seconds Other = defined viscosity unit Differential pressure : inH20 = inches of water kPa = kiloPascals inhg = inches of mercury mmH20 millimetres of water mBar = millibars Other = defined differential Pipe and orifice diameter : in = inches mm = millimetres cm = centimetres ft = feet m = metres Other = defined size Density: lb/ft3 = pounds per cubic foot kg/m 3 = kilograms per cubic metre g/ cm3 = grams per cubic centimetre lb/in3 = poimds per cubic inch Other = defined density unit

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AGA Flow Orifice Calculation Routines Set initial values. C= Q .6:Y=1 1 Calculate the Normal Differential Range

.

HN = Hm. fwMV wj \

2. Calculate the Orifice Sizing Factor , N

suM =

w

3. Calculate Reynolds Number

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358.9628. D 2 . Yn . HN

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4 . Calculate the beta ratio f

C

Po = 1+ ' Y. s Y

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5. Calculate the discharge coefficient at infinite Reynolds Number (Typical)

CINF = 0.5961+ 0.0291p * - 0.229PQ + 0.003(1-

6. Calculate the true discharge coefficient r 0.7

C = CWF + 0.000511 1 0 6 .

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19000J3 o

RD

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8 . Repeat from step 4 until the beta ratio value changes less than 0.000001

9. Calculate orifice bore

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d = po - D Fluid Properties These are calculated using common chemical formulae with each item corrected for pressure and temperature. Some fluids show deviations from the formulae, the should check typical calculated

values against known values. In all cases if accurate laboratory information is available it should be used. Density uses the Redlich-Kwong Equation.

For complete details of all formula and techniques refer to the AGA Report #3 and The Flow Measurement Engineering Handbook By R.W.Miller. These describe the development of the formulas, the application limitations and installation requirements for predictable results as well as a large amount of other valuable information.

Nomenclature

WM Ww h,


Ib/h

Flowrate normal flow

Ib/h

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Differential upper range variable

inches of water

Differential normal

inches of water

Orifice sizing factor

dimensionless

Correction for pipe sizes less than 1.8 inches Pipe inside diameter at flowing temperature Orifice inside diameter

see AGA Report #3

-

inches inches

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lb/ft3

Detteity at - ftew conditions

Absolute Viscosity

centipoise

RD Po c

Reynolds Number

dimensionless

Beta Ratio ; Orifice discharge coefficient

dimensionless

C* 'INF Y

Orifice discharge coefficient for infinite Reynolds Number Gas expansion factor

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dimensionless

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Upstream pressure Ratio of specific heats TapTerm Correction for tap location


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Data Files

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INSTRUCALC V5 Random access file specification for AGA flow elements AGADAT. Dat. Tag Numbers are stored in the sequential file AGADAT.TAG. Its number in the file is the record number in the random access file. Type FileData Calculation info

ProgNum As Integer ElemMatlNom As Integer PipeMatlNum As Integer FloBasis As String * 3 " Vol " a Vent As String * 3 FS(1 To 15) As Single GS (1 To 20) As Single UnS( l To 15) As String * 8

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2 bytes.Program number Liq <4:Gas>20 2 bytes.Element material number 2 bytes Pipe material 3 bytes."Mas" denotes amass calculation, volume 3 bytes. "Yes " or "No" for drainhole 60 bytes. Units conversion factor 80 bytes.( l -15) 120 bytes.Unit Name

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Data sheet info 28 bytes. SdS( l To 7) As Single AraS( l To 16) As String * 25 400 bytes .Data sheet array selections Txtl ( l To 3) As String * 25 75 bytes.Data sheet service,line num, fluid Txt2( l To 3) As String * 60 180 bytes.Data sheet notes TXT3(1 To 7) As String * 10 70 bytes.Data sheet num,spec,rev,date,req,by,appr Record len=1025 End Type All Elements

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ElemMatlNom and PipeMatlNum If material number = 1 Then Material = "301 stainless steel" If material number = 2 Then Material = "304 stainless steel " If material number = 3 Then Material = "310 stainless steel" If material number = 4 Then Material = "316 stainless steel" If material number = 5 Then Material = "330 stainless steel " If material number = 6 Then Material = "347 stainless steel" If material number = 7 Then Material = "Aluminum bronze" If material number = 8 Then Material = "Beryllium copper" If material number = 9 Then Material = "Carbon steel" If material number = 10 Then Material = "Copper" If material number = 11 Then Material = "Cupronickel " If material number = 12 Then Material — "Hastelloy B" If material number = 13 Then Material = "Hastelloy C" If material number = 14 Then Material = "Haynes stellite 25" If material number = 15 Then Material = "Inconel X " If material number = 16 Then Material = "K - Monel "

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If material number 17 Then Material - "Nickel ” If material number = 18 Then Material = "Pyrex glass" If material number = 19 Then Material = "Tantalum " If material number = 20 Then Material = "Titanium " FloBasis "Mas" denotes a mass calculation, "Vol" a volume "Yes" or "No" for drainhole Vent

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Liquid

- AGA - Liquid" If ProgNum - 3 Then Program = "Concentric Orifice Plate - Comer taps If ProgNum = 1 Then Program = "Concentric Orifice Plate - FlangeTaps - AGA Liquid" If ProgNum - 2 Then Program = "Concentric Orifice Plate - D and D/2 taps AGA - Liquid" FS(1) UnS ( 10 GS(1) = Maximum flow UnS(2) GS(2) = Flow temperature FS(3) UnS(3) GS (3) = Inlet pressure FS(4) UnS(4) GS (4) = Differential range GS (5) = Specific gravity at flow conditions GS(6) = Specific gravity at standard conditions FS(7) UnS(7) GS(7) = Viscosity FS(8) UnS(8) GS (8) = Pipe inside diameter FS(12) UnS(12) GS (12) = Orifice size FS(13) UnS(13) GS(13) = Base pressure UnS(14) GS(14) = Base temperature FS(15) UnS(15) GS(15) = Barometric pressure UnS(14) GS (16) = Calibration temperature FS(1) UnS( l ) GS (18) = Normal flow FS(12) UnS(12) GS(19) = Drain hole size FS(4) UnS(4) SDS( l ) = Normal flow differential FS(12) UnS(12) SDS(3) = Plate thickness ratio ( ) SDS 4 = Beta SDS (5) = Chart multiplier

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Gas

If ProgNum = 21 Then Program = "Concentric Orifice Plate - FlangeTaps - AGA - Gas” If ProgNum = 22 Then Program = "Concentric Orifice Plate - D and D/2 taps AGA - Gas" If ProgNum = 23 Then Program = "Concentric Orifice Plate - Comer taps - AGA Gas" FS(1) UnS(l ) GS (1) = Maximum flow UnS(2) GS(2) = Flow temperature 26

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FS(3) UnS(3) FS (4) UnS(4)

GS (3) = Inlet pressure GS (4) = Differential range GS(5) = Molecular weight GS (6) = Ratio of specific heats GS (7) = Viscosity GS(8) = Pipe inside diameter GS (9) = Density GS (10) = Critical pressure GS( ll ) = Critical temperature GS (12) = Orifice size GS (13) = Base pressure GS (14) = Base temperature GS(15) = Barometric pressure GS(16) = Calibration temperature GS(18) = Normal flow GS(19) = Drain hole size SDS( l ) = Normal flow differential SDS(3) = Plate thickness SDS(4) = Beta ratio SDS(5) = Chart multiplier

FS (7) UnS (7) FS(8) UnS(8) FS(9) UnS(9) FS(10) UnS( lO) UnS( ll ) FS(12) UnS(12) FS(13) UnS(13) UnS(14) FS (15) UnS(15) UnS(14) FS(1) UnS( l ) FS(12) UnS(12) FS(4) UnS(4) FS ( 12) UnS(12)

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Miscellaneous Files

)

AGADAT.UNS AGADAT.STP AGASPEC.TXT HEADINGS.DAT AGASUM.DAT AGACALC.DRV AGACALC.COL


AGA Import Orifice Process Data To Import process data into a calculation. Make a sequential file for each calculation. Files to have a filename (Suggest the tag number) with no extension (ie FE-100.). After INSTRUCALC reads the file it will rename the file to "FILENAME.OK". This will divide the files into two lists, those which have been processed and those which have not.

To read a file.

)

1. Go to the required calculation and select the matching units. 2. Take the Import data menu option. 27

!

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3. Find the required file. (Using standard Windows procedures) 4. Select the file and the data will be loaded. 5. Proceed with the calculation and save the data. ( Now in the INSTRUCALC file) 6. The sequential file will be assigned the extension ".OK", and will disappear from the list. 7. If a review is required, use the Windows file procedures for files with an extension ".OK" 8. Revised process data should be provided without extensions. (The Instrument engineer will then have an instant review of work not yet performed.)

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Data input sequential file requirements: (In input order) Gas Flow elements Tag number 1 2 Fluid name Maximum flow 3 Normal flow 4 5 Temperature 6 Inlet pressure 7 Barometric pressure Differential range 8 MW 9 10 / Cv Viscosity 11 Pipe size 12 Density 13 Critical pressure 14 Critical temperature 15 Line number 16 Service 17

Variable name (Seq file) Txtl (3) G(l ) G(18) G(2) G(3) GO 5) G(4) G(5) G(6) G(7) G(8) G(9) G(10) G(ll ) Txtl (2) Txtl ( l )

Liquid flow elements Tag number 1 Fluid name 2 Maximum flow 3 Normal flow 4 Temperature 5 Inlet pressure 6 Barometric pressure 7 Differential range 8 SG @ FTP 9 SG@ Base 10

Variable name (Seq file) Txtl (3) G(l ) G(18) G(2) G(3) G(15) G(4) G(5) G(6) 28

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11 12 13 14

Viscosity Pipe size Line number Service

G(7) G(8) Txtl (2) Txtl (2)

AGA Meter Tube Data

|

The meter tube is the straight sections of pipe, upstream and downstream of the orifice plate, as specified in AGA Report No.3, part 2. The meter tube inside diameter is the inside diameter of the upstream section of the meter tube measured at a temperature of 68° as specified by report No.3, part 2.

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Intitially, in most cases, the meter tube is not available and the standard size is used. This is available in a program look-up table. To find the size, select the meter run size button to display the pipe size screen, enter the nominal size of the pipe and select the search button. The available wall thickness and the corresponding inside diameters for the nominal size are displayed. Select the required size and it will be ed to the calculation. When the meter tube becomes available, measure the inside diameter and backcalculate either the amended flow rate or differential pressure.

)

Metric dimensions are in millimeters and nominal sizes are base on 25 mm per nominal inch. If units other than inches or millimeters are used, the data transfered back to the calculation will be converted to the calculation units.

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FIXED GE0METRY1 Flow Devices Integral Flow Orifice Assemblies Target Meters Elbow Flow Elements Annubar Pitot Tubes Programs are provided for liquid and gas

Program Overview The Integral Flow Orifice Assembly is a device for measuring small flows. The assembly is available in pipe sizes of 1/2, 1, and 1 1/2 inches, with orifices ranging from 0.002 to 1.249 inches . Calculations are available for the square edge, quadrant edge and jewel design, each with options for calculating the orifice size, flowrate or differential range. The program can calculate the discharge coefficient. The Target Flow Meter is a disk ed in the center of the pipe to provide an annular orifice. The square root of force on the disk is proportional to the flowrate. It has the advantage of having no dam affect and does not require any external piping. The meters are available in line sizes of 1/2 to 4 inches with 31

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different size targets for each meter. The program can select the sizes which are applicable to the application.

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The Elbow Flow Element is a standard short or long radius elbow, with taps at 45 degrees on the inside and outside of the bend, to measure the differential created by the centrifugal force of the fluid flowing round the bend. The square root of the differential is proportional to the flowrate. The program will calculate either the differential range or the flowrate. It will provide the data for standard or accept data for non standard elbows. r ii

Annubar is a ed trademark of Dover Industries Incorporated. It is a pitot tube device for insertion in pipe, it produces a differential, the square root of which is proportional to flowrate. They are available for all sizes of pipe and have the same characteristics as orifice plates. The advantages are low pressure loss and low installed cost. The disadvantages are a fixed and sometimes low differential and because it may be a long slender column and be subject to vibration and structural problems. The program has options to select the model or calculate the flowrate. . ••

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These programs are suitable for use with all gaseous and liquid fluids that are clean, single phase, homogenous and Newtonian. All gases, most liquids and most dense phase fluids associated with the petroleum petrochemical and natural gas industries are Newtonian.

FIXED GEOMETRY Program Features Perform sizing calculations Calculate either. - Element size, Flow rate or Differential range Calculate permanent pressure and power loss Calculate accuracy percentage Supply fluid properties at flow conditions Supply steam data Supply pipe sizes

Provide material selection Use English or SI engineering units in any mixture Use mass or volume flow units Import process data Print a calculation sheet using the Windows Print Manager Save the data

32

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Prepare instrument data sheets \

WYSIWYG style Initially general- sheets for bid purposes Supply database of standard specification items After vendor selection, revise for permanent records Print a data sheet using the Windows Print Manager Save the data

Print a summary of saved items

I


This is a program for calculating the size of Integral Orifice Assemplies, Target Meters, Elbow Flow Elements and ‘Annubar’ Pitot Tubes. Programs are avialbel for both gas and liquid. The available options are:

Gas or Liquid Gas or Liquid Gas or Liqued Gas Or Liquid

Integral Flow Orifice Assembly Target Meter Elbow Flowmeter “ Annubar” Pitot Tube

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Program Menu Options

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New calculation Select the required calculation option and the fluid option, then select OK (or doubleclick if at least one of the options is already selected).

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File Default files Recalls file data using the files in the default drives and paths. Other files Recalls file data using the Windows file selection procedure. Flow calc, maintenance Edit Tag Numbers Provides the facility to change the Tag Numbers on file. Or delete records from file. Sort data file Rearrange the Tag Numbers in ascending order. Delete the items marked if the edit was saved. Pressure calc, maintenance Edit Tag Numbers Provides the facility to change the Tag Numbers on file. Or delete records from file. Sort data file Rearrange the Tag Numbers in ascending order. Delete the items marked if the edit was saved . Data files path Path for the default calculation data files. unit file path Path for the default engineering units . Printout headings file path Path for the printout headings. ConvertV3 file stage 2 Instrucalc version 3 file conversion to Windows format.

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Exit

Exits from Instrucalc to Windows Program Manager. Color

Provides color options for Instrucalc displays, using the Windows palette. Edit tables InstruCalc uses Data Tables for Gas, Liquid,Pipe Size and Material properties, these contain data from which exact properties for the flow conditions are calculated. It also has tables for IFOA, Annubar and Elbow data. These option provides an easy means of customizing them. Items can be added, inserted, deleted and changed. Restrictions are built into the

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Materials Coefficient of Expansion table on insertion and deletion because the row number is used to save data in the calculations. Each program can edit the tables used in the program. Take note that some, such as the Gas, Liquid and Pipe Size are used by other programs and may include data required only by them . Editing is perfonned by either clicking the appropriate line in the Grid or entering the line number in Row to Edit and clicking Recall Row. Edit the data and Load Row to the Grid . When a box in the edit line is clicked, information on the data required is displayed above. Save Grid overwrites the old file. A backup file is recommended before you start . The file name is in the heading of the Edit Form and the files are in the program directory. Note that data cannot be edited directly in the grid. Print Summary Goes to the print summary program.

Fixed Geometryl Program Lead Sheet The program will only stop at the Lead Sheet if it fails to find the default paths file.To continue, type in the paths and save the file. The Data Files are specific to a project and an instrument type The Units File may be common for all projects and specific for an instrument type The Headings File maybe specific for a project and common for all instruments

; 35

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FG1 Integral Flow Orifice Assembly Liquid Calculation. J

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Carbon steel

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This is available in 1/2 inch 1 inch and 11/2 inch pipe sizes with standard orifice plates ranging from 0.002 to 1.249 inches diameter. Schedule 40 meter runs are available with precision bored pipe. The 1/2 inch is bored to 0.66 inch (16.76 mm), the 1 inch to 1.093 inch (27.76 mm) and the 11/2 to 1.561 inch (39.65 mm). Orifice plate design can be sharp edge, quadrant edge or jewel.

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Engineering Units . There are four standard unit sets and one selected set available: Pounds per hour and degrees Fahrenheit. Mass Flow - English Units. US gallons per minute and degrees Volume Flow - English Units. Fahrenheit. Kilograms per second and degrees Mass Flow' - SI Units.


Centigrade. Litres per second and degrees Centigrade. A set of units selected from the Liquid Flow Engineering Unit screen

36

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To make or change a Unit set select the option Review units. The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file.

Unit Selection Anew calculation defaults to Mass English Units.

The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen. Fluid Properties. The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply.

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For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is updateable. Base Conditions

The Base Conditions option will display the current values of base pressure, base temperature and the barometric pressure. They should be checked and modified and saved to suit the operating conditions. ISO specifies a base temperature of 14.696 psia (101.325 kilopascals) and 59° (15 degC). AGA specifies a base pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°. Calculation options are: Orifice size Flowrate Differential range It is a good idea to use standard size orifice plates where possible. Select the

37

Differential range and the necessary input data is enabled. The required variable will be disabled and will receive the calculated value.

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Orifice Design Square edge Quadrant edge Jewel The Square edge option covers for most flows, the Quadrant edge is for small flows and the Jewel is for very small flows.

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Pipe ID

To look up the pipe dimensions, click the meter tube button. The pipe sizes screen will be displayed. Enter the nominal pipe size. Click the Search button to display the available sizes. Select the required inside diameter(Double-click or click OK). Material Selection .

Click the Element material to display the materials screen. On the materials screen, select the required material. The Element material option is disabled for a jewel orifice plate. Repeat for the Pipe material.

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Input Data

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The options selected enable the input boxes of the data required for the calculation and disable the input boxes for the calculated outputs and the data not required. The maximum flow rate is the upper range value. The normal flow will be the point of greatest accuracy. The Specific gravity at base conditions is only required for volumetric flow Double click the Orifice diameter text box to display the Standard

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Orifice sizes

Calculate Click the Calculate button. The program will validate the input data. If not valid it will display the unsatisfactory data. If valid it will: Calculate the output data. 38

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1

Display the results. Enable the calculation printout. Enable the data sheet option. Calculation Results The output data should be examined for adequacy. If the differential range is not suitable select a different orifice size Special sizes are available if absolutely necessary. Change data as required and recalculate.

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Filing and Moving On The options in the File menu are:

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Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item.

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New record Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New.-.Using the default path, it saves an existing record as a new record (Used to duplicate similar items i.e. Recall an existing record. Edit as required and Save New). Save As. . . . - Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records. The default paths are: The Data Files . (FGlDAT.TAGandFGlDAT.DAT). The Unit Files . (FG1DAT.UNS). The Printout Headings File (HEADINGS.DAT). Print flow calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager.

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FG1 Target Meter Liquid Calculation.

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Target diameter in- = in 3 [ Pipe inside dia Reynolds ho . How . Norm £ t % Max pressure loss inH 2Q i: hp powei MJSS Haax* power i -::m w loss Unceltajn percent ; r Calculation tactors normal flow : ; - >v " \ T h ; .\ ; / i

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Target meter are available in sizes 1/2 inch to 4 inches, sizes over 1 inch have two target sizes. They are calibrated by selecting a force on the target as the upper range value. This calibration adjustment and the different body and target sizes ensure that all desired intermediate ranges can be covered .

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The program starts at the minimum size and finds a combination suitable for the application.

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Engineering Units. ; !

There are four standard unit sets and one selected set available: : :

Mass Flow - English Units. Volume Flow - English Units. Fahrenheit. Kilograms per second and degrees Mass Flow - SI Units. Centigrade. Litres per second and degrees Centigrade. Volume Flow - SI Units . A set of units selected from the Liquid Flow Units. Engineering Unit screen

Pounds per hour and degrees Fahrenheit. US gallons per minute and degrees

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A new calculation defaults to Mass English Units. The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen.

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The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply. For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered.

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The Base Conditions option will display the current values of base pressure, base temperature and the barometric pressure. They should be checked and modified and saved to suit the operating conditions. ISO specifies abase temperature of 14.696 psia (101.325 kilopascals) and 59° (15 degC). AGA specifies a base pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°.

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Material Selection. Click the Target material to display the materials screen. On the materials screen, select the required material. Repeat for the Pipe material . i:

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The options selected enable the input boxes of the data required for the calculation and disable the input boxes for the calculated outputs and the data not required. The maximum flow rate is the upper range value. 41

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Click the Calculate button. The program will validate the input data. If not valid it will display the unsatisfactory data. If valid it will: Calculate the output data. Display the results. Enable the calculation printout. Enable the data sheet option.

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Program menu - Clears the calculation and returns to the main menu. Prepare data sheet Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New.-.Using the default path, it saves an existing record as a new record (Used to duplicate similar items i.e. Recall an existing record . Edit as required and Save New). Save As . ... Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files File default path - Changes the default paths for the calculation records. The default paths are: The Data Files . (FG1DAT.TAG and FG1DAT.DAT). The Unit Files. (FG1 DAT.UNS). The Printout Headings File (HEADINGS.DAT). Print calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager.

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Engineering Units.

There are four standard unit sets and one selected set available: :

Mass Flow - English Units. Volume Flow - English Units .

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Pounds per hour and degrees Fahrenheit. US gallons per minute and degrees Fahrenheit. Kilograms per second and degrees Centigrade. Litres per second and degrees Centigrade. A set of units selected from the Liquid Flow Engineering Unit screen

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Calculation options are: Flowrate Differential range

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Click the Search button to display the available sizes. Select the required inside diameter(Double-click or click OK). Material Selection

Click the Meter Tube material to display the materials screen. On the materials screen, select the required material. Elbow Mean Radius Select either the Short Radius or Long Radius for automatic determination or enter the radius in the text box.

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Input Data The options selected enable the input boxes of the data required for the calculation and disable the input boxes for the calculated outputs and the data not required . The maximum flow rate is the upper range value. The normal flow will be the point of greatest accuracy. The Specific gravity at base conditions is only required for volumetric flow

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The output data should be examined for adequacy. Change data as required and recalculate. Filing and Moving On :• i

The options in the File menu are: i

Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. \ Ï

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New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record . Save New.-. Using the default path, it saves an existing record as a new record (Used to duplicate similar items i.e. Recall an existing record. Edit as required and Save New). Save As... . - Uses the Windows file access system . Saves to a file

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anywhere. Import data - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records. The default paths are: The Data Fües . (FGlDAT.TAGandFGlDAT.DAT). The Unit Files . (FG1DAT.UNS). The Printout Headings File (HEADINGS.DAT). Print flow calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager.

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Model Pipe size range 1/2 to 2 inches 10 10 1/2 to 2 inches 2 to 5 inches 15 15 2 to 5 inches 16 2 to 5 inches 4 to 42 inches 25

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764 to 16 inH20 1010 to 28 inH20 77 to 1 inH20 360 to 7 inH20 534 to 9 inH20 61 to 2 inH20 272 to 8 inH20 427 to 15 inH20

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Engineering Units. There are four standard unit sets and one selected set available: Pounds per hour and degrees Fahrenheit. Mass Flow - English Units. US gallons per minute and degrees . English Units Flow Volume Fahrenheit. Kilograms per second and degrees Mass Flow - SI Units. Centigrade. Litres per second and degrees Centigrade. Volume Flow - SI Units . A set of units selected from the Liquid Flow Units. Engineering Unit screen

To make or change a Unit set select the option Review units. The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file.

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Unit Selection.

A new calculation defaults to Mass English Units. :

The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen. Fluid Properties .


For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered. 48

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Base Conditions The Base Conditions option will display the current values of base pressure, base temperature and the barometric pressure. They should be checked and modified and saved to suit the operating conditions. ISO specifies a base temperature of 14.696 psia (101.325 kilopascals) and 59° (15 degC). AGA specifies a base pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°.

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Click the Element material to display the materials screen. On the materials screen, select the required material. Repeat for the Pipe material.

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The options selected enable the input boxes of the data required for the calculation and disable the input boxes for the calculated outputs and the data not required. The maximum flow rate is the upper range value. The normal flow will be the point of greatest accuracy. The Specific gravity at base conditions is only required for volumetric flow

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Calculate Click the Calculate button. The program will validate the input data. If not valid it will display the unsatisfactory data. If valid it will: Calculate the output data. Display the results. Enable the calculation printout. Enable the data sheet option.

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Calculation Results The output data should be examined for adequacy. The Auto select model only finds the smallest model. It may not be your preferred choice, try other options with Manual select Change data as required and recalculate.

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The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation.

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Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New . -. Using the default path, it saves an existing record as a new record (Used to duplicate similar items i.e. Recall an existing record. Edit as required and Save New). Save As . . . . - Uses the Windows file access system. Saves to a file anywhere. Import data Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records. The default paths are: The Data Files . (FG1DAT.TAG and FG1DAT.DAT). The Unit Files . (FG1DAT.UNS). . The Printout Headings File (HEADINGS.DAT). Print flow calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager.

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The screen shows the process variables used in a liquid calculation and list the available options. To assure full coverage each (Except Flow Time Base) has an ’’Other” option. This is a defined unit. Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list. The screen shows the current selection. Any unit maybe selected and will be used in the calculation if OK is selected.

To create a File for the File Unit option in the calculation, select the desired units and click the save button.

A double click on any unit option selects that option and returns to the calculation. Data conversion For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted. The Flow Quantity option has Mass and Volume options. The relationship between mass flow and volume flow 52

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is a multiplier and the specific gravity of the fluid. It is conventional when measuring flow by volume that it be at a standard temperature (Usually 60 °). Two specific gravity values are necessary for a volumetric flow calculation, mass flow cannot be converted to volume flow until the specific gravity at standard conditions is available.

Definition of units

Mass flow units : lb = pounds kg = kilograms tonne = 1000 kg = 1Mg g = gram UKton = 2240 lb USton = 2000 lb Other = defined mass unit Volume flow units : USgal = US gallons litre = litres A3 = cubic feet UKgal = UK gallons m3 = cubic metres bbl barrels (42 US gallons) cm3 = cubic centimetres Other = defined volumetric unit Flow time base : /s = per second /m = per minute /h = per hour /d - per day Gauge pressure : psig - pounds per square inch gauge kPag - kiloPascals gauge

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Fixed Geometryl Material Selection The sheet displays the material options and the current selection. The temperature thermal expansion coefficients are selected with the material. A thermal correction for both pipe and flowmeter is made. Either make a new selection (Double click or click then click OK). Or click Cancel to return with no change. The program will return to the calculation.

FG1 Calculation Data Printout

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This program will print the input and output calculation data and one associated comment. The comment is included in the data sheet for reference purposes 54

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It also creates the default printout headings. The headings are printed at the top of all printouts. They are saved in the HEADINGS.DAT file. This is the third default path. If all programs are set to the same path, this becomes the default headings for all program printouts.

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Fixed Geometryl Data Sheet The first use of the data sheet is to obtain competitive bids. It should initially emphasize the engineering requirements and be fairly general regarding the details. When a vendor is selected it should be updated to the exact details so that the data sheet is a record of the instrument purchased. The relevant data from the calculation is automatically displayed. Minor editing , such as rounding can be perfonned. Major editing should be done in the calculation routine in order to preserve the integrity of the calculation. 55

A defined database is available to enter data for those inputs which have a limited number of options. To activate this, double click the input box, the data on file is displayed. Double click the required option and the data is transferred to the data sheet form .

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The database should be customized for the project requirements. To edit the data; click the selected item. Edit the data in the active top line, select Replace, continue with the edit and Save on completion. The Input data menu option has option to enter either the first or the second item in the list for all items. If the database is constructed so that the first item is the first standard selection and the second item is the second standard selection then two standard data sheets are available for a single keystroke. This feature only enters data into empty input boxes. Some input boxes require unique data which is typed in. Space is provided to enter information for non standard options. Enter the title and data , it will be saved with the other data. Three lines of notes of special instructions are available at the bottom of the data sheet. The input data is limited to 25 characters and 60 characters for each of the notes.

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Print data sheet Prints the data sheet using the Windows Print Manager. Refer to Windows Help. Go to calculation . Returns to the calculation form using the same record Update headings Overwrites the headings with the current default set

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Mass Flow - English Units. Volume Flow - English Units . Mass Flow - SI Units .

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Volume Flow - SI Units. Units .

Pounds per hour and degrees Fahrenheit. US gallons per minute and degrees Fahrenheit. Kilograms per second and degrees Centigrade. Litres per second and degrees Centigrade. A set of units selected from the Liquid Flow Engineering Unit screen 57

i

To make or change a Unit set select the option Review units. The Liquid Flow Engineering Unit screen will be displayed . It shows the available options and the current unit selection . Select the required units and save the file.

)

1

!

Unit Selection. :

•

A new calculation defaults to Mass English Units . The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen.

\

Fluid Properties.


:


:

/

)

For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is updateable. Base Conditions The Base Conditions option will display the current values of base pressure, base temperature and the barometric pressure. They should be checked and modified and saved to suit the operating conditions. ISO specifies a base temperature of 14.696 psia (101.325 kilopascals) and 59° (15 degC). AGA specifies abase pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°. Calculation options are: Orifice size

:

:

Flowrate Differential range It is a good idea to use standard size orifice plates where possible. Select the

58

.

i

i i

Differential range and the necessary input data is enabled. The required variable will be disabled and will receive the calculated value.

:

:

Orifice Design Square edge Quadrant edge Jewel

: :

The Square edge option covers for most flows, the Quadrant edge is for small flows and the Jewel is for very small flows

r 1 i !

Pipe ID :

To look up the pipe dimensions, click the meter tube button. The pipe sizes screen will be displayed. Enter the nominal pipe size. Click the Search button to display the available sizes. Select the required inside diameter(Double-click or click OK). 1

Material Selection.

)

\

Click the Element material to display the materials screen. On the materials screen, select the required material. The Element material option is disabled for a jewel orifice plate. Repeat for the Pipe material.

:

:

:

Input Data The options selected enable the input boxes of the data required for the calculation and disable the input boxes for the calculated outputs and the data not required. The maximum flow rate is the upper range value. The normal flow will be the point of greatest accuracy. The Specific gravity at base conditions is only required for volumetric flow Double click the Orifice diameter text box to display the Standard

Orifice sizes Calculate Click the Calculate button. The program will validate the input data. If not valid it will display the unsatisfactory data. If valid it will : Calculate the output data.

I

!

59 r

I Display the results. Enable the calculation printout. Enable the data sheet option.

_

) >

|

Calculation Results The output data should be examined for adequacy. If the differential range is not suitable select a different orifice size Special sizes are available if absolutely necessary. Change data as required and recalculate.

j

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!


:

•

:

Program menu - Clears the calculation and returns to the main menu. Prepare data sheet Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New.-.Using the default path, it saves an existing record as a new record (Used to duplicate similar items , i.e. Recall an existing record. Edit as required and Save New). Save As . .. . - Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records. The default paths are: The Data Files . (FG1DAT.TAG and FG1DAT.DAT). The Unit Files. (FG1DAT.UNS). The Printout Headings File (HEADINGS.DAT). calculation flow Print - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager.

-

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60

TGI Target Meter Gas Calculation. - . ..

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Target meter are available in sizes 1/2 inch to 4 inches, sizes over 1 inch have two target sizes. They are calibrated hy selecting a force on the target as the upper range value. This calibration adjustment and the different body and target sizes ensure that all desired intermediate ranges can be covered .

The program starts at the minimum size and finds a combination suitable for the application.

Engineering Units. There are four standard unit sets and one selected set available:

Mass Flow - English Units. Volume Flow - English Units.

Mass Flow - SI Units. Volume Flow - SI Units.

Units.


) 61

!


)

Unit Selection. A new calculation defaults to Mass English Units . l


;

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Fluid Properties. ?


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For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered .

i

For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixtur e values. The fluid properties database is updateable. Base Conditions The Base Conditions option will display the current values of base pressure, base temperature and the barometric pressure. They should be checked and modified and saved to suit the operating conditions. ISO specifies a base temperature of 14.696 psia (101.325 kilopascals) and 59° (15 degC). AGA specifies a base pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°.

|

:

Material Selection. Click the Target material to display the materials screen. On the materials screen, select the required material. Repeat for the Pipe material .

>

) s'

62

:

Input Data The options selected enable the input boxes of the data required for the calculation and disable the input boxes for the calculated outputs and the data not required. The maximum flow rate is the upper range value. Calculate Click the Calculate button. The program will validate the input data. If not valid it will display the unsatisfactory data. If valid it will: Calculate the output data. Display the results. Enable the calculation printout. Enable the data sheet option. Calculation Results The output data should be examined for adequacy. Change data as required and recalculate.


)

The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New.-.Using the default path, it saves an existing record as a new record (Used to duplicate similar items i.e. Recall an existing record. Edit as required and Save New). Save As.... - Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records. The default paths are: The Data Files . (FG1DAT.TAG and FG1DAT.DAT). The Unit Files . (FG1DAT.UNS). The Printout Headings File (HEADINGS.DAT). Print flow calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager . ,

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63

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FG1 Elbow Flow Meters Gas Calculation. .. ................ .

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Elbow meters can be useful for a quick way of measuring flow in an existing line, find an elbow and install pressure taps on the inside and outside of the taps, connect a differential pressure instrument and you can measure flow. The differential range is non adjustable and not very large Accuracy in the range 4 to 5 percent can be expected.

:


Mass Flow - English Units. Volume Flow - English Units. Mass Flow - SI Units.



To make or change a Unit set select the option Review units . The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection . Select the required units and save the file. 64

:

. !

)

Unit Selection.

A new calculation defaults to Mass English Units. j

The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen. L

Fluid Properties

The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply. For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered. For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is updateable. Base Conditions The Base Conditions option will display the current values of base pressure, base temperature and the barometric pressure. They should be checked and modified and saved to suit the operating conditions. ISO specifies a base temperature of 14.696 psia (101.325 kilopascals) and 59° (15 degC). AGA specifies a base pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°.

!

Calculation options are: Flowrate Differential range Pipe Dimensions :

|

To look up the pipe dimensions, click the meter tube button. The pipe sizes screen will be displayed. Enter the nominal pipe size. Click the Search button to display the available sizes. Select the required inside diameter(Double-click or click OK). 65

Material Selection.

Click the Meter Tube material to display the materials screen. On the materials screen, select the required material .

1

Elbow Mean Radius Select either the Short Radius or Long Radius for automatic determination or enter the radius in the text box. Input Data The options selected enable the input boxes of the data required for the calculation and disable the input boxes for the calculated outputs and the data not required. The maximum flow rate is the upper range value. The normal flow will be the point of greatest accuracy. The Specific gravity at base conditions is only required for volumetric flow

Calculate Click the Calculate button. The program will validate the input data. If not valid it will display the unsatisfactory data. If valid it will: Calculate the output data. Display the results. Enable the calculation printout. Enable the data sheet option. Calculation Results

The output data should be examined for adequacy. Change data as required and recalculate.


The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record.

66

)

Save New.-.Using the default path, it saves an existing record as a new record (Used to duplicate similar items, i.e. Recall an existing record. Edit as required and Save New). Save As . . . . - Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files . File default path - Changes the default paths for the calculation records. The default paths are: The Data Files . (FG1 DAT.TAG and FG1 DAT.DAT). The Unit Files. (FG1DAT.UNS). The Printout Headings File (HEADINGS.DAT). Print flow calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager.

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FG1 Annubar Flow Element Gas Calculation. --

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Annubar is a trademark of Dover Industries Incorporated . The magnitude of the differential produced by an Annubar is a function of the pipe size and the model 67

I

selected. The differential is fixed by the design. For a specified flow rate the transmitter will need to be calibrated to the differential produced by the design selected. There is a maximum differential range, above which there is a danger of structural problems where it may fail because of vibration. There are five designs of increasing ruggedness, four of which have options for on both sides of the pipe. They are either thread mounted or flange mounted, the thread mounted being the most rugged because it has a shorter length.

)

;

Model Features Model Pipe size range 1/2 to 2 inches 10 1/2 to 2 inches 10 2 to 5 inches 15 2 to 5 inches 15 2 to 5 inches 16 25 4 to 42 inches 25 4 to 42 inches 26 4 to 4 inches 35 12 to 96 inches 35 12 to 96 inches 36 12 to 96 inches 45 24 to 96 inches 45 24 to 96 inches 46 24 to 96 inches

Mounting One side Thread One side Flange One side Flange One side Thread Both sides Either One side Flange One side Thread Both sides Either One side Flange One side Thread Both sides Either Oneside Flange One side Thread Both sides Either

Maximum Differential 1500 to 260 inH20 1500 to 260 inH20 87 to 23 inH20 630 to 124 inH20 720 to 164 inH20 142 to 4 inH20 764 to 16 inH20 1010 to 28 inH20 77 to 1 inH20 360 to 7 inH20 534 to 9 ini120 61 to 2 inH20 272 to 8 inH20 427 to 15 inH20

:

T'*

I


Mass Flow - English Units. Volume Flow - English Units . Mass Flow - SI Units. Volume Flow - SI Units. Units .


?

!

To make or change a Unit set select the option Review units . The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file. ;

68

:

Unit Selection. }

A new calculation defaults to Mass English Units . The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen. !

Fluid Properties.

!

The Fluid properties option is enabled when the pressure and temperature are entered . The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply.

For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered. For a mixture select the fust component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is updateable. ,

'

Base Conditions The Base Conditions option will display the current values of base pressure, base temperature and the barometric pressure. They should be checked and modified and saved to suit the operating conditions . ISO specifies a base temperature of 14.696 psia (101.325 kilopascals) and 59° (15 degC). AGA specifies abase pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°.

Calculation options are: Auto Select Model. Manual Select Model Flowrate.

Select the calculation option and the necessary input data is enabled . The required variable will be disabled and will receive the calculated value. The Auto Select will start at the model 10 and find a size, the manual select will

) 69

i

:

'

calculate for the selection and Calculate Flowrate will calculate the flow for your selection of all other data.

1

Pipe ID

To look up the pipe dimensions, click the meter tube button. The pipe sizes screen will be displayed. Enter the nominal pipe size. Click the Search button to display the available sizes. Select the required inside diameter(Double-click or click OK). Material Selection.

Click the Element material to display the materials screen. On the materials screen, select the required material. Repeat for the Pipe material. Input Data The options selected enable the input boxes of the data required for the calculation and disable the input boxes for the calculated outputs and the data not required. The maximum flow rate is the upper range value. The normal flow will be the point of greatest accuracy. The Specific gravity at base conditions is only required for volumetric flow

.

Calculate Click the Calculate button. The program will validate the input data. If not valid it will display the unsatisfactory data. If valid it will: Calculate the output data. Display the results. Enable the calculation printout . Enable the data sheet option. Calculation Results The output data should be examined for adequacy. The Auto select model only finds the smallest model . It may not be your preferred choice, try other options with Manual select . Change data as required and recalculate.


) 70

)

Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item . New record - Clears the screen for a new calculation. Save Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New .- . Using the default path, it saves an existing record as a new record (Used to duplicate similar items i.e. Recall an existing record. Edit as required and Save New). Save As . .. . - Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records. The default paths are: The Data Files. (FG1DAT.TAG and FG1DAT.DAT). The Unit Files. (FG 1DAT .UNS). The Printout Headings File (HEADINGS.DAT). Print flow calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager.

-

,

:

; f !

f

Print (Fixed Geometry1) Summary The program will provide a printout summary of data sheet records on file. This can be accessed from the Fixed Geometry Flow Element Sizing Program menu.

It can provide a printout of either: All fields Selected fields Fields equal to Fields not equal to Fields equal to or less than Fields equal to or greater than Fields less than Fields more than Procedure for a new Summary

j

Select Options Clears all check on the form Clear checks Clears all other data on the form Clear Other Data field new selections Make Each field has four boxes 71

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I :

I

A check box to select the field A box to specify the field width A box to enter data to compare A box to specify the compare method (Double click for

)

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data) Select data relationship And or or Click Print to print using Windows Print Manager File Options Save print options Saves a standard printout Go to Program Menu Form Returns to program menu for further work on this module Exit Returns to the Windows Program Manager

Procedure for a standard printout

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II 1

Select Options Recall saved options Print

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II

Procedure to print all fields Select Options

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Check all Print

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Other Options Select font Windows font selection procedure Select Printer Windows Print manager

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72

FG1 Gas Engineering Units

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- ViscositO ~i r ~ Critical u essuieT M Base Dress! teg jj© psig tO inH 20 g © l ;® psia ;0 mmhga" ï;;ssaKS8®,«?isp |Q kPag lO rnmhgg .© psia | O Pa s O kPaa ’i O inhga ) O ml a.s f b ate gV/ bara B: lO kPaa I baig lO kg .- - . SO- -sdm3 ?IO -atfl % ’ . -- . .. .. . - . ^^ IQ

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The screen shows the process variables used in a gas calculation and list the available options. To assure full coverage each (Except Flow Time Base) has an “ Other” option. Tins is a defined unit . Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list .

The screen shows the current selection. Any unit may be selected and will be used in the calculation if OK is selected. To create a File for the File Unit option in the calculation, select the desired units and click the save button

A double click on any unit option selects that option and returns to the calculation. Data Conversion

For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted. The Flow Quantity option has Mass and Volume options . The relationship between mass flow and volume flow is a multiplier and the molecular weight of the gas, conversion can only be made when the molecular weight has been entered. 73

t

Definition of units

Mass flow units : lb = pounds kg = kilograms tonne = 1000 kg = lMg g = gram UKton = 2240 lb USton = 2000 lb Other = defined mass unit Volume flow units : sft3 = standard cubic feet sdm3 — standard cubic decimetres sm3 — standard cubic metres Msft3 = million standard cubic feet Other = defined volume unit Time base : /s — per second /m = per minute /h = per hour /d = per day Gauge pressure : psig = pounds per square inch gauge kPag = kiloPascals gauge atg = atmospheres gauge inhgg — inches of mercury gauge MPag = megaPascals gauge inH20g = inches of water gauge mmhgg = millimetres of mercury gauge barg = bars gauge kg/cm2g = kilograms per square centimetre gauge Other = defined gauge pressure unit Absolute pressure : psia = pounds per square inch absolute kPaa kiloPascals absolute ata = atmospheres absolute bara = bars absolute Mpaa = megaPascals absolute kg/cm2a = kilograms per square centimetre absolute inhga - inches of mercury absolute mmhga = millimetres of mercury absolute Other - defined absolute pressure unit

i

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—

Temperature : degF = degrees Fahrenheit degF = degrees Centigrade

\

74

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)

.

degR = degrees Rankine degK = degrees Kelvin Other = defined temperature unit Viscosity : = centipoises Pa.s = Pascal seconds cs = centistokes kPa.s = kiloPascal seconds Other - defined viscosity unit Differential pressure : inH20 = inches of water kPa ~ kiloPascals inhg = inches of mercury mmH20 = millimetres of water mBar = millibars Other = defined differential Pipe and orifice diameter : in = inches mm = millimetres cm = centimetres ft = feet m = metres Other = defined size Density:

lb/ft3 = pounds per cubic foot kg/ m3 = kilograms per cubic metre g/cm3 = grams per cubic centimetre lb/in3 = pounds per cubic inch Other = defined density unit

75

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Fixed Geometryl Calculation Routines Annubar Liquid Flow 1 Calculate the differential range /

Hm =

)

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2

w.m

V 2834.717KD

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FA VG7J

2

Inches of water

2 Calculate velocity

W.n

V=

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2

feet pef seconcj 3 Calculate Rod Velocity. There is a minimum rod Reynolds Number below which the flowing fluid will not separate properly from the edges of the Annubar.

RD = 1487

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M' Annubar Gas Flow 1. Calculate the differential range -

2-

t

W. Hm = 358.94KDm2 v FA 1 Y

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-

H Hm = ±k2 y

Repeat steps 2 and 3 again

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Y = 1- 0.011332 13 Apply the expansion factor

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2. Calculate the expansion factor -

1

1273d

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- 0.00342

Hm

Pfk !

-

Nomenclature 0 Pipe inside diameter

inches

YN


lb/cubic foot

FA


dimensionless

<3

Specific gravity at flow temperature

dimensionless

Hm k K

Differential range Ratio of specific heats Flow coefficient

inches of water dimensionless dimensionless

Inlet pressure

psia

,

Pi Fw RD

Annubar width

feet

Rod Reynolds Number

V

Fluid velocity

dimensionless feet per second

Flow rate Expansion factor

Ib/h dimensionless

Viscosity

centipoises

wm. Y

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Reference The Annubar Flow Handbook Dover Industries inc Annubar Is a ed trademark of Dover Industries Inc

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Elbow Flowmeter 1.. Calculate the Reynolds Number _ 6.31533. WM f

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2 Calculate the discharge coefficient -

JZD

KSM

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2D

0.5

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3 „Calculate the differential range /

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wm.

V 358.9268

KSMFAD

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inchMofwater

Nomenclature D Pipe inside diameter

inches

yn

Density

Ib/cubic foot

FA


dimensionless

Differential range

inches of water

Discharge coefficient

dimensionless

^ rb wm

Elbow mean radius

inches

Flow rate

Ib/h

JJ-

Viscosity

centipoises

SM

!

s H-

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Target Meters 1. Calculate the Reynolds Number 6.31533. W

RD = -

M

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2 Calculate the flow rate -

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W = 358,9268KFA 5.941939 1\

B

D

J

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3. Calculate target force -

W,

Ib/h ! i

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N FT = V 6296.4 K/

M

pounds

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Nomenclature Target ratio (Target diameter/Bore diameter) BT (Supplied by manufacturer) P Pipe inside diameter

dimensionless

inches

77 :

1N

Density

Ib/cubic foot

dimensionless

W

Thermal expansion factor Discharge coefficient (Supplied by manufacturer) plow rate

!b/h

I1

Viscosity

centipoises

FA

K

)

dimensionless

Integral Flow Orifice Assemblies 1. Calculate the Reynolds Number -

:

Rd 2. Calculate the discharge coefficient -

6.31533. W d

(

^

Coo = A + Dp 2 + E|34 + Ff38 B = G + Hp 2 + jp -4 C = Coo + BR s

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(Values of A,D,E,F,G,H and J vary with design and size. See manufacturers data) (C for Jewel insert is 0.995) 3. Calculate the expansion factor

-

,

Y = 1- (0.41 + 0.35(34 )

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H 27.73P,k

4. Calculate flow rate -

W=

358.9268 CFAY1d2

^

h\

~

Ib/h

Nomenclature

a D Yn

Pipe inside diameter

inches inches

Density

Ib/cubic foot

FA

Thermal expansion factor Differential range Ratio of specific heats (Gas only)

dimensionless dimensionless inches water dimensionless

Iniet pressure

psia

W

Orifice Reynolds Number Flow rate

dimensionless !b/h

P

Beta ratio

M

Viscosity

C H k

Ff Rd

Orifice bore diameter

Discharge coefficient

:•

V

dimensionless

(d/D)

centipoises

Fluid Properties These are calculated using common chemical formulae with each item corrected for pressure and temperature. Some fluids show deviations from the formulae, the should check typical calculated values against known values. In all cases if accurate laboratory information is available it should be 78

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used.

Density uses the Redlich-Kwong Equation.

For complete details of all formula and techniques refer to The Flow Measurement Engineering Handbook By R.W.Miller and Foxboro Technical Information Tl 037 087. These describe the development of the formulas, the application limitations and installation requirements for predictable results as well as a large amount of other valuable information.

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FIXED GEOMETRY1 Data Files INSTRUCALC V 5 Random access file specification for FG1 flow elements FGIDAT .Dat. Tag Numbers are stored in the sequential file FG1DAT.TAG. Its number in the file is the record number in the random access file. Type FileData Calculation info ProgNum As Integer ElemMatlNom As Integer PipeMatlNum As Integer FloBasis As String * 3 calculation, Code As String * 3 FS(1 To 15) As Single GS( 1 To 20) As Single UnS(l To 15) As String * 8 Data sheet info SdS( l To 7) As Single AraS ( l To 22) As String * 25 Txtl ( l To 3) As String * 25 Txt2( l To 3) As String * 60 TXT3 (1 To 7) As String * 10 End Type

2 bytes.Program number Liq<6 :Gas>20 2 bytes.Element material number 2 bytes Pipe material 3 bytes."Mas " denotes amass "Vol" a volume 3 bytes. " Yes" or "No" for drainhole 60 bytes.Units conversion factor 80 bytes.Variable data 120 bytes .Unit Name

28 bytes. 550 bytes.Data sheet array selections 75 bytes.Data sheet service,line num, fluid 180 bytes.Data sheet notes 70 bytes. Data sheet num,spec,rev,date,req ,by,appr Record len= l 175

Common to all Elements ElemMatlNom and PipeMatlNum If material number = 1 Then Material = "301 stainless steel" If material number = 2 Then Material = "304 stainless steel " If material number = 3 Then Material = "310 stainless steel" If material number = 4 Then Material = "316 stainless steel " If material number = 5 Then Material = "330 stainless steel " If material number - 6 Then Material = "347 stainless steel " If material number = 7 Then Material = "Aluminum bronze" If material number = 8 Then Material = "Beryllium copper" If material number = 9 Then Material = "Carbon steel" If material number = 10 Then Material = "Copper" If material number = 11 Then Material = "Cupronickel " If material number = 12 Then Material = "Hastelloy B" If material number = 13 Then Material = "Hastelloy C" If material number = 14 Then Material = "Haynes stellite 25 " If material number = 15 Then Material = "Inconel X" If material number = 16 Then Material = "K - Monel" 80

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If material number = 17 Then Material = "Nickel" If material number = 18 Then Material = "Pyrex glass " If material number = 19 Then Material = "Tantalum " If material number = 20 Then Material = "Titanium " FloBasis "Mas " denotes amass calculation, "Vol" a volume Liquid }

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If ProgNum = 2 Then Program = "Integral flow orifice meter - liquid" If Code = "CSq " then Orifice = Calculated discharge coefficient - Square edge If Code = "CQu" then Orifice = Calculated discharge coefficient - Quadrant edge If Code = "CJe" then Orifice = Calculated discharge coefficient - Jewel If Code = "ESq " then Orifice = Entered discharge coefficient - Square edge If Code = "EQu" then Orifice = Entered discharge coefficient - Quadrant edge If Code = "EJe" then Orifice = Entered discharge coefficient - Jewel FS(1) UnS ( l ) GS(1) = Maximum flow UnS (2) GS(2) = Flow temperature FS(3) UnS(3) GS(3) = Inlet pressure FS(4) UnS(4) GS(4) = Differential range GS(5) = Specific gravity at flow conditions GS(6) = Specific gravity at standard conditions FS (7) UnS(7) GS(7) = Viscosity FS(8) UnS(8) GS(8) = Pipe inside diameter FS(12) UnS(12) GS(12) = Orifice size FS(13) UnS(13) GS(13) = Base pressure UnS(14) GS(14) = Base temperature FS(15) UnS(15) GS(15) = Barometric pressure coefficient Discharge ( 16 ) GS = FS(1) UnS( l ) GS(18) = Normal flow FS(4) UnS (4) SDS ( l ) = Normal flow differential UnS(8) SDS (2) = Nominal pipe size FS (12) UnS (12) SDS (3) = Plate thickness SDS(4) = Beta ratio SDS(5) = Chart multiplier If ProgNum = 3 Then Program = "Target flow meter - liquid" FS(1) UnS( l ) GS (1) = Maximum flow UnS(2) GS(2) = Flow temperature FS(3) UnS(3) GS(3) = Inlet pressure FS(1) UnS ( l ) GS (4) = Minimum range GS(5) = Specific gravity at flow conditions GS(6) = Specific gravity at standard conditions FS(7) UnS(7) GS(7) = Viscosity FS (12) UnS(12) GS(12) = Target diameter FS(13) UnS(13) GS(13) = Base pressure 81

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-

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UnS(14) FS(15) UnS(15) FS (1) UnS( l ) UnS(8)

GS(14) = Base temperature GS (15) = Barometric pressure GS(18) = Maximum range SDS(2) = Nominal pipe size SDS(5) = Chart multiplier

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If ProgNum = 4 Then Program = " Elbow flow meter - liquid" FS (1) UnS( l ) GS(1) = Maximum flow UnS(2) GS(2) = Flow temperature FS(3) UnS(3) GS(3) Inlet pressure FS(4) UnS(4) GS(4) = Differential range GS(5) = Specific gravity at flow conditions GS(6) = Specific gravity at standard conditions FS(7) UnS(7) GS(7) = Viscosity FS(8) UnS(8) GS(8) = Pipe inside diameter FS(12) UnS(12) GS(12) = Elbow mean radius FS (13) UnS(13) GS(13) = Base pressure UnS(14) GS(14) = Base temperature FS(15) UnS(15) GS(15) = Barometric pressure FS(1) UnS( l ) GS(18) = Normal flow FS(4) UnS(4) SDS( l ) = Normal flow differential UnS (8) SDS(2) = Nominal pipe size SDS ( 5) = Chart multiplier

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If ProgNum = 6 Then Program = "Annubar pitot tube - liquid" If Code = "Thr" then Mount- Thread" If Code = "Fla" then Mount- 'Flange" FS (1) UnS( l ) GS(1) = Maximum flow UnS(2) GS (2) = Flow temperature FS(3) UnS(3) GS(3) = Inlet pressure FS(4) UnS (4) GS(4) - Differential range GS(5) = Specific gravity at flow conditions GS(6) = Specific gravity at standard conditions FS(7) UnS(7) GS(7) = Viscosity FS(8) UnS(8) GS(8) = Pipe inside diameter GS(12) = Model number FS (13) UnS(13) GS (13) = Base pressure UnS(14) GS(14) = Base temperature (15) UnS 15 ( FS ) pressure 15 ) GS( = Barometric FS(1) UnS( l ) GS(18) = Normal flow FS(4) UnS(4) SDS ( l ) = Normal flow differential UnS(8) SDS(2) = Nominal pipe size SDS (5) = Chart multiplier /

82

Gas

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If ProgNum = 22 Then Program = "Integral flow orifice meter - gas" If Code = "CSq " then Orifice = Calculated discharge coefficient - Square edge If Code = "U" then Orifice = Calculated discharge coefficient - Quadrant edge If Code = "Cue" then Orifice = Calculated discharge coefficient - Jewel If Code = "Esq." then Orifice = Entered discharge coefficient - Square edge If Code = "ECU" then Orifice = Entered discharge coefficient - Quadrant edge If Code = "Edge" then Orifice = Entered discharge coefficient - Jewel FS(1 ) UnS( l ) GS(1) = Maximum flow UnS (2) GS(2) = Flow temperature FS(3) UnS(3) GS(3) = Inlet pressure FS(4) UnS(4) GS(4) = Differential range GS(5) = Molecular weight GS(6) = Ratio of specific heats FS(7) UnS(7) GS(7) = Viscosity (8) UnS(8) FS diameter GS (8) = Pipe inside FS(9) UnS(9) GS(9) = Density FS (10) UnS( lO) GS (10) = Critical pressure UnS(ll ) GS(11) = Critical temperature FS(12) UnS(12) GS(12) = Orifice size (13) UnS(13) FS GS(13) = Base pressure UnS(14) GS(14) = Base temperature FS (15) UnS(15) GS(15) = Barometric pressure GS (16) = Discharge coefficient FS(1) UnS( l ) GS (18) = Normal flow FS (4) UnS(4) SDS( l ) = Normal flow differential UnS(8) SDS(2) = Nominal pipe size FS(12) UnS(12) SDS(3) = Plate thickness SDS(4) = Beta ratio SDS(5) = Chart multiplier If ProgNum = 23 Then Program GS(1) = Maximum flow GS(2) = Flow temperature GS (3) = Inlet pressure GS (4) = Minimum range GS (5) = Molecular weight GS(6) = Ratio of specific heats GS(7) = Viscosity GS(9) = Density GS(10) = Critical pressure GS (11) = Critical temperature GS(12) = Target diameter GS (13) = Base pressure

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"Target flow meter - gas" FS(1) UnS( l ) UnS(2) FS(3) UnS(3) FS (1) UnS( l ) FS(7) UnS(7) FS(9) UnS(9) FS(10) UnS( lO) UnS( ll ) FS (12) UnS (12) FS (13) UnS (13) I

83

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UnS(14) FS(15) UnS(15) FS(1) UnS( l ) UnS(8)

GS(14) = Base temperature GS (15) = Barometric pressure GS(18) = Maximum range SDS(2) = Nominal pipe size SDS(5) - Chart multiplier

If ProgNum = 24 Then Program GS(1) = Maximum flow GS(2) = Flow temperature GS(3) = Inlet pressure GS(4) = Differential range GS(5) = Molecular weight GS(6) = Ratio of specific heats GS(7) = Viscosity GS(8) = Pipe inside diameter GS(9) = Density GS (10) = Critical pressure GS ( ll ) = Critical temperature GS (12) = Elbow mean radius GS(13) = Base pressure GS(14) = Base temperature GS(15) = Barometric pressure GS(18) = Normal flow SDS( l ) = Normal flow differential SDS(2) = Nominal pipe size SDS(5) = Chart multiplier

)

"Elbow flow meter - gas" FS(1) UnS( l ) UnS(2) FS(3) UnS(3) FS(4) UnS(4)

FS(7) UnS(7) FS(8) UnS(8) FS(9) UnS(9) FS(10) UnS( lO) UnS( ll ) FS(12) UnS(12) FS(13) UnS(13) UnS(14) FS(15) UnS(15) FS(1) UnS( l ) FS(4) UnS(4) UnS(8)

If ProgNum =26 Then Program = "Annubar pitot tube - gas" If Code = "Thr" then Mount= 'Thread " If Code = "Fla" then Mount="Flange" FS (1) UnS( l ) GS(1) = Maximum flow UnS(2) GS(2) - Flow temperature FS(3) UnS(3) GS(3) = Inlet pressure FS(4) UnS (4) GS (4) = Differential range GS(5) = Molecular weight GS(6) = Ratio of specific heats FS (7) UnS(7) GS(7) = Viscosity FS(8) UnS(8) GS(8) = Pipe inside diameter FS(9) UnS(9) Density ( ) GS 9 = FS (10) UnS( lO) GS (10) = Critical pressure UnS( ll ) GS (11) = Critical temperature GS(12) = Annubar Model number FS (13) UnS(13) GS(13) = Base pressure UnS(14) GS(14) = Base temperature FS(15) UnS (15) GS(15) = Barometric pressure

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FS(1) UnS( l ) FS (4) UnS(4) UnS(8)

GS(18) = Normal flow SDS ( l ) = Normal flow differential SDS (2) = Nominal pipe size SDS(5) = Chart multiplier

:

Miscellaneous Files FG1 DAT.UNS Sequential file. unit data FG1DAT.STP Sequential file. Base conditions FG1SPEC.TXT Sequential file. Data sheet item selections HEADINGS.DAT Sequential file. Printout titles FG1SUM.DAT Sequential file. Standard summary selections FG1CALC. DRV Sequential file. Default drives and paths FG1CALC.COL Sequential file. Color selections

FG1 Import Process Data To Import process data into a calculation:

Make a sequential file for each calculation . Files to have a filename(Suggest the tag number) with no extension (ie FI-100.). After INSTRUCALC reads the file it will rename the file to "FILENAME OK" This will divide the files into two lists, those which have been processed and those which have not.

. .

To read a file. 1. Go to the required calculation and select the required units. 2. Take tire Import data menu option. 3 . Find the required file. (Using standard Windows procedures) 4. Select the file and the data will be loaded. 5. Proceed with the calculation and save the data. (Now in the INSTRUCALC file) 6. The sequential file will be assigned the extension ".OK", and will disappear from the list. 7. If a review is required, use the Windows file procedures for files with an extension ".OK" 8. Revised process data should be provided without extensions. The Instrument engineer will then have an instant review of work not yet performed.

Data input sequential file requirements (In input order)

" Annubar" Gas Flow Element Elbow Gas Flow Element IFOA Gas Flow Element 85

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1 Tag number 2 Fluid name 3 Maximum flow 4 Normal flow 5 Temperature 6 Inlet pressure 7 Barometric pressure 8 Differential range 9 MW 10 /Cv 11 Viscosity 12 Pipe size 13 Density 14 Critical pressure 15 Critical temperature 16 Line number 17 Service

Seq file Txtl (3) G( l ) G(18) G(2) G(3) G(15) G(4) G(5) G (6) G(7) G(8) G(9) G(10) G( ll ) Txtl ( l ) Txtl (2)

Target Gas Flow element 1 Tag number 2 Fluid name 3 Maximum flow 4 Temperature 5 Inlet pressure 6 Barometric pressure 7 MW 8 / Cv 9 Viscosity 10 Pipe size 11 Density 12 Critical pressure 13 Critical temperature 14 Line number 15 Service

Seq file Txtl (3) G( l ) G(2) G(3) G(15) G(5) G(6) G(7) G(8) G(9) G(10) G( ll ) Txtl (2) Txtl ( l )

" Amiubar " Liquid Flow Elements Elbow Liquid Flow Element IFO À Liquid Flow Element 1 2 3 4 5 6 7

Tag number Fluid name Maximum flow Normal flow Temperature Inlet pressure

Barometric pressure

(Seq file)

Txtl (3) G( l ) G(18) G(2) G(3) G(15)

-

i

86

8 Differential range 9 SG @ FTP 10 SG@ Base 11 Viscosity 12 Pipe size 13 Line number 14 Service

/

G(4) G(5) G(6) G(7) G(8) Txtl (2) Txtl (2)

Target Liquid Flow Element Seq file 1 Tag number Txtl (3) 2 Fluid name G( l ) 3 Maximum flow G ( 2) 4 Temperature G (3 ) 5 Inlet pressure G(15) 6 Barometric pressure G(5) SG @ FTP 7 G(6) 8 SG@ Base G(7) 9 Viscosity G(8) 10 Pipe size Txtl (2) 11 Line number Txtl ( l ) 12 Service ! I

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Fixed Geometryl Pipe Inside Diameter

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The orifice pipe run is the straight sections of pipe, upstream and downstream of the orifice plate, as specified in ISO 5167 and AGA3 and ANSI 2530. :

The ISO pipe inside diameter is the average Of 12 measurements of the upstream section of the meter measured at a room temperature. •

Initially, in most cases, the orifice pipe run is not available and the standard size is used. This is available in a program look-up table. To find the size, select the meter run size button to display the pipe size screen, enter the nominal size of the pipe and select the search button. The available wall thickness and the corresponding inside diameters for the nominal size are displayed. Select the required size and it will be transferred to the calculation.

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When the meter tube becomes available, measure the inside diameter and back calculate either the amended flow rate or differential pressure. »

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Metric dimensions are in millimeters and nominal sizes are base on 25 mm per nominal inch. If Units other than inches or millimeters are used, the data transferred back to the calculation will be converted to the calculation units. ) 87

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FIXED GE0METRY2 Flow Meters

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Vortex Meters Rotameters Wedge Flowmeters Programs are provided for liquid and gas

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Program Overview

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The Vortex Meter measures the frequency of vortex shedding from a bluff body mounted in the flow stream. Within limits of velocity and viscosity the flow rate is a linear function of the frequency. It has a greater turn down ratio than head type meters. The program calculates the minimum and maximum flow rates based on flow area in the flow meter, the allowable minimum and maximum velocities and the viscosity limitations.

!

The Rotameter is a variable area device. A float in a tapered tube is moved against gravity by the flowing fluid until an area is exposed which allows it to come to balance. The float position in the tube is a linear indication of the flow rate. Viscosity is a limitation. Floats are designed with a viscosity immunity ceiling to define the maximum viscosity. Sizing is determined by the float density and the flow capacity of the tapered tube in either USGPM of water or 89

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SCFM of air. The program does the unit conversions and supplies the float density.

}

Wedge is a trademark of The Taylor Instrument Company. The Wedge Flowmeter consists of a meter tube and with a vee shaped wedge inserted inside. Pressure taps either side of the wedge measure the differential which is proportional to the square of the flow rate. Meter sizes range for 1 to 12 inches with each size having a selection of different wedges. Chemical seals are available for the pressure taps, making this a rugged flow meter suitable for slurries and viscous fluids. The program will provide the wedge data and calculate either the capacity or differential for the different sizes.

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The programs are suitable for use with all gaseous and liquid fluids that are clean, single phase, homogenous and Newtonian. All gases, most liquids and most dense phase fluids associated with the petroleum petrochemical and natural gas industries are Newtonian. .. .

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Fixed Geometry2 Program Features }

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Programs will: Perform sizing calculations Calculate either.- Meter size,or Flow rate Calculate permanent pressure and power loss Calculate accuracy percentage Supply fluid properties at flow conditions Supply steam data Supply pipe sizes Provide material selection Use English or SI engineering units in any mixture Use mass or volume flow units Import process data Print a calculation sheet using the Windows Print Manager Save the data


WYSIWYG style Initially general- sheets for bid purposes Supply database of standard specification items After vendor selection, revise for permanent records Print a data sheet using the Windows Print Manager Save the data

90

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Print a summary of saved items ] !

Print all records Print selected records Print only records having required characteristics This is a program for calculating the size of Vortex Flow Meters, Rotameters and Wedge Flow Meters for either gas or liquid . The available options are: Vortex Flowmeter Gas or Liquid Gas or Liquid Rotameter Wedge Flowmeter Gas or Liquid

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New calculation

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Select the required calculation option and the fluid option, then select OK (or doubleclick if at least one of the options is already selected).

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File

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Default files Recalls file data using the files in the default drives and paths.

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Other files

Recalls file data using the Windows file selection procedure.

Data file maintenance Edit Tag Numbers Provides the facility to change the Tag Numbers on file Or delete records from file. i

Sort data file Rearrange the Tag Numbers in ascending order. Delete the items marked if the edit was saved.

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File default path Data files Path for the default calculation data files. units Path for the default engineering units file. Headings Path for the printout headings. 2 ConvertV3 file stage Instrucalc version 3 file conversion to Windows format . Exit Exits from Instrucalc to Windows Program Manager.

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Fixed Geometry2 Program Lead Sheet The program will only stop at the Lead Sheet if it fails to find the default paths file. To continue, type in the paths and save the file. The Data Files are specific to a project and an instrument type The Units File may be common for all projects and specific for an instrument type The Headings File maybe specific for a project and common for all instruments i t T

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FG2 Vortex Meter Size Liquid Calculation

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Engineering Units

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Mass Flow - English units Volume Flow - English Units

Mass Flow - SI Units

Volume Flow - SI Units Units

Pounds per hour and degrees Fahrenheit. US gallons per minute and degrees Fahrenheit. Kilograms per second and degrees Centigrade. Litres per second and degrees Centigrade. A set of units selected from the Liquid Flow Engineering Unit screen.

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To make or change a Unit set select the option Review units . The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection . Select the required units and save the file.

93

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Unit Selection '' /

A new calculation defaults to Mass English units . The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen .

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Base Conditions The Base Conditions option will display the current values of base pressure, base temperature and the barometric pressure. They should be checked and modified and saved to suit the operating conditions. ISO specifies a base temperature of 14.696 psia (101.325 kilopascals) and 59° (15 degC). AGA specifies abase pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°..

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Fluid Properties

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For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database can be maintained

Calculation options are: Auto size Manual size Flowrate

The auto size option starts at the smallest size and finds a suitable meter. The manual size calculates for the selected size. The flowrate option calculates the flow for the selected size. Select the calculation option and the necessary input data boxes are enabled. The required variable will be disabled and will receive the calculated value. ) 94 r

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Isolating Manifold

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This allows the sensor to be removed from the line without interrupting the flow. With low density fluids it affects the allowable minimum and maximum velocities .

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Option to allow input data for other sizes to be calculated. L

Input Data The enabled input boxes define the data required for the calculation. The maximum flow rate is the upper range value. The normal flow will be the point of greatest accuracy |

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Calculate Click the Calculate button. The program will validate the input data, Calculate the output data Display the results

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Editing Data The output data should be examined for adequacy. Is the rangeability sufficient? Change data as required and recalculate Filing and Moving On i

The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New.-.Using the default path, it saves an existing record as a new record (Used to duplicate similar items, i.e. Recall an existing record. Edit as required and Save New) Save As . .. . - Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files.

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File default path - Changes the default paths for the calculation records The default paths are: The Data Files (FG2DAT.TAG and FG2DAT.DAT). The Unit Files (FG2DAT.UNS) The Printout Headings File (HEADINGS.DAT) Print flowcalculation - Is enabled after a calculation is made. It displays The screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager

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Liquid Rotameters are sized on the basis of US gallons per minute of water. The calculation data is converted to its Usgpm of water equivalent and a meter is chosen on that basis. The viscosity is limited to the Viscosity Immunity Ceiling usually given in centistokes. The program converts your viscosity for comparison.

Engineering Units


Mass Flow - English units Volume Flow - English Units Mass Flow - SI Units

Pounds per hour and degrees Fahrenheit. US gallons per minute and degrees Fahrenheit. Kilograms per second and degrees Centigrade. 96

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Volume Flow - SI Units Units

Litres per second and degrees Centigrade. A set of units selected from the Liquid Flow Engineering Unit screen. ;

To make or change a Unit set select the option Review units . The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file. :

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Unit Selection A new calculation defaults to Mass English units. The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen. Base Conditions

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The Base Conditions option will display the current values of base pressure, base temperature and the barometric pressure. They should be checked and modified and saved to suit the operating conditions. ISO specifies a base temperature of 14.696 psia (101.325 kilopascals) and 59° (15 degC). AGA specifies a base pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°.

Fluid Properties !


For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered. For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database can be maintained.

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Calculation options are: Meter range Flowrate

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Input Data The enabled input boxes define the data required for the calculation. The maximum flow rate is the upper range value. Specific gravity at base conditions is only required for volumetric flow. Double click the Float specific gravity text box and select the float option

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Calculate Click the Calculate button. The program will validate the input data, Calculate the output data Display the results Editing Data

The output data should be examined for adequacy. Is the calculated equivalent flow USgpm less than the meter rated USgpm? Is the viscosity less than the viscosity immunity ceiling? Change data as required and recalculate .*

Filing and Moving On The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path,, it saves a new record if not previously saved or saves changes to an existing record. Save New.-.Using the default path, it saves an existing record as a new record (Used to duplicate similar items i.e. Recall an existing record. Edit as required and Save New) Save As.... - Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files . File default path - Changes the default paths for the calculation records The default paths are: The Data Files. (FG2DAT.TAG and FG2DAT.DAT). The Unit Files. (FG2DAT.UNS) The Printout Headings File (HEADINGS . DAT) ,

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Print flow calculation Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager

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Engineering Units


Mass Flow - English units Volume Flow - English Units

Mass Flow - SI Units Volume Flow - SI Units Units

Pounds per hour and degrees Fahrenheit . US gallons per minute and degrees

Fahrenheit. Kilograms per second and degrees Centigrade. Litres per second and degrees Centigrade. A set of units selected from the Liquid Flow Engineering Unit screen. 99

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To make or change a Unit set select the option Review units . The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection. Select the required units and save the file. Unit Selection

A new calculation defaults to Mass English units. The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen.

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Base Conditions

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The Base Conditions option will display the current values of base pressure, base temperature and the barometric pressure. They should be checked and modified and saved to suit the operating conditions. ISO specifies a base temperature of 14.696 psia (101.325 kilopascals) and 59° (15 degC). AGA specifies abase pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°.

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Fluid Properties

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The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply. For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered .


Calculation options are: Differential Range Flowrate

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Select the calculation option and the necessary input data is enabled . The required variable will be disabled and will receive the calculated value. 100

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Wedge Ratio Select a wedge ratio Design Select either the Chemical Seal or the Standard design ! i

Material Selection Select the Element material to display the materials screen On the materials screen, select the required material. Repeat for the Meter tube material.

Input Data The enabled input boxes define the data required for the calculation. The maximum flow rate is the upper range value. The normal flow will be the point of greatest accuracy. Specific gravity at base conditions is only required for volumetric flow.

Calculate Click the Calculate button. The program will validate the input data, Calculate the output data. Display the results

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Editing Data The output data should be examined for adequacy. Is the differential range sufficient? Try different wedge ratios Change data as required and recalculate

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The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path,, it saves a new record if not previously saved or saves changes to an existing record . Save New.-.Using the default path, it saves an existing record as a new record (Used to duplicate similar items i.e. Recall an existing record. Edit as required and Save New) Save As.... - Uses the Windows file access system. Saves to a file anywhere.

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Import data - Select the units and read Input data supplied in sequential files . File default path - Changes the default paths for the calculation records The default paths are: The Data Files. (FG2DAT.TAG and FG2DAT.DAT). The Unit Files . (FG2DAT.UNS ) The Printout Headings File (HEADINGS.DAT) Print flow calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program

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The screen shows the process variables used in a liquid calculation and list the available options. To assure full coverage each (Except Flow Time Base) has an “ Other” option. This is a defined unit. Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list. ! 102

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The screen shows the current selection. Any unit may be selected and will be used in the calculation if OK is selected.

To create a File for the File Unit option in the calculation, select the desired units and click the save button. A double click on any unit option selects that option and returns to the calculation. Data conversion

For all items except flow, the unit change represents only a multiplier to convert the input data and the data is always converted . The Flow Quantity option has Mass and Volume options. The relationship between mass flow and volume flow is a multiplier and the specific gravity of the fluid. It is conventional when measuring flow by volume that it be at a standard temperature (Usually 60 degrees Fahrenheit). Two specific gravity values are necessary for a volumetric flow calculation, mass flow cannot be converted to volume flow until the specific gravity at standard conditions is available. Definition of units

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Mass flow units : lb = pounds kg = kilograms tonne = 1000 kg = lMg g = gram UKton = 2240 lb USton = 2000 lb Other = defined mass unit Volume flow units : sft3 = standard cubic feet sdm3 = standard cubic decimetres sm3 = standard cubic metres Msft3 = million standard cubic feet Other = defined volume unit Time base : /s — per second /m - per minute /h = per hour /d = per day Gauge pressure : psig = pounds per square inch gauge kPag = kiloPascals gauge atg = atmospheres gage inhgg = inches of mercury gauge MPag = megaPascals gauge 103

inH20g = inches of water gauge mmhgg = millimetres of mercury gauge barg - bars gauge kg/cm 2g = kilograms per square centimetre gauge Other = defined gauge pressure unit Absolute pressure : psia = pounds per square inch absolute kPaa - kiloPascals absolute ata = atmospheres absolute bara = bars absolute Mpaa = megaPascals absolute kg/cm2a = kilograms per square centimetre absolute inhga = inches of mercury absolute mmhga = mil lim étrés of mercury absolute Other = defined absolute pressure unit Temperature : degF = degrees Fahrenheit degF = degrees Centigrade degR = degrees Rankine degK = degrees Kelvin Other = defined temperature unit

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Velocity ft/s = feet per second m/s = metres per second Other = defined velocity Viscosity : = centipoises Pa.s = Pascal seconds cs = centistokes kPa.s = kiloPascal seconds Other = defined viscosity unit Differential pressure : inH20 - inches of water kPa = kiloPascals inhg = inches of mercury mmH20 = millimetres of water mBar = millibars Other = defined differential Pipe and orifice diameter : in = inches mm - millimetres cm = centimetres

ft = feet m = metres Other = defined size

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Density: Ib/ft3 = pounds per cubic foot kg/m3 = kilograms per cubic metre g/cm3 = grams per cubic centimetre lb/in3 = pounds per cubic inch Other = defined density unitMass flow units : lb = pounds kg = kilograms tonne = 1000 kg = lMg g = gram UKton = 2240 lb USton = 2000 lb Other = defined mass unit Volume flow units : sft3 = standard cubic feet sdm3 = standard cubic decimetres sm3 = standard cubic metres Msft3 = million standard cubic feet Other = defined volume unit Time base : /s = per second /m = per minute /h = per hour /d = per day Gauge pressure : psig = pounds per square inch gauge kPag = kiloPascals gauge atg = atmospheres gage inhgg = inches of mercury gauge MPag = megaPascals gauge inH20g = inches of water gauge mmhgg - millimetres of mercury gauge barg = bars gauge kg/ cm 2g = kilograms per square centimetre gauge Other = defined gauge pressure unit Absolute pressure : psia = pounds per square inch absolute kPaa kiloPascals absolute ata = atmospheres absolute bara = bars absolute Mpaa = megaPascals absolute kg/cm2a = kilograms per square centimetre absolute inhga = inches of mercury absolute mmhga = millimetres of mercury absolute Other = defined absolute pressure unit

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Temperature : degF = degrees Fahrenheit degF - degrees Centigrade degR = degrees Rankine degK = degrees Kelvin Other = defined temperature unit Velocity ft/s = feet per second m/s = metres per second Other = defined velocity Viscosity : = centipoises Pa.s = Pascal seconds cs = centistokes kPa.s = kiloPascal seconds Other = defined viscosity unit Differential pressure : inH20 = inches of water kPa = kiloPascals inhg = inches of mercury mmH20 = millimetres of water mBar = millibars Other - defined differential Pipe and orifice diameter : in = inches mm = millimetres cm = centimetres ft = feet m = metres Other = defined size Density: lb/ft3 = pounds per cubic foot kg/m3 = kilograms per cubic metre g/ cm3 = grams per cubic centimetre lb/in3 - pounds per cubic inch Other = defined density unit

FG2 Material Selection The sheet displays the material options and the current selection. The temperature thermal expansion coefficients are selected with the material. A thermal correction for both pipe and flowmeter is made. Either make a new selection (Double click or click then click OK). Or click Cancel to return with no change. The program will return to the calculation. 106

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FG2 Calculation Data Printout

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This program will print the input and output calculation data and one associated comment. The comment is included in the data sheet for reference puiposes.

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It also creates the default printout headings . The headings are printed at the top of all printouts. They are saved in the HEADINGS.DAT file. This is the third default path. If all programs are set to the same path, this becomes the default headings for all program printouts.

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Cancel. Returns to the calculation form without printing

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OK. Prints the headings and calculation using the Windows Print Manager, then returns to the calculation form

Fixed Geometry2 Data Sheet The first use of the data sheet is to obtain competitive bids. It should initially

107

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emphasize the engineering requirements and be fairly general regarding the details. When a vendor is selected it should be updated to the exact details so that the data sheet is a record of the instrument purchased.

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The relevant data from the calculation is automatically displayed. Minor editing , such as rounding can be performed. Major editing should be done in the calculation routine in order to preserve the integrity of the calculation A defined database is available to enter data for those inputs which have a limited number of options. To activate this, double click the input box, the data on file is displayed. Double click the required option and the data is transferred to the data sheet form.

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The database should be customized for the project requirements. To edit the data; click the selected item. Edit the data in the active top line, select Replace, continue with the edit and Save on completion. The Input data menu option has option to enter either the first or the second item in the list for all items. If the database is constructed so that the first item is the first standard selection and the second item is the second standard selection then two standard data sheets are available for a single keystroke. This feature only enters data into empty input boxes. Some input boxes require unique data which is typed in. Space is provided to enter information for non standard options. Enter the title and data , it will be saved with the other data.

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Three lines of notes of special instructions are available at the bottom of the data sheet. The input data is limited to 25 characters and 60 characters for each of the notes. File options

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Print data sheet Prints the data sheet using the Windows Print Manager. Refer to Windows Help Go to calculation . Returns to the calculation form using the same record Update headings . Overwrites the headings with the current default set

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FG2 Vortex Meter Size Gas Calculation

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The capacity of Vortex meters is determined by their internal cross section area and the minimum and maximum operating velocities. The liquid meters have a minimum viscosity limitation . The program has stored data on meter size 1 inch to 8 inches. And will accept data for others. :


Mass Flow - English units. Volume Flow - English Units . Mass Flow - SI Units.

Volume Flow - SI Units . Units.

Pounds per hour and degrees Fahrenheit . US gallons per minute and degrees

Fahrenheit. Kilograms per second and degrees Centigrade. Litres per second and degrees Centigrade. A set of units selected from the Liquid Flow Engineering Unit screen .

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To make or change a Unit set select the option Review units . The Liquid Flow Engineering Unit screen will be displayed . It shows the available options and the current unit selection. Select the required units and save the file. 109

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Unit Selection )

A new calculation defaults to Mass English units. The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen. Base Conditions

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Fluid Properties

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For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered. For a mixture select the first component . In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is updateable.

Calculation options are Auto size Manual size Flowrate The auto size option starts at the smallest size and finds a suitable meter. The manual size calculates for the selected size. The flowrate option calculates the flow for the selected size. Select the calculation option and the necessary input data boxes are enabled. The required variable will be disabled and will receive the calculated value. 110

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Isolating Manifold

This allows the sensor to be removed from the line without interrupting the flow. With low density fluids it affects the allowable minimum and maximum velocities. ;

Special Size

Option to allow input data for other sizes to be calculated.

;

Input Data The enabled input boxes define the data required for the calculation. The maximum flow rate is the upper range value. The normal flow will be the point of greatest accuracy

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Calculate Click the Calculate button. The program will validate the input data, Calculate the output data Display the results

Editing Data The output data should be examined for adequacy. Is the rangeability sufficient? Change data as required and recalculate

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The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path,, it saves a new record if not previously saved or saves changes to an existing record. Save New. .Using the default path, it saves an existing record as a new record (Used to duplicate similar items, i.e. Recall an existing record. Edit as required and Save New) Save As . . . . Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files .

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File default path - Changes the default paths for the calculation records The default paths are: The Data Files . (FG2DAT.TAG and FG2DAT.DAT). The Unit Files . (FG2DAT.UNS) The Printout Headings File (HEADINGS.DAT) Print flow calculations - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program

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Manager

FG2 Rotameter Size Gas Calculation i

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Gas Rotameters are sized on the basis of standard cubic feet of air The calculation data is converted to its Standard cubic feet of air equivalent and a meter is chosen on that basis.

Engineering Units

There are four standard unit sets and one selected set available: Mass Flow - English units Volume Flow - English Units

Mass Flow - SI Units Volume Flow - SI Units

Pounds per hour and degrees Fahrenheit . US gallons per minute and degrees Fahrenheit. Kilograms per second and degrees Centigrade. Litres per second and degrees Centigrade. 112

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I Units i

A set of units selected from the Liquid Flow Engineering Unit screen.

To make or change a Unit set select the option Review units. The Liquid Flow Engineering Unit screen will be displayed . It shows the available options and the current unit selection. Select the required units and save the file.

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Unit Selection

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A new calculation defaults to Mass English units. The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid Flow Engineering Unit screen.

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Base Conditions

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Fluid Properties


For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered. For a mixture select the first component . In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is updateable.

Calculation options are Meter range Flowrate

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113

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Input Data The enabled input boxes define the data required for the calculation. The maximum flow rate is the upper range value. Double click the Float specific gravity text box and select the float option Calculate Click the Calculate button. The program will validate the input data, Calculate the output data Display the results

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Editing Data The output data should be examined for adequacy. Is the calculated equivalent flow SCFM less than the meter rated SCFM? Change data as required and recalculate Filing and Moving On The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path,, it saves a new record if not previously saved or saves changes to an existing record. Save New . - . Using the default path, it saves an existing record as a new record (Used to duplicate similar items, i.e. Recall an existing record. Edit as required and Save New) Save As.... - Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records The default paths are: The Data Files . (FG2DAT.TAG and FG2DAT.DAT). The Unit Files . (FG2DAT.UNS) The Printout Headings File (HEADINGS.DAT) Print flow calculation - Is enabled after a calculation is made. It displays The screen to print a calculation. Exit - Leaves the program and returns to the Windows Program

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114

FG2 Wedge Flow Meter Size Gas Calculation

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Available in sizes from 1 inch to 12 inches, with 3 or 4 different wedges for each size, the differential is fixed for each size and wedge. The program will calculate the flow or differential pressure for the selected combination. Engineering Units There are four standard unit sets and one selected set available:

Mass Flow - English units Volume Flow - English Units Mass Flow - SI Units Volume Flow - SI Units Units

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Pounds per hour and degrees Fahrenheit. US gallons per minute and degrees Fahrenheit. Kilograms per second and degrees Centigrade. Litres per second and degrees Centigrade. A set of units selected from the Liquid Flow Engineering Unit screen.

To make or change a Unit set select the option Review units. The Liquid Flow Engineering Unit screen will be displayed. It shows the available options and the current unit selection . Select the required units and save the file. Unit Selection

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115

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A new calculation defaults to Mass English units. The Unit Selection can be made at any time. The input data will be converted to the new units. If a volumetric flow unit set is selected and the specific gravity at base conditions is not available the flow is set to zero. Units for any individual input entry can be changed by the selecting the Review Units option and choosing from the Liquid . Flow Engineering Unit screen.

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Base Conditions

The Base Conditions option will display the current values of base pressure, base temperature and the barometric pressure. They should be checked and modified and saved to suit the operating conditions. ISO specifies a base temperature of 14.696 psia (101.325 kilopascals) and 59° (15 degC). AGA specifies a base pressure of 14.73 psia for natural gas, 14.696 for liquids with a vapor pressure equal or less than one atmosphere, and a base temperature of 60°. ’

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The Fluid properties option is enabled when the pressure and temperature are entered. The properties required for a calculation are available for pure liquids and mixtures and are provided in the selected units. Caution should be used for mixtures of dissimilar fluids because the mixture law may not apply. For a pure liquid find the name and select (or double-click) the name, the fluid properties will be entered. For a mixture select the first component. In the component box, enter the percentage. Continue until the remaining percentage equals zero, then select calculate in the component box and the program will calculate and enter the mixture values. The fluid properties database is updateable.

Calculation options are Differential Range Flowrate

Select the calculation option and the necessary input data is enabled . The required variable will be disabled and will receive the calculated value.

Wedge Ratio Select a wedge ratio

116

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Design

Select either the Chemical Seal or the Standard design Material Selection Select the Element material to display the materials screen On tire materials screen, select the required material. Repeat for the Meter tube material .

Input Data The enabled input boxes define the data required for the calculation. The maximum flow rate is the upper range value. The normal flow will be the point of greatest accuracy.

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Calculate Click the Calculate button. The program will validate the input data, Calculate the output data. Display the results

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Editing Data The output data should be examined for adequacy. Is the differential range sufficient? Tty different wedge ratios Change data as required and recalculate


The options in the File menu are: Program menu - Clears the calculation and returns to the main menu. Prepare data sheet - Is enabled after a calculation is made, it displays the screen to prepare a data sheet form for the calculated item. New record - Clears the screen for a new calculation. Save - Using the default path, it saves a new record if not previously saved or saves changes to an existing record. Save New.-. Using the default path, it saves an existing record as a new record (Used to duplicate similar items, i . e. Recall an existing record. Edit as required and Save New) Save As . . .. - Uses the Windows file access system. Saves to a file anywhere. Import data - Select the units and read Input data supplied in sequential files. File default path - Changes the default paths for the calculation records The default paths are: The D ata Files . (FG2DAT.TAG and FG2DAT.DAT). ,

117

The Unit Files . (FG2DAT.UNS) The Printout Headings File (HEADINGS . DAT) Print flow calculation - Is enabled after a calculation is made. It displays the screen to print a calculation. Exit - Leaves the program and returns to the Windows Program Manager

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Print (Fixed Geometry2) Summary

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The program will provide a printout summary of data sheet records on file. Access to this print summary is from the main Fixed Geometry Flow Element Sizing Programs menu.

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It can provide a printout of either: All fields Selected fields Fields equal to Fields not equal to Fields equal to or less than Fields equal to or greater than Fields less than Fields more than

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Procedure for a new Summary l

Select Options Clears all check on the form Clear checks Clears all other data on the form Clear Other Data Make new field selections Each field has four boxes A check box to select the field A box to specify the field width A box to enter data to compare A box to specify the compare method (Double click for data) Select data relationship And or or Click Print to print using Windows Print Manager File Options

Save print options Saves a standard printout Go to Program Menu Form Returns to program menu for further work on this module 118

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Exit Returns to the Windows Program Manager !

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Procedure for a standard printout ! ;

Select Options Recall saved options

Print Procedure to print all fields Select Options Check all

Print :

Other Options Select font Windows font selection procedure Select Printer Windows Print manager

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FG2 Gas Engineering Units !

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The screen shows the process variables used in a liquid calculation and list the available options . To assure full coverage each (Except Flow Time Base) has an “ Other option. This is a defined unit. Double click the option and it will display the name and multiplier to convert it to the standard units. The standard unit is always the first item in the list. The screen shows the current selection. Any unit may be selected and will be used in the calculation if OK is selected.

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Data Conversion

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For all items except flow, the unit change represents only a multiplier to convert the input data and the data is .always converted. The Flow Quantity option has Mass and Volume options. The relationship between mass flow and volume flow is a multiplier and the molecular weight of the gas, conversion can only be made when the molecular weight has been entered. FG2 Gas Engineering Units

i-

Definition of units

Mass flow units : lb = pounds kg = kilograms tonne = 1000 kg = IMg g = gram UKton = 2240 lb USton = 2000 lb Other = defined mass unit Volume flow units : sft3 = standard cubic feet sdm3 = standard cubic decimetres sm3 = standard cubic metres Msft3 = million standard cubic feet Other = defined volume unit Time base : /s = per second /m = per minute /h = per hour /d = per day Gauge pressure : psig = pounds per square inch gauge kPag = kiloPascals gauge 120

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atg = atmospheres gage inhgg = inches of mercury gauge MPag = megaPascals gauge inH20g = inches of water gauge mmhgg = millimetres of mercury gauge barg = bars gauge kg/cm2g = kilograms per square centimetre gauge Other = defined gauge pressure unit Absolute pressure : psia = pounds per square inch absolute kPaa = kiloPascals absolute ata = atmospheres absolute bara = bars absolute Mpaa = megaPascals absolute kg/cm2a = kilograms per square centimetre absolute inhga = inches of mercury absolute mmhga = millimetres of mercury absolute Other = defined absolute pressure unit Température : degF = degrees Fahrenheit degF = degrees Centigrade degR = degrees Rankine degK = degrees Kelvin Other = defined temperature unit Velocity ft/s = feet per second m/s = metres per second Other = defined velocity Viscosity : = centipoises Pa.s = Pascal seconds cs = centistokes kPa.s = kiloPascal seconds Other = defined viscosity unit Differential pressure : inH20 = inches of water kPa = kiloPascals inhg = inches of mercury mmH20 = millimetres of water mBar = millibars Other = defined differential Pipe and orifice diameter : in inches mm = millimetres cm = centimetres

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ft = feet m = metres Other = defined size Density lb/ft3 = pounds per cubic foot kg/m3 = kilograms per cubic metre g/cm3 = grams per cubic centimetre lb/in3 = pounds per cubic inch Other - defined density unit

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Fixed Geometry 2 Calculation Routines Rotameters Liquid Calculation 1. Calculate the equivalent flow in US gallons per minute of water -

Qm =

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wm - .

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188.814 G( (GF - Gf )

2 Calculate the sizing viscosity -

US gallons per minute -

2.6496n

Mes =

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centistokes

3. Calculate the Maximum allowable viscosity

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Gas calculation 1 Calculate the equivalent flow -

.

Q =

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5.862

Standard cubic feet of air equivalent.

Nomenclature

Qm

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Calculated equivalent water flow US gallons per minute

wm

Desired quantity of flowing fluid

Ib/h

Yn

Gas density

lb per cubic foot

Gf

Specific gravity of flowing fluid

dimensionless

Gp

Specific gravity of float

dimensionless

M' es

Rotameter viscosity immunity ceiling

centistokes

M

Viscosity of flowing fluid

centipoises

Vortex meters 1 Calculate the flow area

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square feel 2. Calculate the maximum and minimum flowrate

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MAX = 3600 ASELVMAXy n 3. For liquids callculate the Reynolds Number -

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3600 ASELVMinyn Ib/h

6.31533 Wm.

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Nomenclature A Flow area for required flow

square feet

A SEL Cross section area of selected meter

square feet

D

Supplied by manufacturer (Bore area - Element area) Pipe inside diameter at flowing temperature

Inches


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Reynolds Number

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Required flowrate

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V

Velocity at

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feet per second

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feet per second

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(Supplied by the manufacturer)

MIN

M ^

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Velocity at (Supplied by the manufacturer)

feet per second

Absolute Viscosity

centipoise

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Wedge Flowmeter 1. Set Y = 1 2. Calculate the differential range /

K

=

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V 358.9626F

inches of water 3. If fluid is gas then calculate the expansion factor -

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4. Repeat from 2 until error is less than Q.GOQOi

Nomenclature

wm

Desired quantity of flowing fluid

Ib/h

y«

Fluid density

lb per cubic foot

Hm

Differential range

indies of water

K d2

Wedge coefficient

dimensionless

Inlet pressure Gas expansion factor

psia

Y

P

Wedge ratio ( Supplied by the manufacturer )

dimensionless

,

Pi

dimensionless

Fluid Properties These are calculated using common chemical formulae with each item corrected for pressure and temperature. Some fluids show deviations from the formulae, the should check typical calculated values against known values. In ail cases if accurate laboratory information is available it should be used. Density uses the Redlich-Kwong Equation,

124

i

FIXED GEOMETRY2 Data Files INSTRUCALC V5 Random access file specification for FG2 flow elements FG2DAT. Dat. Tag Numbers are stored in the sequential file FG2DAT.TAG. Its number in the file is the record number in the random access file.

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Type FileData Calculation info ProgNum As Integer 2 bytes . Program number Liq<6:Gas>20 ElemMatlNom As Integer 2 bytes.Element material number PipeMatlNum As Integer 2 bytes Pipe material String 3 bytes."Mas" denotes amass calculation, FloBasis As *3 volume "Vol" a Code As String * 3 3 bytes. "Yes" or "No" for drainhole FS(1 To 15) As Single 60 bytes . Units conversion factor GS (1 To 20) As Single 80 bytes.Variable data UnS( l To 15) As String * 8 120 bytes.Unit Name Data sheet info SdS( l To 7) As Single 28 bytes. AraS( l To 22) As String * 25 550 bytes.Data sheet array selections Txtl ( l To 3) As String * 25 75 bytes.Data sheet service,line num, fluid Txt2( l To 3) As String * 60 180 bytes.Data sheet notes TXT3(1 To 7) As String * 10 70 bytes.Data sheet mim,spec,rev,date,req,by,appr End Type Record len= l 175

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Common for all Elements

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ElemMatlNoni and PipeMatlNum If material number = 1 Then Material = "301 stainless steel " If material number = 2 Then Material = "304 stainless steel" If material number = 3 Then Material = "310 stainless steel" If material number = 4 Then Material = "316 stainless steel " If material number = 5 Then Material = "330 stainless steel" If material number = 6 Then Material = "347 stainless steel " If material number = 7 Then Material = "Aluminum bronze" If material number = 8 Then Material = "Beryllium copper ” If material number = 9 Then Material = "Carbon steel " If material number = 10 Then Material = "Copper" If material number = 11 Then Material = "Cupronickel " If material number = 12 Then Material = "Hastelloy B" If material number = 13 Then Material = "Hastelloy C" If material number = 14 Then Material = "Haynes Stellite 25 " If material number = 15 Then Material = "Inconel X" If material number = 16 Then Material = "K - Monel" If material number = 17 Then Material = "Nickel" If material number = 18 Then Material = "Pyrex glass"

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I If material number = 19 Then Material = "Tantalum" If material number = 20 Then Material = “ Titanium” FloBasis "Mas" denotes a mass calculation, "Vol" a volume

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Liquid

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If ProgNum = 2 Then Program = "Vortex meter - liquid" Code = "No" or "Yes" for an Isolating manifold Code = ""Oth" for other sizing FS(1) UnS ( l ) GS (1) = Maximum flow UnS(2) GS(2) = Flow temperature FS(3) UnS(3) GS(3) = Inlet pressure GS(5) = Specific gravity at flow conditions GS (6) = Specific gravity at standard conditions FS(7) UnS(7) GS(7) = Viscosity FS() UnS(8) GS (8) - Nominal size FS (10) UnS( lO) GS (10) = Vapor pressure FS(12) UnS(12) GS (12) = Flowmeter bore diameter FS (13) UnS (13) GS(13) - Base pressure UnS (14) GS(14) = Base temperature FS(15) UnS(15) GS(15) = Barometric pressure UnS(12)+2 GS(18) = Flow meter bore area FS(1) UnS( l ) SDS( l ) = Maximum flowrate FS (1) UnS ( l ) SDS (2) = Minimum flowrate SDS (5) = Chart multiplier FS (5) UnS(5) SDS(6) = Minimum allowable velocity FS(5) UnS(5) SDS(7) = Maximum allowable velocity

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If ProgNum = 4 Then Program = "Rotameter - liquid " FS(1) UnS( l ) GS(1) = Maximum flow UnS(2) GS (2) = Flow temperature FS(3) UnS(3) GS(3) = Inlet pressure GS (5) = Specific gravity at flow conditions GS (6) = Specific gravity at standard conditions FS(7) UnS(7) GS(7) = Viscosity GS(8) = Float specific gravity GS(12) = Viscosity immunity ceiling FS (13) UnS (13) GS(13) = Base pressure UnS(14) GS(14) = Base temperature (15) ( FS UnS ) 15 pressure 15 Barometric GS ( ) = GS (18) = Rotameter URV USgpm water SDS( l ) = Maximum flow in USgpm water equivalent SDS(2) = Rotameter allowable flow in selected units FS(1) UnS( l ) SDS(5) = Chart multiplier 126

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If ProgNum = 5 Then Program = " Wedge flow meter - liquid " Code = "Che" for chemical seal design, "Std " for standard GS(1) = Maximum flow FS(1) UnS ( l ) GS(2) = Flow temperature UnS(2) GS (3) Inlet pressure FS(3) UnS(3) GS(4) = Differential range FS (4) UnS(4) GS (5) = Specific gravity at flow conditions GS(6) = Specific gravity at standard conditions GS(8) = Nominal size UnS (8) GS (12) = Wedge ratio GS(13) = Base pressure FS (13) UnS(13) GS (14) = Base temperature UnS( 14) GS(15) = Barometric pressure FS (15) UnS(15) GS(18) = Normal flow FS(1) UnS ( l ) SDS( l ) = Normal flow differential FS(4) UnS(4) SDS(5c ) = Chart multiplier

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If ProgNum = 22 Then Program = "Vortex meter - gas" Code = "No" or "Yes" for an Isolating manifold Code = "Oth" for other sizing GS (1) = Maximum flow FS(1) UnS( l ) GS(2) = Flow temperature UnS(2) GS (3) = Inlet pressure FS(3) UnS(3) GS(5) = Molecular weight GS(6) = Ratio of specific heats GS (7) - Viscosity FS(7) UnS (7) GS(8) = Nominal size UnS(8) GS (9) - Density FS(9) UnS(9) GS(10) = Critical pressure FS(10) UnS( lO) GS(11) = Critical temperature UnS(ll ) GS(12) = Flow meter bore diameter FS (12) UnS(12) GS(13) = Base pressure FS(13) UnS (13) GS (14) = Base temperature UnS(14) GS(15) = Barometric pressure FS(15) UnS (15) GS (18) = Flow meter bore area UnS (12)+2 SDS( l ) = Maximum flowrate FS (1) UnS( l ) SDS(2) = Minimum flowrate FS(1) UnS( l ) SDS(5) = Chart multiplier SDS(6) = Minimum allowable velocity FS(5) UnS (5) SDS(7) = Maximum allowable velocity FS (5) UnS(5)

If ProgNum = 24 Then Program = "Rotameter - gas" GS (1) = Maximum flow FS(1) UnS( l ) 127

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UnS(2) GS(2) = Flow temperature FS (3) UnS (3) GS(3) = Inlet pressure GS(5) = Molecular weight GS(8) = Float specific gravity FS(9) UnS(9) GS(9) = Density FS(10) UnS( lO) GS (10) = Critical pressure FS( ll ) UnS( ll ) GS ( ll ) - Critical temperature FS(13) UnS(13) GS (13) = Base pressure UnS(14) GS(14) = Base temperature FS(15) UnS(15) GS (15) - Barometric pressure GS (18) = Rotameter URV SCFM air SDS( l ) = Maximum flow in SCFM air equivalent SDS(2) = Rotameter allowable flow in selected units FS(1) Uns( l ) SDS(5) = Chart multiplier If ProgNum — 25 Then Program = "Wedge flow meter - gas" Code = "Che" for chemical seal design, "Std " for standard FS(1) UnS ( l ) GS (1) = Maximum flow UnS(2) GS (2) = Flow temperature FS(3) UnS(3) GS(3) = Inlet pressure FS(4) UnS(4) GS (4) = Differential range GS (5) - Molecular weight GS (6) = Ratio of specific heats UnS(8) GS(8) = Nominal size FS(9) UnS(9) GS(9) = Density FS(10) UnS( lO) GS (10) = Critical pressure UnS( ll ) GS (11) = Critical temperature GS (12) = Wedge ratio FS( I 3) UnS(13) GS(13) = Base pressure UnS(14) GS(14) = Base temperature ) FS(15 UnS(15) GS (15) = Barometric pressure FS(1) UnS( l ) GS (18) = Normal flow FS(4) UnS(4) ) differential Normal flow l ( SDS = SDS(5) = Chart multiplier

Miscellaneous Files FG2DAT.UNS Sequential file. unit data FG2DAT.STP. Sequential file. Base conditions FG2SPEC.TXT . Sequential file. Data sheet item selections HEADINGS .DAT Sequential file. Printout titles FG2SUM.DAT Sequential file. Standard summary selections FG2 CALC.DRV Sequential file. Default drives and paths FG2 CALC.COL Sequential file. Color selections 12S

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FG2 Import Process Data To Import process data into a calculation :

Make a sequential file for each calculation Files to have a filename(Suggest the tag number) with no extension (ie FE-100.). After INSTRUCALC reads the file it will rename the file to "FILENAME. OK". This will divide the files into two lists, those which have been processed and those which have not. f

To read a file. 1. Go to the required calculation and select the required units. 2. Take the Import data menu option. 3. Find the required file. (Using standard Windows procedures) 4. Select the file and the data will be loaded. 5. Proceed with the calculation and save the data. (Now in the INSTRUCALC file) 6 . The sequential file will be assigned the extension ".OK", and will disappear from the list. 7. If a review is required, use the Windows file procedures for files with an extension ".OK" 8. Revised process data should be provided without extensions. The Instrument engineer will then have an instant review of work not yet performed . Data input sequential file requirements (In input order) Rotameter Gas Flowmeter 1 Tag number 2 Fluid name 3 Required flow 4 Temperature 5 Inlet pressure 6 MW 7 Density 8 Critical pressure 9 Critical temperature 10 Line number 11 Service

Seq file Txtl (3) G( l ) G(2) G(3) G(5) G(9) G(10) G( ll ) Txtl ( l ) Txtl (2)

Rotameter Liquid Flowmeter 1 Tag number 2 Fluid name 3 Required flow 4 Temperature 5 Inlet pressure

Seq file Txtl (3) G( i ) G(2) G(3) 129

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6 SG @ FTP 7 SG @ Base 8 Viscosity 9 Line number 10 Service Vortex Gas Flow Element 1 Tag number 2 Fluid name 3 Maximum flow 4 Temperature 5 Inlet pressure 6 Mw 7 /Cv 8 Viscosity 9 Density 10 Critical pressure 11 Critical temp 12 Line number

G(5) G(6) G(7) Txtl (2) Txtl ( l )

13 Service

(Seq file) Txtl (3) ) GO G(2) G(3) G(5) G(6) G(7) G(8) G(10) G( ll ) Txtl (2) Txtl (2)

Vortex Liquid Flow Element 1 Tag number 2 Fluid name 3 Maximum flow 4 Temperature 5 Inlet pressure 6 SG @ FTP 7 SG@ Base 8 Viscosity 9 Line number 10 Service

Seq file Txtl (3) G( l ) G(2) G(3) G(5) G(6) G(7) Txtl (2) Txtl ( l )

Wedge Gas Flowmeter 1 Tag number 2 Fluid name 3 Maximum flow 4 Normal flow 5 Temperature 6 Inlet pressure 7 Mw 8 /Cv 9 Viscosity 10 Density 11 Critical pressure

(Seq file) Txtl (3) G( l ) G(18) G(2) G(3) G(5) G(6) G(7) G(8) G(10) 130

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12 Critical temp 13 Line number 14 Service Wedge Liquid Flowmeter 1 Tag number 2 Fluid name 3 Maximum flow 4 Normal flow 5 Temperature 6 Inlet pressure 7 Differential range 8 SG @ FTP 9 SG@ Base 10 Pipe size 11 Line number 12 Service

G( ll ) Txtl (2) Txtl (2)

Seq file Txtl (3) G( l ) G(18) G(2) G(3) G(4) G(5) G(6) G( l ) Txtl (2) Txtl ( l )

Fixed Geometry2 Pipe Inside Diameter )

The orifice pipe run is the straight sections of pipe, upstream and downstream of the orifice plate, as specified in ISO 5167 and AGA3 and ANSI 2530. The ISO pipe inside diameter is the average Of 12 measurements of the upstream section of the meter measured at a room temperature.

Initially, in most cases, the orifice pipe run is not available and the standard size is used. This is available in a program look-up table. To find the size, select the meter run size button to display the pipe size screen, enter the nominal size of the pipe and select the search button. The available wall thickness and the corresponding inside diameters for the nominal size are displayed. Select the required size and it will be transferred to the calculation.

When the meter tube becomes available, measure the inside diameter and back calculate either the amended flow rate or differential pressure. Metric dimensions are in millimeters and nominal sizes are base on 25 mm per nominal inch. If Units other than inches or millimeters are used , the data transferred back to the calculation will be converted to the calculation units.

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