DIMENSIONAL CALCULATIONS FOR RELIEF SYSTEMS AND VENT LINES OF

THE NPDGAMMA LIQUID HYDROGEN TARGET

Prepared: H. Nann, Indiana University

Checked : S. Penttila, ORNL
Approved: M. Snow, Indiana University
SCOPE
In this document is summarized the calculations of the sizing of the relief system
and vent stack of the NPDGamma liquid hydrogen target. Calculations were
performed to determine the size of the relief piping such that the hydrogen mass
flow (mass boil-off rate) due to catastrophic vaporization of the liquid hydrogen in
the target vessel or isolation vacuum chamber remains subsonic at all times
Sonic flow represents the maximum possible flow in a piping system and that the
maximum pressure in each component remains well below its bursting point. Also
the two worst case incidents are discussed and shown that the safety system is
correctly dimensioned.
FORMALISM
Calculations are based on the Bates Internal Report # 90-02 [1] and the Crane
Technical Paper No. 410 [2]. Using the formulae and algorithms from these two
reports, computer programs was written to calculate the maximum pressure
occurring during the discharge through the relief system
MODEL
The hydrogen pressure relief system, shown in Figures 1 and 2, consists of:
1. The 1.5 nominal size hydrogen vent line from the target vessel to the relief
valve RV104 which is parallel with a rupture disk RD101 inside the vent
isolation box. The inner diameter of this line is 1.37 inch.
2. The target isolation vacuum chamber is connected with a 6.0 nominal size
commercial steel pipe to the small throughput relief valve RV201, which is
parallel with two rupture disks RD201 and RD202. These two rupture disks
are inside the vent isolation chamber. The inner diameter of this line is 5.75
inch. The 1.5 OD hydrogen fill/vent line runs coaxially inside the 6.0 OD
pipe.
3. All these relief devices are connected to the same volume of the vent
isolation chamber. The vent isolation chamber is described in section 4.

Fig. 1. Conceptual schematic of the LH 2 target system, cryostat, vacuum/fill/vent

line, and vent isolation box.

Coxial
fill/vent line

From
isolation
vacuum
Vent isolation
chamber

Hydrogen
line

Fig. 2. The model view of the vent isolation chamber inside the ventilated vent
isolation cabinet when the cabinet cover has been removed
CALCULATIONS
The calculations of the maximum pressure in the LH 2 target vessel and the
isolation vacuum chamber during the catastrophic failure takes into consideration
all the pipes and bends up to the end of the vent stack outside of the Target
Building, including the pressure relief valves in the vent isolation box. The friction
factors for each component in the relief system were taken from the Crane
Technical Paper No. 410 [2].
Hydrogen gas is much lighter (M=2 g/mole) than NTP air (average molecular
M=29 g/mole) or argon (molecular M=40 g/mole) and will rise in air at
temperatures above 23 K (normal boiling point temperature: 20.3 K). Buoyant
velocities are related to the difference in air and H 2 gas (GH2) densities. The
buoyant velocity of hydrogen in NTP air is 3.9 to 29.5 ft/s.
Section 1 presents the formula for the gas flow rate in terms of the gas flow
resistance coefficient and the mass flow rate from the target. Sections 2 and 3
show the calculations for K from the target and cryostat vacuum to the vent
isolation chamber. Section 4 describes the vent isolation chamber in enough
details to under stand the calculations. Section 5 shows the calculation of K from
the vent isolation chamber to the exit of the vent stack. Section 6 gives the basis

for the estimate of the heat flux which sets the mass flow rate. Sections 7 and 8
presents the results for the pressure in the target vessel and the vacuum chamber
respectively. Section 9 states the conclusions.
1
Formulae for Flow Rates and Pressure Drop in the Relief Line in the Event
of a Catastrophic Vacuum or Target Failure
The following describes calculations based on the formulae and procedures of the
Bates Internal Report # 9002 [1] and the Crane Technical Report No. 410 [2] for
various mass flow rates and nominal size diameters of the vent pipe. The rate of
mass flow through pipes, valves and fittings is given by the Darcy formula
M
w 0.1192Yd 2 p1 p1 p2

KT

where

w = mass flow rate [lb/s]

p1 = inlet (upstream) pressure [psia]
p2 = outlet (downstream) pressure [psia]
d = inner diameter of vent pipe [inch]
Y = net expansion factor for compressible flow through orifices,
nozzles, or pipe (see Table F.1)
K = total resistance coefficient for the vent system
T = absolute temperature of the flowing gas [K]
M = molecular mass of the gas [g/mol]
L = length of the pipe [inch]

The functional dependence of Y versus (p1 p2)/p1 is linear and can be written in
the form
Y = 1 mx
where
m = absolute value of slope
x = (p1 p2)/p1
0 x xmax
(The value xmax corresponds to sonic flow)
Values for m and xmax for different resistance coefficients K are given in Table 1.
Table 1:
larger flow
constant
constant

Net expansion factor Y for compressible flow through pipe to a

area; ratio of specific heat at
K
m
xmax
pressure to specific heat at
2.0
0.618
0.612
volume for hydrogen is = 1.4.
4.0
0.504
0.697
6.0
0.446
0.737
8.0
0.413
0.762
10.0
0.389
0.784
15.0
0.364
0.818
20.0
0.346
0.839
25.0
0.339
0.855
30.0
0.334
0.868
40.0
0.328
0.883
60.0
0.321
0.904
100.0 0.313
0.926

Substituting the linear form for Y into the Darcy equation yields
p2
w 0.1192 d 2 1 mx

1 x

Mx
KT

Squaring both sides of this equation leads to a cubic equation of the form
x3 + ax2 + bx + c = 0
where

2 Fm
Fm 2
F 2w 2
b
Fm 2
w2
c
Fm 2
a

Md 4 p 22
KT

F 0.01423

This cubic equation was numerically solved for x. For subsonic flow, at least one
root must lie in the range 0 < x < xmax. If not, then the flow is sonic. The steadystate pressure is then given by
p
p1 2
1 x

To determine x we therefore must know the resistance coefficient K and the mass
flow rate.
2
Total Resistance Coefficient for the Vent Line from the LH 2 Target Vessel to
the Vent Isolation Chamber
The 1.5 vent line from the target to the vent isolation box contains all pipes,
bends, and pressure relief valves from the target vessel up to the vent isolation
box, see drawing series 312644 in the target website. Individual resistance
coefficients for the various components in the vent line, including the relief valve
RV104 are listed in Table 2. A friction factor of f = 0.021 for clean commercial steel
pipe of nominal 1.5 inch diameter is used. The K-value for the relief valve RV104

was assumed to be the same as that for a globe and angle type stop-check valve
[2], K = 55f.

Table 2:
Individual and total resistance coefficients K for the vent line from the
target vessel to the vent isolation box; reference diameter 1.5 inch.

Component

Resistance Coefficient K

365 inch pipe

4 - 90 pipe bends; r/d
= 1.5
2 - 45 elbows
4 - bellows; 1.5 ID, 2.0
OD, 10 ribs
1 - 6 flex line, 24 ribs
1-standard tee
through run)

(flow

5.11
1.18
0.67
16.20
9.72
0.42

1 gate valve

0.17

1 relief valve

1.16

1 pipe exit

1.00

TOTAL

35.63

The Crane Technical Paper No. 410 [2] does not contain a resistance coefficient
(K) for bellows. Thus the following model was used. A bellow consists of a series
of sudden enlargements and contractions, as shown in the Fig. 3.

Fig. 3. Model of bellows consisting of a series of sudden enlargements and

contractions.
The actual resistance coefficient will be smaller since the edges are rounded and
the cells are small so that vortices cannot develop completely as in a single
sudden enlargement or a single sudden contraction. This overestimate of the
resistance coefficient will be an error on the side of safety. The resistance to flow
due to a sudden enlargement is given by [Ref. 2]

d12
2
K 1e 1 2 1 2 ,
d2

and the resistance due to a sudden contraction is

d2
K 1c 0.5 1 12 0.5 1 2 ,
d2

where d1 d 2 . The subscripts 1 and 2 define the internal diameters of the small
and large pipes, respectively (see Fig. 3). Thus we have for one bellow cell (one
sudden enlargement plus one sudden contraction)
K K 1e K 1c

Example:

d1 = 1.50 inch
d2 = 2.00 inch

K1e

1.5
0.7500
2 0.5625
2 .0
2
1 0.5625 0.1914

K1c 0.51 0.5625 0.2138

K K1e K1c 0.4052

For 10 bellow cells we have K = 4.05.

3
Total Resistance Coefficient for the Vent Line from the Target Isolation
Vacuum Chamber to the Vent Isolation Chamber
The 6 vent line from the target isolation vacuum chamber to the vent isolation
chamber contains all pipes, bends, and pressure relief valves from the vacuum
chamber up to the vent isolation box, see drawing series 312644 in target web
site. Individual resistance coefficients for the various components in the relief line,
including the relief valve RD201 are given in table 3. The actual size of this relief
line is 6.0 inch; however, in order to take into account that the target relief line and
gas pre-cooling system run coaxially inside the 6.0 inch pipe, a reference diameter
of 4.0 inch was chosen. A friction factor of f = 0.017 for clean commercial steel
pipe of nominal 4.0 inch diameter was used.

Table 3:
Individual and total resistance coefficients K for the relief line from
the target isolation vacuum chamber to the vent isolation box; reference diameter
4.0 inch. The flow is calculated through one 4 inch bellows followed by one rupture
disk (RD201).
Component

Resistance Coefficient K

335 inch pipe

1 6 bellow; 10 ribs

1.42
2.03

1 standard tee; flow

through run

0.34

2 standard tees; flow

through branch

2.04

1 4 bellows; 10 ribs
1 rupture disk RD201*

2.46
1.88

1 pipe entrance

0.5

1 pipe exit

1.0

TOTAL

11.67

* according to manufacturer (Fike) for SR-H rupture disks

The Vent Isolation Chamber

The vent isolation chamber (see drawing series 315337) is a cylindrical vessel,
constructed of 10-inch, Schedule 10 NPS stainless steel pipe of thickness 0.165
inch, with CF flanged, flat heads on either end. It is 28 inches long. It is located
inside a ventilated vent isolation cabinet (see Fig. 2). The inlet to the vent isolation
chamber is the 1.5-inch pipe from the LH 2 target through a flanged head. The CFflanged outlet at the other end of the chamber is a 6.0-inch pipe of the vent stack
going outside of the Target Building. The thickness of the two end flanges is 1.120
inch. Additionally, there are two 10-inch full inlet joints to the side of the cylindrical
shell, which are connected to the target isolation vacuum chamber.
Inside the vent isolation chamber (see Fig. 4) are the pressure relief devices for
the target vessel, RV104 (set point: 20 psid) and in parallel RD101 (set point: 30
psid), and for the target isolation vacuum chamber, RD101 (set point: 7 psid) and
in parallel RD102 (set point: 7 psid).

1.5inch
vent line

vent stack
CF flange

Fig. 4 Vent isolation chamber with assembly of the relief valve, RV104, and rupture
disks, RD101, RD201, and RD202. See drawing series 315337

5
Total Resistance Coefficient for the Vent Stack from the Vent Isolation
Chamber to the Outside of the Target Building
The vent stack from the vent isolation chamber contains all pipe, bends, and
pressure relief valves from the vent isolation chamber to the outside of the
experimental hall. Individual resistance coefficients for the various components in
the relief line are given in Table 4. A friction factor of f = 0.015 for clean commercial
steel pipe of nominal 6.0 inch diameter is used.
Table 4:
Individual and total resistance coefficients K for the relief line from
the vent isolation chamber to the outside of the experimental hall; reference
diameter 6.0 inch.
Component

Resistance Coefficient K

70 feet pipe

2.10

3 90 elbows

1.35

2 - 45 elbows

0.48

1 standard tee, 6
ID(flow through branch)

0.84

1 pipe entrance

0.50

1 pipe exit

1.00

TOTAL

6.27

Conversion to 1.5 inch reference diameter pipe:

d
K a K b a
db

1 .5
6.27

6 .0

0.02

Conversion to 4.0 inch reference diameter pipe:

d
K a K b a
db

4.0

6.0

6.27

1.24

To update this, we need to find out what the real vent stack will be. Since we have
to convert to the 1.5 and 4.0 inch reference pipes, this will not change the
conclusion below.
6
TWO WORST ACCIDENT SCENARIOS AND RESULTING HEAT FLUXES
TO LH2
A sketch of the cross section of the LH2 target vessel and the isolation vacuum
chamber (cryostat) is show in Fig. 5. In order to reduce the heat flux into the LH 2
target vessel, vacuum and approximately 10 layers of superinsulation are wrapped
around the LH2 target vessel. Around this, a copper radiation shield, continuously
kept to temperatures at below 100 K, is mounted to protect the LH 2 target vessel
from radiative heating. An additional 1 2 cm thick layer of superinsulation is
wrapped around the copper radiation shield.

Fig. 5. Sketch of the cryostat cross section and the LH 2 target vessel. Around the
LH2 target vessel is vacuum and are several layers of superinsulation, also around
the copper radiation shielding is 1 2 cm thick superinsulation layer. The function
of the superinsulation is to prevent radiative and convection heating and to reduce
the heat transfer to the LH 2 target. The continuously cooled copper radiation shield
establishes an intermediate temperature boundary at 100 K.
There are two maximum credible accident scenarios possible which determine the
size of the pressure relief system:
(A) A loss of the cryostat isolation vacuum through a large air leak causing the
pressure in the target vessel and target lines to rise.
The heat transfer from the warm outer walls of the cryostat into the LH 2 is difficult
to calculate reliably. However, the literature gives several reports where the heat
transfer rates are measured between two surfaces at different temperatures. Most
measurements have been performed using liquid helium as the cryogenic fluid.
However, the differences between liquid helium and liquid hydrogen are small.
Ref. [3] gives a maximum heat transfer rate q&eff = 4.4 103 W/m2 for the case
where the cryogenic fluid is liquid helium at 4 K. The cryostat isolation vacuum is
let up to 1 atm of air. The thickness of the superinsulation around the target vessel
is only 3 mm which is very thin compared to the 1 2 cm thick superinsulation
layers of the NPDGamma target.

The enthalpy of vaporization for hydrogen is hv = 445.6 kJ/kg, the density of LH 2

at the normal boiling point (20.4 K) is = 70.78 kg/m3, the mass of 16 liter of LH2 is
m = 1.14 kg, and the surface area of the target vessel is A = 0.4 m2. Thus the
amount of energy required to boil off the 16 liter of LH 2 is
Q hv m 445.6

kJ
1.15kg 508kJ
kg

and the boil-off rate (mass evolution rate) is

w

q eff A
hv

W
2
0.4m
m2
0.003955kg / s 0.009lb / s 31.3lb / hr
3 J
445.6 10
kg

3
4.4 10

The mean velocity of flow in a nominal 1.5 inch diameter pipe at this boil-off rate is
v 2.40

w
31.3lb / hr
2.40
A
1.406in 2 0.005lb / ft 3 10694 ft / min 54.3m / s

Note: The speed of sound in hydrogen at NTP is vsound 1294m / s

Ref. [4] estimates the heat transfer rate in the NPDGamma LH 2 target due to a
cryostat isolation vacuum failure to air to be q&eff 2000 W/m2. It was assumed
that the target vessel was surrounded by 1 cm thick superinsulation (about 30
layers). This gives a much smaller (30 times smaller) boil-off rate of

W
2
0.4m
q&eff A
kg
m2
w

0.001795
0.0040lb / s 14.4lb / hr
J
hv
s
445.6 103
kg
Here the mean velocity of flow in a nominal 1.5 inch diameter pipe is v 10.0m / s .
2000

Nevertheless, to be on the safe side, we will use the much higher flow rate
estimate, 31.3 lb/h, from the calculation above in our flow calculations below.
(B) A rupture of the target flask or piping inside the vacuum chamber will release
the LH2 into the isolation vacuum chamber and hydrogen will boil off quickly. Here
the LH2 is in contact with a larger warm surface area causing a larger boil-off rate.
Assuming a heat flux of q&eff 1.0 105 W/m2 into the vacuum vessel which has a
surface area of about 1 m 2 in contact with the liquid hydrogen we obtain a mass
flow rate of w = 0.5 lb/s

Steady State Pressure in the Target Vessel during Catastrophic Discharge

The total resistance coefficient from the target vessel to the outside atmosphere is
K = 35.63 + 0.02 = 35.65 (reference diameter: 1.5 inch; actual inner diameter:

1.375 inch, which was used in the calculations below) from section 2. The steadystate target pressure was calculated with the following assumptions:
Flow temperature: T = 293 K, taken at the warmest point in the relief system. This
will overestimate the inlet pressure p1, but this will be an error on the side of safety.
Outlet pressure: p2 = 14.7 psia, venting to air at the normal atmospheric pressure.
Assume:

Mass flow rate: w = 0.009 lb/s

Total resistance coefficient: K = 40.0 from sections 2 and 5

Results:

Sonic flow rate: wsonic = 0.29 lb/s

Target pressure (according to Table 5): p1 = 21.7 psia

Table 5:
Maximum discharge pressures for various mass flow rates w and
resistance coefficients K. The inner diameter of the relief pipe is 1.370 inch. For
comparison, results of calculations for a 10 times larger mass flow rate as above
described are included.
Resistance
Coefficient
K = 20
K = 25
K = 30
K = 40
K = 60

w = 0.09 lb/s w = 0.009 lb/s w = 0.004 lb/s

p1 (psia)
p1 (psia)
p1 (psia)
35.5
15.7
38.9
17.1
42.0
18.6
15.3
47.7
21.7
16.2
57.2
30.2
17.7

8
Steady State Pressure in the Target Isolation Vacuum Chamber during
Catastrophic Discharge
Reference diameter: 4.0 inch: (This takes into account that the target relief line
and gas pre-cooling system runs inside the 6.0 diameter target isolation vacuum
chamber vent line.)
The total resistance coefficient from the insulating vacuum vessel to the outside
atmosphere is K = 11.67 + 1.24 = 12.91
The steady-state pressure in the target isolation vacuum chamber was calculated
with the following assumptions:

Mass flow rate: w = 0.5 lb/s

Flow temperature: T = 293 K, taken at the warmest point in the relief system. This
will overestimate the inlet pressure p1, but this will be an error on the side of safety.
Outlet pressure: p2 = 14.7 psia, venting to air at the normal atmospheric pressure.
Assume a total resistance coefficient: K = 15.0 from sections 3 and 5
Results:
Sonic flow rate wsonic = 3.28 lb/s
Vacuum vessel pressure p1 = 18.6 psia.
9. SUMMARY
The results show that, in the case of a catastrophic cryostat vacuum failure to air,
the LH2 target vessel is subjected during the discharge to a pressure of no more
than 21.7 (16.2) psia if the boil-off rate is assumed to be 0.009 (0.004) lb/s and the
fill/vent piping is a nominal 1.5-inch OD pipe. The maximum pressure during
discharge in the target isolation vacuum chamber for the case of a rupture of the
target flask is 18.6 psia for a 4.0-inch diameter nominal pipe if a boil off rate of
0.50 lb/s is assumed.
In summary, the results of the above calculations show that the proposed relief
piping is properly sized to prevent excessive pressures in the LH 2 target vessel
and isolation vacuum chamber after catastrophic failures. The calculated
discharge pressures are below the pressures at which the relief valves and rupture
disks open (p = 14.7 psia + 20 psid = 34.7 psia for the LH 2 target vessel and p =
14.7 psia + 7 psid = 21.7 psia for the isolation vacuum chamber). This means that,
once the relief devices open, the pressures in the LH 2 target vessel and in the
isolation vacuum chamber will not increase beyond the set points of the relief
devices of 34.7 psia and 21.7 psia, respectively.
References:
[1]
W.M. Schmitt and C.F. Williamson, Boil-off rates of cryogenic targets
subject to catastrophic vacuum failure, Bates Internal Report 90-02 (1990).
[2]
Flow of Fluids through Valves, Fittings, and Pipe, CRANE Technical Paper
No. 410 (1988).
[3]
S.M. Harrison, IEEE Trans. Appl. Superconduct. 12, 1343 (2002).[4]S.I.
Penttila and S. Covrig, Hydrogen release rate from the NPDGamma liquid
hydrogen target into the BL-13 shielding in a failure of target vacuum and
hydrogen boundaries, ORNL-SNS Document FUND13NPDG-24-ES0001-R00
Details (2008).