formulab 0.48.1 → 0.49.0

package/CHANGELOG.md

@@ -7,6 +7,36 @@ and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0
 
 ## [Unreleased]
 
+## [0.49.0] - 2026-09-24
+
+### Fixed
+
+- **`chemical/reliefValve()` mixed API 520's US-unit coefficient with SI inputs.** The gas branch
+  used C = 520 × … (lb/h, psia, in²) with kg/h and bar, which made every gas or steam area 7.6×
+  too large. The liquid branch did the same with the liquid constant and was about 141× too large.
+  For example, 5,000 kg/h of nitrogen at 10 barg now needs 536 mm² (orifice J), not 4,073 mm² (P).
+  Both branches now use the API 520 Part I SI equations and reproduce its Example 1 (gas,
+  3,699 mm²) and the first step of Example 5 (liquid, 3,066 mm² at Kw 0.97). The old golden test
+  compared only the ratio of the steam and gas areas, which no constant factor can change.
+- **`chemical/flowControl()` reported Kv as Cv.** The metric liquid equation Q × √(SG/ΔP) gives Kv,
+  but it was returned as `cv`, and `kv` was then 0.865 × Kv. Cv was therefore 13.5% too low: 100 gpm
+  across 25 psi now gives Cv 20, not 17.3. The gas branch used N8 = 94.8, the mass-flow constant,
+  with a volumetric flow and with M in the numerator. It now uses the volumetric N9 = 2460 for Kv,
+  with the flow in m³/h at 0 °C and 101.325 kPa. Gas Cv was about 22× too high.
+
+### Added
+
+- `ReliefValveInput.specificHeatRatio` (default 1.4 gas, 1.3 steam) and `compressibility`
+  (default 1.0), which the API 520 gas equation takes.
+
+## [0.48.2] - 2026-09-24
+
+### Fixed
+
+- **`battery/chargingProfile()` minutes and average C-rate came from the rounded hours.** For example,
+  5 Ah at 2.5 A to a 0.25 A cutoff gave `cvPhaseTimeMin` 43.8 (0.73 h × 60) instead of 43.6 and
+  `totalTimeMin` 139.8 instead of 139.6. Every output is now rounded once from the unrounded value.
+
 ## [0.48.1] - 2026-09-24
 
 ### Fixed

package/dist/battery/chargingProfile.d.ts.map

@@ -1 +1 @@
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package/dist/battery/chargingProfile.js

@@ -23,20 +23,25 @@ export function chargingProfile(input) {
     if (!(ccEndSocPercent > 0) || ccEndSocPercent >= 100) {
         throw new RangeError('ccEndSocPercent must be greater than 0 and less than 100');
     }
-    // CC phase delivers ccEndSocPercent of capacity
-    const ccPhaseAh = roundTo(capacityAh * (ccEndSocPercent / 100), 2);
-    const cvPhaseAh = roundTo(capacityAh - ccPhaseAh, 2);
+    // Every output is rounded once, from the unrounded value. Deriving minutes from the rounded
+    // hours (or the C-rate from the rounded total) would carry the hour rounding into them.
+    const ccAh = capacityAh * (ccEndSocPercent / 100);
+    const cvAh = capacityAh - ccAh;
     // CC phase time = Ah / current
-    const ccPhaseTimeH = roundTo(ccPhaseAh / chargingCurrentA, 2);
-    const ccPhaseTimeMin = roundTo(ccPhaseTimeH * 60, 1);
+    const ccH = ccAh / chargingCurrentA;
     // CV phase time approximation: average current = (Icc + Icut) / 2
-    const avgCvCurrent = (chargingCurrentA + cutoffCurrentA) / 2;
-    const cvPhaseTimeH = roundTo(cvPhaseAh / avgCvCurrent, 2);
-    const cvPhaseTimeMin = roundTo(cvPhaseTimeH * 60, 1);
-    const totalTimeH = roundTo(ccPhaseTimeH + cvPhaseTimeH, 2);
-    const totalTimeMin = roundTo(totalTimeH * 60, 1);
-    // Average C-rate over entire charge
-    const averageCRate = roundTo(capacityAh / (totalTimeH * capacityAh), 4);
+    const cvH = cvAh / ((chargingCurrentA + cutoffCurrentA) / 2);
+    const totalH = ccH + cvH;
+    const ccPhaseAh = roundTo(ccAh, 2);
+    const cvPhaseAh = roundTo(cvAh, 2);
+    const ccPhaseTimeH = roundTo(ccH, 2);
+    const ccPhaseTimeMin = roundTo(ccH * 60, 1);
+    const cvPhaseTimeH = roundTo(cvH, 2);
+    const cvPhaseTimeMin = roundTo(cvH * 60, 1);
+    const totalTimeH = roundTo(totalH, 2);
+    const totalTimeMin = roundTo(totalH * 60, 1);
+    // Average C-rate over the entire charge: one capacity delivered over the total time
+    const averageCRate = roundTo(1 / totalH, 4);
     return {
         ccPhaseTimeH,
         ccPhaseTimeMin,

package/dist/battery/chargingProfile.js.map

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package/dist/chemical/flowControl.d.ts

@@ -3,9 +3,13 @@ import type { FlowControlInput, FlowControlResult } from './types.js';
  * Control Valve Cv Calculator
  *
  * @formula
- *   - Liquid: Cv = Q × √(SG / ΔP)  (Q in GPM, ΔP in psi)
- *   - Gas: Cv = Q / (N × P1) × √(SG × T / ΔP)
- *   - Kv = 0.865 × Cv
+ *   - Liquid: Kv = Q × √(SG / ΔP)  (Q m³/h, ΔP bar) — the same as Cv = Q × √(SG / ΔP) in gpm and psi
+ *   - Gas/steam: Kv = Q / (N9 × P1 × Y) × √(M × T × Z / x), N9 = 2460 (Q m³/h at 0 °C and
+ *     101.325 kPa, P1 bar absolute, T K); x = ΔP / P1 limited to Fk × xT; Y = 1 − x / (3 Fk xT)
+ *   - Cv = Kv / 0.865 (1 Cv = 0.865 Kv)
+ *
+ * N9 follows from the mass-flow form W = N6 × Kv × Y × √(x × P1 × ρ1) with N6 = 31.6 and the
+ * ideal-gas densities at inlet and at 0 °C, 101.325 kPa.
  *
  * @reference ISA-75.01.01-2012 — Flow equations for sizing control valves
  * @reference IEC 60534-2-1 — Industrial-process control valves

package/dist/chemical/flowControl.d.ts.map

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package/dist/chemical/flowControl.js

@@ -3,9 +3,13 @@ import { roundTo } from '../utils.js';
  * Control Valve Cv Calculator
  *
  * @formula
- *   - Liquid: Cv = Q × √(SG / ΔP)  (Q in GPM, ΔP in psi)
- *   - Gas: Cv = Q / (N × P1) × √(SG × T / ΔP)
- *   - Kv = 0.865 × Cv
+ *   - Liquid: Kv = Q × √(SG / ΔP)  (Q m³/h, ΔP bar) — the same as Cv = Q × √(SG / ΔP) in gpm and psi
+ *   - Gas/steam: Kv = Q / (N9 × P1 × Y) × √(M × T × Z / x), N9 = 2460 (Q m³/h at 0 °C and
+ *     101.325 kPa, P1 bar absolute, T K); x = ΔP / P1 limited to Fk × xT; Y = 1 − x / (3 Fk xT)
+ *   - Cv = Kv / 0.865 (1 Cv = 0.865 Kv)
+ *
+ * N9 follows from the mass-flow form W = N6 × Kv × Y × √(x × P1 × ρ1) with N6 = 31.6 and the
+ * ideal-gas densities at inlet and at 0 °C, 101.325 kPa.
  *
  * @reference ISA-75.01.01-2012 — Flow equations for sizing control valves
  * @reference IEC 60534-2-1 — Industrial-process control valves
@@ -37,15 +41,9 @@ export function flowControl(input) {
     let cv;
     let isChoked = false;
     if (fluidType === 'liquid') {
-        // ISA liquid sizing: Cv = Q(m³/h) × √(SG / ΔP(bar))
-        // Convert kPa to bar: 1 bar = 100 kPa
+        // IEC 60534 liquid sizing in metric units gives Kv: Kv = Q(m³/h) × √(SG / ΔP(bar))
         const dpBar = pressureDrop / 100;
-        if (dpBar <= 0) {
-            cv = 0;
-        }
-        else {
-            cv = flowRate * Math.sqrt(sg / dpBar);
-        }
+        cv = dpBar <= 0 ? 0 : (flowRate * Math.sqrt(sg / dpBar)) / 0.865;
     }
     else {
         // Gas/Steam sizing
@@ -61,15 +59,13 @@ export function flowControl(input) {
         const p1Bar = inletPressure / 100;
         const T = temperature + 273.15;
         const MW = molecularWeight ?? 29; // default air
-        // N8 = 94.8 for metric (m³/h, bar, K)
-        const N8 = 94.8;
+        // N9 for Kv with Q in m³/h at 0 °C, 101.325 kPa, pressure in bar (IEC 60534-2-1)
+        const N9 = 2460;
         const Y = 1 - xEffective / (3 * xCritical); // Expansion factor
-        if (p1Bar <= 0 || xEffective <= 0) {
-            cv = 0;
-        }
-        else {
-            cv = flowRate / (N8 * p1Bar * Y) * Math.sqrt(MW * T / xEffective);
-        }
+        const Z = 1.0;
+        cv = p1Bar <= 0 || xEffective <= 0
+            ? 0
+            : (flowRate / (N9 * p1Bar * Y)) * Math.sqrt((MW * T * Z) / xEffective) / 0.865;
     }
     const kv = cv * 0.865;
     // Estimate pipe velocity (assuming DN50 pipe)

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package/dist/chemical/reliefValve.d.ts

@@ -1,14 +1,24 @@
 import type { ReliefValveInput, ReliefValveResult } from './types.js';
 /**
- * Relief Valve Sizing — API 520 Simplified
+ * Relief Valve Sizing — API 520 Part I, SI units
  *
  * @formula
- *   - Gas: A = W / (C × Kd × P1 × Kb × Kc) × √(T×Z / M)
- *   - Liquid: A = Q / (Kd × Kw × Kc) × √(SG / ΔP)
+ *   - Gas/vapour, critical flow: A = W / (C × Kd × P1 × Kb × Kc) × √(T × Z / M)
+ *     with C = 0.03948 × √(k × (2 / (k + 1))^((k + 1) / (k − 1)))
+ *     (A mm², W kg/h, P1 kPa absolute, T K, M kg/kmol)
+ *   - Liquid: A = 11.78 × Q / (Kd × Kw × Kc × Kv) × √(G / (P1 − P2))
+ *     (A mm², Q L/min, P1 − P2 kPa)
+ *   - Relieving pressure P1 = set pressure × (1 + overpressure) + atmospheric
  *   - Standard orifice selection per API 526
  *
- * @reference API 520 Part I (2020) — Sizing and Selection of Pressure-Relieving Devices
+ * Steam is sized with the gas equation at k = 1.3 unless `specificHeatRatio` is given; API 520's
+ * dedicated Napier steam equation is not implemented. Kb, Kw, Kc and Kv are taken as 1.0.
+ *
+ * @reference API 520 Part I — Sizing and Selection of Pressure-Relieving Devices (SI equations)
  * @reference API 526 (2017) — Flanged Steel Pressure-Relief Valves
+ * @validation API 520 Part I Example 1 (gas: 24,270 kg/h, 348 K, Z 0.90, M 51, k 1.11, P1 670 kPa a
+ *   → 3,699 mm²) and the first step of Example 5 (liquid: 6,814 L/min, G 0.9, Kw 0.97, ΔP 1,551.6 kPa
+ *   → 3,066 mm²), as reproduced by the `fluids` library
  *
  * When the required area exceeds the largest API 526 orifice ('T', 16,774 mm²), the result
  * still reports 'T' as the closest standard size but sets `orificeExceedsMax: true` — a single
@@ -17,6 +27,9 @@ import type { ReliefValveInput, ReliefValveResult } from './types.js';
  * `suggestedMinValves` gives the first-order parallel count (`ceil(requiredArea / T)`); an
  * actual multi-valve installation must be re-sized per API 520, since inlet and back-pressure
  * corrections change each valve's capacity.
+ *
+ * @throws {RangeError} molecularWeight, specificGravity, specificHeatRatio (must exceed 1) or
+ *   compressibility is not positive
  */
 export declare function reliefValve(input: ReliefValveInput): ReliefValveResult;
 //# sourceMappingURL=reliefValve.d.ts.map

package/dist/chemical/reliefValve.d.ts.map

@@ -1 +1 @@
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+{"version":3,"file":"reliefValve.d.ts","sourceRoot":"","sources":["../../src/chemical/reliefValve.ts"],"names":[],"mappings":"AACA,OAAO,KAAK,EAAE,gBAAgB,EAAE,iBAAiB,EAAE,MAAM,YAAY,CAAC;AAoBtE;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;GA+BG;AACH,wBAAgB,WAAW,CAAC,KAAK,EAAE,gBAAgB,GAAG,iBAAiB,CA2FtE"}

package/dist/chemical/reliefValve.js

@@ -17,15 +17,25 @@ const API_ORIFICES = [
     { letter: 'T', area: 16774 },
 ];
 /**
- * Relief Valve Sizing — API 520 Simplified
+ * Relief Valve Sizing — API 520 Part I, SI units
  *
  * @formula
- *   - Gas: A = W / (C × Kd × P1 × Kb × Kc) × √(T×Z / M)
- *   - Liquid: A = Q / (Kd × Kw × Kc) × √(SG / ΔP)
+ *   - Gas/vapour, critical flow: A = W / (C × Kd × P1 × Kb × Kc) × √(T × Z / M)
+ *     with C = 0.03948 × √(k × (2 / (k + 1))^((k + 1) / (k − 1)))
+ *     (A mm², W kg/h, P1 kPa absolute, T K, M kg/kmol)
+ *   - Liquid: A = 11.78 × Q / (Kd × Kw × Kc × Kv) × √(G / (P1 − P2))
+ *     (A mm², Q L/min, P1 − P2 kPa)
+ *   - Relieving pressure P1 = set pressure × (1 + overpressure) + atmospheric
  *   - Standard orifice selection per API 526
  *
- * @reference API 520 Part I (2020) — Sizing and Selection of Pressure-Relieving Devices
+ * Steam is sized with the gas equation at k = 1.3 unless `specificHeatRatio` is given; API 520's
+ * dedicated Napier steam equation is not implemented. Kb, Kw, Kc and Kv are taken as 1.0.
+ *
+ * @reference API 520 Part I — Sizing and Selection of Pressure-Relieving Devices (SI equations)
  * @reference API 526 (2017) — Flanged Steel Pressure-Relief Valves
+ * @validation API 520 Part I Example 1 (gas: 24,270 kg/h, 348 K, Z 0.90, M 51, k 1.11, P1 670 kPa a
+ *   → 3,699 mm²) and the first step of Example 5 (liquid: 6,814 L/min, G 0.9, Kw 0.97, ΔP 1,551.6 kPa
+ *   → 3,066 mm²), as reproduced by the `fluids` library
  *
  * When the required area exceeds the largest API 526 orifice ('T', 16,774 mm²), the result
  * still reports 'T' as the closest standard size but sets `orificeExceedsMax: true` — a single
@@ -34,9 +44,12 @@ const API_ORIFICES = [
  * `suggestedMinValves` gives the first-order parallel count (`ceil(requiredArea / T)`); an
  * actual multi-valve installation must be re-sized per API 520, since inlet and back-pressure
  * corrections change each valve's capacity.
+ *
+ * @throws {RangeError} molecularWeight, specificGravity, specificHeatRatio (must exceed 1) or
+ *   compressibility is not positive
  */
 export function reliefValve(input) {
-    const { requiredCapacity, setPressure, backPressure, temperature, fluidType, molecularWeight = 29, specificGravity = 1.0, overpressure = 10, dischargeCoefficient, } = input;
+    const { requiredCapacity, setPressure, backPressure, temperature, fluidType, molecularWeight = 29, specificGravity = 1.0, overpressure = 10, dischargeCoefficient, specificHeatRatio = fluidType === 'steam' ? 1.3 : 1.4, compressibility = 1.0, } = input;
     // The gas/steam sizing equation divides by sqrt(M) after taking its square root, so a
     // non-positive molecular weight gives an infinite or imaginary orifice area.
     if (!(molecularWeight > 0)) {
@@ -45,6 +58,12 @@ export function reliefValve(input) {
     if (!(specificGravity > 0)) {
         throw new RangeError('specificGravity must be greater than 0');
     }
+    if (!(specificHeatRatio > 1)) {
+        throw new RangeError('specificHeatRatio must be greater than 1');
+    }
+    if (!(compressibility > 0)) {
+        throw new RangeError('compressibility must be greater than 0');
+    }
     // Atmospheric pressure
     const patm = 101.325; // kPa
     const P1 = setPressure + patm + (setPressure * overpressure / 100); // kPa absolute (relieving)
@@ -52,42 +71,28 @@ export function reliefValve(input) {
     let requiredArea; // mm²
     if (fluidType === 'gas' || fluidType === 'steam') {
         const Kd = dischargeCoefficient ?? 0.975;
-        const Kb = 1.0; // Back pressure correction (conventional, balanced assumed)
-        const Kc = 1.0; // Combination correction
+        const Kb = 1.0; // Back pressure correction (conventional valve below critical back pressure)
+        const Kc = 1.0; // Combination correction (no rupture disk)
         const T = temperature + 273.15;
-        const Z = 1.0; // Compressibility factor
-        const M = molecularWeight;
-        // C = coefficient depending on ratio of specific heats (k), API 520 Part I eq. for critical
-        // (choked) flow. C(k=1.4) = 356.06, matching the value commonly published for diatomic gases
-        // (air, nitrogen) in API 520 Part I Table 8 / secondary process-safety references — see the
-        // golden test in reliefValve.test.ts, which checks the k=1.4-vs-1.3 area ratio this constant
-        // implies against an independently computed C(1.4)/C(1.3).
-        const k = fluidType === 'steam' ? 1.3 : 1.4;
-        const C = 520 * Math.sqrt(k * Math.pow(2 / (k + 1), (k + 1) / (k - 1)));
-        // W in kg/h, P1 in kPa, T in K, M in g/mol
-        // A (mm²) = W × √(T×Z/M) / (C × Kd × P1 × Kb × Kc) × 1e6 (unit conversion)
-        const numerator = requiredCapacity * Math.sqrt(T * Z / M);
-        const denominator = C * Kd * (P1 / 100) * Kb * Kc; // P1 in bar for formula
-        requiredArea = (numerator / denominator) * 1e3; // convert to mm²
+        const k = specificHeatRatio;
+        // API 520 SI coefficient: C(1.4) = 0.02703, C(1.35) = 0.02669
+        const C = 0.03948 * Math.sqrt(k * Math.pow(2 / (k + 1), (k + 1) / (k - 1)));
+        requiredArea = (requiredCapacity / (C * Kd * P1 * Kb * Kc)) * Math.sqrt((T * compressibility) / molecularWeight);
     }
     else {
         // Liquid
         const Kd = dischargeCoefficient ?? 0.65;
-        const Kw = 1.0; // Back pressure correction
+        const Kw = 1.0; // Back pressure correction (conventional valve)
         const Kc = 1.0;
         const Kv = 1.0; // Viscosity correction
         const dp = P1 - (backPressure + patm); // kPa
-        const SG = specificGravity;
+        const G = specificGravity;
         if (dp <= 0) {
             requiredArea = 0;
         }
         else {
-            // Q = W / (ρ × 3600) → m³/s, convert to m³/h
-            // A (mm²) = Q_m³h / (Kd × Kw × Kc × Kv) × √(SG/dp_bar) × conversion
-            const rho = SG * 999; // kg/m³
-            const Qm3h = requiredCapacity / rho;
-            const dpBar = dp / 100;
-            requiredArea = (Qm3h / (Kd * Kw * Kc * Kv)) * Math.sqrt(SG / dpBar) * 1e4 / 3.6;
+            const QLpm = (requiredCapacity / (G * 999)) * 1000 / 60; // kg/h → L/min
+            requiredArea = ((11.78 * QLpm) / (Kd * Kw * Kc * Kv)) * Math.sqrt(G / dp);
         }
     }
     // Select the smallest standard orifice that covers the required area. API 526 tops out at

package/dist/chemical/reliefValve.js.map

@@ -1 +1 @@
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package/dist/chemical/types.d.ts

@@ -216,6 +216,7 @@ export interface InjectionCycleResult {
  * Control Valve Cv Calculator Types
  */
 export interface FlowControlInput {
+    /** m³/h — actual volume for liquids; for gas and steam, volume at 0 °C and 101.325 kPa (Nm³/h). */
     flowRate: number;
     inletPressure: number;
     outletPressure: number;
@@ -246,6 +247,10 @@ export interface ReliefValveInput {
     specificGravity?: number;
     overpressure?: number;
     dischargeCoefficient?: number;
+    /** Ratio of specific heats k for gas/steam (default 1.4 gas, 1.3 steam). */
+    specificHeatRatio?: number;
+    /** Compressibility factor Z for gas/steam (default 1.0). */
+    compressibility?: number;
 }
 export interface ReliefValveResult {
     requiredArea: number;

package/dist/chemical/types.d.ts.map

@@ -1 +1 @@
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package/package.json

@@ -1,6 +1,6 @@
 {
   "name": "formulab",
-  "version": "0.48.1",
+  "version": "0.49.0",
   "description": "Manufacturing & Engineering calculation formulas library - 203 industrial calculations across 15 domains for OEE, Cpk, SPC, FMEA, Nelson Rules, metal weight, CNC machining, GD&T, battery, environmental, pipe flow, logistics, IE time study, and more",
   "type": "module",
   "main": "./dist/index.js",