DCMH.

CH4051_Process Safety
Introduction to Relief System

Prepared by:

Dr. Mardhati Zainal Abidin

Universiti Teknologi PETRONAS

AP Ir. Dr. Risza Rusli

University of Doha for Science & Technology

For:
Ho Chi Minh City University of Technology

1
 Objectives

At the end of this chapter, students should be able to

• Identify of causes of overpressure

• Understand the concept of reliefs

2
 Introduction

How Can High Pressure Develop?

Some possible causes of the high pressure:

 Over-pressurization from an upstream (or downstream high pressure
source) - compressed gas, high pressure liquid, “dead ended”
positive displacement pump,etc
 Operator error ; External fire
 Overfilling and hydraulic compression
 Thermal expansion of fluid/gas in a “blocked in”system
 Runaway exothermic chemical reaction and self heating
• Generation of non-condensable gas, e.g. nitrogen or carbon dioxide
• Increased vapor pressure of contents with temperature

3
 Introduction
Relief System Protection

 Should pressure rise to an unsafe level: potential for mechanical failure

(rupture) of equipment. Rather than allowing this to happen the pressure is
released.

 Relieved fluids may be harmless & released (e.g. water or steam) or

taken to downstream processing equipment, i.e. a scrubber/absorber or
a flare

 Part of Engineering Design and layered safety approach

 Last layer of preventive protection. Prevent a more costly upset incident

and potentially compromise safety, environment, equipment,
production …

 System designed to release material into a plant- wide containment and

4
disposal process
 Relief System Protection

Relief System Discharge Some examples of relief devices

are:
Open Discharge
- Relieves to atmosphere • Pressure/vacuum valves
- Non-combustibles and non- (a.k.a. conservation vents)
toxic • Pressure relief valves
• Rupture disks
Closed Discharge • Emergency vents
- Relieves to flare or process
- Process fluids

5
 Open Discharge
Open discharge refers to a relief path directly to the atmosphere via an open
vent or drain line. This type of discharge is recommended only for non-
flammable and non-toxic services. Typically, open discharge is employed to
relieve the following fluids:
• Air
• Steam
• Water Example of Open
• Nitrogen Discharge of Vapor
(Air):

Example of Open
Discharge of Liquid
(Cooling Water):

6
 Close Discharge

 Closed Discharge refers to a relief path

into a flare header system, an operating
process system, a closed drain system,
or any other system that is not open to
the atmosphere. This type of discharge
is recommended for the relief of
hazardous fluids.

 Hazards that would make closed

discharge the most appropriate relief
method include, but are not limited to,
the following:
 Flammability
 Toxicity
 Reactivity
 Special Hazards (i.e. corrosive,
oxidizer, carcinogen, etc.) 7
Pressure/Vacuum Valves (a.k.a. Conservation Vents)

Pressure/vacuum
valves, also known as
conservation vents, are
reclosing devices for
the protection of low-
pressure tanks
(constructed for
internal pressures less
than 15 psig) against
overpressure and
undervacuum,
including that which
occurs normally as a
result of liquid
movement into or out of
8
such tanks.
 Pressure Relief Valves

Pressure relief valves are reclosing devices for the

protection of pressure vessels, boilers, and related
systems (constructed for internal pressures of 15 psig
or greater) against overpressure.

9
 Rupture Disk

Rupture disks are non-reclosing devices for

the protection of pressure vessels and related
systems (constructed for internal pressures of
15 psig or greater) against overpressure.

10
 Emergency Vents

Emergency Vents are devices for the protection of low-pressure tanks

(constructed for internal pressures less than 15 psig) against infrequent
overpressure emergencies.

Taken from: https://cmspumps.com/protego-emergency-vents/

Definitions Used to Describe Reliefs System

Set Pressure:
Pressure at which the relief device begins to open/activate.
Maximum Allowable Working Pressure (MAWP):
The maximum gauge pressure permissible at the top of a vessel for a
designated temperature

As T increases, MAWP ? Decreases since the material

loses its strength

As T idecreases, MAWP ? Decreases due to low T

embrittlement of metals

Vessel fails at 4 or 5 times the MAWP.

 Set Pressure versus MAWP

13
Extract from: https://amarineblog.com/2019/12/18/pressure-level-relationships-
chart/
Definitions Used to Describe Reliefs System

Overpressure: Pressure increase over set pressure during relieving.

Expressed as % of set pressure. Must be specified prior to relief design.
Typically 10%

14
Definitions Used to Describe Reliefs System

Accumulation: The pressure increase over the MAWP of the vessel during
the relief process. Expressed as % of MAWP.
Overpressure & Accumulation

16
 Definitions Used to Describe Reliefs
Backpressure: The pressure at the outlet of the relief device during the relief
process resulting from pressure in the discharge system.
Must be considered in any relief system design since it will affect the operation.
Two types of backpressure: 1. Superimposed 2. Built-up

17
 Superimposed Backpressure
Superimposed backpressure is the static
pressure that exists at the outlet of a
pressure relief device (PRD) at the time the
device is required to operate ('Ready-to-
operate' mode). Superimposed
backpressure is the result of pressure in the
discharge system coming from other sources
i.e., Pressure control valve (PCV), pressure
relief valve (PRV), etc.

18
 Built-up Backpressure
Built-up backpressure is the increase in pressure at the outlet of a pressure
relief device that develops as a result of flow after the pressure relief device
(PRD) opens ('relieving' mode).

Based on the above figure, the spring PSV shall be capable for handling
pressure not more than 7.5 psig, so that PSV will start to open at 10 psig.
19
Extracted from: http://process-eng.blogspot.com/2011/02/built-up-
and-superimposed-back-pressure_2304.html
 Blowdown
Reseat or close pressure
Pop or opening pressure

Blowdown = Difference
between pop and reseat
pressure

• Normal PRV has definite

pop and reseat
pressures

• These two pressures can

be noted on a gauge as
shown.

20
Requirements for Standard Pressure Vessels and
the Relief Valves Protecting the Vessel

The ASMEBoiler and Pressure

Vessel Code Section VIII sets
out requirements for standard
pressure vessels (left) and the
relief valves protecting them
(right) as a percentage of the
maximum allowable working
pressure (MAWP).
 Applicable Codes, Standards and References
International Code requirements include:

• ASME Boiler & Pressure Vessel Codes

• ASME B31.3 / Petroleum Refinery Piping
• ASME B16.5 / Flanges & Flanged Fittings
• API
 RP 520 Part I & II (Recommended practices for the design & installation of
PRV’s)
 RP 521 (Guide for pressure relief & depressuring systems)
 STD 526 (Flanged steel safety relief valves for petroleum refineries)
 STD 527 (Commercial seat tightness of safety relief valves w/ metal-to-
metal seats)
 STD 527
 STD 2000 (Venting atmospheric & low pressure storage tanks)
 STD 620 (Design and construction of large, welded, low pressure storage
tanks)
 STD 650 (Welded Steel Tanks for Oil Storage; i.e., “Atmospheric Tanks”)
 Code Requirements for Relieving Pressure

Relieving pressure shall not

exceed MAWP (accumulation)
by more than:

• 3% for fired and unfired

steam boilers
• 10% for vessels
equipped with a
single pressure
relief device
• 16% for vessels
equipped with
multiple pressure
relief devices
• 21% for fire contingency

23
 Relief Devices – Preliminary Tasks

Basic Questions to be asked?

 Are relief devices needed?

 Where should relief units be installed?

 What type of relief device to use?

 Then strategize to develop credible relief scenarios

• Obtain data for sizing relief devices
• Perform relief sizing calculations
• Collection and treatment of exiting materials
• Installation of relief system
• Testing and maintenance of relief devices

24
Safe Installation of Pressure Relief Devices
First step - Specify where relief devices must be
installed.
Second - appropriate relief device type must be
selected (depends on the nature of material relieved &
relief characteristics required.
Third - Develop scenarios that describe ways in which
a relief can occur. It is to determine mass flow rate
through the relief and physical state of material
relieved.
Fourth - Data are collected on the relief
process, including physical properties
of the ejected material, and the relief is
sized.

Fifth - Finally, the worst-case scenario is

selected and the final relief design is achieved.
Typical Relief Architecture - Process and Relief
System Design

Standard
Process Vessel relief valve

Vent Balanced
Relief System bellows

Knockout Drum Rupture disc

Scrubber Condenser

Incinerator
Flare
 Where should relief units be installed?
Locating Reliefs

• All process and storage vessels.

• Pumps (positive displacement), compressors, turbines.
Many have internal reliefs.
• Blocked, liquid-filled lines.

• Jackets on vessels.

Valves
closed
27
Location of Reliefs – General Guidelines

28
 Location of Reliefs – General Guidelines
Types of questions asked as the basis are
• What happens with loss of cooling, heating, or agitation?
• What happens if the process is contaminated or has a mischarge of a
catalyst or monomer?
• What happens if the operator makes an error?
• What is the consequence of closing valves (block valves) on vessels or in
lines that are filled with liquids and exposed to heat or refrigeration?
• What happens if a line fails, for example, a failure of a high-pressure gas line
into a low-pressure vessel?
• What happens if the unit operation is engulfed in a fire?
• What conditions cause runaway reactions, and how are relief systems
designed to handle the discharge as a result of runaway reactions?

29
 Polymerization Reactor, Example 1
Specify the location of reliefs in the simple polymerization reactor system which
include (1) pumping 100 lb of initiator into reactor R-1, (2) heating to the reaction
temperature of 240°F, (3) adding monomer for a period of 3 hr, and (4) stripping the
residual monomer by means of a vacuum
using valve V-15. Because the reaction is
exothermic, cooling during monomer
addition with cooling water
is necessary.

30
 Polymerization Reactor – Rational for Relief
Installation
a. Reactor (R-1): A relief is installed on this reactor because, in general, every process
vessel needs a relief - labeled as PSV-1 for pressure safety valve 1.
b. Positive displacement pump (P-1): Positive displacement pumps are overloaded,
overheated, and damaged if they are dead-headed without a pressure-relieving
device (PSV-2).
c. Heat exchanger (E-1): Heat exchanger tubes can rupture from excessive pressures
when water is blocked in (V-10 and V-11 are closed) and the exchanger is heated (by
steam, for example). This hazard is eliminated by adding PSV-3.
d. Drum (D-1): Again, all process vessels need relief valves, PSV-4.
e. Reactor coil: This reactor coil can be pressure-ruptured when water is blocked in
(V-4, V-5, V-6, and V-7 are closed) and the coil is heated with steam or even the sun.
Add PSV-5 to this coil.
Polymerization Reactor, Example 1
 Choosing Relief Types

 Select type and size

 Materials: gases, liquids, gases &
liquids, solids
 Properties, e.g., corrosive, flammable,
toxic, inert
 Process conditions
 Vent: atmosphere, treatment
systems (scrubber, flare, condenser,
incinerator)
 Two general relief device categories:
spring operated
rupture discs
 Two major types of spring-operated
valves:
conventional
balanced bellows
 Spring Relief Valve Types

1 - “Relief” valve for liquids

a) Begins to open at set pressure
b) Fully open at 25% overpressure

2 - “Safety” valve for gases

a) Pops open above set pressure
b) Flow keeps valve open
c) Reseats at ~ 4 % below set pressure (blowdown)

3 - “Safety relief” valve for liquids & gases

a) Functions as a relief valve for liquids
b) Functions as a safety valve for gases
Conventional Relief Valve

Conventional Relief
Valve
 Conventional Relief Valve

Conventional Type • Operation: pressure drop

across valve seat

• Flow rate increases with

increase in pressure drop

• Set pressure: spring tension

adjusted for ~10 % above
normal operating pressure
• Set pressure and flow rate
through valve are dependent on
downstream pressure or
backpressure
 Pros & Cons:
Conventional Valve

 Advantages
• Most reliable type if properly sized and operated
• Versatile -- can be used in many services

 Disadvantages
• Relieving pressure affected by back pressure
• Susceptible to chatter if built-up back pressure is too high
 Bellows Relief Valve

Bellows
Relief Valve
 Bellows Relief Valve

Balanced Bellows Type

• Spring and back of valve seat
are separated from fluid by a
bellows
• Back of valve is open to
atmosphere
• Valve opens near the set
pressure regardless of the
backpressure level
• Flow rate through valve is
dependent on the
backpressure level
 Pros & Cons:
Balanced Bellows Valve

 Advantages
+ Relieving pressure not affected by back pressure
+ Can handle higher built-up back pressure
+ Protects spring from corrosion

 Disadvantages
• Bellows susceptible to fatigue/rupture
• May release flammables/toxics to atmosphere
• Requires separate venting system
 Rupture Devices

Rupture Disc & Rupture Pin

* Consist of a calibrated
sheet of metal or
buckling pin designed to
rupture at a well-
specified pressure
* Remains open after
rupture
* Subject to pressure
cycling fatigue
 Rupture Discs

• A rupture disc is a thin diaphragm (generally a solid metal disc) designed

to rupture (or burst) at a designated pressure. It is used as a weak element
to protect vessels and piping against excessive pressure (positive or
negative).
• They are often used as the primary pressure relief device.
• Used in very rapid pressure rise situations like runaway reactions.
• They can also be used in conjunction with a pressure relief valve (installed
in series to a spring-loaded PRV) to:
o Provide corrosion protection for the PRV.
o Prevent loss of toxic or expensive process materials.
o Reduce fugitive emissions to meet environmental requirements.
 Rupture Discs

Alligatoring is caused by operating too close to the

set pressure.
Conventional Metal Rupture Disc
Conventional Rupture Pin Device

• A rupture pin is designed to be a non-reclosing

pressure relief device, similar to a rupture disc
• A piston is held in the closed position with a
buckling pin which will fail at a set pressure.
Comparison of Rupture Pins To Rupture Discs

Advantages
+ Not subject to premature failure due to fatigue
+ Can be operated closer to its set point
+ Setpoint is insensitive to operating temperature
+ Available as balanced or unbalanced device
+ Capable of operating as low as 0.1 psig (0.007 barg)
+ Suitable for liquid service
+ Resetting after release usually requires no breaking of
flanges
+ Replacement pins are 1/3 to 1/4 the cost of replacement discs
Comparison of Rupture Pins To Rupture Discs

Disadvantages
• The elastomer o-ring seal limits the maximum operating temperature
to about 450oF (230oC)
• Initial cost of installation is greater than for a rupture disc twice as
costly for 2” carbon steel up to seven times as costly for 8” stainless
steel
Piston Type Pilot Operated Safety Relief Valve

• The main valve of a pilot-

operated relief valve is
controlled by a smaller pilot
valve that is a spring operated
relief valve.
• When the pilot valve reaches
the set pressure, it opens and
releases the pressure above
the main valve.
• The large valve piston then
opens and exhausts the
system fluid.
• The pilot and main valves
reseat when the inlet pressure
drops below the set pressure.
Piston Type Pilot Operated Safety Relief Valve

Piston Type Pilot

Operated PRV
Advantages / Disadvantages Pilot Operated Valve

Advantages
+ Relieving pressure not affected by backpressure
+ Can operate at up to 98% of set pressure
+ Less susceptible to chatter (some models)

Disadvantages
– Pilot is susceptible to plugging
– Limited chemical and high temperature use by “O-ring”
seals
– Vapor condensation and liquid accumulation above the piston may
cause problems
– Potential for back flow
 When to Use a Spring-Operated Valve

 Losing entire contents is unacceptable

o Fluids above normal boiling point
o Toxic fluids

 Need to avoid failing low

 Return to normal operations quickly

 Withstand process pressure changes, including vacuum

 Where back-pressure does not exceed 10% of the set pressure

 When to Use a Rupture Disc/Pin

 Capital and maintenance savings

 Losing the contents is not an issue

 Benign service (nontoxic, non-hazardous)

 Need for fast-acting device

 Potential for relief valve plugging

 High viscosity liquids

 When to Use Both Spring-Operated Valve &
Rupture Disc/Pin

 Need a positive seal (toxic material, material balance requirements)

 Protect safety valve from corrosion

 System contains solids

When to Use a Pilot-Operated Relief Valves

 The set pressure is required to be close to the operating pressure.

 Calibration is required without removing the valve.

 Handling of large relief flows are required.

 The service is non-fouling.

 Where the back-pressure on the valves are very high (typically 50% or
higher).
 Relief Event Scenarios

 A description of one specific relief event

 Usually each relief has more than one relief event, more than one scenario

 Examples include:

 Overfilling/overpressuring

 Fire

 Runaway reaction

 Blocked lines with subsequent expansion

 Developed through Process Hazard Analysis (PHA)

Recall: Polymerization Reactor, Example 1

Source: Crowl, D.A. and J.F. Louvar, 2002

 Relief Scenario for Example 1

Relief
Scenario
Identification

Vessel full of liquid and P-1 inadvertently actuated

Cooling coil is broken and water enters reactor at 200 gpm and
PSV-1a & 50 psig
PSV-1b
N2 regulator fails with critical flow in 1” line into reactor
Runaway reaction (loss of cooling)
V1 is inadvertently closed; relief required for pump at 100 gpm
PSV-2
at 50 psig
PSV-3 Confined water line is heated with 125 psig steam

N2 regulator fails, resulting in critical flow in 1/2” line

PSV-4
The other R-1 scenario will be relieved via PSV-1
Water blocked inside coil, and heat of reaction causes thermal
PSV-5
expansion
Relief Installation Guidelines

Two rupture discs with pressure

gauge between the two discs to
detect for leakage; toxic
materials

Rupture disc to protect more

expensive relief valve with a
pressure gauge to detect leaks

Two rupture discs connected

with 3-way valve to allow
maintenance on one disc
 Relief Installation Guidelines

Crowl, D.A. and J.F. Louvar, 2012, Figure 9-10

 Data for Relief Sizing

These data are required for making relief sizing calculations.

 Physical property data
 Chemical reaction rate behavior
 Single phase releases: vapor, liquid, solid
 Multiple phase releases
 Runaway reaction relief: commonly liquid & vapor
 Gas or dust explosions from combustion apparatus
 Such data are part of the process safety information needed for a
PHA
Take note that data estimated using engineering assumptions are not
acceptable because an error may result in catastrophic and
hazardous failures.
 Reaction Behavior Measurement

 For accurate relief vent area estimations, experimental data are most
important, especially for 2-phase releases.

 Calorimeters are used to characterize behavior during normal

reaction or runaway reaction.

 Sample is progressively heated in a calorimeter to search for

exothermic events.
 Test data include temperature, pressure, time, reaction onset
temperature, maximum heat rate, maximum pressure rate, and
amount of non- condensable gas formed.
Calorimeter for Characterizing Runaway Reaction

Crowl, D.A. and J.F. Louvar, Chemical Process Safety, 2nd ed, Prentice Hall, 2002
Runaway Reaction Behaviour
 Issue with reliefs: Chatter

• If a relief system is not designed correctly, the valve may chatter

violently.

• Chattering is the rapid, alternating opening and closing of a Pressure

Relief Valve.

• Resulting vibration may cause misalignment, valve seat damage and, if

prolonged, can cause mechanical failure of valve internals and associated
piping.

• The major cause of valve chatter is an oversized relief valve. In this

case the valve opens a short time to reduce the pressure and the
pressure then rises rapidly to open the valve again.

• Other principal causes: Excessive inlet pressure drop / Excessive built-

up back pressure / Valve handling widely differing rates
Issue with reliefs: Chatter
 Chatter – Probable Solution

Probable design solutions to overcome chattering; for example,

1. excessive inlet pressure drops can be prevented with larger inlet pipe
sizes and fewer elbows and constrictions;
2. high backpressures can be prevented by increasing the size of the exit
lines and eliminating elbows and constrictions; and
3. oversized valves can be prevented by adding different-size valves to
cover the range of release scenarios.
Simultaneously, the following considerations is essential for effectiveness
of overall relief systems: Properly install relief devices / Regularly inspect
relief devices, or Perform needed/required maintenance on relief devices
End of Session
Thank you