Chemical Process Safety

Chapter 9: Relief Systems

 Introduction
What: A relief system protects the process from the
damaging effects of high pressure.

How: A relief system removes energy from a

process by discharging mass with an energy
content.
Mass with energy
How Can High Pressures Develop?

High pressures can result from:

1.Overheating
2.Over pumping
3.Reaction runaway
4.Liquid thermal expansion
5.Failure of regulator
6.External fire
7.Combustion of gases / dusts
8.Freezing
9.Loss of mixing
10.Many others!
 Relief Design Procedure
Locate Reliefs

Choose Relief
Types
Choose Worst
Define Case
Scenarios
Design Relief
Acquire Data: System
*Physical Props.
*Self Heat Rate
*Others

Figure 8-1

Single Phase Two Phase

 Potential Lines of Defense
 Inherently Safe Design
- Low pressure processes

 Passive Control
- Overdesign of process equipment

 Active Control
- Install Relief Systems
 Definitions - 1
Relief system: The network components around a relief device,
including the pipe to the relief, the relief device, discharge
pipelines, knockout drum, scrubber, flare, or other types of
equipment that assist in the safe relief process.
 Definitions - 2
*Set Pressure The pressure measured at the valve inlet at which a safety relief
valve should begin to lift under service conditions
*Overpressure The pressure increase above set pressure at the valve inlet at
which the discharge capacity is attained. Usually expressed as a percentage of
set pressure.
*Accumulation The pressure increase over a maximum safe working pressure
of the vessel or system when the safety relief valve is discharging at its rated
capacity is called accumulation. The term refers to the vessel or system to be
protected and not to the valve. Accumulation is the same as over-pressure
when the valve is set at the design pressure of the vessel.
*Re-Seat Pressure The pressure measured at the valve inlet at which the safety
relief valve closes
*Blow-Down The difference between the set pressure and the re-seating
pressure expressed as a percentage of the set pressure or as a pressure
difference.
*Simmer The pressure zone between the valve set pressure and the popping
pressure. In this pressure zone the valve is only slightly open and therefore
discharging a small percentage of its rated capacity
 Definitions - 3
Set Pressure: Pressure at which the relief device
begins to open.
Maximum Allowable Working Pressure (MAWP):
Maximum design pressure at the top of a vessel for
a designated temperature.
As T increases, MAWP decreases since the material
loses its strength
As T decreases, the MAWP decreases due to low
temperature embrittlement of metals
Vessel fails at 4 to 5 times the MAWP time MAWP.
 Definitions - 4
Overpressure: Pressure increase over set pressure
during relieving. Expressed as % of set pressure.
Must be specified prior to relief design. Typically
10%

Pressure

Set Pressure

Relief begins to open

Time -->
This is a plot of the pressure in a process as a function of time. The pressure continues to
increase after the relief device opens. The arrow points to the overpressure. The
overpressure is expressed as a percentage of the set pressure.
 Definitions - 5
Accumulation: The pressure increase over the
MAWP of the vessel during the relief process.
Expressed as % of MAWP.
Pressure

MAWP
Set Pressure

Relief begins to open

Time -->

The arrow points to the accumulation. The accumulation

is expressed as a percent of the MAWP.
 Definitions - 6
Backpressure: The pressure downstream of the relief
device during the relieving process.
Must be considered in any relief system design.
Two types of backpressure:
1. Superimposed
2. Built-up
Backpressure - Superimposed

• Pressure in
discharge header
before valve
opens

• Can be constant or
variable
 Backpressure – Built-up

• Pressure in discharge
header due to
frictional losses after
valve opens

•Total Backpressure = Superimposed + Built-up

Reseat or close pressure
Pop or opening pressure
• Normal PRV has
definite pop and
reseat pressures
• These two
pressures can be
noted on a gauge
as shown.
Popping Pressure The pressure at which the
valve disc rapidly moves from a slightly open
(simmer) position to a practically full open
position.

Blowdown = Difference between pop

and reseat pressure
 Relief devices
Type 1: Spring-loaded Reliefs
Fig. 8-7 Setpressure 
( PPROCESS  PDOWNSTREAM )
 Flow  ( PPROCESS  PDOWNSTREAM )
Setpressure and flow affected
by backpressure:
Setpressure increases
Flow decreases

1. CONVENTIONAL
As back pressure
SPRING
increase
Spring-loaded Reliefs
Spring-loaded Reliefs
Spring-Loaded Relief
Installed on Vessel
Spring-Loaded Relief
Installed in Plant
 Advantages / Disadvantages
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
 Spring-loaded Reliefs

Setpressure  ( PPROCESS  PAMBIENT )

Flow  ( PPROCESS  PDOWNSTREAM )
Setpressure not affected
by backpressure.
Flow decreases with backpressure.

2. BALANCED BELLOWS
 BALANCED BELLOWS

Usually, balanced bellows valves are

recommended if the backpressure is
more than 15% of the set pressure.
Advantages / Disadvantages
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
– Flow thru valve is affected by back pressure
Bellows PRV
There are three subcategory types of spring-loaded pressure reliefs

1. The relief valve is primarily for liquid service. The relief valve
(liquid only) begins to open at the set pressure. This valve reaches
full capacity when the pressure reaches 25% overpressure. The
valve closes as the pressure returns to the set pressure.
2. The safety valve is for gas service. Safety valves pop open when
the pressure exceeds the set pressure. This is accomplished by using
a discharge nozzle that directs high-velocity material toward the
valve seat. After blowdown of the excess pressure, the valve reseats
at approximately 4% below the set pressure
3. The safety relief valve is used for liquid and gas service. Safety
relief valves function as relief valves for liquids and as safety valves
for gases.
 Chatter

• Chattering is the rapid, alternating

opening and closing of a PR Valve.
• Resulting vibration may cause
misalignment, valve seat damage
and, if prolonged, can cause
mechanical failure of valve internals
and associated piping.
• Chatter may occur in either liquid or
vapor services
 Chatter - Principal Causes
• Excessive inlet pressure drop
• Excessive built-up back pressure
• Oversized valve
 Chatter Mechanism
Excessive Inlet Pressure Drop
Undersized
inlet piping
Consider the pressure drop
from all these connections
 Relief devices

Type 2: 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).

• There are five major types available

– Conventional tension-loaded rupture disc
– Pre-scored tension-loaded rupture disc
– Composite rupture disc
– Reverse buckling rupture disc with knife blades
– Pre-scored reverse buckling rupture disc
 Rupture Discs

• They are often used as the primary pressure relief

device.
– Very rapid pressure rise situations like runaway reactions.
– When pressure relief valve cannot respond quick enough.

• They can also be used in conjunction with a pressure

relief valve to: (use pressure gauge in between)
– Provide corrosion protection for the PRV.
– Prevent loss of toxic or expensive process materials.
– Reduce fugitive emissions to meet environmental
requirements.
 Rupture Disk

* Calibrated metal disk

* Remains open after
rupture
* Subject to pressure
cycling fatigue
RUPTURE DISK
Rupture Disk
Rupture Disk
Rupture Discs Are Well Suited For Some
Applications

Advantages

+ Reduced short emissions - no simmering or

leakage prior to bursting.
+ Protect against rapid pressure rise caused by heat
exchanger tube ruptures or internal deflagrations.
+ Less expensive to provide corrosion resistance.
+ Less tendency to plug.
+ Provide secondary protective device for lower
probability contingencies requiring large relief
areas.
Rupture Discs Are Less Well
Suited For Other Applications

Disadvantages

– Don’t reclose after relief.

– Burst pressure cannot be tested.
– Require periodic replacement.
– Greater sensitivity to mechanical damage.
– Greater sensitivity to temperature.
– Sensitive to pressure cycling causing metal
fatigue.
 Disc
Corroded
Through
Damaged during
Installation
 Classic
Alligatoring

Alligatoring is caused by operating too close to the set

pressure.
 Rupture Disk
Tell-tale pressure gauge Spring Relief

PI
Protects spring
device against Rupture
Disk
corrosion,
plugging.
Protects spring reliefs: corrosion
plugging

Absolute protection, no weeping: toxicants

flammables

Problem: Piece of rupture disk might break off and

plug spring relief
 Piston Type Pilot Operated Safety
Relief Valve
https://www.youtube.com/watch?v=b

Upper surface is larger,

causing a greater
downward pressure.
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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
– Vapor condensation and liquid accumulation above the
piston may cause problems
– Potential for back flow
 Code Requirements
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
Discharge directed
downward
Discharge too
near deck
Long moment arm
 Will these bolts hold
when the PRV relieves?
Bellows plugged
in spite of sign
 Runaway Reactions - 1

Cooling Water Exothermic

Reaction

Why important: Common problem with exothermic

reactions.
 Runaway Reactions - 2
How?
1. Loss of coolant.
2. Increased temperature.
3. Increased energy generation.
High pressure due to: Vapor pressure of liquid.
Vapor decomposition products.
Larger vessels respond faster - less heat transfer thru
walls!!!
Some chemicals can achieve self heat rates of 100’s
deg. C/min! Styrene, Acrylic Acid
 Runaway Reactions - 3
Some ways for runaways to occur:
• Loss of cooling.
• Overcharge reactant.
• External fire.
• Mis-charge reactant.
• Low reaction temperature in semi-batch
reactor. This is called a sleeping reactor.
• Loss of agitation.
Most reactive runaways result in 2-phase flow thru
relief and require a relief area 2 to 10 times larger
than single phase relief.
Runaway Reactions - 4
 Table 8-1 Relief Locations

• All process and storage vessels.

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

Cooling Water
• Jackets on vessels.
Valves
Hot
closed
Hot

• Others Valves
closed
Also read Example 9-1
ADD RELIEF SYSTEM TO THE FOLLOWING
PROCESS DRAWING

F1
The drum can be isolated
with the control valves;
pressure relief is required.
We would like to recover
without shutdown; we
select a relief valve.

F1
ADD RELIEF SYSTEM TO THE FOLLOWING
PROCESS DRAWING

Positive
displacement
pump
 The positive displacement
pump will be damaged if
the flow is stopped; we
need to provide relief.
We would like to recover
without shutdown; we
select a relief valve.

Positive
displacement
pump
ADD RELIEF SYSTEM TO THE FOLLOWING
PROCESS DRAWING

Why are all

those valves
in the process?
The extra “hand”`valves
enable us to isolate and
remove the heat exchanger
without stopping the
process.
The shell side of the heat
exchanger can be isolated;
we need to provide relief.
We would like to recover
without shutdown; we
select a relief valve.
 Relief Locations Example
Cooling Water

Reflux
Condenser
Relief Locations:
1. Blocked in cooling water line
Cooling on reflux condenser.
Water
2. Relief on reactor – variety of
scenarios.
3. Relief on pump – need to
check with manufacturer of
pump.
4. Blocked in heating coils
 Relief Scenarios
What: Describe situations or sequences of events
that result in high pressure.
• Could be dozens of scenarios for a particular piece
of equipment, particularly with reactors.
• Select worst case, i.e. case that requires largest
relief area.
Generally, worst case is:
• Runaway Reaction.
• External Fire.
 Relief Scenarios - Example
High P
High Pressure In Reactor
Nitrogen
1.Failure of high pressure
nitrogen regulator
Cooling 2.Hole in cooling water coil.
Water 3.Pump continues to run after
filling.
4.Fire exposure
5.Runaway reaction