Design for

Overpressure and
Underpressure
Protection

Slide Show

Slides with Text

Exit

Design for
Overpressure and
Underpressure
Protection
SLIDE PRESENTATION
NEXT
HOME

Outline
Introduction

Reliefs

Runaways

Safeguards

Introduction
Causes of Overpressure and
Underpressure
Reliefs
Effluent Handling Systems for
Reliefs
Runaway Reactions
Overpressure Protection for
Internal Fires and Explosions

For Further Information:

Refer to the Appendix
Supplied with this Presentation

NEXT
PREVIOUS
Text

Home

Causes of Overpressure
Operating Problem
Equipment Failure
Process Upset
External Fire
Utility Failures
NEXT
PREVIOUS
Text

Home

Causes of Underpressures
Operating Problem
Equipment Failure

NEXT
PREVIOUS
Text

Home

Presentation 1 of 3: Reliefs

Causes of
Overpressure/Underpressure
Presentation 1: Reliefs

Presentation 2: Runaways
Presentation 3: Safeguards

NEXT
PREVIOUS
Text

Home

Pressure Relief Devices

Spring-Loaded Pressure Relief Valve
Rupture Disc
Buckling Pin
Miscellaneous Mechanical
NEXT
PREVIOUS
Text

Home

Spring-Loaded
Pressure Relief Valve

NEXT
PREVIOUS
Text

Home

Rupture Disc

NEXT
PREVIOUS
Text

Home

Buckling Pin Relief Valve

Closed
Pressure Below
Set Pressure

Full Open
Pressure at or Above
Set Pressure

(Buckles in Milliseconds at a Precise Set Pressure)

NEXT
PREVIOUS
Text

Home

Simple Mechanical
Pressure Relief

NEXT
PREVIOUS
Text

Home

Types of Spring-Loaded
Pressure Reliefs
Safety Valves for Gases and Vapors
Relief Valves for Liquids
Safety Relief Valves for Liquids
and/or Gases

NEXT
PREVIOUS
Text

Home

Types of Safety Valves

Conventional
Balanced Bellows, and
Pilot-Operated

NEXT
PREVIOUS
Text

Home

Conventional Safety Valve

NEXT
PREVIOUS
Text

Home

Balanced Bellows Safety Valve

NEXT
PREVIOUS
Text

Home

Pilot-Operated Safety Valve

NEXT
PREVIOUS
Text

Home

Types of Relief Valves

Conventional
Balanced Bellows

NEXT
PREVIOUS
Text

Home

Types of Rupture Discs

Metal
Graphite
Composite
Others
NEXT
PREVIOUS
Text

Home

Rupture Disc and Pressure

Relief Valve Combination

NEXT
PREVIOUS
Text

Home

Vacuum Relief Devices

Vacuum Relief Valves
Rupture Discs
Conservation Vents
Manhole Lids
Pressure Control
NEXT
PREVIOUS
Text

Home

Conservation Vent

NEXT
PREVIOUS
Text

Home

Pressure or Vacuum Control

Add Air or Nitrogen
Maintain Appropriately

NEXT
PREVIOUS
Text

Home

Relief Servicing
Inspection
Testing

NEXT
PREVIOUS
Text

Home

Relief Discharges
To Atmosphere
Prevented
Effluent System

NEXT
PREVIOUS
Text

Home

Effluent Systems
Knock-Out Drum
Catch Tank
Cyclone Separator

NEXT
PREVIOUS
Text

Home

Effluent System (continued)

Condenser
Quench Tank
Scrubber
Flares/Incinerators
NEXT
PREVIOUS
Text

Home

Effluent Handling System

NEXT
PREVIOUS
Text

Home

Presentation 2 of 3: Runaways

Causes of
Overpressure/Underpressure
Presentation 1: Reliefs

Presentation 2: Runaways
Presentation 3: Safeguards

NEXT
PREVIOUS
Text

Home

Runaway Reaction
Temperature Increases
Reaction Rate Increases
Pressure Increases

NEXT
PREVIOUS
Text

Home

Causes of Runaway Reactions

Self-Heating
Sleeper

Characteristics of Runaway
Tempered
Gassy
Hybrid
NEXT
PREVIOUS
Text

Home

Self-Heating Reaction
Loss of Cooling
Unexpected Addition of Heat
Too Much Catalyst or Reactant
Operator Mistakes
Too Fast Addition of Catalyst or Reactant
NEXT
PREVIOUS
Text

Home

Sleeper Reactions
Reactants Added But Not Mixed
(Error)
Reactants Accumulate
Agitation Started .. Too Late

NEXT
PREVIOUS
Text

Home

Tempered Reaction
Heat Removed by Evaporation
Heat Removal Maintains a Constant
Temperature

NEXT
PREVIOUS
Text

Home

Gassy System
No Volatile Solvents
Gas is Reaction Product

NEXT
PREVIOUS
Text

Home

Hybrid System
Tempered
Gassy

NEXT
PREVIOUS
Text

Home

Reliefs for Runaway Reactions

Two Phase (or Three Phases:
Liquid, Vapor, and Solid) Flow
Relief Area: 2 to 10 Times the
Area of a Single Gaseous Phase

NEXT
PREVIOUS
Text

Home

Two Phase Flow

NEXT
PREVIOUS
Text

Home

Relief Valve Sizing

Methodology
Special Calorimeter Data
Special Calculation Methods

NEXT
PREVIOUS
Text

Home

Characterization of
Runaway Reactions
ARC

APTAC

VSP

PHI-TEC

RSST

Dewars

NEXT
PREVIOUS
Text

Home

Presentation 3 of 3:
Safeguards

Causes of
Overpressure/Underpressure
Presentation 1: Reliefs

Presentation 2: Runaways
Presentation 3: Safeguards

NEXT
PREVIOUS
Text

Home

Safeguards
Safety Interlocks
Safeguard Maintenance System
Short-Stopping

NEXT
PREVIOUS
Text

Home

Safety Interlocks
Agitator Not Working: Stop Monomer
Feed and Add Full Cooling
Abnormal Temperature: Stop
Monomer Feed and Add Full Cooling

NEXT
PREVIOUS
Text

Home

Safety Interlocks
(continued)
Abnormal Pressure: Stop Monomer Feed
and Add Full Cooling
Abnormal Heat Balance: Stop Monomer
Feed and Add Full Cooling
Abnormal Conditions: Add Short-Stop

NEXT
PREVIOUS
Text

Home

Safeguard Maintenance
System
Routine Maintenance
Management of Change
Mechanical Integrity Checks
Records
NEXT
PREVIOUS
Text

Home

Short-Stops to Stop Reaction

Add Reaction Stopper
Add Agitation with No Electrical
Power

NEXT
PREVIOUS
Text

Home

Protection for Internal

Fires and Explosions
Deflagrations
Detonations

NEXT
PREVIOUS
Text

Home

Protection Methods for

Internal Fires and Explosions
Deflagration Venting
Deflagration Suppression
Containment
NEXT
PREVIOUS
Text

Home

Protection Methods for

Internal Fires and Explosions
(continued)

Reduction of Oxidant
Reduction of Combustible
Flame Front Isolation
NEXT
PREVIOUS
Text

Home

Protection Methods for

Internal Fires and Explosions
(continued)

Spark Detection and Extinguishing

Flame Detection and Extinguishing
Water Spray and Deluge Systems

NEXT
PREVIOUS
Text

Home

Deflagration Venting
Vent Area via NFPA 68
Vent Safely

NEXT
PREVIOUS
Text

Home

Vent of Gas Deflagration

NEXT
PREVIOUS
Text

Home

Vent of Dust Deflagration

NEXT
PREVIOUS
Text

Home

Deflagration Suppression
System

NEXT
PREVIOUS
Text

Home

Containment
Prevent Rupture and Vessel
Deformation
Prevent Rupture but Deform
Vessel

NEXT
PREVIOUS
Text

Home

Reduction of Oxidant
Vacuum Purging
Pressure Purging
Sweep-Through Purging

NEXT
PREVIOUS
Text

Home

Reduction of Combustible
Dilution with Air
NFPA 69

NEXT
PREVIOUS
Text

Home

Flame Front Isolation

NEXT
PREVIOUS
Text

Home

Spark/Flame Detection
and Extinguishing

NEXT
PREVIOUS
Text

Home

Water Spray or
Deluge Systems
NEXT
PREVIOUS
Text

Home

Deluge System

NEXT
PREVIOUS
Text

Home

Conclusion

NEXT
PREVIOUS
Text

Home

End of Slide Presentation

Causes of
Overpressure/Underpressure
Presentation 1: Reliefs

Presentation 2: Runaways
Presentation 3: Safeguards

NEXT
PREVIOUS
Text

Home

Design for
Overpressure and
Underpressure
Protection
SLIDES WITH TEXT
Introduction
Reliefs
Runaways
Safeguards

This presentation includes technical information

concerning the design for overpressure and
underpressure protection. The presentation is designed
to help students and engineers to:

NEXT
PREVIOUS
Slide

Home

Design for
Overpressure and
Underpressure
Protection
Introduction
Reliefs
Runaways
Safeguards

Understand the technologies, special engineering

devices, and methods that are used for the protection
against overpressure and underpressure (vacuum)
incidents,

NEXT
PREVIOUS
Slide

Home

Design for
Overpressure and
Underpressure
Protection
Introduction
Reliefs
Runaways
Safeguards

Understand the root causes of overpressure and

underpressure incidents, and
Design plants with the appropriate features to protect
against overpressure and underpressure incidents.

NEXT
PREVIOUS
Slide

Home

Six Sections
1. Introduction
2. Causes of Overpressure and
Underpressure
3. Reliefs
4. Effluent Handling Systems for Reliefs
5. Runaway Reactions, and
6. Overpressure Protection for Internal Fires
and Explosions
Introduction
Reliefs

This presentation is divided into six sections:

NEXT

Runaways

PREVIOUS

Safeguards

Slide

Home

Six Sections
1. Introduction
2. Causes of Overpressure and
Underpressure
3. Reliefs
4. Effluent Handling Systems for Reliefs
5. Runaway Reactions, and
6. Overpressure Protection for Internal Fires
and Explosions
Introduction
Reliefs
Runaways
Safeguards

The Introduction button on your left will lead you to this

introduction and an explaination of the Causes of
Overpressure and Underpressure

NEXT
PREVIOUS
Slide

Home

Six Sections
1. Introduction
2. Causes of Overpressure and
Underpressure
3. Reliefs
4. Effluent Handling Systems for Reliefs
5. Runaway Reactions, and
6. Overpressure Protection for Internal Fires
and Explosions
Introduction
Reliefs
Runaways
Safeguards

The Reliefs Button sends you to Sections 3 and 4,

covering Reliefs and Effluent Handling Systems for
Reliefs

NEXT
PREVIOUS
Slide

Home

Six Sections
1. Introduction
2. Causes of Overpressure and
Underpressure
3. Reliefs
4. Effluent Handling Systems for Reliefs
5. Runaway Reactions, and
6. Overpressure Protection for Internal Fires
and Explosions
Introduction
Reliefs

The Runaways Button leads to a discussion on

Runaway Reactions, and . . .

NEXT

Runaways

PREVIOUS

Safeguards

Slide

Home

Six Sections
1. Introduction
2. Causes of Overpressure and
Underpressure
3. Reliefs
4. Effluent Handling Systems for Reliefs
5. Runaway Reactions, and
6. Overpressure Protection for Internal Fires
and Explosions
Introduction
Reliefs
Runaways
Safeguards

The Safeguards Button will take you to a section on

Overpressure Protection fot Internal Fires and
Explosions

NEXT
PREVIOUS
Slide

Home

Appendix Contains
Detailed Information

Introduction
Reliefs
Runaways
Safeguards

This design package includes an appendix with detailed

information for each of the sections of this presentation.
The appendix also includes an extensive list of relevant
references.

NEXT
PREVIOUS
Slide

Home

Causes of Overpressure
Operating Problem

Introduction
Reliefs
Runaways
Safeguards

The major causes of overpressure include:

Operating problems or mistakes such as an operator mistakenly
opening or closing a valve to cause the vessel or system pressure to
increase. An operator, for example, may adjust a steam regulator to
give pressures exceeding the maximum allowable working pressure
(MAWP) of a steam jacket.

NEXT
PREVIOUS
Slide

Home

Causes of Overpressure
Operating Problem

Introduction
Reliefs
Runaways
Safeguards

Although the set pressure is usually at the MAWP, the design safety
factors should protect the vessel for higher pressures; a vessel fails
when the pressure is typically several times the MAWP.

NEXT
PREVIOUS
Slide

Home

Causes of Overpressure
Operating Problem
Equipment Failure

Introduction
Reliefs
Runaways
Safeguards

Equipment failures; for example a heat exchanger tube rupture that

increases the shell side pressure beyond the MAWP. Although the set
pressure is usually the MAWP, the design safety factors should protect
the vessel for higher pressures; a vessel fails when the pressure is
typically several times the MAWP.

NEXT
PREVIOUS
Slide

Home

Causes of Overpressure
Operating Problem
Equipment Failure
Process Upset
External Fire
Utility Failures
Introduction
Reliefs
Runaways
Safeguards

Process upset; for example a runaway reaction causing high

temperatures and pressures.
External heating, such as, a fire that heats the contents of a vessel
giving high vapor pressures, and
Utility failures, such as the loss of cooling or the loss of agitation
causing a runaway reaction.

NEXT
PREVIOUS
Slide

Home

Causes of Underpressures

Introduction
Reliefs
Runaways
Safeguards

The causes of underpressure or the inadvertent creation of a

vacuum are usually due to operating problems or equipment
failures.

NEXT
PREVIOUS
Slide

Home

Causes of Underpressures
Operating Problem

Introduction
Reliefs
Runaways
Safeguards

Operating problems include mistakes such as pumping liquid

out of a closed system, or cooling and condensing vapors in a
closed system.

NEXT
PREVIOUS
Slide

Home

Causes of Underpressures
Operating Problem
Equipment Failure

Introduction
Reliefs
Runaways
Safeguards

Equipment failures include an instrument malfunction (e.g.

vacuum gage) or the loss of the heat input of a system that
contains a material with a low vapor pressure.

NEXT
PREVIOUS
Slide

Home

Part 1 of 3: Reliefs

Introduction
Reliefs

NEXT

Runaways

PREVIOUS

Safeguards

Slide

Home

Pressure Relief Devices

Introduction
Reliefs
Runaways
Safeguards

Pressure relief devices are added to process equipment to

prevent the pressures from significantly exceeding the MAWP
(pressures are allowed to go slightly above the MAWP during
emergency reliefs).

NEXT
PREVIOUS
Slide

Home

Pressure Relief Devices

Spring-Loaded Pressure Relief Valve
Rupture Disc
Buckling Pin
Miscellaneous Mechanical
Introduction
Reliefs
Runaways
Safeguards

The pressure relief devices include spring-loaded pressure relief

valves, rupture discs, buckling pins, and miscellaneous
mechanical devices.

NEXT
PREVIOUS
Slide

Home

Spring-Loaded
Pressure Relief Valve

Introduction
Reliefs
Runaways
Safeguards

This is a sketch of a spring-loaded pressure relief valve. As the

pressure in the vessel or pipeline at point A exceeds the
pressure created by the spring, the valve opens. The relief
begins to open at the set pressure which is usually at or below
the MAWP; this pressure is usually set at the MAWP.

NEXT
PREVIOUS
Slide

Home

Rupture Disc

Introduction
Reliefs
Runaways
Safeguards

This is a sketch of a rupture disc. In this case the disc ruptures

when the pressure at A exceeds the set pressure. Recognize,
however, that it is actually the differential pressure (A-B), that
ruptures the disc.

NEXT
PREVIOUS
Slide

Home

Buckling Pin Relief Valve

Closed
Pressure Below
Set Pressure

Full Open
Pressure at or Above
Set Pressure

(Buckles in Milliseconds at a Precise Set Pressure)

Introduction
Reliefs
Runaways
Safeguards

This sketch shows a buckling pin pressure relief valve. As

shown, when the pressure exceeds the set pressure, the pin
buckles and the vessel contents exit through the open valve.
The rupture disc and the buckling pin relief valves stay open
after they are opened.

NEXT
PREVIOUS
Slide

Home

Buckling Pin Relief Valve

Closed
Pressure Below
Set Pressure

Full Open
Pressure at or Above
Set Pressure

(Buckles in Milliseconds at a Precise Set Pressure)

Introduction
Reliefs
Runaways
Safeguards

The spring operated valves close as the pressure decreases

below the blowdown pressure. The blowdown pressure is the
difference between the set pressure and closing pressure.

NEXT
PREVIOUS
Slide

Home

Simple Mechanical
Pressure Relief

Introduction
Reliefs
Runaways
Safeguards

A simple mechanical pressure relief is a weighted man-way

cover as shown in this sketch. Another mechanical relief is a Utube filled with water (or equivalent).

NEXT
PREVIOUS
Slide

Home

Types of Spring-Loaded
Pressure Reliefs
Safety Valves for Gases and Vapors
Relief Valves for Liquids
Safety Relief Valves for Liquids
and/or Gases

Introduction
Reliefs
Runaways
Safeguards

There are three types of spring-loaded pressure relief valves:

Safety valves are specifically designed for gases.
Relief valves are designed for liquids, and
Safety relief valves are designed for liquids and/or gases.

NEXT
PREVIOUS
Slide

Home

Types of Safety Valves

Conventional
Balanced Bellows, and
Pilot-Operated

Introduction
Reliefs
Runaways
Safeguards

There are three types of safety valves; that is:

Conventional,
Balanced bellows, and
Pilot-operated.

NEXT
PREVIOUS
Slide

Home

Conventional Safety Valve

Introduction
Reliefs
Runaways
Safeguards

A conventional safety valve is designed to provide full opening

with minimum overpressure. The disc is specially shaped to
give a pop action as the valve begins to open.

NEXT
PREVIOUS
Slide

Home

Balanced Bellows Safety Valve

Introduction
Reliefs
Runaways
Safeguards

A balanced bellows safety valve is specially designed to reduce

the effect of the back pressure on the opening pressure. As
illustrated in this sketch the differential pressure that is required
to open the valve is the pressure inside the vessel minus the
atmospheric pressure.

NEXT
PREVIOUS
Slide

Home

Balanced Bellows Safety Valve

Introduction
Reliefs
Runaways
Safeguards

The bellows design allows the outside air and pressure to be on

the downstream side of the valve seal. Once the relief is open,
then the flow is a function of the differential pressure A-B.

NEXT
PREVIOUS
Slide

Home

Pilot-Operated Safety Valve

Introduction
Reliefs
Runaways
Safeguards

A pilot-operated safety valve is a spring-loaded valve. As

illustrated, the vessel pressure helps to keep the valve closed.
When the pressure exceeds the set pressure (or the spring
pressure), the pressure on top of the valve is vented and the
valve opens.

NEXT
PREVIOUS
Slide

Home

Pilot-Operated Safety Valve

Introduction
Reliefs
Runaways
Safeguards

The set pressure of this type of valve can be closer to the

operating pressure compared to conventional and balanced
bellows valves. The disadvantages, however, are (a) the
process fluid needs to be clean, (b) the seals must be resistant
to the fluids, and (c) the seals and valves must be appropriately
maintained.

NEXT
PREVIOUS
Slide

Home

Pilot-Operated Safety Valve

Introduction
Reliefs
Runaways
Safeguards

These disadvantages are also true for spring operated reliefs.

Pilot-operated valves are not used in liquid service; they are
normally used in very clean and low pressure applications.

NEXT
PREVIOUS
Slide

Home

Types of Relief Valves

Conventional
Balanced Bellows

Introduction
Reliefs

Relief valves (for liquid service) are either the conventional or

the balanced bellows types.

NEXT

Runaways

PREVIOUS

Safeguards

Slide

Home

Types of Rupture Discs

Metal
Graphite
Composite
Others
Introduction
Reliefs
Runaways
Safeguards

As illustrated, there are many different types of rupture discs.

They are especially applicable for very corrosive environments;
for example: discs made of carbon or Teflon coating are used
for corrosive service.

NEXT
PREVIOUS
Slide

Home

Types of Rupture Discs

Metal
Graphite
Composite
Others
Introduction
Reliefs
Runaways
Safeguards

A rupture disc that is used for pressure reliefs may need a

specially designed mechanical support if it is also used in
vacuum service.

NEXT
PREVIOUS
Slide

Home

Rupture Disc and Pressure

Relief Valve Combination

Introduction
Reliefs
Runaways
Safeguards

Rupture discs, as illustrated, are sometimes used in

combination with a spring operated relief device. In this case
the disc gives a positive seal compared to the disc-to-seal
design of a spring operated valve.

NEXT
PREVIOUS
Slide

Home

Rupture Disc and Pressure

Relief Valve Combination

Introduction
Reliefs
Runaways
Safeguards

This is useful when handling very toxic materials where even a

very small release (through the seal) may be hazardous, or
when handling materials that polymerize.
The spring operated relief following the rupture disc reseats
when the pressure drops below the blow-down pressure.

NEXT
PREVIOUS
Slide

Home

Rupture Disc and Pressure

Relief Valve Combination

Introduction
Reliefs
Runaways
Safeguards

This design, therefore, stops the discharge from the vessel.

The discharge is not stopped if only a rupture disc is used. This
design (rupture disc followed by a spring-operated relief) is
discouraged by some practitioners.

NEXT
PREVIOUS
Slide

Home

Rupture Disc and Pressure

Relief Valve Combination

Introduction
Reliefs
Runaways
Safeguards

In this design, as illustrated, a pressure detection device (per

ASME Code), e.g., a pressure indicator, needs to be placed
between the disc and the spring-operated valve. This pressure
reading is checked periodically to be sure the rupture disc has
its mechanical integrity.

NEXT
PREVIOUS
Slide

Home

Rupture Disc and Pressure

Relief Valve Combination

Introduction
Reliefs
Runaways
Safeguards

A pin-hole leak in the rupture disc could increase the pressure

on the discharge side of the disc. This is a major problem
because it increases the relief pressure, that is: the differential
pressure across the disc is the rupturing mechanism.

NEXT
PREVIOUS
Slide

Home

Rupture Disc and Pressure

Relief Valve Combination

Introduction
Reliefs
Runaways
Safeguards

Another major problem with this design is the possibility that a

piece of the rupture disc could plug the discharge orifice of the
spring operated relief. This problem is prevented by specifying
a rupture disc that will maintain its integrity when it is ruptured;
that is, non-fragmenting.

NEXT
PREVIOUS
Slide

Home

Vacuum Relief Devices

Vacuum Relief Valves
Rupture Discs
Conservation Vents
Manhole Lids
Pressure Control
Introduction
Reliefs
Runaways
Safeguards

Vacuum relief devices are: vacuum relief valves, rupture discs,

conservation vents, manhole lids designed for vacuum relief,
and pressure control.

NEXT
PREVIOUS
Slide

Home

Conservation Vent

Introduction
Reliefs
Runaways
Safeguards

A conservation vent is illustrated in this sketch. As shown, it is

designed to relieve a pressure usually for pressures in the
region of 6 inches of water. It is also designed to let air into the
vessel to prevent a vacuum, usually a vacuum no more than 4
inches of water.

NEXT
PREVIOUS
Slide

Home

Pressure or Vacuum Control

Add Air or Nitrogen
Maintain Appropriately

Introduction
Reliefs
Runaways
Safeguards

Sometimes pressure or vacuum control systems are used to add air or

nitrogen to the vessel to maintain a slight pressure. In this case, the
system needs to be appropriately maintained because a malfunction
could result in an overpressure or underpressure. In either case the
consequence could be a ruptured vessel.

NEXT
PREVIOUS
Slide

Home

Relief Servicing
Inspection
Testing

Introduction
Reliefs
Runaways
Safeguards

Every relief device needs to be inspected and tested before

installation and then at predetermined intervals during its
lifetime. The interval depends on the service history, vendor
recommendations, and regulatory requirements, but it is usually
once a year.

NEXT
PREVIOUS
Slide

Home

Relief Servicing
Inspection
Testing

Introduction
Reliefs
Runaways
Safeguards

Operating results and experience may indicate shorter or longer

intervals.
Records must be carefully maintained for every inspection and
test, and for the entire life of the plant.

NEXT
PREVIOUS
Slide

Home

Relief Discharges
To Atmosphere

Introduction
Reliefs
Runaways
Safeguards

Discharges from pressure relief devices may be sent directly to

the atmosphere if they are innocuous, discharged in a safe
manner, and regulations permit it.

NEXT
PREVIOUS
Slide

Home

Relief Discharges
To Atmosphere
Prevented

Introduction
Reliefs
Runaways
Safeguards

An additional option is to prevent releases by (a) designing

vessels with high MAWPs to contain all overpressure scenarios,
or (b) add a sufficient number of safeguards and/or controls to
make overpressure scenarios essentially impossible.

NEXT
PREVIOUS
Slide

Home

Relief Discharges
To Atmosphere
Prevented
Effluent System

Introduction
Reliefs

The third option is to design an effluent system to capture all

nocuous liquids and gases.

NEXT

Runaways

PREVIOUS

Safeguards

Slide

Home

Effluent Systems
Knock-Out Drum
Catch Tank
Cyclone Separator

Introduction
Reliefs
Runaways
Safeguards

An effluent system may contain a

Knock-out drum
Catch tank
Cyclone separator

NEXT
PREVIOUS
Slide

Home

Effluent System (continued)

Condenser
Quench Tank
Scrubber
Flares/Incinerators
Introduction
Reliefs
Runaways
Safeguards

Condenser
Quench tank
Scrubber, and/or
Flares or incinerators
An effluent handling system may have any combination of the above unit
operations.

NEXT
PREVIOUS
Slide

Home

Effluent Handling System

Introduction
Reliefs
Runaways
Safeguards

One effluent handling system is illustrated in this sketch. Every

element of an effluent system needs to be designed very
carefully. The design requires detailed physical and chemical
properties, and the correct design methodology for each unit
operation.

NEXT
PREVIOUS
Slide

Home

Effluent Handling System

Introduction
Reliefs
Runaways
Safeguards

It should also be recognized that it is important to size the relief

appropriately, because the size of the entire effluent system is
based on this discharge rate. The design methodology is in the
references noted in the Appendix of this package.

NEXT
PREVIOUS
Slide

Home

Part 2 of 3: Runaways

Introduction
Reliefs

NEXT

Runaways

PREVIOUS

Safeguards

Slide

Home

Runaway Reaction
Temperature Increases
Reaction Rate Increases
Pressure Increases

Introduction
Reliefs
Runaways
Safeguards

A runaway reaction is an especially important overpressure scenario. A

runaway reaction has an accelerating rate of temperature increase, rate
of reaction increase, and usually rate of pressure increase. The
pressure, of course, increases if the reaction mass has a volatile
substance, such as, a solvent or a monomer; or if one of the reaction
products is a gas.

NEXT
PREVIOUS
Slide

Home

Causes of Runaway Reactions

Self-Heating
Sleeper

Characteristics of Runaway
Tempered
Gassy
Hybrid
Introduction
Reliefs
Runaways
Safeguards

In general, there are two causes of runaway reactions (selfheating and sleeper) and three characteristics of runaways
(tempered, gassy, and hybrid).

NEXT
PREVIOUS
Slide

Home

Causes of Runaway Reactions

Self-Heating
Sleeper

Characteristics of Runaway
Tempered
Gassy
Hybrid
Introduction
Reliefs
Runaways
Safeguards

When protecting a system for overpressures due to runaway reactions

the engineer needs to know the type of runaway and needs to
characterize the behavior of the specific runaway with a special
calorimeter. This specific methodology is described in this section of this
presentation.

NEXT
PREVIOUS
Slide

Home

Self-Heating Reaction
Loss of Cooling
Unexpected Addition of Heat
Too Much Catalyst or Reactant
Operator Mistakes
Too Fast Addition of Catalyst or Reactant
Introduction
Reliefs
Runaways
Safeguards

One self-heating scenario occurs when the reaction is

exothermic and a loss of cooling gives an uncontrolled
temperature rise. A few causes of self-heating scenarios are
shown.

NEXT
PREVIOUS
Slide

Home

Sleeper Reactions
Reactants Added But Not Mixed
(Error)
Reactants Accumulate
Agitation Started .. Too Late

Introduction
Reliefs
Runaways
Safeguards

Sleeper reactions are usually the result of an operator error. Two

examples include: (a) the addition of two immiscible reactants when the
agitator is mistakenly in the off position, and (b) the addition of a reactant
to the reaction mass when the temperature is mistakenly lower than that
required to initiate the reaction.

NEXT
PREVIOUS
Slide

Home

Sleeper Reactions
Reactants Added But Not Mixed
(Error)
Reactants Accumulate
Agitation Started .. Too Late

Introduction
Reliefs

In these cases the runaway is initiated by starting the agitator

and adding heat respectively.

NEXT

Runaways

PREVIOUS

Safeguards

Slide

Home

Tempered Reaction
Heat Removed by Evaporation
Heat Removal Maintains a Constant
Temperature

Introduction
Reliefs
Runaways
Safeguards

Tempered runaway reactions maintain their temperature when the

energy exiting the relief device is equal to the energy generated in the
reactor due to the exothermic reaction. The reaction heat is absorbed by
the evaporation of the volatile components. The vapor pressure in a
tempered system can typically be characterized by an Antoine type
equation.

NEXT
PREVIOUS
Slide

Home

Gassy System
No Volatile Solvents
Gas is Reaction Product

Introduction
Reliefs
Runaways
Safeguards

A system that is characterized as gassy has no volatile

solvents or reactants. The pressure build-up is due to the
generation of noncondensible gas such as N2 or CO2.

NEXT
PREVIOUS
Slide

Home

Hybrid System
Tempered
Gassy

Introduction
Reliefs
Runaways
Safeguards

A hybrid system is the combination of a tempered and a gassy

system. Under runaway conditions, the pressure increases due
to the vapor pressure of the volatile components as well as from
the generation of noncondensible gaseous reaction products.

NEXT
PREVIOUS
Slide

Home

Reliefs for Runaway Reactions

Two Phase (or Three Phases:
Liquid, Vapor, and Solid) Flow

Introduction
Reliefs
Runaways
Safeguards

Under runaway conditions, when the relief device opens, the

relief discharge is a foam; that is, the gases are entrained with
the liquid.

NEXT
PREVIOUS
Slide

Home

Reliefs for Runaway Reactions

Two Phase (or Three Phases:
Liquid, Vapor, and Solid) Flow

Introduction
Reliefs
Runaways
Safeguards

To maintain a constant temperature in the reactor (i.e. control the

runaway reaction), the relief valve is sized to remove all the heat
generated from the exothermic reaction via the heat removed with the
discharged mass, which is typically a foam. Detailed information on
runaway reactions is found in the appendix.

NEXT
PREVIOUS
Slide

Home

Reliefs for Runaway Reactions

Two Phase (or Three Phases:
Liquid, Vapor, and Solid) Flow
Relief Area: 2 to 10 Times the
Area of a Single Gaseous Phase

Introduction
Reliefs
Runaways
Safeguards

The required relief area to remove this heat with the foam is two
to ten times the area that would be required by releasing a
single gaseous phase.

NEXT
PREVIOUS
Slide

Home

Two Phase Flow

Introduction
Reliefs
Runaways
Safeguards

This is a picture that illustrates the two-phase flow

characteristics of a relief discharge due to a runaway reaction.
As illustrated, the discharge is similar to the release of foam
from a freshly opened bottle of pop after being shakened. If the
relief is not designed for two-phase flow, the pressures would
increase rapidly and the vessel could rupture.

NEXT
PREVIOUS
Slide

Home

Relief Valve Sizing

Methodology
Special Calorimeter Data
Special Calculation Methods

Introduction
Reliefs
Runaways
Safeguards

The relief valve sizing methodology for runaway reactions is

very complex. It requires the characterization of the runaway
reaction using a specially designed calorimeter.
Relief valve sizing, additionally, requires special calculation
methods that are described in the Appendix of this package.

NEXT
PREVIOUS
Slide

Home

Characterization of
Runaway Reactions

Introduction
Reliefs
Runaways
Safeguards

The characterization of runaway reactions includes the

determination of the rates of rise of the temperature and
pressure under adiabatic conditions. The test results also
characterize the reaction type, that is, tempered, gassy, and/or a
hybrid system.

NEXT
PREVIOUS
Slide

Home

Characterization of
Runaway Reactions
ARC
VSP
RSST

Introduction
Reliefs
Runaways
Safeguards

Various calorimeters are used for this characterization:

The accelerating rate calorimeter (ARC)
The vent sizing package (VSP)
The reactive system screening tool (RSST)

NEXT
PREVIOUS
Slide

Home

Characterization of
Runaway Reactions

Introduction
Reliefs
Runaways
Safeguards

ARC

APTAC

VSP

PHI-TEC

RSST

Dewars

The automated pressure-tracking adiabatic calorimeter (APTAC)

The Phi-Tec, and
Dewars.
Each of these calorimeters have advantages and disadvantages
that need to be understood when studying a specific system.

NEXT
PREVIOUS
Slide

Home

Part 3 of 3: Safeguards

Introduction
Reliefs

NEXT

Runaways

PREVIOUS

Safeguards

Slide

Home

Safeguards

Introduction
Reliefs
Runaways
Safeguards

This section of the presentation covers safeguards. Safeguards

include the methods and controls used to prevent runaways. As
illustrated previously, a containment system (a safeguard), can
be very complex and expensive. Alternatively, a series of
safeguards may be justified.

NEXT
PREVIOUS
Slide

Home

Safeguards
Safety Interlocks
Safeguard Maintenance System
Short-Stopping

Introduction
Reliefs

Safeguards include safety interlocks, safeguard maintenance

system, and/or short-stopping.

NEXT

Runaways

PREVIOUS

Safeguards

Slide

Home

Safety Interlocks
Agitator Not Working: Stop Monomer
Feed and Add Full Cooling
Abnormal Temperature: Stop
Monomer Feed and Add Full Cooling

Introduction
Reliefs
Runaways
Safeguards

The list of alternative interlocks is fairly extensive. Usually more than

one interlock and some redundancy and diversity is required for each
runaway scenario. As the number of interlocks increases, the reliability
of the system increases. These are examples of safety interlocks for a
semibatch polymerization reactor.

NEXT
PREVIOUS
Slide

Home

Safety Interlocks
(continued)
Abnormal Pressure: Stop Monomer Feed
and Add Full Cooling
Abnormal Heat Balance: Stop Monomer
Feed and Add Full Cooling
Abnormal Conditions: Add Short-Stop

Introduction
Reliefs
Runaways
Safeguards

This is a list of additional interlocks. Other interlocks (manual)

that are not on this list include: gages with manual shutdowns,
and alarms with manual shutdowns.

NEXT
PREVIOUS
Slide

Home

Safeguard Maintenance
System
Routine Maintenance
Management of Change
Mechanical Integrity Checks
Records
Introduction
Reliefs
Runaways
Safeguards

A safeguard maintenance system includes routine maintenance,

management of change, mechanical integrity checks, and the
appropriate records. These are the steps that are required to be
sure the safeguards and interlocks perform appropriately under
emergency conditions and/or potential runaway reaction
scenarios.

NEXT
PREVIOUS
Slide

Home

Safeguard Maintenance
System
Routine Maintenance
Management of Change
Mechanical Integrity Checks
Records
Introduction
Reliefs
Runaways
Safeguards

The maintenance of safeguard systems is especially important, because:

Safeguards and interlocks do not operate on a day-to-day basis, but
When they are required to operate (emergency conditions) they need
to operate flawlessly.
See ISA SP 84.01 for details for the design of safety instrumented
systems.

NEXT
PREVIOUS
Slide

Home

Short-Stops to Stop Reaction

Add Reaction Stopper
Add Agitation with No Electrical
Power

Introduction
Reliefs
Runaways
Safeguards

A short-stopping system, stops a runaway reaction by adding a

reaction stopper solution to the reacting mass. The reactionstopper stops the reaction in time to short-circuit the progress of the
reaction. A reaction stopper needs to be added when the reaction
mass is relatively cold. If the mass is too hot, a short-stopper will
not work.

NEXT
PREVIOUS
Slide

Home

Short-Stops to Stop Reaction

Add Reaction Stopper
Add Agitation with No Electrical
Power

Introduction
Reliefs
Runaways
Safeguards

Good agitation, of course, is required to adequately mix the reaction

mass with the inhibitor. Since a power failure is often the initiating
event of a runaway, an alternative method of agitation needs to be
included in the design. A compressed nitrogen system together with
a sparge ring is one alternative.

NEXT
PREVIOUS
Slide

Home

Protection for Internal

Fires and Explosions
Deflagrations
Detonations

Introduction
Reliefs
Runaways
Safeguards

This section of the presentation covers protection methods for

internal fires and explosions.
Overpressure protection is needed for process equipment that
can potentially explode due to an internal deflagration or
detonation.

NEXT
PREVIOUS
Slide

Home

Protection for Internal

Fires and Explosions
Deflagrations
Detonations

Introduction
Reliefs
Runaways
Safeguards

A deflagration is defined as the propagation of a combustion

zone at a velocity in the unreacted medium that is less than the
speed of sound. A detonation has a velocity greater than the
speed of sound in the unreacted medium.

NEXT
PREVIOUS
Slide

Home

Protection for Internal

Fires and Explosions
Deflagrations
Detonations

Introduction
Reliefs
Runaways
Safeguards

The burning material can be a combustible gas, a combustible

dust, a combustible mist, or a hybrid mixture (a mixture of a
combustible gas with either a combustible dust or combustible
mist). The reaction actually occurs in the vapor phase between
the fuel and the air or some other oxidant.

NEXT
PREVIOUS
Slide

Home

Protection Methods for

Internal Fires and Explosions
Deflagration Venting
Deflagration Suppression
Containment
Introduction
Reliefs
Runaways
Safeguards

The protection methods used for fires or explosions include

Deflagration venting
Deflagration suppression
Containment

NEXT
PREVIOUS
Slide

Home

Protection Methods for

Internal Fires and Explosions
(continued)

Reduction of Oxidant
Reduction of Combustible
Flame Front Isolation
Introduction
Reliefs
Runaways
Safeguards

Reduction of the oxidant

Reduction of the combustible
Flame front isolation

NEXT
PREVIOUS
Slide

Home

Protection Methods for

Internal Fires and Explosions
(continued)

Spark Detection and Extinguishing

Flame Detection and Extinguishing
Water Spray and Deluge Systems

Introduction
Reliefs
Runaways
Safeguards

Spark detection and extinguishing

Flame detection and extinguishing
Water or foam spray deluge systems

NEXT
PREVIOUS
Slide

Home

Deflagration Venting
Vent Area via NFPA 68

Introduction
Reliefs
Runaways
Safeguards

The technology required for venting deflagrations is given in

NFPA 68. Deflagration venting is usually the simplest and least
costly means of protecting process equipment against damage
due to the internal pressure rise from deflagrations.

NEXT
PREVIOUS
Slide

Home

Deflagration Venting
Vent Area via NFPA 68
Vent Safely

Introduction
Reliefs
Runaways
Safeguards

If equipment is located inside a building, the vents must be

discharged through a vent duct system to a safe location
outside of the building. The design of the vent duct system is
critical to avoid excessive pressures developed during the
venting process. See NFPA 68 for details.

NEXT
PREVIOUS
Slide

Home

Deflagration Venting
Vent Area via NFPA 68
Vent Safely

Introduction
Reliefs
Runaways
Safeguards

A safe location will avoid injury to personnel and minimize

damage to equipment outside of the building. The next two
pictures illustrate that the safe venting may not be trivial.

NEXT
PREVIOUS
Slide

Home

Vent of Gas Deflagration

Introduction
Reliefs
Runaways
Safeguards

This is a picture of the venting of a gas deflagration. As illustrated,

the flame propagates a significant distance from the vessel. The
length of the flame is estimated using an equation found in NFPA
68. The main purpose of venting is to protect the mechanical
integrity of the equipment. As illustrated, even when it is vented
safely, this is a major event.

NEXT
PREVIOUS
Slide

Home

Vent of Dust Deflagration

Introduction
Reliefs
Runaways
Safeguards

This is a picture of the venting of a dust deflagration. As illustrated,

the burning dust continues to burn at great distances from the vent.
With dusts, this burning zone is larger because the container has a
larger fuel-to-air ratio compared to the gas deflagration scenario.
These pictures clearly illustrate the problems with venting
deflagrations.

NEXT
PREVIOUS
Slide

Home

Deflagration Suppression
System

Introduction
Reliefs
Runaways
Safeguards

One alternative to venting a deflagration is suppression. This

sketch illustrates a deflagration suppression system that
includes (a) a flame or pressure detector, (b) a quick opening
valve, and (c) the addition of a flame suppressant.

NEXT
PREVIOUS
Slide

Home

Deflagration Suppression
System

Introduction
Reliefs
Runaways
Safeguards

The commonly used suppression agents include water,

potassium acid phosphate, sodium bicarbonate, and Halon
substitutes. The technology for deflagration suppression is
described in NFPA 69.

NEXT
PREVIOUS
Slide

Home

Containment
Prevent Rupture and Vessel
Deformation
Prevent Rupture but Deform
Vessel
Introduction
Reliefs
Runaways
Safeguards

The thickness of vessel walls may be increased to contain the

pressure of a deflagration.
The wall thickness can be large enough to prevent the
deformation of the vessel, or
The wall thickness may be large enough to prevent a rupture,
but allow the vessel to deform.

NEXT
PREVIOUS
Slide

Home

Reduction of Oxidant
Vacuum Purging
Pressure Purging
Sweep-Through Purging

Introduction
Reliefs
Runaways
Safeguards

Protection for overpressures is also provided with an inert gas

blanket to prevent the occurrence of a deflagration. Before
introducing a flammable substance to a vessel, the vessel must
also be purged with an inert gas to reduce the oxidant
concentration sufficiently so that the gas mixture cannot burn.

NEXT
PREVIOUS
Slide

Home

Reduction of Oxidant
Vacuum Purging
Pressure Purging
Sweep-Through Purging

Introduction
Reliefs
Runaways
Safeguards

The purging methods include vacuum purging, pressure

purging, and sweep-through purging. See NFPA 69 and the
book by Crowl and Louvar for more details.

NEXT
PREVIOUS
Slide

Home

Reduction of Combustible
Dilution with Air
NFPA 69

Introduction
Reliefs
Runaways
Safeguards

A deflagration can also be prevented by reducing the concentration

of the combustible material so that the concentration is below the
lower flammability limit (LFL). This is usually accomplished by
dilution with nitrogen. The specifications for this type system are
given in NFPA 69.

NEXT
PREVIOUS
Slide

Home

Flame Front Isolation

Introduction
Reliefs
Runaways
Safeguards

As illustrated, isolation devices are used in piping systems to prevent the

propagation of a flame front. The method illustrated has a fast-acting
block valve.
This isolation system prevents the propagation of the flame front; more
importantly it prevents deflagration transitions to detonations.

NEXT
PREVIOUS
Slide

Home

Spark/Flame Detection
and Extinguishing

Introduction
Reliefs
Runaways
Safeguards

Another method of preventing the propagation of deflagrations in

pipelines is the early detection and extinguishment of sparks or flames.
In this type system, a detector activates an automatic extinguishing
system that sprays water or other extinguishing agents into the fire. This
system is similar to the deflagration suppression system discussed
previously.

NEXT
PREVIOUS
Slide

Home

Water Spray or
Deluge Systems
Introduction
Reliefs
Runaways
Safeguards

Process equipment and structures are very effectively protected against

fire by water spray or deluge systems. They can be activated manually
or automatically. They are designed to cool the equipment or structural
members so that the heat from a fire will not weaken them.

NEXT
PREVIOUS
Slide

Home

Deluge System

Introduction
Reliefs
Runaways
Safeguards

This picture shows a typical deluge system in operation. In this

example, the deluge system is automatically activated when the
concentration of the flammable gas below the vessel is detected
to be at or over 25% of the lower flammability limit.

NEXT
PREVIOUS
Slide

Home

Conclusion
Introduction
Reliefs
Runaways
Safeguards

This concludes our technology package covering overpressure and

underpressure protection. The appendix of this package contains
more detailed information. The enclosed references contain the
state-of-the-art technology to assist engineers and students with
their detailed designs.

NEXT
PREVIOUS
Slide

Home

End of Slide Presentation

(with text)

Causes of
Overpressure/Underpressure
Presentation 1: Reliefs

Presentation 2: Runaways
Presentation 3: Safeguards

HOME
PREVIOUS
Slide

Exit