Overpressure Scenarios

and
Required Relief Rates
PART I
 Required Data

Procure latest PIDs

Heat and Mass Balance Report

Rotating Equipment Datasheet (performance curves,

etc.)

Vessel and Heat Exchanger Datasheets (drawings)

Operating/Emergency procedures

Review current project specific document-Relief &

Blowdown Philosophy
 Overpressure Scenario Identification
Start with PIDs and PFDs
Analyze on equipment-by-equipment basis
Typically start at front end of process
Identify sources of feed & its maximum pressure
Identify all heat input sources including external fire
No credit for favorable instrument or operator response
Include comments to explain rationale
 Industry Guidelines

API RP 521

API 2000

Project Specific Guidelines

 API RP 521
1. Fire
2. Closed outlets (Vapor BO or Liquid BO)
3. Failure Opening/closing of Control Valve
4. Thermal Expansion
5. Tube rupture
6. Check Valve Leakage
7. Reflux failure
8. Abnormal heat input
9. Power Failure
10. Utility failure (CW+IA+FG+Steam)
 External Fire

Causes:

1. Explosion caused by the ignition of a flammable

leaking gas

2. Leakage of flammable hydrocarbon inventory

 Applicability Guidelines

Equipment must be located with in a fire zone

Some portion of the equipment must be located below the

maximum fire height (API RP 521 uses 25 feet)

In some cases, the time required to reach relief pressure

may render the scenario not credible
 Sizing Equation-
Q=21000*F*A^0.82 (Btu/hr)

Q=34500*F*A^0.82 (Btu/hr)

Wetted Surface Area-

Liquid full such as Treaters: 100%

Surge Drums, KO drums, Process vessels: NLL

Fractionating Columns: NLL + Hold up

Working storage (MAWP >15 psig): Max level up to 25 ft

Spheres: Up to max horizontal diameter or 25 ft whichever

is greater

Heat Of Vaporization-Latent heats will be based on the heat

required to vaporize the first 10% by mass.

Q = m * Hv@ relief
 Shell and Tube Exchangers
Individual exchangers often not individually protected for
fire
Often rely on downstream vessels for protection
If downstream relief is used, check if loads should be
additive (e.g., exchanger and vessel are in same fire zone)
Shell side and tube side may be treated differently (many
companies neglect tube side due to small surface area)
 Air Coolers

Condensing versus liquid cooling services may be treated

differently (see API RP 521 Section 3.15.7)

Many air coolers are located above the maximum fire height

API has special equations for air coolers

Exact treatment of fire case for air coolers should be

defined in the Project Guidelines
 Filters, Strainers, etc.

Equipment less than 24 OD is exempt from ASME VIII (and

typically fire relief requirement)

Many companies have additional exclusions for small filters

Equipment fabricated from pipe may be treated differently

than ASME stamped equipment

Often rely on downstream equipment for relief check

Project Guidelines on rules to use
 Inlet Control Valve Failure:-

Causes-

Instrumentation failure may occur due to

-Transmission signal failure

-Process Measuring element failure

Mechanical failure may occur due to

-Stem breakage
-Plug jamming
-Misoperation

May result in control valve opening or to move in

opposite direction of its design failure position.
 Determining Applicability

Trace all inlet lines to vessel to identify inlet control devices

Trace upstream from any control devices to determine

maximum expected upstream pressure

Upstream pressure will be normal or maximum operating

pressure

Can selected upstream pressure exceed downstream

equipment design pressure?

Consider relative vessel volumes when the upstream

volume is much less than the downstream volume
 Glycol Contactor Glycol Flash Tank

PSV-1 Dry Gas

@ 750 psig HC Vapors
200 psig
Lean Glycol

Vapor Vapor
Wet Gas LC
675 psig Liquid
LC
Liquid
LV LV

Rich Glycol
 Glycol Contactor Glycol Flash Tank

PSV-1 Dry Gas

@ 750 psig HC Vapors
200 psig
Lean Glycol

Vapor Vapor
Wet Gas LC
675 psig Liquid
Fails
LC
Liquid Open
LV LV

Rich Glycol
 Glycol Contactor Glycol Flash Tank

PSV-1 Dry Gas

@ 750 psig HC Vapors
200 psig
Lean Glycol

Vapor Vapor
Wet Gas LC
675 psig Liquid
Fails
LC
Liquid Open
LV LV

Rich Glycol
 API RP 521 Section 3.10.3

The scenario to consider is that one inlet valve will be in a

fully opened position regardless of the control valve failure
position. Therefore, the required relief capacity is the
difference between the maximum expected inlet flow and
the normal outlet flow adjusted for relieving conditions and
considering unit turndown
 Determining Required Relief Rate

Use control valve manufacturers calculations

Determine valve flow coefficients
Consider partially or fully open bypass
Calculate flow across control valve at downstream relief
pressure
Take credit for normal outflow in volumetric terms
 Gas Blowby Special Considerations

Potential for Two Phase Relief in Downstream Vessel

Perform relative inventory check to determine how much

downstream vessel will fill

Assume downstream level control remains in normal

position

Relief behavior depends on liquid level

- Below inlet nozzle all vapor relief

- Between inlet nozzle and full, perform disengagement

calculation vapor or two phase

- Full liquid displacement equal to volume of

incoming vapor
 Check Downstream Fill Level

Overfill Liquid
Displacement

Potential
Two Phase
Vapor
Inlet from
LC Valve
All Vapor
Venting

LC
Normal
Level
LV
 Gas Blowby Special Considerations

Calculating Flow Across Level Control Valve

Consider assuming two phase flow across valve to reduce

relief requirement
 Heat Exchanger
Tube Rupture
Causes:
- Vibration, corrosion, erosion, thermal shock, differential
shell side to tube side expansion (fixed tube sheet
exchanger), brittle fracture potential, tube to baffle chafing,
degradation of tubes and tube sheets.
High Pressure

Low Pressure
High Pressure

Low Pressure

Corrosion of Tube
High Pressure

Low Pressure

Corrosion of Tube
Pinhole Leak
High Pressure

Low Pressure

Corrosion of Tube
Tube Failure
 Low Pressure on Tube Side

Low Pressure

High Pressure

Corrosion of Tube
Tube Failure
 Determining Applicability

1. Determine maximum high-pressure side pressure (Phi)

- Design Pressure
- relief device set pressure
- other mechanical limitation
2. Determine low-pressure side test pressure along with
associated equipment and piping (Plow)
Compare the two pressures
- If (Phi) > (Plow) then tube rupture relief is required
Not generally applied to double pipe exchangers or other
types of exchangers with schedule pipe for tubes
 API 521 Section 3.18.3
The required rate is determined assuming:

Single tube has been broken down.

The high-pressure side fluid is assumed to flow through the

broken tube.

This is often simplified by conservatively estimating the flow rate

based on two orifices/one orifice.

If there is flash across the broken tube then two phase flow
needs to consider.

Use Cranes equations based on maximum pressure on high

pressure side and relief pressure on low side.
 Additional Considerations

Relief fluid properties are generally not the same as those

upstream of the tube rupture:

- Flashing across tube rupture

- Heating due to contact with hot side fluid

- Displacement of low-pressure side fluid

For high pressure differentials, dynamic analysis is

sometimes applied
 Blocked Outlet (Vapor Or Liquid)

Causes-
Instrumentation System failure may occur
-Transmission signal failure
-Process Measuring element failure

Mechanical failure may occur due to

-Stem breakage
-Plug jamming
-Manual valve mal operation

May result in control valve/block valve to move in

closed position.
Determining Applicability For Blocked Vapor

Identify potential mechanism resulting in blockage

Identify sources of overpressure include compressors,

high-pressure supply headers, and process heat
 Flash Drum-Blocked Vapor

PSV-1 Dry Gas

@ 200 psig
Fails
Close
HC Liquid
250 psig Vapor

CV
LC
Liquid
LV
 Determining Applicability For Blocked
Liquid
Identify potential mechanism resulting in blockage

Identify sources of overpressure include pumps, high-

pressure supply headers.

Adequate indication and response time may render

overfilling not credible

- Independent high level alarm

- 20 minutes of retention after alarm prior to overfill

Often not considered for columns and vessels with no

normal liquid inflow (suction scrubbers, etc.)
 Flash Drum-Blocked Liquid

PSV-1 Dry Gas

@ 200 psig

HC Liquid
250 psig Vapor

CV Fails
LC Close
Liquid
LV
 Required Relief Rates
Centrifugal pumps and compressors
- Performance curves define flow at relief
PD pumps
- Use design flow rate
Reciprocating compressors
- Use reduced volumetric efficiency
High pressure supply headers
- Normal inlet flow
Thermal Expansion
Causes:

Hydraulic expansion can result from several causes, the most

common of which are the following:

a. An exchanger is blocked-in on the cold side with flow in the

hot side.

b. Piping or vessels are blocked-in while they are filled with cold
liquid and are subsequently heated by heat tracing, coils, ambient
heat gain, solar radiation or fire.
Heat Exchanger Thermal Expansion

o
90 F
o
Cold Side 120 F

Hot Side

o o
220 F 110 F
 Cold Side Inadvertently
Blocked Prior to Hot Side
o
90 F
o
Cold Side 120 F

Hot Side

o o
220 F 110 F
 Cold Side Temperature Increases

o
170 F
Cold Side

Hot Side

q=(Cubic Expansion o
220 F
Coeff.*Q)/(1000*sp.gravity*
specific heat capacity)
 Is a relief device required?

Guidelines on piping from, Decide Whether to Use Thermal

Relief Valves, CEP 12/93; Bravo and Beatty

- Yes, for lines more than 80 feet long

- No, for lines with an ID less than 1.5

- No, for lines with high operating temperatures

API RP 521 on exchangers

- Locking open a block valve and posting signs may be

adequate protection
 Check Valve Leakage

Causes-

-Stuck Open
-Broken flapper
-Check valve seat leakage

May result in overpressure due to leakage through check valve

if the maximum normal operating pressure of the high-
pressure system is greater than the design pressure of vessels
present upstream of the check valve.
 Check Valve Leakage

- Leakage rate can be assumed equal to the 10% of the

maximum normal forward flow (vapor or liquid).

-The reverse flow rate through a single check valve can be

determined using the normal flow characteristics (i.e.,
forward-flow Cv) of the check valve. Leakage rate can be
assumed to be 10 % forward flow Cv.
 Overhead Condenser
Failure, Reflux Failure, Abnormal Heat Input
Or Power Failure
Causes-

Utility Failure, Mechanical failure of rotary equipments, Shutting down

of utility compressor, Failure opening of control valve, Pumps or fail
closure of control valve on supply line may result in complete loss of a
utility or the partial loss of a utility, Instrumentation failure or loss of
transformer/MCC/Busbar
 Condenser
PC
Overhead (V)

Reflux (R)
Accumulator
LC
Feed (F)

Reboiler
Column
Heat in (Q) LC
Bottoms (B)
 Loss of Coolant
Condenser to Condenser

PC
Overhead (V)

Reflux (R)
Accumulator
LC
Feed (F)

Reboiler
Column
Heat in (Q) LC
Bottoms (B)
Loss of
Reflux Condenser
PC
Overhead (V)

Reflux (R)
Accumulator
LC
Feed (F)

Process

Reboiler
Column
LC Steam
Heat in (Q)
Bottoms (B)
 Determining Applicability

In general, loss of cooling (from condenser or pump-around

exchanger) will result in overpressure for distillation
systems

Loss of reflux can also result in flooding of condenser

 In Conclusion

Collect information required to perform analysis

Review relevant guidelines

Determine all overpressure scenarios that apply to each

piece of equipment

Analyze required relief rates using standard methods

Be conservative at first
Thank You