Design For Overpressure and Underpressure Protection: Slide Show Exit Slides With Text

Design for
Overpressure and
Underpressure
Protection
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Design for
Overpressure and
Underpressure
Protection
SLIDE PRESENTATION
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Outline
Introduction Introduction
Causes of Overpressure and
Underpressure
Reliefs Reliefs
Effluent Handling Systems for
Reliefs
Runaways Runaway Reactions
Safeguards Overpressure Protection for

Internal Fires and Explosions
For Further Information:
Refer to the Appendix
Supplied with this Presentation
NEXT
PREVIOUS
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Causes of Overpressure
Operating Problem
Equipment Failure
Process Upset
External Fire
Utility Failures
NEXT
PREVIOUS
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Causes of Underpressures
Operating Problem
Equipment Failure
NEXT
PREVIOUS
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Presentation 1 of 3: Reliefs
Causes of NEXT
Presentation 2: Runaways
Overpressure/Underpressure
PREVIOUS
Presentation 1: Reliefs Presentation 3: Safeguards
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Pressure Relief Devices
Spring-Loaded Pressure Relief Valve
Rupture Disc
Buckling Pin
Miscellaneous Mechanical
NEXT
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Spring-Loaded
Pressure Relief Valve
NEXT
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Rupture Disc
NEXT
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Buckling Pin Relief Valve
Closed Full Open

Pressure Below Pressure at or Above
Set Pressure Set Pressure
(Buckles in Milliseconds at a Precise Set Pressure)
NEXT
PREVIOUS
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Simple Mechanical
Pressure Relief
NEXT
PREVIOUS
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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
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Types of Safety Valves
Conventional
Balanced Bellows, and
Pilot-Operated
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Conventional Safety Valve
NEXT
PREVIOUS
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Balanced Bellows Safety Valve
NEXT
PREVIOUS
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Pilot-Operated Safety Valve
NEXT
PREVIOUS
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Types of Relief Valves
Conventional
Balanced Bellows
NEXT
PREVIOUS
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Types of Rupture Discs
Metal
Graphite
Composite
Others
NEXT
PREVIOUS
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Rupture Disc and Pressure
Relief Valve Combination
NEXT
PREVIOUS
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Vacuum Relief Devices
Vacuum Relief Valves
Rupture Discs
Conservation Vents
Manhole Lids
Pressure Control
NEXT
PREVIOUS
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Conservation Vent
NEXT
PREVIOUS
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Pressure or Vacuum Control
Add Air or Nitrogen
Maintain Appropriately
NEXT
PREVIOUS
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Relief Servicing
Inspection
Testing
NEXT
PREVIOUS
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Relief Discharges
To Atmosphere
Prevented
Effluent System
NEXT
PREVIOUS
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Effluent Systems
Knock-Out Drum
Catch Tank
Cyclone Separator
NEXT
PREVIOUS
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Effluent System (continued)
Condenser
Quench Tank
Scrubber
Flares/Incinerators
NEXT
PREVIOUS
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Effluent Handling System
NEXT
PREVIOUS
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Presentation 2 of 3: Runaways
Causes of NEXT
PREVIOUS
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Runaway Reaction
Temperature Increases
Reaction Rate Increases
Pressure Increases
NEXT
PREVIOUS
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Causes of Runaway Reactions
Self-Heating
Sleeper
Characteristics of Runaway
Tempered
Gassy
Hybrid
NEXT
PREVIOUS
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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
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Sleeper Reactions
Reactants Added But Not Mixed
(Error)
Reactants Accumulate
Agitation Started .. Too Late
NEXT
PREVIOUS
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Tempered Reaction
Heat Removed by Evaporation
Heat Removal Maintains a Constant
Temperature
NEXT
PREVIOUS
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Gassy System
No Volatile Solvents
Gas is Reaction Product
NEXT
PREVIOUS
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Hybrid System
Tempered
Gassy
NEXT
PREVIOUS
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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
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Two Phase Flow
NEXT
PREVIOUS
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Relief Valve Sizing
Methodology
Special Calorimeter Data
Special Calculation Methods
NEXT
PREVIOUS
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Characterization of
Runaway Reactions
ARC APTAC
VSP PHI-TEC
RSST Dewars
NEXT
PREVIOUS
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Presentation 3 of 3:
Safeguards
Causes of NEXT
PREVIOUS
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Safeguards
Safety Interlocks
Safeguard Maintenance System
Short-Stopping
NEXT
PREVIOUS
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Safety Interlocks
Agitator Not Working: Stop Monomer
Feed and Add Full Cooling
Abnormal Temperature: Stop
Monomer Feed and Add Full Cooling
NEXT
PREVIOUS
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Safety Interlocks
(continued)
Abnormal Pressure: Stop Monomer Feed
and Add Full Cooling
Abnormal Heat Balance: Stop Monomer
Abnormal Conditions: Add Short-Stop
NEXT
PREVIOUS
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Safeguard Maintenance
System
Routine Maintenance
Management of Change
Mechanical Integrity Checks
Records
NEXT
PREVIOUS
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Short-Stops to Stop Reaction
Add Reaction Stopper
Add Agitation with No Electrical
Power
NEXT
PREVIOUS
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Protection for Internal
Fires and Explosions
Deflagrations
Detonations
NEXT
PREVIOUS
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Protection Methods for
Deflagration Venting
Deflagration Suppression
Containment
NEXT
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(continued)
Reduction of Oxidant
Reduction of Combustible
Flame Front Isolation
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(continued)
Spark Detection and Extinguishing

Flame Detection and Extinguishing
Water Spray and Deluge Systems
NEXT
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Vent Area via NFPA 68
Vent Safely
NEXT
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Vent of Gas Deflagration
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Vent of Dust Deflagration
NEXT
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System
NEXT
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Containment
Prevent Rupture and Vessel
Deformation
Prevent Rupture but Deform
Vessel
NEXT
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Vacuum Purging
Pressure Purging
Sweep-Through Purging
NEXT
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Dilution with Air
NFPA 69
NEXT
PREVIOUS
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NEXT
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Spark/Flame Detection
and Extinguishing
NEXT
PREVIOUS
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Water Spray or
Deluge Systems
NEXT
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Deluge System
NEXT
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Conclusion
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End of Slide Presentation
Causes of NEXT
PREVIOUS
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Design for
Overpressure and
Underpressure
Protection
SLIDES WITH TEXT
Introduction
This presentation includes technical information NEXT
Reliefs concerning the design for overpressure and
Runaways underpressure protection. The presentation is designed PREVIOUS
Safeguards to help students and engineers to: Slide Home
Design for
Overpressure and
Underpressure
Protection
Introduction
Understand the technologies, special engineering NEXT
Reliefs devices, and methods that are used for the protection
Runaways against overpressure and underpressure (vacuum) PREVIOUS
Safeguards incidents, Slide Home
Design for
Overpressure and
Underpressure
Protection
Introduction
Understand the root causes of overpressure and NEXT
Reliefs underpressure incidents, and
Runaways Design plants with the appropriate features to protect PREVIOUS
Safeguards against overpressure and underpressure incidents. 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
This presentation is divided into six sections: NEXT
Reliefs
Runaways PREVIOUS
Safeguards Slide Home
Six Sections
1. Introduction
Underpressure
3. Reliefs
and Explosions
Introduction
The Introduction button on your left will lead you to this NEXT
Reliefs introduction and an explaination of the Causes of
Runaways Overpressure and Underpressure PREVIOUS
Six Sections
1. Introduction
Underpressure
3. Reliefs
and Explosions
Introduction
The Reliefs Button sends you to Sections 3 and 4, NEXT
Reliefs covering Reliefs and Effluent Handling Systems for
Runaways Reliefs PREVIOUS
Six Sections
1. Introduction
Underpressure
3. Reliefs
and Explosions
Introduction
The Runaways Button leads to a discussion on NEXT
Reliefs Runaway Reactions, and . . .
Runaways PREVIOUS
Six Sections
1. Introduction
Underpressure
3. Reliefs
and Explosions
Introduction
The Safeguards Button will take you to a section on NEXT
Reliefs Overpressure Protection fot Internal Fires and
Runaways Explosions PREVIOUS
Appendix Contains
Detailed Information
Introduction
This design package includes an appendix with detailed NEXT
Reliefs information for each of the sections of this presentation.
Runaways The appendix also includes an extensive list of relevant PREVIOUS
Safeguards references. Slide Home
Operating Problem
Introduction The major causes of overpressure include:

Operating problems or mistakes such as an operator mistakenly
NEXT
Reliefs opening or closing a valve to cause the vessel or system pressure to
Runaways increase. An operator, for example, may adjust a steam regulator to PREVIOUS
give pressures exceeding the maximum allowable working pressure
Safeguards (MAWP) of a steam jacket. Slide Home
Operating Problem
Introduction Although the set pressure is usually at the MAWP, the design safety NEXT
Reliefs factors should protect the vessel for higher pressures; a vessel fails when
the pressure is typically several times the MAWP.
Runaways PREVIOUS
Operating Problem
Equipment Failure
Introduction Equipment failures; for example a heat exchanger tube rupture that NEXT
Reliefs increases the shell side pressure beyond the MAWP. Although the set
pressure is usually the MAWP, the design safety factors should protect
Runaways the vessel for higher pressures; a vessel fails when the pressure is PREVIOUS
Safeguards typically several times the MAWP.
Slide Home
Operating Problem
Equipment Failure
Process Upset
External Fire
Utility Failures
Introduction Process upset; for example a runaway reaction causing high
temperatures and pressures. NEXT
Reliefs External heating, such as, a fire that heats the contents of a vessel
Runaways giving high vapor pressures, and PREVIOUS
Utility failures, such as the loss of cooling or the loss of agitation
Safeguards causing a runaway reaction. Slide Home
Introduction The causes of underpressure or the inadvertent creation of a NEXT

Reliefs vacuum are usually due to operating problems or equipment
failures.
Runaways PREVIOUS
Operating Problem
Introduction Operating problems include mistakes such as pumping liquid NEXT

Reliefs out of a closed system, or cooling and condensing vapors in a
closed system.
Runaways PREVIOUS
Operating Problem
Equipment Failure
Introduction Equipment failures include an instrument malfunction (e.g. NEXT

Reliefs vacuum gage) or the loss of the heat input of a system that
contains a material with a low vapor pressure.
Runaways PREVIOUS
Part 1 of 3: Reliefs
Introduction
NEXT
Reliefs
Runaways PREVIOUS
Introduction Pressure relief devices are added to process equipment to NEXT

Reliefs prevent the pressures from significantly exceeding the MAWP
(pressures are allowed to go slightly above the MAWP during
Runaways emergency reliefs). PREVIOUS
Spring-Loaded Pressure Relief Valve
Rupture Disc
Buckling Pin
Miscellaneous Mechanical
Introduction The pressure relief devices include spring-loaded pressure relief NEXT
Reliefs valves, rupture discs, buckling pins, and miscellaneous
mechanical devices.
Runaways PREVIOUS
Spring-Loaded
Pressure Relief Valve
Introduction This is a sketch of a spring-loaded pressure relief valve. As the NEXT

Reliefs pressure in the vessel or pipeline at point A exceeds the
pressure created by the spring, the valve opens. The relief
Runaways begins to open at the set pressure which is usually at or below PREVIOUS
the MAWP; this pressure is usually set at the MAWP.
Rupture Disc
Introduction This is a sketch of a rupture disc. In this case the disc ruptures NEXT
Reliefs when the pressure at A exceeds the set pressure. Recognize,
however, that it is actually the differential pressure (A-B), that
Runaways ruptures the disc. PREVIOUS
Closed Full Open

Introduction This sketch shows a buckling pin pressure relief valve. As NEXT
Reliefs shown, when the pressure exceeds the set pressure, the pin
buckles and the vessel contents exit through the open valve.
Runaways The rupture disc and the buckling pin relief valves stay open PREVIOUS
Safeguards after they are opened.
Slide Home
Closed Full Open

Introduction The spring operated valves close as the pressure decreases NEXT
Reliefs below the blowdown pressure. The blowdown pressure is the
Runaways
difference between the set pressure and closing pressure. PREVIOUS
Simple Mechanical
Pressure Relief
Introduction A simple mechanical pressure relief is a weighted man-way NEXT

Reliefs cover as shown in this sketch. Another mechanical relief is a U-
tube filled with water (or equivalent).
Runaways PREVIOUS
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 There are three types of spring-loaded pressure relief valves: NEXT
Reliefs Safety valves are specifically designed for gases.
Runaways
Relief valves are designed for liquids, and PREVIOUS
Safety relief valves are designed for liquids and/or gases.
Types of Safety Valves
Conventional
Balanced Bellows, and
Pilot-Operated
Introduction There are three types of safety valves; that is: NEXT
Reliefs Conventional,
Runaways
Balanced bellows, and PREVIOUS
Pilot-operated.
Conventional Safety Valve
Introduction A conventional safety valve is designed to provide full opening NEXT

Reliefs with minimum overpressure. The disc is specially shaped to
Runaways
give a pop action as the valve begins to open. PREVIOUS
Introduction A balanced bellows safety valve is specially designed to reduce NEXT

Reliefs the effect of the back pressure on the opening pressure. As
illustrated in this sketch the differential pressure that is required
Runaways to open the valve is the pressure inside the vessel minus the PREVIOUS
atmospheric pressure.
Introduction The bellows design allows the outside air and pressure to be on NEXT
Reliefs the downstream side of the valve seal. Once the relief is open,
then the flow is a function of the differential pressure A-B.
Runaways PREVIOUS
Introduction A pilot-operated safety valve is a spring-loaded valve. As NEXT

Reliefs illustrated, the vessel pressure helps to keep the valve closed.
When the pressure exceeds the set pressure (or the spring
Runaways pressure), the pressure on top of the valve is vented and the PREVIOUS
valve opens.
Introduction The set pressure of this type of valve can be closer to the
operating pressure compared to conventional and balanced
NEXT
Reliefs bellows valves. The disadvantages, however, are (a) the
Runaways process fluid needs to be clean, (b) the seals must be resistant PREVIOUS
to the fluids, and (c) the seals and valves must be appropriately
Safeguards maintained. Slide Home
Introduction These disadvantages are also true for spring operated reliefs. NEXT
Reliefs Pilot-operated valves are not used in liquid service; they are
normally used in very clean and low pressure applications.
Runaways PREVIOUS
Types of Relief Valves
Conventional
Balanced Bellows
Introduction Relief valves (for liquid service) are either the conventional or NEXT
Reliefs the balanced bellows types.
Runaways PREVIOUS
Metal
Graphite
Composite
Others
Introduction As illustrated, there are many different types of rupture discs. NEXT
Reliefs They are especially applicable for very corrosive environments;
Runaways
for example: discs made of carbon or Teflon coating are used PREVIOUS
for corrosive service.
Metal
Graphite
Composite
Others
Introduction A rupture disc that is used for pressure reliefs may need a NEXT
Reliefs specially designed mechanical support if it is also used in
Runaways
vacuum service. PREVIOUS
Introduction Rupture discs, as illustrated, are sometimes used in NEXT

Reliefs combination with a spring operated relief device. In this case
the disc gives a positive seal compared to the disc-to-seal
Runaways design of a spring operated valve. PREVIOUS
Introduction This is useful when handling very toxic materials where even a NEXT
Reliefs very small release (through the seal) may be hazardous, or
when handling materials that polymerize.
Runaways The spring operated relief following the rupture disc reseats PREVIOUS
Safeguards when the pressure drops below the blow-down pressure.
Slide Home
Introduction This design, therefore, stops the discharge from the vessel. NEXT
Reliefs The discharge is not stopped if only a rupture disc is used. This
design (rupture disc followed by a spring-operated relief) is
Runaways discouraged by some practitioners. PREVIOUS
Introduction In this design, as illustrated, a pressure detection device (per NEXT

Reliefs ASME Code), e.g., a pressure indicator, needs to be placed
between the disc and the spring-operated valve. This pressure
Runaways reading is checked periodically to be sure the rupture disc has PREVIOUS
its mechanical integrity.
Introduction A pin-hole leak in the rupture disc could increase the pressure NEXT
Reliefs on the discharge side of the disc. This is a major problem
because it increases the relief pressure, that is: the differential
Runaways pressure across the disc is the rupturing mechanism. PREVIOUS
Introduction Another major problem with this design is the possibility that a NEXT
Reliefs piece of the rupture disc could plug the discharge orifice of the
spring operated relief. This problem is prevented by specifying
Runaways a rupture disc that will maintain its integrity when it is ruptured; PREVIOUS
that is, non-fragmenting.
Vacuum Relief Devices
Vacuum Relief Valves
Rupture Discs
Conservation Vents
Manhole Lids
Pressure Control
Introduction Vacuum relief devices are: vacuum relief valves, rupture discs, NEXT
Reliefs conservation vents, manhole lids designed for vacuum relief,
Runaways
and pressure control. PREVIOUS
Conservation Vent
Introduction A conservation vent is illustrated in this sketch. As shown, it is NEXT

Reliefs 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
Runaways vessel to prevent a vacuum, usually a vacuum no more than 4 PREVIOUS
inches of water.
Pressure or Vacuum Control
Add Air or Nitrogen
Maintain Appropriately
Introduction Sometimes pressure or vacuum control systems are used to add air or NEXT
Reliefs nitrogen to the vessel to maintain a slight pressure. In this case, the
system needs to be appropriately maintained because a malfunction
Runaways could result in an overpressure or underpressure. In either case the PREVIOUS
Safeguards consequence could be a ruptured vessel.
Slide Home
Relief Servicing
Inspection
Testing
Introduction Every relief device needs to be inspected and tested before NEXT
Reliefs installation and then at predetermined intervals during its
lifetime. The interval depends on the service history, vendor
Runaways recommendations, and regulatory requirements, but it is usually PREVIOUS
once a year.
Relief Servicing
Inspection
Testing
Introduction Operating results and experience may indicate shorter or longer NEXT
Reliefs intervals.
Records must be carefully maintained for every inspection and
Runaways test, and for the entire life of the plant. PREVIOUS
Relief Discharges
To Atmosphere
Introduction Discharges from pressure relief devices may be sent directly to NEXT
Reliefs the atmosphere if they are innocuous, discharged in a safe
Runaways
manner, and regulations permit it. PREVIOUS
Relief Discharges
To Atmosphere
Prevented
Introduction An additional option is to prevent releases by (a) designing NEXT

Reliefs vessels with high MAWPs to contain all overpressure scenarios,
Runaways
or (b) add a sufficient number of safeguards and/or controls to PREVIOUS
make overpressure scenarios essentially impossible.
Relief Discharges
To Atmosphere
Prevented
Effluent System
Introduction The third option is to design an effluent system to capture all NEXT
Reliefs nocuous liquids and gases.
Runaways PREVIOUS
Effluent Systems
Knock-Out Drum
Catch Tank
Cyclone Separator
Introduction An effluent system may contain a NEXT

Reliefs Knock-out drum
Runaways
Catch tank PREVIOUS
Cyclone separator
Effluent System (continued)
Condenser
Quench Tank
Scrubber
Flares/Incinerators
Introduction Condenser
Quench tank
NEXT
Reliefs Scrubber, and/or
Runaways Flares or incinerators PREVIOUS
An effluent handling system may have any combination of the above unit
Safeguards operations. Slide Home
Introduction One effluent handling system is illustrated in this sketch. Every NEXT
Reliefs element of an effluent system needs to be designed very
carefully. The design requires detailed physical and chemical
Runaways properties, and the correct design methodology for each unit PREVIOUS
operation.
Introduction It should also be recognized that it is important to size the relief NEXT
Reliefs appropriately, because the size of the entire effluent system is
based on this discharge rate. The design methodology is in the
Runaways references noted in the Appendix of this package. PREVIOUS
Part 2 of 3: Runaways
Introduction
NEXT
Reliefs
Runaways PREVIOUS
Runaway Reaction
Temperature Increases
Reaction Rate Increases
Pressure Increases
Introduction A runaway reaction is an especially important overpressure scenario. A

runaway reaction has an accelerating rate of temperature increase, rate
NEXT
Reliefs of reaction increase, and usually rate of pressure increase. The
Runaways pressure, of course, increases if the reaction mass has a volatile PREVIOUS
substance, such as, a solvent or a monomer; or if one of the reaction
Safeguards products is a gas. Slide Home
Self-Heating
Sleeper
Tempered
Gassy
Hybrid
Introduction In general, there are two causes of runaway reactions (self- NEXT
Reliefs heating and sleeper) and three characteristics of runaways
Runaways
(tempered, gassy, and hybrid). PREVIOUS
Self-Heating
Sleeper
Tempered
Gassy
Hybrid
Introduction When protecting a system for overpressures due to runaway reactions NEXT
Reliefs the engineer needs to know the type of runaway and needs to
characterize the behavior of the specific runaway with a special
Runaways calorimeter. This specific methodology is described in this section of this PREVIOUS
Safeguards presentation.
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 One self-heating scenario occurs when the reaction is NEXT

Reliefs exothermic and a loss of cooling gives an uncontrolled
Runaways
temperature rise. A few causes of self-heating scenarios are PREVIOUS
shown.
Sleeper Reactions
(Error)
Introduction Sleeper reactions are usually the result of an operator error. Two NEXT
Reliefs 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
Runaways to the reaction mass when the temperature is mistakenly lower than that PREVIOUS
Safeguards required to initiate the reaction.
Slide Home
Sleeper Reactions
(Error)
Introduction In these cases the runaway is initiated by starting the agitator NEXT
Reliefs and adding heat respectively.
Runaways PREVIOUS
Tempered Reaction
Heat Removed by Evaporation
Heat Removal Maintains a Constant
Temperature
Introduction Tempered runaway reactions maintain their temperature when the energy
exiting the relief device is equal to the energy generated in the reactor
NEXT
Reliefs due to the exothermic reaction. The reaction heat is absorbed by the
Runaways evaporation of the volatile components. The vapor pressure in a PREVIOUS
tempered system can typically be characterized by an Antoine type
Safeguards equation. Slide Home
Gassy System
No Volatile Solvents
Gas is Reaction Product
Introduction A system that is characterized as gassy has no volatile NEXT

Reliefs solvents or reactants. The pressure build-up is due to the
Runaways
generation of noncondensible gas such as N2 or CO2. PREVIOUS
Hybrid System
Tempered
Gassy
Introduction A hybrid system is the combination of a tempered and a gassy NEXT

Reliefs system. Under runaway conditions, the pressure increases due
Runaways
to the vapor pressure of the volatile components as well as from PREVIOUS
the generation of noncondensible gaseous reaction products.
Introduction Under runaway conditions, when the relief device opens, the NEXT
Reliefs relief discharge is a foam; that is, the gases are entrained with
Runaways
the liquid. PREVIOUS
Introduction To maintain a constant temperature in the reactor (i.e. control the NEXT
Reliefs runaway reaction), the relief valve is sized to remove all the heat
generated from the exothermic reaction via the heat removed with the
Runaways discharged mass, which is typically a foam. Detailed information on PREVIOUS
Safeguards runaway reactions is found in the appendix.
Slide Home
Relief Area: 2 to 10 Times the
Area of a Single Gaseous Phase
Introduction The required relief area to remove this heat with the foam is two NEXT
Reliefs to ten times the area that would be required by releasing a
Runaways
single gaseous phase. PREVIOUS
Two Phase Flow
Introduction This is a picture that illustrates the two-phase flow

characteristics of a relief discharge due to a runaway reaction.
NEXT
Reliefs As illustrated, the discharge is similar to the release of foam
Runaways from a freshly opened bottle of pop after being shakened. If the PREVIOUS
relief is not designed for two-phase flow, the pressures would
Safeguards increase rapidly and the vessel could rupture. Slide Home
Relief Valve Sizing
Methodology
Special Calorimeter Data
Special Calculation Methods
Introduction The relief valve sizing methodology for runaway reactions is NEXT
Reliefs very complex. It requires the characterization of the runaway
reaction using a specially designed calorimeter.
Runaways Relief valve sizing, additionally, requires special calculation PREVIOUS
Safeguards methods that are described in the Appendix of this package.
Slide Home
Characterization of
Runaway Reactions
Introduction The characterization of runaway reactions includes the NEXT

Reliefs determination of the rates of rise of the temperature and
pressure under adiabatic conditions. The test results also
Runaways characterize the reaction type, that is, tempered, gassy, and/or PREVIOUS
a hybrid system.
Characterization of
Runaway Reactions
ARC
VSP
RSST
Introduction Various calorimeters are used for this characterization: NEXT

Reliefs The accelerating rate calorimeter (ARC)
The vent sizing package (VSP)
Runaways The reactive system screening tool (RSST) PREVIOUS
Characterization of
Runaway Reactions
ARC APTAC
VSP PHI-TEC
RSST Dewars
Introduction The automated pressure-tracking adiabatic calorimeter (APTAC) NEXT

Reliefs The Phi-Tec, and
Dewars.
Runaways Each of these calorimeters have advantages and disadvantages PREVIOUS
Safeguards that need to be understood when studying a specific system.
Slide Home
Part 3 of 3: Safeguards
Introduction
NEXT
Reliefs
Runaways PREVIOUS
Safeguards
Introduction This section of the presentation covers safeguards. Safeguards NEXT

Reliefs include the methods and controls used to prevent runaways. As
illustrated previously, a containment system (a safeguard), can
Runaways be very complex and expensive. Alternatively, a series of PREVIOUS
safeguards may be justified.
Safeguards
Safety Interlocks
Safeguard Maintenance System
Short-Stopping
Introduction Safeguards include safety interlocks, safeguard maintenance NEXT

Reliefs system, and/or short-stopping.
Runaways PREVIOUS
Safety Interlocks
Agitator Not Working: Stop Monomer
Abnormal Temperature: Stop
Monomer Feed and Add Full Cooling
Introduction The list of alternative interlocks is fairly extensive. Usually more than one NEXT
Reliefs interlock and some redundancy and diversity is required for each
runaway scenario. As the number of interlocks increases, the reliability of
Runaways the system increases. These are examples of safety interlocks for a PREVIOUS
Safeguards semibatch polymerization reactor.
Slide Home
Safety Interlocks
(continued)
Abnormal Pressure: Stop Monomer Feed
and Add Full Cooling
Abnormal Heat Balance: Stop Monomer
Abnormal Conditions: Add Short-Stop
Introduction This is a list of additional interlocks. Other interlocks (manual) NEXT

Reliefs that are not on this list include: gages with manual shutdowns,
Runaways
and alarms with manual shutdowns. PREVIOUS
System
Routine Maintenance
Records
Introduction A safeguard maintenance system includes routine maintenance,
management of change, mechanical integrity checks, and the
NEXT
Reliefs appropriate records. These are the steps that are required to
Runaways be sure the safeguards and interlocks perform appropriately PREVIOUS
under emergency conditions and/or potential runaway reaction
Safeguards scenarios. Slide Home
System
Routine Maintenance
Records
Introduction The maintenance of safeguard systems is especially important, because:
Safeguards and interlocks do not operate on a day-to-day basis, but
NEXT
Reliefs When they are required to operate (emergency conditions) they need
Runaways to operate flawlessly. PREVIOUS
See ISA SP 84.01 for details for the design of safety instrumented
Safeguards systems. Slide Home
Power
Introduction A short-stopping system, stops a runaway reaction by adding a

reaction stopper solution to the reacting mass. The reaction-stopper
NEXT
Reliefs stops the reaction in time to short-circuit the progress of the
Runaways reaction. A reaction stopper needs to be added when the reaction PREVIOUS
mass is relatively cold. If the mass is too hot, a short-stopper will
Safeguards not work. Slide Home
Power
Introduction Good agitation, of course, is required to adequately mix the reaction

mass with the inhibitor. Since a power failure is often the initiating
NEXT
Reliefs event of a runaway, an alternative method of agitation needs to be
Runaways included in the design. A compressed nitrogen system together with PREVIOUS
a sparge ring is one alternative.
Deflagrations
Detonations
Introduction This section of the presentation covers protection methods for NEXT
Reliefs internal fires and explosions.
Overpressure protection is needed for process equipment that
Runaways can potentially explode due to an internal deflagration or PREVIOUS
Safeguards detonation.
Slide Home
Deflagrations
Detonations
Introduction A deflagration is defined as the propagation of a combustion NEXT

Reliefs zone at a velocity in the unreacted medium that is less than the
speed of sound. A detonation has a velocity greater than the
Runaways speed of sound in the unreacted medium. PREVIOUS
Deflagrations
Detonations
Introduction The burning material can be a combustible gas, a combustible NEXT

Reliefs dust, a combustible mist, or a hybrid mixture (a mixture of a
combustible gas with either a combustible dust or combustible
Runaways mist). The reaction actually occurs in the vapor phase between PREVIOUS
the fuel and the air or some other oxidant.
Containment
Introduction The protection methods used for fires or explosions include NEXT
Reliefs Deflagration venting
Runaways
Deflagration suppression PREVIOUS
Containment
(continued)
Introduction Reduction of the oxidant NEXT

Reliefs Reduction of the combustible
Runaways
Flame front isolation PREVIOUS
(continued)
Spark Detection and Extinguishing

Flame Detection and Extinguishing
Water Spray and Deluge Systems
Introduction Spark detection and extinguishing NEXT

Reliefs Flame detection and extinguishing
Runaways
Water or foam spray deluge systems PREVIOUS
Introduction The technology required for venting deflagrations is given in NEXT

Reliefs NFPA 68. Deflagration venting is usually the simplest and least
Runaways
costly means of protecting process equipment against damage PREVIOUS
due to the internal pressure rise from deflagrations.
Vent Safely
Introduction If equipment is located inside a building, the vents must be NEXT

Reliefs discharged through a vent duct system to a safe location
outside of the building. The design of the vent duct system is
Runaways critical to avoid excessive pressures developed during the PREVIOUS
venting process. See NFPA 68 for details.
Vent Safely
Introduction A safe location will avoid injury to personnel and minimize NEXT
Reliefs damage to equipment outside of the building. The next two
pictures illustrate that the safe venting may not be trivial.
Runaways PREVIOUS
Vent of Gas Deflagration
Introduction This is a picture of the venting of a gas deflagration. As illustrated,

the flame propagates a significant distance from the vessel. The
NEXT
Reliefs length of the flame is estimated using an equation found in NFPA
Runaways 68. The main purpose of venting is to protect the mechanical PREVIOUS
integrity of the equipment. As illustrated, even when it is vented
Safeguards safely, this is a major event. Slide Home
Vent of Dust Deflagration
Introduction 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.
NEXT
Reliefs With dusts, this burning zone is larger because the container has a
Runaways larger fuel-to-air ratio compared to the gas deflagration scenario. PREVIOUS
These pictures clearly illustrate the problems with venting
Safeguards deflagrations. Slide Home
System
Introduction One alternative to venting a deflagration is suppression. This NEXT

Reliefs sketch illustrates a deflagration suppression system that
Runaways
includes (a) a flame or pressure detector, (b) a quick opening PREVIOUS
valve, and (c) the addition of a flame suppressant.
System
Introduction The commonly used suppression agents include water, NEXT

Reliefs potassium acid phosphate, sodium bicarbonate, and Halon
Runaways
substitutes. The technology for deflagration suppression is PREVIOUS
described in NFPA 69.
Containment
Prevent Rupture and Vessel
Deformation
Prevent Rupture but Deform
Vessel
Introduction The thickness of vessel walls may be increased to contain the

pressure of a deflagration.
NEXT
Reliefs The wall thickness can be large enough to prevent the
Runaways deformation of the vessel, or PREVIOUS
The wall thickness may be large enough to prevent a rupture, but
Safeguards allow the vessel to deform. Slide Home
Vacuum Purging
Pressure Purging
Introduction Protection for overpressures is also provided with an inert gas NEXT
Reliefs blanket to prevent the occurrence of a deflagration. Before
introducing a flammable substance to a vessel, the vessel must
Runaways also be purged with an inert gas to reduce the oxidant PREVIOUS
concentration sufficiently so that the gas mixture cannot burn.
Vacuum Purging
Pressure Purging
Introduction The purging methods include vacuum purging, pressure NEXT

Reliefs purging, and sweep-through purging. See NFPA 69 and the
book by Crowl and Louvar for more details.
Runaways PREVIOUS
Dilution with Air
NFPA 69
Introduction A deflagration can also be prevented by reducing the concentration NEXT

Reliefs of the combustible material so that the concentration is below the
lower flammability limit (LFL). This is usually accomplished by
Runaways PREVIOUS
dilution with nitrogen. The specifications for this type system are
Safeguards given in NFPA 69. Slide Home
Introduction As illustrated, isolation devices are used in piping systems to prevent the NEXT
Reliefs propagation of a flame front. The method illustrated has a fast-acting
block valve.
Runaways This isolation system prevents the propagation of the flame front; more PREVIOUS
Safeguards importantly it prevents deflagration transitions to detonations.
Slide Home
Spark/Flame Detection
and Extinguishing
Introduction Another method of preventing the propagation of deflagrations in

pipelines is the early detection and extinguishment of sparks or flames. NEXT
Reliefs In this type system, a detector activates an automatic extinguishing
system that sprays water or other extinguishing agents into the fire. This PREVIOUS
Runaways system is similar to the deflagration suppression system discussed
Safeguards previously.
Slide Home
Water Spray or
Deluge Systems
Introduction Process equipment and structures are very effectively protected against NEXT
Reliefs fire by water spray or deluge systems. They can be activated manually
or automatically. They are designed to cool the equipment or structural
Runaways members so that the heat from a fire will not weaken them. PREVIOUS
Deluge System
Introduction This picture shows a typical deluge system in operation. In this NEXT
Reliefs example, the deluge system is automatically activated when the
Runaways
concentration of the flammable gas below the vessel is detected PREVIOUS
to be at or over 25% of the lower flammability limit.
Conclusion
Introduction This concludes our technology package covering overpressure and NEXT
Reliefs underpressure protection. The appendix of this package contains
more detailed information. The enclosed references contain the
Runaways PREVIOUS
state-of-the-art technology to assist engineers and students with
Safeguards their detailed designs. Slide Home
End of Slide Presentation
(with text)
Causes of HOME
PREVIOUS
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Safeguards Overpressure Protection for

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Spark Detection and Extinguishing

Introduction The major causes of overpressure include:

Introduction The causes of underpressure or the inadvertent creation of a NEXT

Introduction Operating problems include mistakes such as pumping liquid NEXT

Introduction Equipment failures include an instrument malfunction (e.g. NEXT

Introduction Pressure relief devices are added to process equipment to NEXT

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

Closed Full Open

Closed Full Open

Introduction A simple mechanical pressure relief is a weighted man-way NEXT

Introduction A conventional safety valve is designed to provide full opening NEXT

Introduction A balanced bellows safety valve is specially designed to reduce NEXT

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

Introduction Rupture discs, as illustrated, are sometimes used in NEXT

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

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

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

Introduction An effluent system may contain a NEXT

Introduction A runaway reaction is an especially important overpressure scenario. A

Introduction One self-heating scenario occurs when the reaction is NEXT

Introduction A system that is characterized as gassy has no volatile NEXT

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

Introduction This is a picture that illustrates the two-phase flow

Introduction The characterization of runaway reactions includes the NEXT

Introduction Various calorimeters are used for this characterization: NEXT

Introduction The automated pressure-tracking adiabatic calorimeter (APTAC) NEXT

Introduction This section of the presentation covers safeguards. Safeguards NEXT

Introduction Safeguards include safety interlocks, safeguard maintenance NEXT

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

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

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

Introduction A deflagration is defined as the propagation of a combustion NEXT

Introduction The burning material can be a combustible gas, a combustible NEXT

Introduction Reduction of the oxidant NEXT

Spark Detection and Extinguishing

Introduction Spark detection and extinguishing NEXT

Introduction The technology required for venting deflagrations is given in NEXT

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

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

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

Introduction One alternative to venting a deflagration is suppression. This NEXT

Introduction The commonly used suppression agents include water, NEXT

Introduction The thickness of vessel walls may be increased to contain the

Introduction The purging methods include vacuum purging, pressure NEXT

Introduction A deflagration can also be prevented by reducing the concentration NEXT

Introduction Another method of preventing the propagation of deflagrations in

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