Safety in Equipment Design – Part 1

CHE 141
 Why do we need to install a relief device?

http://www.engineeringexpert.net/Engineeri
ng-Expert-Witness-Blog/?p=2697
Pressure Relief Devices

Sources of Overpressure in the Vessel

 Fire
 Uncontrolled chemical reaction which
produces gas and/or excessive heat
 Liquid thermal expansion
 Blocked outlet
 Liquid overfill
 Heat Exchanger Tube Rupture
Pressure Relief Devices

Prevents overpressure in vessels and

piping system.
Relieves excess volume to maintain safe
pressure.
Set pressure is usually equal to vessel’s
design pressure.
Pressure Relief Devices

However, relief devices does not necessarily

protect a vessel against:
High temperature
Thermal Stress
Corrosion / Erosion
Explosion / Detonation
Pressure Relief Devices

1. Open Vent or Goose Neck

 Size the vent such

that it can relieve the
pressure in the
vessel during
emergency
conditions
Pressure Relief Devices

2. Liquid Overflow
Pipe
 Size the liquid
overflow line such
that it can release
the accumulating
liquid in the vessel.
Pressure Relief Devices

3. Rupture Disks

P vessel < P set P vessel  P set

Pressure Relief Devices

4. Relief Valves

P vessel < P set P vessel  P set

 Pressure Relief Devices

The destination of the pressure

relief device vent should
thoroughly be evaluated.
Flare System (Disposal System)

Flares are important safety

devices used in refineries
and petrochemical facilities.
They safely burn excess
hydrocarbon gases which
cannot be recovered or
recycled. Excess
hydrocarbon gases are burnt
in the flare systems in an
environmentally-sound
manner, as an alternative to
releasing the vapour directly
into the atmosphere.
Flare System (Disposal System)

There are generally two types of flares:

1. Elevated flares, where the flare tip is

between 20 to 150 meters above ground.

2. Ground flares, where the flare tip is about

two to three meters above ground, which is
fenced off with a high heat-shield fencing,
which also acts as a safety zone.
What can be seen or heard during flaring?

1. A flame or a glow:

Members of the public may become

concerned when they see flaring and
mistake them for fires.
The elevated flare presents itself as a flame.
The ground flare is not visible in the day. At
night, it may cast an orange glow in the night
sky, depending on cloud cover.
What can be seen or heard during flaring?

2. Smoke:

Sometimes, a white cloud may be observed

around the flare. It is actually steam that is
injected into the flare system to support
clean combustion.
While we strive to achieve smokeless flaring,
it may not always be possible during
operational situations.
On some occasions, there may be black
smoke from the flare.
What can be seen or heard during flaring?

3. Noise:

Flaring may produce a rumbling noise. It

may sound like thunder.
This is due to the turbulent mixing of gases,
air and steam. The sound is similar to what
you hear when you fan a campfire, and
oxygen is mixed with the flame.

Should we control the noise generated from

flare?
Flare System (Disposal System)

http://en.wikipedia.org/wiki/Gas_flare
Stack Supports
Design Procedures

Flare Tip Diameter

Flare tip diameter is generally sized on a

velocity basis, although pressure drop must
also be checked.

Flare tip sizing for flares used to comply with

EPA air emission standards is governed by
rules defined in the Federal Register. To
comply with these requirements, the maximum
velocity of a steam-assisted elevated flare is
given in the ff. equation:
Design Procedures

where:
Vmax = maximum permissible velocity at
the flare tip, ft/s
Bv = Heating value of the gas being
flared, Btu / scf
Design Procedures

By determining the maximum allowed velocity, Vmax

(ft/sec), and knowing the total volumetric
flow rate, Qtot (acfm), including vent stream and
auxiliary fuel gas, a minimum flare tip diameter,
Dmin (in), can be calculated. It is standard practice to
size the flare so that the design velocity of
flow rate Qtot, is 80 percent of Vmax, i.e.:
Design Procedures

The flare tip diameter, D, is the calculated

diameter, D = Dmin, rounded up to the next
commercially available size.

The minimum flare size is 1 inch; larger

sizes are available in 2-inch increments from
2 to 24 inches and in 6-inch increments
above 24 inches. The maximum size
commercially available is 90 inches.
Design Procedures

Flare Height

The height of a flare is determined based on

the ground level limitations of thermal
radiation intensity, luminosity, noise, height
of surrounding structures, and the dispersion
of the exhaust gases.

In addition, consideration must also be given

for plume dispersion in case of possible
emission ignition failure.