Safety in Equipment Design - Part 2

CHE 141
Liquid Overfill Hazard
Layers of Protection

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Layers of Protection
Layers of Protection

http://en.wikipedia.org/wiki/File:Safety_Layer_Protection.png
 Why do we need to install a relief device?

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ng-Expert-Witness-Blog/?p=2697
Pressure Relief Valve
Pressure Relief Valve
Pressure Relief Valve
Relief Valve Codes and Standards

API 2000  for tanks with design pressure of

less than 15 psig

For pressure vessels (DP ≥ 15 psig):

ASME Boiler & Pressure Code, Sec. VIII
API 520 Part 1
API 520 Part 2
API 521
API 526
Backpressure

Back pressure is defined as the pressure that

exists at PSV’s outlet.

It has impact to performance of PSV, hence

its value should be informed to vendor
therefore shall be stated in the datasheet.

Good concept understanding of the back

pressure is helpful when calculating its value.
Total Backpressure = Superimposed + Built-up

Superimposed back pressure is pressure

coming from other sources when PSV in
“ready/closed mode”. It may be constant or
variable depends on the sources.

Built up back pressure is pressure

generated as a result of fluid flowing through
PSV in “open mode.” Typically, this is the
pressure drop (or frictional losses) during
relief condition.
Total Backpressure = Superimposed + Built-up
Backpressure

10 barg
1. What is the superimposed
backpressure on the PSV?
2. What is the built-up
backpressure on the PSV?
3. What is the total
backpressure on the PSV?
Types of Relief Valves

Conventional Relief Valve

•Backpressure < 10% of Set Pressure

Balanced Bellows Relief Valve

•10% of Set Pressure < Backpressure < 50% of Set
Pressure

Pilot-Operated Relief Valve

•Backpressure > 50% of Set Pressure
Types of Relief Valves

Conventional Balanced Bellows

Types of Relief Valves

Pilot Operated
Types of Relief Valves

Which relief valve is not affected by

backpressure?

A.Conventional
B.Balanced Bellows
C.Pilot Operated
Design Pressure

In setting the design pressure of

equipment and vessels, always consider
the transient conditions that may happen in
the process unit (e.g. loss of reflux,
abnormal heat input in the reboiler,
exothermic reactions, pressure surges,
etc.).
Design Pressure

As a guideline, the following can be

considered in setting the internal design
pressure of vessels.

Operating Pressure Design Pressure

0 – 25 psig 50 psig
25 – 250 psig Operating + 25 psig
250 – 1000 psig Operating + 10%
Over 1000 psig Operating + 5%
Vessel Pressurization Curve

Pressure
ASME Design Margin:
Burst Pressure = 3X of Design Pressure

Time
Vessel Pressurization Curve

“Unfailed”
Vessel w/o PRV
Burst Pressure

Pressure
Hydrotest Pressure
Vessel w/ PRV

PRV at 100% opening = should correspond to

maximum allowable accumulation
PRV starts to open

Time
Relief Valve Operation
Accumulation Pressure
Quiz

1. The normal operating pressure of a vessel is

500 psig. What should be its design
pressure?
2. The same vessel is protected by a PSV.
What should be the set pressure of the PSV?
3. For fire case, what is the relief pressure of
the PSV on the said vessel?
4. For other relief cases, what is the relief
pressure of the PSV on the said vessel?
Determine the Pressure Relief Rate

Accumulation = + Generation
– Consumption
+ In
– Out
For Gases: PV = znRT

Make “Out” (relief device) large enough to

prevent “P” from dangerously rising!
Relief Scenario/Cases

Typical Sources of Overpressure in the

Vessel
 Blocked outlet
 Fire
 Liquid thermal expansion due to abnormal
heat input (e.g. solar heating, exothermic
reaction, failure of heat exchanger control)
 Heat Exchanger Tube Rupture
 Blocked Outlet

What much flow should we allow the PSV to

pass to avoid overpressure?

Accumulation = Gen. – Consump. + In – Out

Out = In = 100 m3/hr
Fire Case – Liquid Filled Vessel with
Design Pressure > 15 psig (API STD)
Fire Case

Vessel contains water at

ambient temperature.
The design pressure of
the vessel is 10 barg.
Max. Liquid
Non-fire Level = 90%
Vessels dimension: 2 m resistant of T/T
ID, 4 m T/T, 2:1 elliptical foam-based
heads insulation. 3m

Calculate the required 0m

relief rate through the
PSV.
Heat Exchanger Tube Rupture

What will happen if we have tube rupture?

 If the design pressure of the tubeside is higher than
the shellside, “coolant” will pressurize the shellside until
the shellside leaks!
Heat Exchanger Tube Rupture
(API Standard)

Per API STD 521: Tube rupture case may

not be considered in sizing a relief valve if
the design pressure of the low pressure side
is 10/13 of the design pressure of the high
pressure side.
Heat Exchanger Tube Rupture
(API STD)

Do we need a relief valve?

Case 1: Design pressure of tubeside is 10 barg.
Design pressure of shellside is 10 barg.
Case 2: Design pressure of tubeside is 10 barg.
Design pressure of shellside is 1 barg.
Heat Exchanger Tube Rupture (Liquid)

Tube ID = 0.834 inches

Shellside Design Pressure = 1 barg

Calculate the required relief rate through the PSV.

Liquid Thermal Expansion (API STD)

If the operator closes the

valve at the “Liquid
Product” line and the
electric heater continues
to operate, what will
happen?

Do we need a relief
valve here?
Liquid Thermal Expansion (API STD)
Liquid Thermal Expansion (API STD)

Maximum heat from electric

heater = 37,470 kJ/hr

Cubic expansion coefficient =

0.0067 per degC

Vessel is insulated using non-

fire resistant foam

Fluid specific gravity = 0.4177

Specific heat at relieving

condition = 3.838 kJ/kgC

Calculate the required relief

rate through the PSV.
Liquid Thermal Expansion (API STD)

The cubic expansion coefficient for the trapped liquid

can be approximated by:

T1 = below the relief temperature

T2 = above the relief temperature
1 = density at T1 at relief pressure
2 = density at T2 at relief pressure

Other references include Perry’s 8th ed. Table 2-137.

Pressure Relief Valve Sizing

Relief valve nozzle sizing formulas given in

API 520 Part 1 for liquid relief, vapor relief
(chocked and non-chocked), steam relief,
two-phase relief.

Relief valve selected based on scenario

requiring largest orifice area.

Select a standard orifice higher than the

minimum required.
API 526 Standard Orifice Sizes

Select a standard orifice higher

than the minimum required.