1/51 Pressure Relief Grace under pressure – Ernest Hemingway Harry J. Toups LSU Department of...

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Pressure Relief

“Grace under pressure”

– Ernest Hemingway

Harry J. Toups LSU Department of Chemical Engineering with significant material from SACHE 2003 Workshop presentation by Scott Ostrowski (ExxonMobil)

and Professor Emeritus Art Sterling

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What is the Hazard?

Despite safety precautions …

– Equipment failures– Human error, and– External events, can sometimes lead to …

Increases in process pressures beyond safe levels, potentially resulting in …

OVERPRESSURE due to a RELIEF EVENT

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What are Relief Events?

External fire Flow from high pressure source Heat input from associated equipment Pumps and compressors Ambient heat transfer Liquid expansion in pipes and surge

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Potential Lines of Defense

Inherently Safe Design

Passive Control

Active Control

– Low pressure processes

– Install Relief Systems

– Overdesign of process equipment

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What is a Relief System?

A relief device, and

Associated lines and process equipment to safely handle the material ejected

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Why Use a Relief System?

Inherently Safe Design simply can’t eliminate every pressure hazard

Passive designs can be exceedingly expensive and cumbersome

Relief systems work!

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Pressure Terminology

MAWP Design pressure Operating

pressure Set pressure Overpressure Accumulation Blowdown

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Code Requirements

General Code requirements include:

– ASME Boiler & Pressure Vessel Codes– ASME B31.3 / Petroleum Refinery Piping– ASME B16.5 / Flanges & Flanged Fittings

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Code Requirements

Relieving pressure shall not exceed MAWP (accumulation) by more than:

– 3% for fired and unfired steam boilers

– 10% for vessels equipped with a single pressure relief device

– 16% for vessels equipped with multiple pressure relief devices

– 21% for fire contingency

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Relief Design MethodologyLOCATE RELIEFS

CHOOSETYPE

DEVELOP SCENARIOS

SIZE RELIEFS(1 or 2 Phase)

CHOOSE WORST CASE

DESIGN RELIEF SYSTEM

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Locating Reliefs – Where? All vessels Blocked in sections of cool liquid lines

that are exposed to heat Discharge sides of positive

displacement pumps, compressors, and turbines

Vessel steam jackets Where PHA indicates the need

LOCATE RELIEFS

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Choosing Relief Types

Spring-Operated Valves

Rupture Devices

CHOOSETYPE

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Spring-Operated Valves

Conventional Type

CHOOSETYPE

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Picture: Conventional Relief Valve

ConventionalRelief Valve

CHOOSETYPE

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Superimposed Back Pressure

Pressure in discharge header before valve opens

Can be constant or variable

CHOOSETYPE

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Built-up Back Pressure

Pressure in discharge header due to frictional losses after valve opens

Total = Superimposed + Built-up

CHOOSETYPE

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Spring-Operated Valves

Balanced Bellows Type

CHOOSETYPE

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Picture: Bellows Relief ValveBellows

Relief Valve

CHOOSETYPE

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Pros & Cons:Conventional Valve Advantages

+ Most reliable type if properly sized and operated+ Versatile -- can be used in many services

Disadvantages– Relieving pressure affected by back pressure– Susceptible to chatter if built-up back pressure is

too high

CHOOSETYPE

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Pros & Cons:Balanced Bellows Valve

Advantages+ Relieving pressure not affected by back pressure+ Can handle higher built-up back pressure+ Protects spring from corrosion

Disadvantages– Bellows susceptible to fatigue/rupture– May release flammables/toxics to atmosphere– Requires separate venting system

CHOOSETYPE

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Rupture Devices

Rupture Disc

Rupture Pin

CHOOSETYPE

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ConventionalMetal Rupture Disc

CHOOSETYPE

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ConventionalRupture Pin Device

CHOOSETYPE

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When to Use a Spring-Operated Valve Losing entire contents is unacceptable

– Fluids above normal boiling point– Toxic fluids

Need to avoid failing low Return to normal operations quickly Withstand process pressure changes,

including vacuum

CHOOSETYPE

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When to Use a Rupture Disc/Pin Capital and maintenance savings Losing the contents is not an issue Benign service (nontoxic, non-

hazardous) Need for fast-acting device Potential for relief valve plugging High viscosity liquids

CHOOSETYPE

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When to Use Both Types

Need a positive seal (toxic material, material balance requirements)

Protect safety valve from corrosion

System contains solids

CHOOSETYPE

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Relief Event Scenarios A description of one specific relief event Usually each relief has more than one relief

event, more than one scenario Examples include:

– Overfilling/overpressuring– Fire– Runaway reaction– Blocked lines with subsequent expansion

Developed through Process Hazard Analysis (PHA)

DEVELOP SCENARIOS

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An Example: Batch Reactor Control valve on

nitric acid feed line stuck open, vessel overfills

Steam regulator to jacket fails, vessel overpressures

Coolant system fails, runaway reaction

DEVELOP SCENARIOS

Product

RawMaterialFeeds

Organic substrateCatalystNitric Acid

Reactor ~ 100 gallons

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Sizing Reliefs

Determining relief rates

Determine relief vent area

SIZE RELIEFS(Single Phase)

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Scenarios Drive Relief Rates

Overfill (e.g., control valve failure)

Fire

Blocked discharge

SIZE RELIEFS(Single Phase)

– Maximum flow rate thru valve into vessel

– Vaporization rate due to heat-up

– Design pump flow rate

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Overfill Scenario Calcs

Determined maximum flow thru valve (i.e., blowthrough)

Liquids:

Gases:

SIZE RELIEFS(Single Phase)

PgACQ cvm 2

)1/()1(

12

ogc

ovchokedm

TRMg

APCQ

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Fire Scenario Calcs

API 520 gives all equations for calculating fire relief rate, step-by-step

1. Determine the total wetted surface area

2. Determine the total heat absorption

3. Determine the rate of vapor or gas vaporized from the liquid

SIZE RELIEFS(Single Phase)

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Determine Wetted Area

SIZE RELIEFS(Single Phase)

180/wet BDLEDA

DEB 21cos 1

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Determine Heat Absorption Prompt fire-fighting & adequate

drainage:

Otherwise:

where

SIZE RELIEFS(Single Phase)

82.0wet000,21

Btu/hr

AFQ

82.0wet500,34

Btu/hr

AFQ

Q is the heat absorption (Btu/hr)F is the environmental factor

– 1.0 for a bare vessel– Smaller values for insulated vessels

Awet is the wetted surface area (ft2)

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Determine Vaporization Rate

vap/HQW

where

W = Mass flow, lbs/hr

Q = Total heat absorption to the wetted surface, Btu/hr

Hvap = Latent heat of vaporization, Btu/lb

SIZE RELIEFS(Single Phase)

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Determine Relief Vent Area Liquid

Service

where

bs25.1

)ref

(

bpvovQ

gpm 38.02/1)psi(2in

PPKKKCA

A is the computed relief area (in2) Qv is the volumetric flow thru the relief (gpm) Co is the discharge coefficient Kv is the viscosity correction Kp is the overpressure correction Kb is the backpressure correction (/ref) is the specific gravity of liquid Ps is the gauge set pressure (lbf/in2) Pb is the gauge backpressure (lbf/in2)

SIZE RELIEFS(Single Phase)

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Determine Relief Vent Area Gas

Service

where

MTz

PKCA

bomQ

A is the computed relief area (in2) Qm is the discharge flow thru the relief (lbm/hr) Co is the discharge coefficient Kb is the backpressure correction T is the absolute temperature of the discharge (°R) z is the compressibility factor M is average molecular weight of gas (lbm/lb-mol) P is maximum absolute discharge pressure (lbf/in2) is an isentropic expansion function

SIZE RELIEFS(Single Phase)

valverelief for the pressureset theis s

pipingfor s33.1max

fire toexposed sfor vessel s2.1max

vesselspressure unfiredfor s1.1max

7.14max

PPP

PPPP

PP

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Determine Relief Vent Area Gas

Service

where

)1/()1(

125.519

is an isentropic expansion function

is heat capacity ratio for the gas Units are as described in previous

slide

SIZE RELIEFS(Single Phase)

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A Special Issue: Chatter

Spring relief devices require 25-30% of maximum flow capacity to maintain the valve seat in the open position

Lower flows result in chattering, caused by rapid opening and closing of the valve disc

This can lead to destruction of the device and a dangerous situation

SIZE RELIEFS(Single Phase)

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Chatter - Principal Causes

Valve Issues– Oversized valve– Valve handling widely differing rates

Relief System Issues– Excessive inlet pressure drop– Excessive built-up back pressure

SIZE RELIEFS(Single Phase)

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Worst Case Event Scenario

Worst case for each relief is the event requiring the largest relief vent area

Worst cases are a subset of the overall set of scenarios for each relief

The identification of the worst-case scenario frequently affects relief size more than the accuracy of sizing calcs

CHOOSE WORST CASE

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Design Relief System Relief System is more than a safety

relief valve or rupture disc, it includes:

DESIGN RELIEF SYSTEM

– Backup relief device(s)– Line leading to relief device(s)– Environmental conditioning of relief device– Discharge piping/headers– Blowdown drum– Condenser, flare stack, or scrubber

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Installation, Inspection, and Maintenance To undermine all the good efforts of a

design crew, simply …

1. Improperly install relief devices

2. Fail to regularly inspect relief devices, or

3. Fail to perform needed/required maintenance on relief devices

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?? Reduced Inlet Piping

Anything wronghere?

ReducedInlet Piping

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?? Plugged Bellows, Failed Inspection, Maintenance

Bellows pluggedin spite of sign

Anything wronghere?

FailedInspectionProgram

Signs ofMaintenance

Issues

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?? Discharges Pointing DownAnything wrong

here?

Anything wronghere?

DischargesPointing Down

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?? Long Moment Arm

Anything wronghere?

LongMoment Arm

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?? Will these bolts hold in a relief event

Anything wronghere?

Will thesebolts hold

in arelief event?

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Mexico City Disaster

Major Contributing Cause:Major Contributing Cause:Missing Safety ValveMissing Safety Valve

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Summary

Pressure Relief– Very Important ACTIVE safety element– Connected intimately with Process Hazard

Analysis– Requires diligence in design, equipment

selection, installation, inspection and maintenance

Look forward to …– Two-phase flow methodology/exercise

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References

Crowl and Louvar – Chemical Process Safety, Chapters 8 and 9

Ostrowski – Fundamentals of Pressure Relief Devices

Sterling – Safety Valves: Practical Design, Practices for Relief, and Valve Sizing

END OF PRESENTATION