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
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END OF PRESENTATION