Overpressure Protection

and Relief Valves

Systems School
2008
Overpressure Protection

2
 Course Contents

• Introduction to relief systems

• Applicable codes and standards
• Work process for relief system design
• Relief device terminology
• Causes of overpressure & determination of relief
loads

3
 Course Contents

• Relief valve sizing

• Relief device selection
• Relief device installation & isolation
• Reaction forces, noise, & vibration

4
INTRODUCTION
TO
RELIEF SYSTEMS

5
Relief Systems
Relief devices are considered the last line of defense against
catastrophic failure of mechanical equipment.

The function of relief devices is to:

• Prevent an overpressure scenario in the plant
• Protect equipment & piping
• Protect personnel
• Prevent loss of production time
• Prevent loss of material
• Prevent an environmental release

Relief valves are mandated by:

• National, state and local requirements
• Industry codes and standards
• Client and KBR requirements

6
Relief Systems

• Some examples of
relief devices are:
– Pressure relief valves
– Rupture disks
– Pressure vacuum
valves
– Emergency vents

7
Relief Systems

Relief system discharge

– Open Discharge
• Relieves to atmosphere
• Non-combustibles and non-toxic
– Closed Discharge
• Relieves to flare or process
• Process fluids

8
Typical Relief System

Flare Stack

Flare Header

Relief valve

Flare Knockout
Rupture Disk Drum

9
Applicable Codes, Standards
and
References

1
Applicable Codes, Standards and References

• OSHA
- 1910.119 (Process safety management of highly hazardous chemicals)
- 1910.106 (Flammable and combustible liquids)

• ASME
- Boiler and Pressure Vessel Code Section I
- Boiler and Pressure Vessel Code Section VIII
- Power Piping B31.1
- Chemical Plant/Petroleum Refinery Piping B31.3

• NFPA 30 Flammable and combustible liquids code

• Client specifications

1
Applicable Codes, Standards and References

• API
– RP 520 Part I & II (Recommended practices for the design &
installation of PRVs)

– RP 521 (Guide for pressure relief & depressuring systems)

– STD 526 (Flanged steel safety relief valves for petroleum refineries)
– STD 527 (Commercial seat tightness of safety relief valves w/ metal-to-
metal seats)

– STD 2000 (Venting atmospheric & low pressure storage tanks)

– STD 620 (Design and construction of large, welded, low pressure storage
tanks)

1
Applicable Codes, Standards and References

• KBR Systems Engineering Methods

– SEM 1-303 Overpressure Protection

– SEM 1-304 Overpressure Protection for Storage Tanks
– SEM 1-301 Design Pressure Philosophy
– SEM 1-306 Relief Valve Discharge Systems
– SEM 1-103 Entrance and Exit Losses for PRV Inlet and
Outlet Piping

• KBR
- P24-5DS- Conventional PRV numbering system
- P24-6DS- Balanced bellows PRV numbering system
- P24-1E- Pressure Relief Valves
- P50-1D- Overpressure Protection and Vent Philosophy

1
Work Process for Relief System
Design

1
Work Process for Relief System Design
Relief system design is a two step process.
1. Evaluation of overpressure contingencies
(Process analysis)
2. Calculation of relief loads
(Sizing)
Required data:
– Heat and Material Balances
– Process Flow Diagrams (PFD’s)
– Piping and Instrumentation Drawings (P&ID’s)
– Equipment Load Sheets & Mechanical Data Sheets
– Instrument Data (Control valve detail, RO sizes, etc.)

1
Work Process for Relief System Design

• Feasibility Phase - (Pre FEED)

- Process related major relieving scenarios are evaluated; the
relief loads are estimated; and from this, the relief header size
and flare tip size are estimated.

• FEED Phase
- All scenarios for all PRV’s are evaluated; calculations are
performed for design cases to establish the inlet, PRV, and outlet
sizes.

• Detailed Engineering Phase

- Calculations for all scenarios are performed.
- Procurement activity begins.
- Flare header and piping support systems are given immediate
attention due to construction and lead time concerns.

1
Work Process for Relief System Design

Final Review Phase

- Reviewers check and question specific cases suspected as
overlooked.
- Safety reviews conducted in accordance with OSHA
1910.119 (Process safety management of highly hazardous
chemicals).
- Process Hazard Analysis (PHA)
- Safety and operability studies are conducted, usually by the
client.

1
RELIEF DEVICE TERMINOLOGY

1
Relief Device Terminology
• Relief Valve - A spring-loaded pressure relief valve
actuated by the static pressure upstream of the valve.
The valve opens normally in proportion to the pressure
increase over the opening pressure. Used primarily with
incompressible fluids.
• Safety Valve - A spring-loaded pressure relief valve
actuated by the static pressure upstream of the valve and
characterized by rapid opening or pop action. Normally
for compressible fluids.
• Safety Relief Valve – A spring-loaded pressure relief
valve used as either a safety or relief valve.
• Pressure Relief Valve (PRV) – A generic term for all of
the above.

1
Relief Device Terminology

• Set Pressure - Pressure at which the PRV is set to begin

opening.

• Overpressure - Pressure increase over set pressure of

the PRV at which the PRV is fully open, expressed as %
of set pressure.

• Accumulation - Pressure increase over MAWP of vessel

during relief, expressed as % of set pressure or in psi.

• Back pressure - The pressure at the outlet of the PRV.

2
Relief Device Terminology

• Superimposed back pressure - The pressure at the

PRV outlet before the PRV opens, resulting from
pressure in the discharge system.
- Constant superimposed back pressure does not
change appreciably under any condition of operation
whether the PRV is open or closed.
- Variable superimposed back pressure is pressure in
discharge system that may fluctuate.

• Built-up back pressure - The pressure that develops in

the discharge header when the relief valve opens.

• Total back pressure = Superimposed + Built-up back-

pressures

2
Back Pressure - Example

N O R M A L P R E S S U R E = 0 .3
P S IG F R IC T IO N L O S S = 1 0 P S IG
D U R IN G S IM U L T A N E O U S R E L IE F
F R O M O T H E R R E L IE F V A L V E S

F R IC T IO N
L O S S = 5 P S IG

8 " W A T E R
S E A L F LA R E S T A C K

F LA R E K O D R U M

Superimposed Back Pressure = 8/(2.31*12) = 0.3 psig constant

Total Built-up Back Pressure = 15 psig
Total Back Pressure = 15.3 psig
2
Relief Device Terminology

• Blowdown – Pressure at which a PRV reseats after

relieving, typically expressed as % of set pressure or as a
pressure differential percentage (usually reseating @
93% of set pressure, or 7% blowdown). Blowdown is
adjustable and depends on the valve design,
manufacturer, and setting.

• Cold differential test pressure (CDTP) – Set pressure

at which a PRV is adjusted to begin opening on a test
stand. CDTP includes correction for constant back
pressure and/or an elevated service temperature.

2
Relief Device Terminology

• Simmer - The audible or visual release of fluid across the PRV just
prior to opening at set pressure. Excessive simmering is detrimental
to valve seating surfaces.

• Chattering - Rapid opening and closing of a PRV in quick

succession. Chattering is also detrimental to the PRV seating
surfaces, often causing the PRV to leak in normal operation.
Chattering can be caused by:
• Oversized PRV
• Inlet losses exceeds 3% of Pset
• Excessive back pressure
• Broken or leaking balanced bellows

• Lift - The rise or travel of the PRV disc during opening.

2
Allowable Overpressures (set pressure
100 psig)

Hydrotest pressure 130 psig (ASME Sec VIII) 30%

(ANSI B31.3
Allowable overpressure for 110/120/133 psig (ASME))
10/20/33%
piping

Allowable overpressure (fire case) 121 psig (ASME Sec VIII) 21%
21% of Set Pressure
Allowable overpressure (for
multiple valves and cases other 116 psig (ASME Sec VIII) 16%
than fire) 16% of Set Pressure

Allowable overpressure (for single

valves and cases other than fire) 110 psig (ASME Sec VIII) 10%
10% of set Pressure

Allowable overpressure for

106 psig (ASME Sec I)
Boiler Code vessels
6% of Set Pressure
6%
Design pressure 100 psig
Blowdown Reseating 93 psig
Maximum vessel operating Max Opr. Pressure
pressure 90 psig

2
CAUSES OF OVERPRESSURE &
DETERMINATION OF RELIEF
LOADS

2
Causes of Overpressure (Session 1)

• External Fire
• Blocked Outlet
• Automatic Control Failure
• Exchanger Tube Rupture
• Thermal Expansion

2
Causes of Overpressure (Session 2)
• Fractionation tower failure
• Abnormal heat or vapor input
• Liquid overfill of storage and surge vessels
• Human error
• Chemical reactions
• Vacuum relief
• Overall utility failures
• Multiple failures - cascading related and unrelated
failures
• Atmospheric tank protection
2
External Fire

 External fire must be considered anytime there is

the possibility of the formation of a liquid
hydrocarbon pool under process equipment (even
if the vessel contents are not flammable) and
ignition sources are present.
 Radiant heat causes liquid contents of a vessel to
boil or vapor contents of a vessel to expand, thus
increasing vessel pressure.
 Either the equipment or the system is considered
fully blocked in and isolated when the external fire
occurs.

2
External Fire

 All ASME stamped equipment must be protected

for external fire unless fire can be specifically ruled
out or the equipment/system cannot be blocked in.
 Individual piping and piping components are not
generally considered to require relief protection
from an external fire. However, interconnecting
piping between equipment will be included in the
calculation for fire relief requirements for multiple
equipment systems.
 All equipment surfaces contained in a 70’ diameter
and a 25’ high envelope are considered to be
engulfed in a single fire.

3
Relief Load - External Fire Scenario
• Liquid Vaporization:
Heat Absorbed, BTU/h (Q)
Q = 21000FA 0.82 (in most cases with proper drainage)
Q = 34500A 0.82 (for remote, unmanned areas and areas
with poor fire-fighting facilities or poor
drainage)
A = Fire wetted surface area, ft2
F = Environmental factor
= 1.0 by default (no fireproofing)
= 0.3 for fireproof insulation
The following do not qualify for fireproofing:
- aluminum covering over insulation
- polyurethane foam insulation
- partial covering by SST bands
3
Relief Load - External Fire Scenario
• Relief rate, lb/h (W)
W = Q/L
L = Latent heat of fluid, Btu/lb

• Vapor expansion:
Relief Area A = F’A’/P10.5 See SEM 1-303 for details

• ASME allows 21% overpressure of

equipment exposed to an external fire.

3
Fire Case Sizing Example

Fire wetted area A= dL + 1.084 d2

= *5*5 + 1.084 *52
= 105.5 ft2
Heat absorbed Q = 21000 F A 0.82
=21000 *1*(105.5) 0.82
= 957825 BTU/hr
Relief rate W = Q / 
= 957825 / 560
= 1710.40 #/hr

3
Fire Case Sizing Example

Relieving Temp = 150F = 610 R

S E T @ 1 0 0 p s ig
= boiling temp of fluid at 135.7 psia
H LL
W ZT
Orifice area A= 15' 10'
CP1KdKb M
L=5'

API 520 FIREHT

1*610

25'
1710.4
A=
356*0.975*135.7*1 44 20' 5'

= 0.135 in2

Select ‘E’ orifice, area = 0.196 in2

Rated capacity = 1710.4*0.196/0.135 = 2483 lb/hr
3
Blocked Outlet

• Can be caused by:

– Inadvertent valve closing by operator
– Instrument failure
– Mechanical failure
– Utility failure, etc.
• Source pressure exceeds downstream
equipment design pressure. Sources are
pumps, compressors, high pressure utilities,
high pressure upstream fluids, etc.
• Use of ‘LO’ or ‘CSO’ valves not encouraged
but may be allowed by the client.

3
Blocked Outlet - Example 1

Set @
100 psig

Design
V-2 Pressure
100 psig

V-1

Pop=
200 psig

3
Blocked Outlet - Example 2

PSV 2 P1 shut-off pressure = 100 psig

E1 Shell design pressure = 86 psig
V1 LC
P1 discharge pressure = 69 psig
PSV1 set pressure = 86 psig
PSV 1
Evaluate Blocked Outlet

P1 E1

Relieving

Operating
Head

Capacity
3
Automatic Control Failure

• An automatic controller or control valve

can fail due to:
– Instrument air failure, local or global
– Loss of signal (wiring failure)
– Mechanical malfunction of control valve
– DCS hardware/software failure
– Improper manual operation by console operator
– Hand wheel left engaged on control valve
– Plugging

3
Automatic Control Failure

• For local control valve failure, consider both

fully open and fully closed positions
regardless of the actuator failure mode.
• Credit can be taken for flow paths which are
normally open and are not affected by this
failure. But no double jeopardy.
• For global instrument air or power failure
scenarios, a system is evaluated considering
all control valves in the system going to their
failure modes.

3
Automatic Control Failure - Example 1

I
P
PIC
PY
PSV1
PSV2
200 psig
PT 100 psig
PV-001
V2
FC

V1 V2
L1

L2
PV-001 fails in open position:
Relief rate = max flow through PV-001 - normal V2 flow
PV-001 fails in close position, evaluate blocked outlet for PSV1
4
Exchanger Tube Rupture
• Tubes of shell and tube heat exchangers may fail due
to thermal shock, mechanical vibration, corrosion.
• 10/13 rule: Relief protection is not required if the low
pressure side design pressure is 0.77 of the high
pressure side design pressure per some industry
standards.
• KBR design does not consider the 10/13 rule
because designing to the ‘0.77 rule’ does not mean
that tubes can no longer rupture.
– Must evaluate possible overpressure of connected
equipment and/or possibility of chemical reaction.
• Credit is taken for normally open paths i.e. low
pressure side outlet line is not considered blocked

4
Exchanger Tube Rupture - Example
PSV-005 E-4
SET @ 60 PSIG

V-5
T-5
DP = Pdes = 231 psig
Pdes = 300 psig
60 PSIG
E-5

E-5 tube side design pressure = 300 psig

E-5 shell side design pressure = 231 psig
PSV-005 must be evaluated for tube rupture even though E-5 is designed per the
0.77 rule
4
Thermal Expansion

• Required for liquid-filled equipment and piping that can be

blocked in and subsequently heated by:
– Solar radiation
– Hot side of a heat exchanger
– Heat tracing
• Generally provided for long sections of OSBL piping
exposed to solar radiation
• CSO or LO valves can eliminate the need for thermal
relief valves. The client must agree that the valves are
under administrative control.

4
Thermal Expansion
Required relief rate in GPM = *H .
500 *SG*CP
 = coefficient of thermal expansion
H = heat flux
Exchangers use max heat duty in BTU/hr.
Solar radiation = 300 BTU/hr/ft2
SG = specific gravity
CP = specific heat capacity of liquid, BTU/lb-F
• For thermal protection of piping, KBR generally provides 3/4” x 1”
PRV’s and calculations are not performed.

4
Fractionation Tower Overpressure Protection

Reflux failure
• Controlling case for PRV sizing in majority of towers
• Can occur due to:
– Reflux pump failure
– Overhead condenser failure
– Power failure
– Reflux control valve fails closed
– Overhead condenser flooded due to draw-off control valve closure
– Non-condensibles accumulation in the condenser
– Operator error resulting in a blocked outlet scenario

4
Fractionation Tower Overpressure Protection
• Loss of cold feed
– Caused by feed control valve closure or feed
pump failure.
– Causes temporary surge in vapor rate.
• Excess heat to reboilers
– Caused by
• Steam control valve failure wide open
• Excessive fuel to fired reboiler
– Relieve additional vapors generated by reboiler
• Reboiler tube rupture

4
Abnormal Heat or Vapor Input

• Excess steam input to reboilers increases vapor

generation.
• Excess fuel firing to heaters increases vapor
generation.
• Excess heat to the hot side of an exchanger may
generate vapors in the cold liquid side.

4
Liquid Overfill of Storage or Surge Vessels

• Liquid is continued to be pumped into a vessel

when the outflow has stopped. (Blocked Outlet)
• Liquid inflow exceeds outflow.
• Overfilling from an offsite pump during start-up
and inventory.

4
Human Error

• Inadvertent opening or closing of block valves.

• Panic response results in incorrect action.
• Incorrect interpretation of multiple simultaneous
alarms.
• No Double Jeopardy

4
Chemical Reactions

• Exothermic reactions can ‘runaway’

– Relief rate determination is complex; and
therefore done in conjunction with the client,
the catalyst manufacturer, the process
licensor, KBR Process Dept.
• Inadvertent mixing of two reactive streams
• Decomposition or polymerization due to
abnormal heat input or loss of cooling

5
Vacuum Relief

• Ideally, equipment that could be

subject to partial vacuum
conditions is designed to withstand
a full vacuum.
• For large diameter columns,
storage tanks, etc., designing to a
full vacuum is cost prohibitive.

5
Vacuum Relief

• Causes of vacuum
– Fluid withdrawal while inlet blocked
– Excessive condensation in column overhead
condenser
– Condensation of vapors due to drop in atmospheric
temperature
– Suction side of compressor blocked
– Condensing side of exchanger blocked in while
cooling medium side continues

5
Utility Failures

Local or Global

• Electric power failure

• Steam Failure
• Cooling Water Failure
• Refrigerant Failure
• Instrument air failure

5
Cascading Failures

• One failure leads to another

• Steam turbines: steam failure leads to power
failure.
• IA compressor is power driven; therefore, power
failure leads to IA failure.
• CW pumps are power driven; therefore, power
failure leads to CW failure.

5
Atmospheric Storage Tank Protection

• API 2000
• Fire relief must be evaluated
unless tank has frangible roof
• Gauge hatch vent & manway
vents are used for fire relief
• Fire generally does not engulf
the entire tank
• PVRV’s may be used for
normal and emergency venting
• PVRV sizing is typically done
using vendor capacity curves
or computer programs

5
Atmospheric Storage Tank Protection
• Inbreathing (vacuum relief) is required for:
– max product outflow at no inflow
– contraction of vapors due to atmospheric temperature drop
– failure of nitrogen blanket valve closed
• Out breathing (pressure relief) required for:
– max product inflow at no outflow
– expansion of vapors due to atmospheric temperature rise
– failure of nitrogen blanket valve wide open
• Set pressure and PVRV size are chosen so max
pressure or vacuum does not exceed tank design
• PVRV’s installed directly on roof nozzle

5
RELIEF VALVE SIZING

5
Relief Valve Sizing

W ZT
Vapor Sizing Equation A=
(for critical flow)
C P1KdKb M

W
Steam Sizing Equation A=
(for ASME VIII) 51.5 P1KdKnKsh

GPM SG
Liquid Sizing Equation A=
(capacity certified) 38 KdKbKv P1 - P2

5
Relief Valve Sizing
• P1 = Upstream relieving pressure, psia
• A = Required orifice area, in2
• C = Coefficient based on specific heat ratio
• Kb = Back pressure correction factor
• Kn = Correction factor for Napier Equation
• Ksh = Correction factor for steam superheat
• Kd = Coefficient of discharge
• Kv = Correction factor for viscosity
• P2 = Total back pressure, psia
• W = Required flow rate, lb/hr
• Z = Compressibility
• M = Molecular weight
• T = Upstream relieving temp, R
• SG = Specific gravity of liquid
• GPM=Required flow rate of a liquid, gpm

5
Coefficient of Discharge, Kd

• Dependent on the relief valve design & manufacturer

• National Boiler Board certifies capacities of all relief
valves
• RV manufacturer back calculates Kd from certified
capacity and test conditions
• When manufacturer is not known, Kd = 0.975 for vapor
and 0.65 for liquid
• RV capacity must be checked based on vendor
published Kd
• For all vapor and liquid PRV’s, the PRV manufacturer
should confirm orifice sizing calculations

6
Standard Orifice Sizes

6
• RELIEF DEVICE SELECTION

6
Relief Device Selection

Relief device selection is primarily based on:

– Back pressure allowance
– Client preferences
– Service (fluid, relieving temperature, operating
pressure, etc.)

6
Relief Device Selection

6
• RELIEF DEVICE INSTALLATION
&
ISOLATION

6
Relief Device Installation

6
Relief Device Installation

6
Relief Valve Isolation

6
Relief Valve Isolation

6
Default RV Inlet and Outlet Lead Lengths

7
• REACTION FORCES,
VIBRATIONS,
AND
NOISE

7
Reaction Force Calculations

• During discharge, momentum and pressure of

the flowing fluid cause:
- Acoustic Induced Vibrations
- Flow Induced Vibrations
• Discharge piping may require additional
considerations such as additional pipe supports,
added pipe thickness, etc.
• Noise level calculations are performed by
Environmental Engineering based on EPCON
RV datasheet