The example examines a PRD attached to the pressure vessel.

The following demand case have been

defined as potential dangers: Fire, Blocked Discharge, Liquid Overfill and Electric Power Failure.

Vessel Design:

• Start Date = 01-Jan-2000

• Material = SA-285 Gr. C
• Design Conditions = 155 psig @450 oF
• Inside Diameter = 97.625 in
• Base Material Thk. = 0.8125 in
• Corrosion Allowance = 0.125 in
• Length = 30 ft
• Allowable Stress = 13.750 psi
• Weld Joint Efficiency = 0.85
• Process Fuid = C3-C4
• Fluid Cost = $0.05 per pound
• Operating Conditions = 101 psig @121 oF

PRD Design:

• Installation Date = 01-Jan-2000

• PRD Area = 3.14 in2
• Inlet Size = 2.0 in
• Set Pressure = 155 psig
• Back Pressure = 10 psig
• Flow Rate Capacity through PRD = 35,081 lb/hr
• Current Inspection Test Interval = 5 years
• Discharge Location = Flare
• Failure to Open Class = Moderate
• Leak Class = Moderate
• Tolerable Leak = Yes
• Tolerable Stuck Open Valve = No
• Time to Repair PRD = 2 Days
• Unit Flare Recovery System = No

Overpressure Demand Case:

• Demand Case 1 = Fire

Overpressure Potential = 4 x MAWP
• Demand Case 2 = Blocked Discharge
Equipment Type = Centrifugal Rotating Pump
Heat Source Type = Internal Heat Source
Heat Source Temperature = 121 oF
Overpressure Potential = 149.52 psig
• Demand Case 3 = Liquid Overfill
Equipment Type = Centrifugal Rotating Pump
Deadhead Pressure = 180 psig
Heat Source Type = Internal Heat Source
Heat Source Temperature = 121 oF
 Overpressure Potential = 180 psig
• Demand Case 4 = Electric Power Failure
Equipment Type = Centrifugal Rotating Pump
Heat Source Type = Internal Heat Source
Heat Source Temperature = 121 oF
Overpressure Potential = 149.52 psig

1. PROBABILITY FOR PRD FAILURE TO OPEN

1.1 PRD Probability Failure on Demand (Pfod,j)
• PRD Type = Conventional; Fluid Severity = Moderate → Based on Table 7.5 β = 1.8; ηdef =
23.9
• Discharge location = Flare → Fc = 0.75
• Fenv = 1
• Updated/Modified characteristic life (ηmod)

𝜂𝑚𝑜𝑑 = 𝐹𝑐 ∙ 𝐹𝑒𝑛𝑣 ∙ 𝜂𝑑𝑒𝑓 = 0.75 × 1 × 23.9 = 17.925 𝑦𝑒𝑎𝑟𝑠

Inspection 1

- Prior POFOD
Test result = Pass
Inspection interval (tinsp) = Inspection Date (1) – Install Date = 2005 – 2000 = 5 years
1.8
𝑝𝑟𝑑 𝑡𝑖𝑛𝑠𝑝 𝛽 5
𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 = 1 − 𝑒𝑥𝑝 [− ( ) ] = 1 − 𝑒𝑥𝑝 [− ( ) ] = 0.096
𝜂𝑚𝑜𝑑 17.925
𝑝𝑟𝑑 𝑝𝑟𝑑
𝑃𝑝,𝑝𝑟𝑖𝑜𝑟 = 1 − 𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 = 1 − 0.096 = 0.904 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑

- Conditional POFOD
Test result = Pass; Effectiveness = B (Usually Effective) → Based on Table 7.8 CFpass =
0.7
𝑝𝑟𝑑 𝑝𝑟𝑑
𝑃𝑓,𝑐𝑜𝑛𝑑 = (1 − 𝐶𝐹𝑝𝑎𝑠𝑠 ) × 𝑃𝑝,𝑝𝑟𝑖𝑜𝑟 = (1 − 0.7) × 0.904 = 0.271 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑

- Weighted POFOD
Test result = Pass; Effectiveness = B (Usually Effective) → Based on Table 7.9 equation
used is,
𝑝𝑟𝑑 𝑝𝑟𝑑 𝑝𝑟𝑑 𝑡𝑖𝑛𝑠𝑝 𝑝𝑟𝑑 𝑡𝑖𝑛𝑠𝑝
𝑃𝑓,𝑤𝑔𝑡 = 𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 − 0.2 ∙ 𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 ( ) + 0.2 ∙ 𝑃𝑓,𝑐𝑜𝑛𝑑 ( )
𝜂 𝜂
5 5
= 0.096 − 0.2 × 0.096 ( ) + 0.2 × 0.271 ( )
17.925 17.925
= 0.1057 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑

- Revised Characteristic Life (ηupd)

𝑡𝑖𝑛𝑠𝑝 5
𝜂𝑢𝑝𝑑 = 1 = 1 = 16.8966 𝑦𝑒𝑎𝑟𝑠
(−𝑙𝑛 [1 − 𝑃
𝑝𝑟𝑑
])
𝛽 (−𝑙𝑛[1 − 0.1057])1.8
𝑓,𝑤𝑔𝑡
- For every inspection the following parameters must hold true
ηupd ≥ ηmod for passing inspections
ηupd ≤ ηmod for failing inspections
 Test Result = Pass; ηupd = 16.8966; ηmod = 17.925
→ ηmod used for Inspection 2 = 17.925 years

Inspection 2

- Prior POFOD
Test result = Pass
Inspection interval (tinsp) = Inspection Date (2) – Install Date = 2010 – 2000 = 10 years
𝑝𝑟𝑑 𝑡𝑖𝑛𝑠𝑝 𝛽 10 1.8
𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 = 1 − 𝑒𝑥𝑝 [− ( ) ] = 1 − 𝑒𝑥𝑝 [− ( ) ] = 0.2951
𝜂𝑚𝑜𝑑 17.925
𝑝𝑟𝑑 𝑝𝑟𝑑
𝑃𝑝,𝑝𝑟𝑖𝑜𝑟 = 1 − 𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 = 1 − 0.2951 = 0.7049 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑

- Conditional POFOD
Test result = Pass; Effectiveness = B (Usually Effective) → Based on Table 7.8 CFpass =
0.7
𝑝𝑟𝑑 𝑝𝑟𝑑
𝑃𝑓,𝑐𝑜𝑛𝑑 = (1 − 𝐶𝐹𝑝𝑎𝑠𝑠 ) × 𝑃𝑝,𝑝𝑟𝑖𝑜𝑟
= (1 − 0.7) × 0.7049
= 0.2115 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑

- Weighted POFOD
Test result = Pass; Effectiveness = B (Usually Effective) → Based on Table 7.9 equation
used is,
𝑝𝑟𝑑 𝑝𝑟𝑑 𝑝𝑟𝑑 𝑡𝑖𝑛𝑠𝑝 𝑝𝑟𝑑 𝑡𝑖𝑛𝑠𝑝
𝑃𝑓,𝑤𝑔𝑡 = 𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 − 0.2 ∙ 𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 ( ) + 0.2 ∙ 𝑃𝑓,𝑐𝑜𝑛𝑑 ( )
𝜂 𝜂
10 10
= 0.2951 − 0.2 × 0.2951 ( ) + 0.2 × 0.2115 ( )
17.925 17.925
= 0.2851 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑

- Revised Characteristic Life (ηupd)

𝑡𝑖𝑛𝑠𝑝 10
𝜂𝑢𝑝𝑑 = 1 = 1 = 18.341 𝑦𝑒𝑎𝑟𝑠
𝑝𝑟𝑑
(−𝑙𝑛 [1 − 𝑃𝑓,𝑤𝑔𝑡 ])𝛽 (−𝑙𝑛[1 − 0.2851])1.8

- For every inspection the following parameters must hold true

ηupd ≥ ηmod for passing inspections
ηupd ≤ ηmod for failing inspections
Test Result = Pass; ηupd = 18.341; ηmod = 17.925
→ ηupd used for Pfod calculation = 18.341 years

• Current Inspection interval (t) = 5 years

𝛽 1.8
𝑡 5
• 𝑃𝑓𝑜𝑑 = 1 − 𝑒𝑥𝑝 [− 𝜂 ] = 1 − 𝑒𝑥𝑝 [− 18.341] = 0.092 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑
𝑢𝑝𝑑

• Overpressure Adjustment Factor (FOP)

𝑃𝑜,𝑓𝑖𝑟𝑒 (4×155)
- 𝐹𝑜𝑝,𝑓𝑖𝑟𝑒 = 𝑃𝑠𝑒𝑡 155
= = 4 → Based on Equation 1.31, Fop,fire = 0.2
𝑃𝑜,𝐵𝐷149.52
- 𝐹𝑜𝑝,𝐵𝐷 = 𝑃 = 155 = 0.96 (≤ 1.3) → Based on Equation 1.31, Fop,BD = 1
𝑠𝑒𝑡
𝑃 180
- 𝐹𝑜𝑝,𝐿𝑂 = 𝑜,𝐿𝑂 = = 1.16 (≤ 1.3) → Based on Equation 1.31, Fop,LO = 1
𝑃𝑠𝑒𝑡 155
 𝑃𝑜,𝐸𝐹 149.52
- 𝐹𝑜𝑝,𝐸𝐹 = = = 0.96 (≤ 1.3) → Based on Equation 1.31, Fop,EF = 1
𝑃𝑠𝑒𝑡 155
• PRD POFOD for Each Overpressure Demand Case
𝑃𝑓𝑜𝑑,𝑗 = 𝑃𝑓𝑜𝑑 ∙ 𝐹𝑜𝑝,𝑗
- 𝑃𝑓𝑜𝑑,𝑓𝑖𝑟𝑒 = 0.092 × 0.2 = 0.0184 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑
- 𝑃𝑓𝑜𝑑,𝐵𝐷 = 0.092 × 1 = 0.092 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑
- 𝑃𝑓𝑜𝑑,𝐿𝑂 = 0.092 × 1 = 0.092 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑
- 𝑃𝑓𝑜𝑑,𝐸𝐹 = 0.092 × 1 = 0.092 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑

1.2 PRD Demand Rate (DRj)

• Assumed : Administrative Control = N/A
• Based on Table 7.2, value of EFj and DRRFj for each overpressure demand case is,
Overpressure Demand Case EFj DRRFj
Fire 0.004 0.1
Liquid Overfilling 0.1 0.1
Electrical Power Failure 0.08 1
Blocked Discharge 0.1 1

• 𝑫𝑹𝒋 = 𝑬𝑭𝒋 ∙ 𝑫𝑹𝑹𝑭𝒋

𝐷𝑅𝑓𝑖𝑟𝑒 = 0.004 × 0.1 = 0.0004 𝑑𝑒𝑚𝑎𝑛𝑑𝑠/𝑦𝑒𝑎𝑟
𝐷𝑅𝐵𝐷 = 0.1 × 0.1 = 0.01 𝑑𝑒𝑚𝑎𝑛𝑑𝑠/𝑦𝑒𝑎𝑟
𝐷𝑅𝐿𝑂 = 0.08 × 1 = 0.08 𝑑𝑒𝑚𝑎𝑛𝑑𝑠/𝑦𝑒𝑎𝑟
𝐷𝑅𝐸𝐹 = 0.01 × 1 = 0.1 𝑑𝑒𝑚𝑎𝑛𝑑𝑠/𝑦𝑒𝑎𝑟

1.3 POF of Protected Equipment as a Result of Overpressure (Pf,j)

𝑷𝒐,𝒋
(𝟑.𝟒𝟔𝟒𝟖𝟑𝟕∙ )
𝑷𝒇,𝒋 = (𝟎. 𝟎𝟑𝟏𝟐𝟖𝟖𝟏 ∙ 𝒈𝒇𝒇𝒕𝒐𝒕𝒂𝒍 ∙ 𝑫𝒇 ∙ 𝑭𝑴𝑺 ) ∙ 𝒆 𝑴𝑨𝑾𝑷

• gfftotal of protected equipment (pressure vessel) = 3.06 x 10-5

• Assumed FMS = 1
• Assumed DF Class = None → Df = 1
4×155
(3.464837× )
• 𝑃𝑓,𝑓𝑖𝑟𝑒 = (0.0312881 × 3.06 ∙ 10−5 × 1 × 1) × 𝑒 155

= 1.0002 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑦𝑒𝑎𝑟
149.52
(3.464837× )
𝑃𝑓,𝐵𝐷 = (0.0312881 × 3.06 ∙ 10−5 × 1 × 1) × 𝑒 155

= 2.71 × 10 −5 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑦𝑒𝑎𝑟
180
(3.464837× )
𝑃𝑓,𝐿𝑂 = (0.0312881 × 3.06 ∙ 10−5 × 1 × 1) × 𝑒 155

= 5.35 × 10 −5 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑦𝑒𝑎𝑟
149.52
(3.464837× )
𝑃𝑓,𝐸𝐹 = (0.0312881 × 3.06 ∙ 10−5 × 1 × 1) × 𝑒 155

= 2.71 × 10 −5 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑦𝑒𝑎𝑟

1.4 POF of PRD

𝒑𝒓𝒅
𝑷𝒇,𝒋 = 𝑷𝒇𝒐𝒅,𝒋 ∙ 𝑫𝑹𝒋 ∙ 𝑷𝒇,𝒋

𝑝𝑟𝑑
𝑃𝑓,𝑓𝑖𝑟𝑒 = 0.0184 × 0.0004 × 1.0002 = 7.3615 × 10−6 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑦𝑒𝑎𝑟
𝑝𝑟𝑑
𝑃𝑓,𝐵𝐷 = 0.092 × 0.1 × 2.71 ∙ 10−5 = 2.4913 × 10−7 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑦𝑒𝑎𝑟
𝑝𝑟𝑑
𝑃𝑓,𝐿𝑂 = 0.092 × 0.01 × 5.35 ∙ 10−5 = 4.9242 × 10−8 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑦𝑒𝑎𝑟
 𝑝𝑟𝑑
𝑃𝑓,𝐸𝐹 = 0.092 × 0.08 × 2.71 ∙ 10−5 = 1.993 × 10−7 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑦𝑒𝑎𝑟

2. PROBABILITY FOR PRD LEAKAGE

2.1 Set Pressure Factor (Fset)
Based on Table 7.7 equation of Set Pressure Factor for Conventional PRV is,
𝑃 101
0.90 − 𝑚𝑖𝑛 [0.90; 𝑃 𝑠 ] 0.90 − 𝑚𝑖𝑛 [0.90;
𝐹𝑠𝑒𝑡 = 1 − [ 𝑠𝑒𝑡
]= 1−[ 155]] = 0.724
0.90 0.90

2.2 POL of PRD

• PRD Type = Conventional; Fluid Severity = Moderate → Based on Table 7.5 β = 1.6; ηdef =
15.5
• Soft seat adjustment factor, Fs = 1
• Fenv = 1
• Modified characteristic life (ηmod)

𝜂𝑚𝑜𝑑 = 𝐹𝑠 ∙ 𝐹𝑒𝑛𝑣 ∙ 𝜂𝑑𝑒𝑓 = 1 × 1 × 15.5 = 15.5 𝑦𝑒𝑎𝑟𝑠

Inspection 1

- Prior POFOD
Test result = No Leak
Inspection interval (tinsp) = Inspection Date (1) – Install Date = 2005 – 2000 = 5 years
𝑝𝑟𝑑 𝑡𝑖𝑛𝑠𝑝 𝛽 5 1.6
𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 = 1 − 𝑒𝑥𝑝 [− ( ) ] = 1 − 𝑒𝑥𝑝 [− ( ) ] = 0.1509
𝜂𝑚𝑜𝑑 15.5
𝑝𝑟𝑑 𝑝𝑟𝑑
𝑃𝑝,𝑝𝑟𝑖𝑜𝑟 = 1 − 𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 = 1 − 0.1509 = 0.8491 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑

- Conditional POFOD
Test result = No Leak (Pass); Effectiveness = B (Usually Effective) → Based on Table 7.8
CFpass = 0.7
𝑝𝑟𝑑 𝑝𝑟𝑑
𝑃𝑓,𝑐𝑜𝑛𝑑 = (1 − 𝐶𝐹𝑝𝑎𝑠𝑠 ) × 𝑃𝑝,𝑝𝑟𝑖𝑜𝑟
= (1 − 0.7) × 0.8491
= 0.2547 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑

- Weighted POFOD
Test result = No Leak (Pass); Effectiveness = B (Usually Effective) → Based on Table 7.9
equation used is,
𝑝𝑟𝑑 𝑝𝑟𝑑 𝑝𝑟𝑑 𝑡𝑖𝑛𝑠𝑝 𝑝𝑟𝑑 𝑡𝑖𝑛𝑠𝑝
𝑃𝑓,𝑤𝑔𝑡 = 𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 − 0.2 ∙ 𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 ( ) + 0.2 ∙ 𝑃𝑓,𝑐𝑜𝑛𝑑 ( )
𝜂 𝜂
5 5
= 0.1509 − 0.2 × 0.1509 ( ) + 0.2 × 0.2547 ( )
15.5 15.5
= 0.1576 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑

- Revised Characteristic Life (ηupd)

𝑡𝑖𝑛𝑠𝑝 5
𝜂𝑢𝑝𝑑 = 1 = 1 = 15.051 𝑦𝑒𝑎𝑟𝑠
(−𝑙𝑛 [1 − 𝑃
𝑝𝑟𝑑
])
𝛽 (−𝑙𝑛[1 − 0.1576])1.6
𝑓,𝑤𝑔𝑡
- For every inspection the following parameters must hold true
ηupd ≥ ηmod for passing inspections
 ηupd ≤ ηmod for failing inspections
Test Result = No Leak (Pass); ηupd = 15.051; ηmod = 15.5
→ ηmod used for Inspection 2 = 15.5 years

Inspection 2

- Prior POFOD
Test result = Leak (Fail)
Inspection interval (tinsp) = Inspection Date (2) – Install Date = 2010 – 2000 = 10 years
𝑝𝑟𝑑 𝑡𝑖𝑛𝑠𝑝 𝛽 10 1.6
𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 = 1 − 𝑒𝑥𝑝 [− ( ) ] = 1 − 𝑒𝑥𝑝 [− ( ) ] = 0.391
𝜂𝑚𝑜𝑑 15.5
𝑝𝑟𝑑 𝑝𝑟𝑑
𝑃𝑝,𝑝𝑟𝑖𝑜𝑟 = 1 − 𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 = 1 − 0.391 = 0.6089 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑

- Conditional POFOD
Test result = Leak (Fail); Effectiveness = B (Usually Effective) → Based on Table 7.8
CFpass = 0.7 and CFfail = 0.95
𝑝𝑟𝑑 𝑝𝑟𝑑 𝑝𝑟𝑑
𝑃𝑓,𝑐𝑜𝑛𝑑 = 𝐶𝐹𝑓𝑎𝑖𝑙 ∙ 𝑃𝑓,𝑝𝑟𝑖𝑜𝑟 + (1 − 𝐶𝐹𝑝𝑎𝑠𝑠 ) × 𝑃𝑝,𝑝𝑟𝑖𝑜𝑟
= 0.95 × 0.391 + (1 − 0.7) × 0.6089
= 0.5541 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑

- Weighted POFOD
Test result = Leak (Fail); Effectiveness = B (Usually Effective) → Based on Table 7.9
equation used is,
𝑝𝑟𝑑 𝑝𝑟𝑑
𝑃𝑓,𝑤𝑔𝑡 = 𝑃𝑓,𝑐𝑜𝑛𝑑 = 0.5541 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑

- Revised Characteristic Life (ηupd)

𝑡𝑖𝑛𝑠𝑝 10
𝜂𝑢𝑝𝑑 = 1 = 1 = 11.43 𝑦𝑒𝑎𝑟𝑠
𝑝𝑟𝑑
(−𝑙𝑛 [1 − 𝑃𝑓,𝑤𝑔𝑡 ])𝛽 (−𝑙𝑛[1 − 0.5541])1.6
- For every inspection the following parameters must hold true
ηupd ≥ ηmod for passing inspections
ηupd ≤ ηmod for failing inspections
Test Result = Leak (Fail); ηupd = 11.43; ηmod = 15.5
→ ηupd used for Pleak calculation = 11.43 years

• Current Inspection interval (t) = 5 years

𝛽 1.6
𝑡 5
• 𝑃𝑙𝑒𝑎𝑘 = 1 − 𝑒𝑥𝑝 [− 𝜂 ] = 1 − 𝑒𝑥𝑝 [− 11.43] = 0.234 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑑𝑒𝑚𝑎𝑛𝑑
𝑢𝑝𝑑

• Probability of Leakage of PRD

𝑝𝑟𝑑
𝑃𝑙𝑒𝑎𝑘 = 𝑃𝑙𝑒𝑎𝑘 ∙ 𝐹𝑠𝑒𝑡 = 0.234 × 0.724 = 0.169 𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠/𝑦𝑒𝑎𝑟

3. CONSEQUENCE OF PRD FAILURE TO OPEN

3.1 Fluid Properties of Representative Fluida
• Based on Table 4.2 fluid properties for C3-C4
- NBP = -6.3 oF
- Density (ρ) = 33.61 lb/ft3
- AIT = 696 oF
 - Ideal Gas Constant A = 2.632
Ideal Gas Constant B = 3.19E-01
Ideal Gas Constant C = -1.35E-04
Ideal Gas Constant D = 1.47E-08
• Operating Temperature (Ts) = 121 oF = 580.67 oR
Operating Pressure (Ps) = 101 Psig
• Spesific Heat of Released Fluid (Cp)
𝐶𝑝 = 𝐴 + 𝐵𝑇 + 𝐶𝑇 2 + 𝐷𝑇 3
= 2.632 + (3.19𝐸 −01 × 580.67) + (−1.35𝐸 −04 × 580.672 ) + (−1.35𝐸 −04 × 580.673 )
= 145.11
• Release Fluid Ideal Gas Spesific Heat Capacity Ratio (k)
Universal Gas Constant = 1.987 Btu/lbmol oR
𝐶𝑝 145.11
𝑘= = = 1.014
𝐶𝑝 − 𝑅 145.11 − 1.987

3.2 Release Hole Area (An)

Small Medium Large Rupture Max
Release Hole Number, d (in) 0.25 1 4 16 8
Generic Failure Frequency, gff
8.00.E-06 2.00.E-05 2.00.E-06 6.00.E-07
→ for Vessel-COLTOP

𝝅𝒅𝟐𝒏
𝑨𝒏 =
𝟒
3.14 × 0.252
𝐴𝑠𝑚𝑎𝑙𝑙 = = 0.049 𝑖𝑛2
4
3.14 × 12
𝐴𝑚𝑒𝑑𝑖𝑢𝑚 = = 0.786 𝑖𝑛2
4
3.14 × 42
𝐴𝑙𝑎𝑟𝑔𝑒 = = 12.571 𝑖𝑛2
4
3.14 × 162
𝐴𝑟𝑢𝑝𝑡𝑢𝑟𝑒 = = 201.143 𝑖𝑛2
4
3.14 𝑥 82
𝐴𝑚𝑎𝑥8 = = 50.286 𝑖𝑛2
4

3.3 Theoritical Release Rate (Wn)

Consequence of failure to open for PRD is calculated for every overpressure scenario. The
overpressure potential is implemented in place of the operating pressure.
• Discharged Coefficient, Cd → 0.61
• Conversion Factor C2 (See Table 3.B.2.1 in Annex 3.B) → 1 (for US unit)
• Storage of Normal Operating Temperature, Ts = 580.67 oR
• Release Fluid Molecular Weight, MW = 51 lb/lbmol
• Gravitational Constant, gc = 32.2 lb-ft/lbf-s2
• Universal Gas Constant, R = 1545 ft.lbf/lbmol oR
• Transition Back Pressure (Ptrans) = 10 psig = 24.7 psia
 • Overpressure potential (Ps) of each overpressure scenario
Overpressure Potential, Ps
Overpressure Scenario
(Psia)
Fire 634.7 Ps > Ptrans
Blocked Discharge 164.22 Ps > Ptrans
Liquid Overfilling 194.7 Ps > Ptrans
Electrical Power Failure 164.22 Ps > Ptrans

• Fluid phase at ambient (after release) = Gas

• Equation used for Vapor (Gas) with Ps > Ptrans is,
𝑘+1
𝐶𝑑 𝑘 ∙ 𝑀𝑊 ∙ 𝑔𝑐 2 𝑘−1
𝑊𝑛 = ∙ 𝐴𝑛 ∙ 𝑃𝑠 √( )( )
𝐶2 𝑅 ∙ 𝑇𝑠 𝑘+1
→ Example for Fire Overpressure Scenario, Medium (1 in) Release Hole Area:

𝑙𝑏 𝑙𝑏. 𝑓𝑡 1.014+1
0.61 𝑙𝑏𝑓 1.014 𝑥 51 𝑙𝑏𝑚𝑜𝑙 𝑥 32.2 2
2 𝑙𝑏𝑓. 𝑠 2 1.014−1
𝑊𝑚𝑒𝑑𝑖𝑢𝑚 = 𝑥 0.786 𝑖𝑛 𝑥 634.7 2 √( )( )
1 𝑖𝑛 𝑓𝑡. 𝑙𝑏𝑓 1.014 + 1
1545 𝑥 580.67 𝑜𝑅
𝑙𝑏𝑚𝑜𝑙. 𝑜𝑅

= 7.938 𝑙𝑏/𝑠

→ Theoritical Release Rate of Each Overpressure Scenario

Wsmall Wmedium Wlarge Wrupture Wmax8
Overpressure Scenario
(lb/s) (lb/s) (lb/s) (lb/s) (lb/s)
Fire 0.495 7.938 126.960 2,031.425 513.313
Blocked Discharge 0.128 2.054 32.849 525.604 132.813
Liquid Overfilling 0.152 2.435 38.946 623.158 157.463
Electrical Power Failure 0.128 2.054 32.849 525.604 132.813

𝑊𝑛 = 𝑚𝑖𝑛[𝑊𝑛 ; 𝑊𝑚𝑎𝑥8 ]
3.4 Total Amount of Fluid Available for Release
• Inventory Fluid Mass
𝑚𝑎𝑠𝑠𝑐𝑜𝑚𝑝 = 𝜌𝑙 × 𝐿𝑖𝑞𝑢𝑖𝑑 𝑉𝑜𝑙𝑢𝑚𝑒
- Equipment volume = πr2t = 3.14 x (8.14/2)^2 x 30 = 1559.7 ft3
- Assumed: Liquid volume = Equipment volume = 1559.7 ft3
𝑙𝑏
𝑚𝑎𝑠𝑠𝑐𝑜𝑚𝑝 = 33.61 3 × 1559.7 𝑓𝑡 3 = 52,420.913 𝑙𝑏
𝑓𝑡
• Additional Mass
𝑚𝑎𝑠𝑠𝑎𝑑𝑑,𝑛 = 180 ∙ 𝑚𝑖𝑛[𝑊𝑛 ; 𝑊𝑚𝑎𝑥8 ]
→ Example for Fire Overpressure Scenario, Medium (1 in) Release Hole Area:
𝑚𝑎𝑠𝑠𝑎𝑑𝑑,𝑚𝑒𝑑𝑖𝑢𝑚 = 180 ∙ 𝑚𝑖𝑛[7.938; 513.313] = 1,428.864 𝑙𝑏

→ Additional Mass of Each Overpressure Scenario

massadd,small massadd,medium massadd,large massadd,rupture
Overpressure Scenario
(lb) (lb) (lb) (lb)
Fire 89.077 1,428.864 22,852.738 92,396.250
Blocked Discharge 23.047 369.699 5,912.835 23,906.274
Liquid Overfilling 27.325 438.317 7,010.285 28,343.390
Electrical Power Failure 23.047 369.699 5,912.835 23,906.274
 • Available Mass for Release
Value of massinv not available, used equation below,
𝑚𝑎𝑠𝑠𝑎𝑣𝑎𝑖𝑙,𝑛 = 𝑚𝑎𝑠𝑠𝑐𝑜𝑚𝑝 + 𝑚𝑎𝑠𝑠𝑎𝑑𝑑,𝑛
→ Example for Fire Overpressure Scenario, Medium (1 in) Release Hole Area:
𝑚𝑎𝑠𝑠𝑎𝑣𝑎𝑖𝑙,𝑚𝑒𝑑𝑖𝑢𝑚 = 52,420.913 𝑙𝑏 + 1,428.864 𝑙𝑏 = 53,850.381 𝑙𝑏

→ Available Mass for Release of Each Overpressure Scenario

Massavail,small Massavail,medium Massavail,large Massavail,rupture
Overpressure Scenario
(lb) (lb) (lb) (lb)
Fire 52,510.59 53,850.381 75,274.26 144,817.767
Blocked Discharge 52,444.56 52,791.216 58,334.35 76,327.791
Liquid Overfilling 52,448.84 52,859.834 59,431.80 80,764.907
Electrical Power 52,444.56 52,791.216 58,334.35 76,327.791
Failure

3.5 Type of Release

𝑪𝟑
𝒕𝒏 =
𝑾𝒏
• Conversion Factor C3 (See Table 3.B.2.1 in Annex 3.B) → 10000 (for US unit)
→ Example for Fire Overpressure Scenario, Medium (1 in) Release Hole Area:
10000
𝑡𝑚𝑒𝑑𝑖𝑢𝑚 = 7.938
= 1259 𝑠𝑒𝑐 > 180 𝑠𝑒𝑐 → Continuous

→ Time to Release of Each Overpressure Scenario

Time to Relase, Sec
Overpressure Scenario
tsmall tmedium tlarge trupture
Fire 20,207.29 1,259.74 78.77 4.92
Blocked Discharge 78,099.90 4,868.82 304.42 19.03
Liquid Overfilling 65,873.47 4,106.62 256.77 16.05
Electrical Power 78,099.90 4,868.82 304.42 19.03
Failure

→ Type of Release of Each Overpressure Scenario

Overpressure Type of Release
Scenario Small Medium Large Rupture
Fire Continuous Continuous Instantaneous Instantaneous
Blocked Discharge Continuous Continuous Continuous Instantaneous
Liquid Overfilling Continuous Continuous Continuous Instantaneous
Electrical Power Continuous Continuous Continuous Instantaneous
Failure

3.6 Detection and Isolation System

Small Medium Large Rupture
Leak Detection System Classification A A A A
Isolation System A A A A
Release rate Reduction Factor, factdi 0.25 0.25 0.25 0.25
Leak Duration, ldmax 20 min 10 min 5 min -
3.7 Release Rate and Mass
• Release Rate, Raten (For Continuous)
𝑟𝑎𝑡𝑒𝑛 = 𝑊𝑛 (1 − 𝑓𝑎𝑐𝑡𝑑𝑖 )
→ Example for Fire Overpressure Scenario, Medium (1 in) Release Hole Area:
𝑙𝑏 𝑙𝑏
𝑟𝑎𝑡𝑒𝑚𝑒𝑑𝑖𝑢𝑚 = 𝑊𝑚𝑒𝑑𝑖𝑢𝑚 (1 − 𝑓𝑎𝑐𝑡𝑑𝑖 ) = 7.938 × (1 − 0.25) = 5.95
𝑠 𝑠
→ Release Rate of Each Overpressure Scenario
Ratesmall Ratemedium Ratelarge Raterupture
Overpressure Scenario
(lb/s) (lb/s) (lb/s) (lb/s)
Fire 0.37 5.95 95.22 1,523.57
Blocked Discharge 0.10 1.54 24.64 394.20
Liquid Overfilling 0.11 1.83 29.21 467.37
Electrical Power Failure 0.10 1.54 24.64 394.20

• Actual Leak Duration, ldn

𝑚𝑎𝑠𝑠𝑎𝑣𝑎𝑖𝑙,𝑛
𝑙𝑑𝑛 = 𝑚𝑖𝑛 [{ } , {60 ∙ 𝑙𝑑𝑚𝑎𝑥 }]
𝑟𝑎𝑡𝑒𝑛
→ Example for Fire Overpressure Scenario, Large (4 in) Release Hole Area:
75,274.26 𝑙𝑏
𝑙𝑑𝑙𝑎𝑟𝑔𝑒 = 𝑚𝑖𝑛 [{ } , {60 ∙ 5}] = 300 𝑠𝑒𝑐
𝑙𝑏
95.22 𝑠

→ Leak Duration of Each Overpressure Scenario

ldsmall ldmedium ldlarge ldrupture
Overpressure Scenario
(lb/s) (lb/s) (lb/s) (lb/s)
Fire 1,200 600 300 -
Blocked Discharge 1,200 600 300 -
Liquid Overfilling 1,200 600 300 -
Electrical Power Failure 1,200 600 300 -

• Release Mass, massn (For Instantaneous)

𝑚𝑎𝑠𝑠𝑛 = 𝑚𝑖𝑛[{𝑟𝑎𝑡𝑒𝑛 ∙ 𝑙𝑑𝑛 }; 𝑚𝑎𝑠𝑠𝑎𝑣𝑎𝑖𝑙,𝑛 ]
→ Example for Fire Overpressure Scenario, Large (4 in) Release Hole Area:
𝑙𝑏
𝑚𝑎𝑠𝑠𝑙𝑎𝑟𝑔𝑒 = 𝑚𝑖𝑛 [{95.22 ∙ 300} ; 75,274.26 𝑙𝑏] = 28,565.92 𝑙𝑏
𝑠

→ Release Mass for of Each Overpressure Scenario

masssmall massmedium masslarge massrupture
Overpressure Scenario
(lb) (lb) (lb) (lb)
Fire 445.38 3,572.16 28,565.92 -
Blocked Discharge 115.24 924.25 7,391.04 -
Liquid Overfilling 136.63 1,095.79 8,762.86 -
Electrical Power Failure 115.24 924.25 7,391.04 -

3.8 Flammable and Explosive Consequences

• Final Phase = Gas
• Representative Fluid = C3-C4
• Op. Temperature = 121 oF < AIT = 696 oF → Auto Ignition Not Likely
• Based on Table 4.9 Personnel Injury Flammable Consequence Equation Constants is,
 - For Continuous Release → a = 125.2 and b = 1
- For Instantaneous Release → a = 57.72 and b = 0.75
• Based on Table 4.8 Component Damage Flammable Consequence Equation Constants is,
- For Continuous Release → a = 49.48 and b = 1
For Instantaneous Release → a = 27.96 and b = 0.72
• Flammable Consequence Area for Personnel Injury
For Continuous Release:
𝐶𝐴𝐶𝑂𝑁𝑇
𝑛 = 𝑎(𝑟𝑎𝑡𝑒𝑛 )𝑏
For Instantaneous Release:
𝐶𝐴𝐼𝑁𝑆𝑇
𝑛 = 𝑎(𝑚𝑎𝑠𝑠𝑛 )𝑏

→ Example for Fire Overpressure Scenario, Medium (1 in) and Large (4 in) Release Hole
Area:
𝐴𝐼𝑁𝐿
𝐶𝐴𝑖𝑛𝑗,𝑚𝑒𝑑𝑖𝑢𝑚 = 𝑎 (𝑟𝑎𝑡𝑒𝑛 )𝑏 = 125.2(5.95)1 = 745.39 𝑓𝑡 2 = 69.25 𝑚2
𝐴𝐼𝑁𝐿
𝐶𝐴𝑖𝑛𝑗,𝑙𝑎𝑟𝑔𝑒 = 𝑎 (𝑚𝑎𝑠𝑠𝑛 )𝑏 = 57.72(28,565)0.75 = 126,827.23 𝑓𝑡 2 = 11,782.635 𝑚2

→ Flammable Consequence for Personnel Injury of Each Overpressure Scenario

𝑪𝑨𝑨𝑰𝑵𝑳 𝑨𝑰𝑵𝑳 𝑨𝑰𝑵𝑳 𝑨𝑰𝑵𝑳
𝒊𝒏𝒋,𝒔𝒎𝒂𝒍𝒍 𝑪𝑨𝒊𝒏𝒋,𝒎𝒆𝒅𝒊𝒖𝒎 𝑪𝑨𝒊𝒏𝒋,𝒍𝒂𝒓𝒈𝒆 𝑪𝑨𝒊𝒏𝒋,𝒓𝒖𝒑𝒕𝒖𝒓𝒆
Overpressure Scenario
(𝒎𝟐 ) (𝒎𝟐 ) (𝒎𝟐 ) (𝒎𝟐 )
Fire 4.32 69.25 11,782.25 39,806.91
Blocked Discharge 1.12 17.92 286.55 24,623.74
Liquid Overfilling 1.32 21.24 339.74 25,689.70
Electrical Power Failure 1.12 17.92 286.55 24,623.74

• Flammable Consequence Area for Component Damage

→ Example for Fire Overpressure Scenario, Medium (1 in) and Large (4 in) Release Hole
Area:
𝐴𝐼𝑁𝐿
𝐶𝐴𝑐𝑚𝑑,𝑚𝑒𝑑𝑖𝑢𝑚 = 𝑎 (𝑟𝑎𝑡𝑒𝑛 )𝑏 = 49.48(5.95)1 = 294.58 𝑓𝑡 2 = 27.37 𝑚2
𝐴𝐼𝑁𝐿
𝐶𝐴𝑐𝑚𝑑,𝑙𝑎𝑟𝑔𝑒 = 𝑎 (𝑚𝑎𝑠𝑠𝑛 )𝑏 = 27.96(28,565)0.72 = 45,159.37 𝑓𝑡 2 = 4,195.31 𝑚2

→ Flammable Consequence for Component Damage of Each Overpressure Scenario

𝑨𝑰𝑵𝑳 𝑨𝑰𝑵𝑳 𝑨𝑰𝑵𝑳
Overpressure 𝑪𝑨𝑨𝑰𝑵𝑳
𝒄𝒎𝒅,𝒔𝒎𝒂𝒍𝒍 𝑪𝑨𝒄𝒎𝒅,𝒎𝒆𝒅𝒊𝒖𝒎 𝑪𝑨𝒄𝒎𝒅,𝒍𝒂𝒓𝒈𝒆 𝑪𝑨𝒄𝒎𝒅,𝒓𝒖𝒑𝒕𝒖𝒓𝒆
Scenario (𝒎𝟐 ) (𝒎𝟐 ) (𝒎𝟐 ) (𝒎𝟐 )
Fire 1.71 27.37 4,195.31 13,500.34
Blocked Discharge 0.44 7.08 113.25 8,513.04
Liquid Overfilling 0.52 8.40 134.27 8,866.52
Electrical Power 0.44 7.08 113.25 8,513.04
Failure

• Final Flammable Consequence Area

→ Example for Fire Overpressure Scenario
𝑓𝑙𝑎𝑚
𝑓𝑙𝑎𝑚 ∑4𝑛−1 𝑔𝑓𝑓𝑛 ∙𝐶𝐴𝑖𝑛𝑗,𝑛
- 𝐶𝐴𝑖𝑛𝑗 =( 𝑔𝑓𝑓𝑡𝑜𝑡𝑎𝑙
)
(𝟖. 𝟎𝟎𝑬−𝟎𝟔 × 𝟒. 𝟑𝟐) + (𝟐. 𝟎𝟎𝑬−𝟎𝟓 × 𝟔𝟗. 𝟐𝟓) + (𝟐. 𝟎𝟎𝑬−𝟎𝟔 × 𝟏𝟏, 𝟕𝟖𝟐. 𝟐𝟓) + (𝟔. 𝟎𝟎𝑬−𝟎𝟕 × 𝟑𝟗, 𝟖𝟎𝟔. 𝟗𝟏 )
=[ ]
𝟑. 𝟎𝟔𝑬 − 𝟎𝟓
𝟐
= 𝟏, 𝟓𝟗𝟕. 𝟎𝟎 𝒎
 𝑓𝑙𝑎𝑚
𝑓𝑙𝑎𝑚 ∑4𝑛−1 𝑔𝑓𝑓𝑛 ∙𝐶𝐴𝑐𝑚𝑑,𝑛
- 𝐶𝐴𝑐𝑚𝑑 = ( )
𝑔𝑓𝑓𝑡𝑜𝑡𝑎𝑙
(𝟖. 𝟎𝟎𝑬−𝟎𝟔 × 𝟏. 𝟕𝟏) + (𝟐. 𝟎𝟎𝑬−𝟎𝟓 × 𝟐𝟕. 𝟑𝟕) + (𝟐. 𝟎𝟎𝑬−𝟎𝟔 × 𝟒, 𝟏𝟗𝟓. 𝟑𝟏) + (𝟔. 𝟎𝟎𝑬−𝟎𝟕 × 𝟏𝟑, 𝟓𝟎𝟎. 𝟑𝟒 )
=[ ]
𝟑. 𝟎𝟔𝑬 − 𝟎𝟓
𝟐
= 𝟓𝟓𝟕. 𝟐𝟓 𝒎
- Mitigation System : Inventory blowdown, coupled with isolation system classification
B or higher → Consequence Area Reduction factor (factmit) = 0.25
𝒇𝒍𝒂𝒎
𝑪𝑨𝒊𝒏𝒋 = 𝟏, 𝟓𝟗𝟕. 𝟎𝟎 𝒎𝟐 × (𝟏 − 𝟎. 𝟐𝟓) = 𝟏, 𝟏𝟗𝟕. 𝟕𝟓 𝒎𝟐
𝒇𝒍𝒂𝒎
𝑪𝑨𝒄𝒎𝒅 = 𝟓𝟓𝟕. 𝟐𝟓 𝒎𝟐 × (𝟏 − 𝟎. 𝟐𝟓) = 𝟒𝟏𝟕. 𝟗𝟒 𝒎𝟐

→ Final Flammable Consequence of Each Overpressure Scenario

𝒇𝒍𝒂𝒎 𝒇𝒍𝒂𝒎
𝑪𝑨𝒊𝒏𝒋 𝑪𝑨𝒄𝒎𝒅
Overpressure Scenario
(𝒎𝟐 ) (𝒎𝟐 )
Fire 1,197.75 417.94
Blocked Discharge 385.16 134.30
Liquid Overfilling 405.12 141.19
Electrical Power Failure 385.16 134.30

3.9 Toxic Consequences

No Toxic fluid on the stream → 𝐶𝐴𝑡𝑜𝑥 𝑡𝑜𝑥
𝑖𝑛𝑗 = 0 & 𝐶𝐴𝑐𝑚𝑑 = 0
3.10 Final Consequence Area
→ Example for Fire Overpressure Scenario
• Final Personnel Injury Consequence Area
𝑓𝑙𝑎𝑚
𝐶𝐴𝑖𝑛𝑗 = 𝑚𝑎𝑥[𝐶𝐴𝑖𝑛𝑗 ; 𝐶𝐴𝑡𝑜𝑥 2
𝑖𝑛𝑗 ] = 𝑚𝑎𝑥[1,197.75 𝑚 ; 0] = 1,197.75 𝑚
2

• Final Component Damage Consequence Area

𝑓𝑙𝑎𝑚
𝐶𝐴𝑐𝑚𝑑 = 𝑚𝑎𝑥[𝐶𝐴𝑐𝑚𝑑 ; 𝐶𝐴𝑡𝑜𝑥 2
𝑐𝑚𝑑 ] = 𝑚𝑎𝑥[417.94 𝑚 ; 0] = 417.94 𝑚
2

→ Final Consequence Area of Each Overpressure Scenario

Overpressure Scenario CA (m2)
Fire 1,197.75
Blocked Discharge 385.16
Liquid Overfilling 405.12
Electrical Power Failure 385.16

3.11 Financial Consequences

3.11.1 Component Damage Cost (FCcmd)
• Material cost factor (matcost) for Carbon Steel = 1
• Generic failure frequency for each release hole size:
gffsmall = 8.00E-06 failure/year
gffmedium = 2.00E-05 failure/year
gfflarge = 2.00E-06 failure/year
gffrupture = 6.00E-07 failure/year
gfftotal = 3.06E-05 failure/year
• Equipment repair cost for each release hole size:
holecostsmall = $10,000
holecostmedium = $25,000
holecostlarge = $50,000
 holecostrupture = $100,000
∑𝟒𝒏=𝟏 𝒈𝒇𝒇𝒏 ∙𝒉𝒐𝒍𝒆𝒄𝒐𝒔𝒕𝒏
• 𝑭𝑪𝒄𝒎𝒅 = ( 𝒈𝒇𝒇𝒕𝒐𝒕𝒂𝒍
) ∙ 𝒎𝒂𝒕𝒄𝒐𝒔𝒕
(8.10−06 × 10,000)+(2.10−05 × 25,000)+(2.10−06 × 50,000)+(6.10−07 ×100,000)
=[ 3.06𝑥10−05
]
= $24,183.01/𝑓𝑎𝑖𝑙𝑢𝑟𝑒

3.11.2 Damage Cost to Surrounding Equipment in Affected Area (FCaffa)

• Process unit replacement costs for component (equipcost) = $1,200/m2
→ Example for Fire Overpressure Scenario
𝐹𝐶𝑎𝑓𝑓𝑎 = 𝐶𝐴𝑐𝑚𝑑 ∙ 𝑒𝑞𝑢𝑖𝑝𝑐𝑜𝑠𝑡 = 417.94 𝑚2 × $1,200/𝑚2 = $501,523.53

→ Damage Cost to Surrounding Equipment of Each Overpressure Scenario

Overpressure Scenario FCaffa ($)
Fire 501,523.53
Blocked Discharge 161,160.71
Liquid Overfilling 169,427.48
Electrical Power Failure 161,160.71

3.11.3 Potential Injury Cost (FCinj)

• Cost associated with serious injury of fatality personnel (injcost) = $5,000,000
• Population Density of personnel in the unit (popdens) = 0.00005
→ Example for Fire Overpressure Scenario
𝐹𝐶𝑖𝑛𝑗 = 𝐶𝐴𝑖𝑛𝑗 ∙ 𝑝𝑜𝑝𝑑𝑒𝑛𝑠 ∙ 𝑖𝑛𝑗𝑐𝑜𝑠𝑡
= 1,197.75 𝑚2 × 0.00005 × $5,000,000
= $299,436.98

→ Potential Injury Cost of Each Overpressure Scenario

Overpressure Scenario FCinj ($)
Fire 299,436.98
Blocked Discharge 96,290.56
Liquid Overfilling 101,279.00
Electrical Power Failure 96,290.56

3.11.4 Business Interruption Cost (FCprod)

• Estimated outage for each release hole size:
Outagesmall = 3 days
Outagemedium = 4 days
Outagelarge = 5 days
Outagerupture = 21 days
∑𝟒𝒏=𝟏 𝒈𝒇𝒇𝒏 ∙𝑶𝒖𝒕𝒂𝒈𝒆𝒏
• 𝑶𝒖𝒕𝒂𝒈𝒆𝒄𝒎𝒅 = ( ) ∙ 𝑶𝒖𝒕𝒂𝒈𝒆𝒎𝒖𝒍𝒕
𝒈𝒇𝒇𝒕𝒐𝒕𝒂𝒍
(8. 10−06 × 3) + (2. 10−05 × 4) + (2. 10−06 × 5) + (6. 10−07 × 21)
=[ −05
]× 1
3.06𝑥10
= 4.14 𝑑𝑎𝑦𝑠
• Outageaffa = 0
• Daily Production (prodcost) = 100,000 $/day
• 𝐹𝐶𝑝𝑟𝑜𝑑 = (𝑂𝑢𝑡𝑎𝑔𝑒𝑐𝑚𝑑 + 𝑂𝑢𝑡𝑎𝑔𝑒𝑎𝑓𝑓𝑎 ) ∙ 𝑝𝑟𝑜𝑑𝑐𝑜𝑠𝑡
= (4.14 𝑑𝑎𝑦𝑠 + 0) × $100,000
 = $413,725.49/𝑑𝑎𝑦

3.11.5 Environmental Cleanup Costs (FCenv)

Fluid release phase is Gas, then no fluid spilled to environment, no need Cleanup Costs
→ FCenv = 0

3.11.6 Final Financial Consequences

→ Example for Fire Overpressure Scenario
𝑭𝑪 = 𝑭𝑪𝒄𝒎𝒅 + 𝑭𝑪𝒂𝒇𝒇𝒂 + 𝑭𝑪𝒊𝒏𝒋 + 𝑭𝑪𝒑𝒓𝒐𝒅 + 𝑭𝑪𝒆𝒏𝒗
= $24,183.01 + $501,523.53 + $299,436.98 + $413,725.49 + 0
= $1,238,869

→ Financial Consequence of Each Overpressure Scenario

Overpressure Scenario FC ($)
Fire 1,238,869.00
Blocked Discharge 437,908.50
Liquid Overfilling 437,908.50
Electrical Power Failure 437,908.50

4. CONSEQUENCE OF PRD LEAKAGE

4.1 Leakage Rate
𝑝𝑟𝑑
• Flow Capacity of PRD, 𝑊𝑐 = 35,081 lb/hr
• Mild to moderata leakage rate (lratemild)
𝑝𝑟𝑑 𝑙𝑏
𝑙𝑟𝑎𝑡𝑒𝑚𝑖𝑙𝑑 = 0.01 ∙ 𝑊𝑐 = 0.01 × 35,081 = 350.8 𝑙𝑏/ℎ𝑟
ℎ𝑟

• Stuck open leakage rate (lrateso)

𝑝𝑟𝑑 𝑙𝑏
𝑙𝑟𝑎𝑡𝑒𝑠𝑜 = 0.25 ∙ 𝑊𝑐 = 0.25 × 35,081 = 8,770 𝑙𝑏/ℎ𝑟
ℎ𝑟
4.2 Leakage and Stuck Open Duration
• Inlet size of PRD = 2 in; Discharge Location = Flare → Based on Table 7.14 Leakage
Duration (Dmild) = 15 days
• Stuck Open Duration
30 𝑚𝑖𝑛
𝐷𝑠𝑜 = = 0.021 𝑑𝑎𝑦𝑠
60 𝑚𝑖𝑛/ℎ𝑟 ∙ 24 ℎ𝑟/𝑑𝑎𝑦

4.3 Consequence of Lost Inventory

• PRD discharge to flare, but Unit Flare Recovery System is not installed → Recovery Factor
(Fr) = 1
• Fluid cost, Costflu = $0.05/lb
𝑚𝑖𝑙𝑑
𝐶𝑜𝑠𝑡𝑖𝑛𝑣 = 24 ∙ 𝐹𝑟 ∙ 𝐶𝑜𝑠𝑡𝑓𝑙𝑢 ∙ 𝐷𝑚𝑖𝑙𝑑 ∙ 𝑙𝑟𝑎𝑡𝑒𝑚𝑖𝑙𝑑
$0.05 𝑙𝑏
= 24 × 1 × × 15 𝑑𝑎𝑦𝑠 × 350.8
𝑙𝑏 ℎ𝑟
= $6,315
𝑠𝑜
𝐶𝑜𝑠𝑡𝑖𝑛𝑣 = 24 ∙ 𝐹𝑟 ∙ 𝐶𝑜𝑠𝑡𝑓𝑙𝑢 ∙ 𝐷𝑠𝑜 ∙ 𝑙𝑟𝑎𝑡𝑒𝑠𝑜
$0.05 𝑙𝑏
= 24 × 1 × × 0.021 𝑑𝑎𝑦𝑠 × 8,770
𝑙𝑏 ℎ𝑟
= $219
 4.4 Environmental Consequence
There are no associated environmental consequence → Cenv = 0
4.5 Repair and Maintenance Consequence
PRD Inlet Size = 2 in < NPS 6 Inlet Size → Costsd = $1,000
4.6 Consequence of Lost Production
• Tolerable leak = Yes → 𝐶𝑝𝑟𝑜𝑑
𝑚𝑖𝑙𝑑
=0
• Daily Production = 100,000 $/day
Time to repair PRD, Dsd = 2 days
𝑠𝑜
$
𝐶𝑝𝑟𝑜𝑑 = 𝑈𝑛𝑖𝑡𝑝𝑟𝑜𝑑 ∙ 𝐷𝑠𝑑 = 100,000 × 2 𝑑𝑎𝑦𝑠 = $200,000
𝑑𝑎𝑦
4.7 Leakage Consequence
• Mild to Moderate Leakage
𝑪𝒎𝒊𝒍𝒅
𝒍 = 𝑪𝒎𝒊𝒍𝒅
𝒊𝒏𝒗 + 𝑪𝒆𝒏𝒗 + 𝑪𝒔𝒅 + 𝑪𝒑𝒓𝒐𝒅
𝒎𝒊𝒍𝒅

= $6,315 + 0 + 0 + 0
= $6,315
• Stuck Open Leakage
𝑪𝒔𝒐 𝒔𝒐
𝒍 = 𝑪𝒊𝒏𝒗 + 𝑪𝒆𝒏𝒗 + 𝑪𝒔𝒅 + 𝑪𝒑𝒓𝒐𝒅
𝒔𝒐

= $219 + 0 + $1,000 + $200,000

= $201,219
• Final Leakage Consequence
𝒑𝒓𝒅
𝑪𝒍𝒆𝒂𝒌 = 𝟎. 𝟗 ∙ 𝑪𝒎𝒊𝒍𝒅
𝒍 + 𝟎. 𝟏 ∙ 𝑪𝒔𝒐
𝒍
= 0.9 × $6,315 + 0.1 × $201,219
= $25,805

5. RISK OF PRD FAILURE TO OPEN

• Risk of PRD failure to open associated with Fire overpressure demand case
𝑝𝑟𝑑 𝑝𝑟𝑑 𝑝𝑟𝑑
𝑅𝑖𝑠𝑘𝑓,𝑓𝑖𝑟𝑒 = 𝑃𝑓,𝑓𝑖𝑟𝑒 ∙ 𝐶𝑓,𝑓𝑖𝑟𝑒 = (7.3615 × 10−6 ) × $1,238,869 = $9.120

• Risk of PRD failure to open associated with Blocked Discharge overpressure demand case
𝑝𝑟𝑑 𝑝𝑟𝑑 𝑝𝑟𝑑
𝑅𝑖𝑠𝑘𝑓,𝐵𝐷 = 𝑃𝑓,𝐵𝐷 ∙ 𝐶𝑓,𝐵𝐷 = (2.4913 × 10−7 ) × $695,359.77 = $0.173

• Risk of PRD failure to open associated with Liquid Overfilling overpressure demand case
𝑝𝑟𝑑 𝑝𝑟𝑑 𝑝𝑟𝑑
𝑅𝑖𝑠𝑘𝑓,𝐿𝑂 = 𝑃𝑓,𝐿𝑂 ∙ 𝐶𝑓,𝐿𝑂 = (4.9242 × 10−8 ) × $708,614.98 = $0.035

• Risk of PRD failure to open associated with Electrical Power Failure overpressure demand
case
𝑝𝑟𝑑 𝑝𝑟𝑑 𝑝𝑟𝑑
𝑅𝑖𝑠𝑘𝑓,𝐸𝐹 = 𝑃𝑓,𝐸𝐹 ∙ 𝐶𝑓,𝐸𝐹 = (1.993 × 10−7 ) × $695,359.77 = $0.139

• Total Risk of PRD Failure to Open

𝒑𝒓𝒅 𝒑𝒓𝒅 𝒑𝒓𝒅
𝑹𝒊𝒔𝒌𝒇 = ∑𝑷𝒇,𝒋 ∙ 𝑪𝒇,𝒋
= $9.120 + $0.173 + $0.035 + $0.139
= $9.467/𝑦𝑒𝑎𝑟
6. RISK OF PRD LEAKAGE
𝒑𝒓𝒅 𝒑𝒓𝒅 𝒑𝒓𝒅
𝑹𝒊𝒔𝒌𝒍𝒆𝒂𝒌 = 𝑷𝒍𝒆𝒂𝒌 ∙ 𝑪𝒍𝒆𝒂𝒌
𝑓𝑎𝑖𝑙𝑢𝑟𝑒𝑠
= 0.169 × $25,805
𝑦𝑒𝑎𝑟
= $4,371/𝑦𝑒𝑎𝑟

7. TOTAL PRD RISK

𝒑𝒓𝒅 𝒑𝒓𝒅
𝑹𝒊𝒔𝒌𝒑𝒓𝒅 = 𝑹𝒊𝒔𝒌𝒇 + 𝑹𝒊𝒔𝒌𝒍𝒆𝒂𝒌
= $9.467 + $4,371
= $4,380.467/𝑦𝑒𝑎𝑟

8. RISK CATEGORY
PoF Level Determination

CoF Level Determination

• Risk of Fail to Open Failure Mode (taken from highest risk of all the overpressure scenario)
PoF = 7.3615×10-06 failure/year → Level 1
CoF = $1,238,869 → Level D
Risk Category = 1-D (Medium)
• Risk of Leakage Failure Mode
PoF = 0.169 failure/year → Level 5
CoF = $25,805 → Level A
Risk Category = 5-A (Medium)

• Final Risk Category = Medium