Overpressure Protection of Pressure Piping

OVERPRESSURE PROTECTION OF PRESSURE PIPING
The overpressure protection philosophy of pressure piping from various codes/jurisdiction perspectives
is summarized below:
ABSA:
In Alberta, ABSA is the jurisdictional authority that regulates the pressure equipment safety. Alberta
government delegates this authority to ABSA through this legislation called Safety Codes Act (SCA). The
regulation that governs the pressure equipment safety under the act is called Pressure Equipment Safety
Regulation. The requirement for overpressure protection is stated in the following section of the
regulation: various
Section 38: Overpressure Protection
38(1) an owner of pressure equipment must ensure it has overpressure protection that is
(a) A pressure relief valve that meets the requirements of the ASME Code, or
(b) Other means of overpressure protection acceptable to the Administrator.
(2) A pressure relief device must be set to open before the pressure in the pressure equipment exceeds
the maximum allowable working pressure of the pressure equipment.
(3) An owner of pressure equipment must ensure that the overpressure protection system is designed
and maintained so that the maximum pressure in the pressure equipment does not exceed the prescribed
limit of overpressure allowed in the applicable code declared in force by this Regulation.
Note: It is important to recognize the fact that a pressure piping system is considered as a pressure
equipment as stated in the Safety Codes Act.
As per the above, a pressure piping system must have overpressure protection. A pressure relief valve is
a primary device for overpressure protection unless a written permission from ABSA administrator is
obtained to use other devices or method of protection. Rupture discs and pin devices are regarded as
alternate means of overpressure protection. While seeking a relief valve exemption, detailed
justification is required by ABSA administrator explaining why a pressure relief valve is not considered
and how the alternate method can effectively protect the piping system.
ASME B31.3 Ed. 2006:
ASME B31.3 outlines the overpressure protection requirements for pressure piping in the following
paragraph:
301.2.2 Required Pressure Containment or Relief: (a) Provision shall be made to safely contain or relieve
(see Para. 322.6.3) any pressure to which the piping may be subjected. Piping not protected by a
pressure relieving device, or that can be isolated from a pressure relieving device, shall be designed for at
least the highest pressure that can be developed.
As per the above, the designer has two choices for selecting the design thickness and corresponding
design pressure which are classified below:
Piping designed to contain the overpressure(wall thickness acts as a primary overpressure protection):
In this case, piping component thickness and rating shall be selected to satisfy the pressure at the most
severe condition of coincident internal or external pressure and temperature. No other pressure
protection is required such as a pressure relieving device or a pressure limiting device. However user is
warranted to ensure that the MOP of the piping is kept higher than the highest pressure than can
reasonably be achieved by system, addressing all credible scenarios of overpressure.
A wellhead highline (piping connecting a wellhead to the first pressure control device) is a good example
of this scenario where design pressure is normally chosen to contain maximum sustained pressure (well
shut-in pressure).
Piping designed for normal operating conditions and relieved for overpressure situation:
The majority of plant piping is designed on this philosophy. In this case, the piping is intended to operate
at normal conditions; any upset pressure arising from the different scenarios shall be relieved by a
pressure relieving device. The designer shall ensure that piping being protected can’t be isolated from
pressure relieving device during the normal operation. For instance, inlet piping to a pressure vessel
shall have full access to the pressure safety valve on the vessel- and, if a block valve is provided for
isolation purpose then it shall be left car sealed open, ensuring full access to the PSV.
Some examples are: piping downstream of a control valve, pump discharge piping etc.
Contrary to CSA Z662, ASME B31.3 considers a single overpressure protection device suitable for the
requirement of pressure relief; no additional pressure control device is required for pressure protection.
In both of the above cases the designer shall consider all sources of pressure and select the one that
overpressures the piping to the highest magnitude. The following factors should be considered for the
sources of pressure:
 Ambient Effects (Solar heat addition, other abnormal heat inputs etc.)
 Pressure oscillations and surges (due to fluid transients- water hammers etc.)
 Improper operation (shock wave due to quick valve closure etc.)
 Decomposition of unstable fluids, chemical reactions, integral explosions and accumulation of
non-condensable
 Static head
 Failure of control devices (piping exposed to higher than design pressure)
 Utility failure (API RP 521)
 Loss of utilities, electric, steam, cooling water, instrument air
 Blocked outlet
 Exchanger tube rupture
ASME SECTION VIII:
Under UG 140 Para, ASME SECTION VIII allows overpressure protection by system design if the pressure
is self-limiting, and this pressure is less than MOP of the system, and the following conditions are met:
1. The user takes responsibility of limiting the pressure by system design.

2. A detailed analysis in the form of process hazard study such as HAZOP, what-if study shall be
conducted. The objective of the study is to identify all the sources of overpressure and ensure
none of them will exceed the MOP of the system. These sources are defined in API RP 521
which shall be considered during evaluation.
3. The analysis shall be documented and authenticated by the individual who is responsible for
safe operation of the vessel.
The code also outlines a case where a piping system may be protected from over pressure by
system design even if the pressure is not self-limiting. However the primary requirement is that the
piping system is not for a service where release of fluid may result in safety or environmental
hazard. This disqualifies typical hydrocarbon piping system from using this exemption.
ROLE OF INSTRUMENTATION AS AN ALTERNATIVE TO PRESSURE RELIEF DEVICES:
Use of instrumentation as an alternate to a pressure relive device is not cited in any of the above codes,
except for API RP 521 sec 4.2.1 quoted below:
“Fail-safe devices automatic start up equipment and other conventional instrumentation should not be a
substitute for properly sized pressure relieving devices as protection against single jeopardy overpressure
scenarios. There can be circumstances however where the use of pressure relief devices is impractical
and reliance on instrumented safeguards is needed .Where this is the case if permitted by local
regulations a pressure relieving device might not be required.”
Here are some advantages for having a slam shut instrumentation over a pressure relief device:
 No substance release to atmosphere avoiding nuisance (no revenue loss)

 Requires operator intervention to detect the problem
 Position monitoring through SCADA
 Capital cost saving for flare system install (for acid gases which can’t be vented to atm.)
Also, it is important to distinguish between control and protective instrumentation.

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OVERPRESSURE PROTECTION OF PRESSURE PIPING

Section 38: Overpressure Protection

(b) Other means of overpressure protection acceptable to the Administrator.

ASME B31.3 Ed. 2006:

ASME SECTION VIII:

1. The user takes responsibility of limiting the pressure by system design.

ROLE OF INSTRUMENTATION AS AN ALTERNATIVE TO PRESSURE RELIEF DEVICES:

 No substance release to atmosphere avoiding nuisance (no revenue loss)

Also, it is important to distinguish between control and protective instrumentation.

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