CHENG 465

Chemical Process Safety

Chapter 9
Introduction to Reliefs

Dr. Bassam Alhamad

 Continuing Education
Course

Design Considerations
for
Overpressure Protection

February 17, 2011

American Institute of Chemical Engineers

Delaware Valley Section
9-1. Relief Concepts

Pressure relief systems are required for the following reasons:

1. To protect personnel from the dangers of overpressurizing equipment
2. To minimize chemical losses during pressure upsets
3. To prevent damage to equipment
4. To prevent damage to adjoining property
5. To reduce insurance premiums
6. To comply with governmental regulations
Typical pressure versus time curves for runaway
reactions are illustrated in Figure 9-2
• Figure 9-2. Pressure
versus time for runaway
reactions:
• (A) relieving vapor,
• (B)relieving froth (two-
phase flow), and
• (C) closed reaction
vessel.
Definitions
• Set pressure: The pressure at which the relief device begins to activate.
• Maximum allowable working pressure (MAWP): The maximum gauge pressure
permissible at the top of a vessel for a designated temperature. This is sometimes
called the design pressure. Vessel failure typically occurs at 4 or 5 times the
MAWP, although vessel deformation may occur at as low as twice the MAWP.
• Operating pressure: The gauge pressure during normal service, usually 10%
below the MAWP.
• Accumulation: The pressure increase over the MAWP of a vessel during the relief
process. It is expressed as a percentage of the MAWP.
• Overpressure: The pressure increase in the vessel over the set pressure during
the relieving process. Overpressure is equivalent to the accumulation when the
set pressure is at the MAWP. It is expressed as a percentage of the set pressure.
• Backpressure: The pressure at the outlet of the relief device during the relief
process resulting from pressure in the discharge system.
• Blowdown: The pressure difference between the relief set pressure and the relief
reseating pressure. It is expressed as a percentage of the set pressure.
• Maximum allowable accumulated pressure: The sum of the MAWP and the
allowable accumulation.
• Relief system: The network of components around a relief device, including the
pipe to the relief, the relief device, discharge pipelines, knockout drum, scrubber,
flare, or other types of equipment that assist in the safe relief process.
The relationship between these terms is
illustrated in Figures 9-3 and 9-4.
Figure 9-4. Guidelines for relief pressures.
Adapted from API RP 521, Guide for Pressure-Relieving and Depressuring Systems, 4th ed.
(Washington, DC: American Petroleum Institute, 1997), p. 30.
9-3. Location of Reliefs

• The procedure for specifying the location of reliefs requires

the review of every unit operation in the process and of
every process operating step.
• The engineer must anticipate the potential problems that
may result in increased pressures.
• Pressure relief devices are installed at every point identified
as potentially hazardous, that is, at points where upset
conditions create pressures that may exceed the MAWP.
The types of questions asked in this review process are:
• What happens with loss of cooling, heating, or agitation?
• What happens if the process is contaminated or has a
mischarge of a catalyst or monomer?
• What happens if the operator makes an error?
• What is the consequence of closing valves (block valves) on
vessels or in lines that are filled with liquids and exposed to
heat or refrigeration?
• What happens if a line fails, for example, a failure of a high-
pressure gas line into a low-pressure vessel?
• What happens if the unit operation is engulfed in a fire?
• What conditions cause runaway reactions, and how are relief
systems designed to handle the discharge as a result of
runaway reactions?
Some guidelines for locating reliefs are
summarized in Table 9-1.
Why do all vessels need relief valves?
Relief valves are essential safety devices used on vessels to protect them from
overpressure situations. Here are a few key reasons why relief valves are necessary:
1. Pressure Relief: Vessels, such as tanks, containers, or pipelines, can experience
pressure buildup due to various factors like thermal expansion, process upsets,
equipment failure, or external events. If the pressure exceeds the vessel's safe
operating limit, it can lead to catastrophic failure or rupture. Relief valves are designed
to open and relieve excess pressure, preventing the vessel from exceeding its design
limits.
2. Equipment Protection: Overpressure can damage or compromise the integrity of
equipment connected to the vessel, such as pumps, valves, or instrumentation. By
relieving excessive pressure, relief valves help protect downstream equipment from
potential damage, reducing the risk of costly repairs or equipment failures.
3. Personnel Safety: Excessive pressure in a vessel poses a significant safety risk to
personnel working in the vicinity. A sudden vessel failure or rupture can release
hazardous materials, cause explosions, or result in flying debris, endangering the lives
of workers. Relief valves are crucial in preventing such incidents by maintaining the
pressure within safe limits.
4. Regulatory Compliance: Many industrial processes and facilities are subject to safety
regulations and codes that require the use of relief valves on vessels. Compliance with
these regulations ensures the safety of workers, property, and the environment.
Properly installed and maintained relief valves assist in meeting these regulatory
requirements.
Why pumps and compressors need relief valves on
the discharge side?
Pumps and compressors often require relief valves on the discharge side for several
important reasons:
1. Overpressure Protection: In certain operational scenarios, pumps and
compressors can experience conditions that lead to excessive discharge pressure.
This may occur due to factors such as sudden valve closure, system blockages, or
changes in process conditions. A relief valve on the discharge side acts as a safety
device, opening to relieve excess pressure and prevent system damage or failure.
2. Equipment Protection: High discharge pressures can be detrimental to the
integrity and performance of downstream equipment, such as pipes, valves, or
process vessels. By including a relief valve on the discharge side, excessive pressure
can be diverted away from the system, safeguarding the connected equipment
from potential damage.
3. System Safety: Excessive pressure in a pumping or compression system can pose
risks to personnel, property, and the environment. A relief valve on the discharge
side helps maintain safe operating conditions by preventing pressure buildup
beyond the system's design limits. By promptly relieving excess pressure, the risk of
equipment failure, leaks, or catastrophic incidents is mitigated.
4. Control and Regulation: Relief valves on the discharge side provide an important
means of controlling and regulating system pressure. By setting the relief valve to a
specific pressure limit, operators can maintain the desired pressure range within
the system. This allows for safe and efficient operation, prevents pressure spikes,
and ensures that the system operates within its intended design parameters.
Why do vessel steam jackets need relief valves?
Vessel steam jackets require relief valves for several important reasons:
1. Overpressure Protection: Steam jackets are used to heat vessels and maintain
specific temperatures for processes involving liquids, gases, or solids. If there is an issue
with the steam supply or control system, the pressure within the jacket can increase
beyond safe limits. This can lead to the vessel or jacket's failure, potentially causing
damage to equipment, injury to personnel, or release of hazardous substances. Relief
valves on steam jackets provide a means to release excess pressure and prevent over-
pressurization.
2. Thermal Expansion: Steam jackets undergo thermal expansion as they heat up. If the
system does not accommodate this expansion adequately, it can result in increased
pressure within the jacket. Relief valves serve to alleviate the pressure caused by
thermal expansion and prevent damage to the jacket or vessel.
3. Process Upsets: Process upsets or malfunctions can occasionally occur, leading to a
sudden increase in temperature or pressure within the jacket. This can be caused by
factors such as control system failures, blockages, or operator errors. Relief valves on
steam jackets act as a safety mechanism to prevent excessive pressure buildup during
such events, protecting the vessel and associated equipment.
4. System Safety: In the event of a failure or rupture in the vessel or jacket, the release
of steam can create hazardous conditions for personnel or the surrounding
environment. Relief valves on steam jackets help mitigate the risks associated with such
failures by maintaining pressure within safe limits and preventing catastrophic events.
Example 9-1.
• Specify the location of reliefs in the simple polymerization
reactor system illustrated in Figure 9-5. The major steps in
this polymerization process include:

(1) pumping 100 lb of initiator into reactor R-1,

(2) heating to the reaction temperature of 240°F,
(3) adding monomer for a period of 3 hr, and
(4) stripping the residual monomer by means of a vacuum
using valve V-15. Because the reaction is exothermic,
cooling during monomer addition with cooling water is
necessary.
Figure 9-5. Polymerization reactor without safety reliefs.
Solution:
The review method for specifying the location of reliefs follows.
Refer to Figures 9-5 and 9-6 and Table 9-1 for relief locations.
a. Reactor (R-1): A relief is installed on this reactor because, in general,
every process vessel needs a relief. This relief is labelled PSV-1 for pressure
safety valve 1.
b. Positive displacement pump (P-1): Positive displacement pumps are
overloaded, overheated, and damaged if they are dead-headed without a
pressure-relieving device (PSV-2). This type of relief discharge is usually
recycled back to the feed vessel.
c. Heat exchanger (E-1): Heat exchanger tubes can rupture from excessive
pressures when water is blocked in (V-10 and V-11 are closed) and the
exchanger is heated (by steam, for example). This hazard is eliminated by
adding PSV-3.
d. Drum (D-1): Again, all process vessels need relief valves, PSV-4.
e. Reactor coil: This reactor coil can be pressure-ruptured when water is
blocked in (V-4, V-5, V-6, and V-7 are closed) and the coil is heated with
steam or even the sun. Add PSV-5 to this coil.
9-4. Relief Types and Characteristics

• Specific types of relief devices are chosen for specific

applications, such as for liquids, gases, liquids and
gases, solids, and corrosive materials; they may be
vented to the atmosphere or vented to containment
systems (scrubber, flare, condenser, incinerator, and
the like).
• In engineering terms the type of relief device is
specified on the basis of the details of the relief
system, process conditions, and physical properties
of the relieved fluid.
 There are two general categories of relief devices (spring-operated and
rupture discs) and two major types of spring-operated valves (conventional
and balanced-bellows), as illustrated in Figure 9-7.

For a conventional spring-operated relief, the valve • Rupture discs are specially designed to rupture at a
opens based on the pressure drop across the valve specified relief set pressure. They usually consist of a
seat; that is, the set pressure is proportional to the calibrated sheet of metal designed to rupture at a well-
pressure drop across the seat. Thus, if the specified pressure. They are used alone, in series, or in
backpressure downstream of the valve increases, the parallel to spring-loaded relief devices. They can be made
set pressure will increase and the valve may not open from a variety of materials, including exotic corrosion-
at the correct pressure. In addition, the flow through resistant materials.
the conventional relief is proportional to the difference • An important problem with rupture discs is the flexing of
in pressure across the seat. The flow through the relief, the metal as process pressures change. Flexing could lead
therefore, is reduced as the backpressure increases. to premature failure at pressures below the set pressure.
• Another problem with rupture disc systems is that once
they open, they remain open
Rupture discs are frequently installed in series to a spring-loaded relief
(1) to protect an expensive spring-loaded device from a corrosive
environment,
(2) to give absolute isolation when handling extremely toxic chemicals
(spring-loaded reliefs may weep),
(3) to give absolute isolation when handling flammable gases,
(4) to protect the relatively complex parts of a spring-loaded device from
reactive monomers that could cause
plugging, and
(5) to relieve slurries that may plug spring-loaded devices.
There are three subcategory types of spring-
loaded pressure reliefs:
1. The relief valve is primarily for liquid service. The relief valve (liquid only)
begins to open at the set pressure. This valve reaches full capacity when the
pressure reaches 25% overpressure. The valve closes as the pressure
returns to the set pressure.
2. The safety valve is for gas service. Safety valves pop open when the
pressure exceeds the set pressure. This is accomplished by using a
discharge nozzle that directs high-velocity material toward the valve seat.
After blowdown of the excess pressure, the valve reseats at approximately
4% below the set pressure; the valve has a 4% blowdown.
3. The safety relief valve is used for liquid and gas service. Safety relief
valves function as relief valves for liquids and as safety valves for gases.
Example 9-2. - Specify the types of relief devices needed for the polymerization
reactor in Example 9-1. (see Figure 9-6)
• Solution
Each relief is reviewed in relation to the relief system and the properties of
the relieved
a. PSV-1a is a rupture disc to protect PSV-1b from the reactive monomers
(plugging from polymerization).
b. PSV-1b is a safety relief valve because a runaway reaction will give two-
phase flow, both liquid and vapor.
c. PSV-2 is a relief valve because this relief is in a liquid service line. A
conventional valve is satisfactory.
d. PSV-3 is a relief valve because it is for liquid only. A conventional relief
device is satisfactory in this service.
e. PSV-4 is a safety relief valve because liquid or vapor service is possible.
Because this vent will go to a scrubber with possibly large backpressures, a
balanced bellows is specified.
f. PSV-5 is a relief valve for liquid service only. This relief provides protection
for the following scenario: The liquid is blocked in by closing all valves; the
heat of reaction increases the temperature of the surrounding reactor fluid;
and pressures are increased inside the coil because of thermal expansion.
• After specifying the location and type of all relief devices, the relief
scenarios are developed.
Buckling-Pin Reliefs
• A buckling-pin relief is similar to a rupture disc; that is, when the pressure
buckles the pin, the valve opens fully. As shown in Figure 9-8, this is a
relatively simple device. The major advantage of a buckling-pin relief is
that the pin buckles at a precise pressure, and the major disadvantage of
this device is that when the pin buckles, the valve opens and stays open
Pilot-Operated Reliefs

• The main valve of a pilot-operated relief valve is

controlled by a smaller pilot valve that is a spring-
operated relief valve as shown in Figure 9-9. When
the pilot valve reaches the set pressure, it opens
and releases the pressure above the main valve.
The large valve piston then opens and exhausts the
system fluid. The pilot and main valves reseat
when the inlet pressure drops below the set
pressure.
• Pilot-operated relief valves are commonly used
when a large relieving area at high set pressures is
required. The set pressure of this type of valve can
be very close to the operating pressure. Pilot-
operated valves are frequently chosen when
operating pressures are within 5% of set pressures.
The pilot valve exhausts either to the outlet of the
main valve or to the atmosphere. Pilot-operated
relief valves are commonly used in clean services.
Chatter

• if a system is not designed correctly, the valve may chatter violently.

• Chattering is the rapid opening and closing of a relief valve that can cause
valve seat damage or the mechanical failure of the internals
• The major cause of valve chatter is an oversized relief valve.
• In this case the valve opens a short time to reduce the pressure and the
pressure then rises rapidly to open the valve again. This pulsating action
can be very destructive. The major causes of chatter are excessive inlet
pressure drop, high backpressures, and oversized valves.
• These problems have design solutions; for example, (1) excessive inlet
pressure drops can be prevented with larger inlet pipe sizes and fewer
elbows and constrictions; (2) high backpressures can be prevented by
increasing the size of the exit lines and eliminating elbows and
constrictions; and (3) oversized valves can be prevented by adding
different size valves to cover the range of release scenarios.
Advantages and Disadvantages of Various Reliefs
• The major advantages and disadvantages of the different types of reliefs
are shown in Table 9-2.
9-5. Relief Scenarios
A relief scenario is a description of one specific relief event.
Usually each relief has more than one relief event, and the
worst-case scenario is the scenario or event that requires the
largest relief vent area. Examples of relief events are:

1. A pump is dead-headed; the pump relief is sized to handle

the full pump capacity at its rated pressure.
2. The same pump relief is in a line with a nitrogen regulator;
the relief is sized to handle the nitrogen if the regulator fails.
3. The same pump is connected to a heat exchanger with live
steam; the relief is sized to handle steam injected into the
exchanger under uncontrolled conditions, for example, a
steam regulator failure.
• For each specific relief all possible scenarios are identified and cataloged.
This step of the relief method is extremely important: The identification of
the actual worst-case scenario frequently has a more significant effect on
the relief size than the accuracy of relief sizing calculations.
• The scenarios developed for the reactor system described in Figure 9-6
are summarized in Table 9-3.
Some
installation
guidelines are
illustrated in
Figure 9-10
Relief Design Considerations

• Designer of relief systems must be familiar with governmental codes, industrial

standards, and insurance requirements. This is particularly important because local
government standards may vary.
• Codes of particular interest are published by the American Society of Mechanical
Engineers, the American Petroleum Institute, and the National Board of Fire
Underwriters.
• It is also important to recognize that company philosophy and the regulatory
authorities have a significant influence on the design of the final disposal system,
primarily from the standpoint of pollution.
• For this reason reliefs are now rarely vented to the atmosphere.
• Most cases a relief is first discharged to a knockout system to separate the liquid from
the vapor; here the liquid is collected and the vapor is discharged to another
treatment unit
• This subsequent vapor treatment unit depends on the hazards of the vapor; it may
include a condenser, scrubber, incinerator, flare, or a combination of them. This type
of system is called a total containment system; one is illustrated in Figure 9-11. Total
containment systems are commonly used, and they are becoming an industrial
standard.
Flares
• The objective of a flare is to burn the combustible or toxic gas to produce combustion
products that are neither toxic nor combustible.
• The diameter of the flare must be suitable to maintain a stable flame and to prevent
a blowout (when vapor velocities are greater than 20% of the sonic velocity).
• The height of a flare is fixed on the basis of the heat generated and the resulting
potential damage to equipment and humans. The usual design criterion is that the
heat intensity at the base of the stack is not to exceed 1500 Btu/hr/ft2
• The effects of thermal radiation are:
Example 9-4. Determine the stack
height required to give a heat
intensity of 1500 Btu/hr/ft2 at a
distance of 410 ft from the base of
the flare. The flare diameter is 4 ft,
the flare load is 970,000 lb/hr, and
the molecular weight of the vapor is
44.
4𝜋𝑞 𝑋 − 960𝑄 𝑀
𝐻 = −60𝑑 + 0.5 120𝑑 −
𝜋𝑞
What do "blisters" mean while dealing with flares in
industrial chemical plants
In the context of flares in industrial chemical plants, "blisters" typically refers to the formation of
bubbles or pockets of flammable gases within the flare system. Blisters can occur when the
composition of the waste gas being routed to the flare includes volatile components, such as
hydrocarbons or other flammable substances.
• When the waste gas enters the flare system, it undergoes a process of combustion or flaring to
safely dispose of the flammable components. However, if the waste gas contains volatile
substances that vaporize or generate gases during the flaring process, these gases can form
bubbles or pockets within the flare system. These bubbles are commonly referred to as blisters.
• Blisters can present operational and safety concerns in flare systems. The presence of these
pockets of flammable gases can potentially create uneven burning or combustion within the
flare, leading to flame instability, increased emissions, or reduced flare performance. Blisters
can also increase the risk of flashback, where the flame travels back through the flare system
towards the source of the waste gas.
To mitigate the formation of blisters and ensure safe and efficient flare operation, various
measures can be implemented, such as:
1. Proper waste gas characterization: Thoroughly understanding the composition and properties
of the waste gas being routed to the flare system allows for better design and operation to
minimize blister formation.
2. Flare system design: Ensuring the flare system is appropriately sized, designed, and equipped
with features like steam or air-assisted flaring to promote complete combustion and minimize
the formation of blisters.
3. Waste gas treatment: Implementing pre-treatment processes, such as vapor recovery or gas
conditioning, to remove or reduce the concentration of volatile components in the waste gas
before it enters the flare system.
4. Monitoring and maintenance: Regular monitoring of flare system performance, inspection,
and maintenance to detect and address any blister-related issues promptly.
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Simplified Flare Header Schematic

Flare Stack

Flare Header

Relief valve

Flare Knockout
Drum
Rupture Disk

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Automatic Control Failure – Vapor

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

D1 D2
L1

L2

PV-001 fails in open position:

Relief rate = max flow through PV-001 - normal V2 flow
PV-001 fails in closed position, evaluate blocked outlet for PSV1
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AIChE – DVS
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Automatic Control Failure – Liquid

PRV-1 Set @ 10 barg

PRV-2 Set @ 5 barg

V-1

V-2

P-1 FV-1

FV-1 fails in open position:

Relief rate = P-1 Capacity at Relief Pressure
FV-1 fails in closed position, evaluate liquid overfilling for PRV-1
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AIChE – DVS
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Automatic Control Failure – Vapor Blow-Through

PRV-1 Set @ 10 barg

PRV-2 Set @ 5 barg

V-1

V-2

LV-1

LV-1 fails in open position, Liquid Inventory Drains Into V-2

Relief rate = Flow Capacity of LV-1 for V-1 Vapor (Provided V-1 Liquid
Inventory Cannot Overfill V-2)
LV-1 fails in closed position, evaluate liquid overfilling for PRV-1
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Exchanger Tube Rupture - Example

PSV-005
SET @ 60 PSIG
E-4

T-5 V-5

DP =
Pdes = 231 psig

60 PSIG Pdes = 300 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
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