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Overpressure Protection
in the Process Industry
Overpressure Protection
in the Process Industry
A Critical View
Marc Hellemans
Elsevier
Radarweg 29, PO Box 211, 1000 AE Amsterdam, Netherlands
The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, United Kingdom
50 Hampshire Street, 5th Floor, Cambridge, MA 02139, United States
Copyright © 2022 Elsevier Inc. All rights reserved.
No part of this publication may be reproduced or transmitted in any form or by
any means, electronic or mechanical, including photocopying, recording, or any
information storage and retrieval system, without permission in writing from the pub-
lisher. Details on how to seek permission, further information about the Publisher’s
permissions policies and our arrangements with organizations such as the Copyright
Clearance Center and the Copyright Licensing Agency, can be found at our website:
www.elsevier.com/permissions.
This book and the individual contributions contained in it are protected under copy-
right by the Publisher (other than as may be noted herein).
Notices
Knowledge and best practice in this field are constantly changing. As new research and
experience broaden our understanding, changes in research methods, professional
practices, or medical treatment may become necessary.
Practitioners and researchers must always rely on their own experience and knowledge
in evaluating and using any information, methods, compounds, or experiments de-
scribed herein. In using such information or methods they should be mindful of their
own safety and the safety of others, including parties for whom they have a professional
responsibility.
To the fullest extent of the law, neither the Publisher nor the authors, contributors, or
editors, assume any liability for any injury and/or damage to persons or property as a
matter of products liability, negligence or otherwise, or from any use or operation of
any methods, products, instructions, or ideas contained in the material herein.
British Library Cataloguing-in-Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Cataloging-in-Publication Data
A catalog record for this book is available from the Library of Congress
ISBN: 978-0-323-90956-3

For Information on all Elsevier publications visit our website at

https://www.elsevier.com/books-and-journals

Publisher: Susan Dennis

Acquisitions Editor: Anita Koch
Editorial Project Manager: Judith Clarisse Punzalan
Production Project Manager: Sruthi Satheesh
Cover Designer: Greg Harris
Typeset by Aptara, New Delhi, India
Contents

ABOUT THE AUTHOR......................................................................................... xi

ACKNOWLEDGMENTS..................................................................................... xiii
INTRODUCTION................................................................................................. xv

CHAPTER 1 Studies on overpressure relief systems.................................1

1.1 Introduction................................................................................ 1
1.2 Factors of noncompliance.......................................................... 3
1.3 Leaking safety relief valves........................................................ 8
1.4 Comments on a case study.......................................................10
1.4.1 Operational inspection.....................................................11
1.4.2 Inspection of valves..........................................................12

CHAPTER 2 Background to pressure relief design..................................17

2.1 Introduction...............................................................................17
2.2 Principles of pressure relief......................................................18
2.2.1 General design philosophy..............................................18
2.2.2 Key principles and design sequence...............................19
2.2.3 Safety and pressure relief alternatives...........................23
2.2.4 R
 ecommended pressure relief stream design and
documentation���������������������������������������������������������������� 24

CHAPTER 3  ritical view on designing pressure safety devices

C
according to PED, ASME, and ISO/EN or API........................27
3.1 Introduction...............................................................................27
3.2 Structure comparison of the codes...........................................31
3.2.1 Harmonized European standards....................................31
3.2.2 The ASME code................................................................32
v
vi Contents

3.3 C
 omparison of performance characteristics for pressure
relief valves������������������������������������������������������������������������������� 33
3.3.1 Functional characteristics...............................................33
3.3.2 Flow capacity comparisons.............................................36
3.4 Testing.......................................................................................46
3.4.1 According to European normalization.............................46
3.4.2 T
 ests to determine operating characteristics
according to ASME���������������������������������������������������������� 49
3.4.3 Valves used in the test programs....................................51
3.4.4 Sizing and spring setting according to EN/ISO 764-7..........56
3.5 International harmonization.....................................................59

CHAPTER 4 Keeping overpressure protection up to date........................61

4.1 Influencing factors for overpressure protection change..........61
4.2 Lifecycle management..............................................................67
4.2.1 Protecting safety relief valves with rupture discs...........70
4.2.2 Cost of ownership and asset management.....................75

CHAPTER 5 Management of change and pressure relief analysis...........83

CHAPTER 6 Codes, recommendations, and sizing methods....................91

6.1 Introduction...............................................................................91
6.2 US directives..............................................................................91
6.3 European directives...................................................................93
6.4 Other worldwide directives.......................................................98
6.5 Other specific directives............................................................99
6.6 Former directives and codes.....................................................99

CHAPTER 7  mergency depressurization valves versus pressure

E
relief devices.......................................................................101
7.1 Introduction.............................................................................101
7.2 Pressure system safety regulations........................................104
7.3 Types of safety systems...........................................................105
7.3.1 The pressure control valves...........................................106
7.3.2 T
 he emergency shutdown and emergency
depressurizing systems������������������������������������������������ 107
7.3.3 The pressure relief devices............................................108
 Contents vii

7.4 Safety instrumented systems and safety integrity levels.......108

7.5 Design perspectives................................................................110
7.6 Operational perspective..........................................................111
7.7 The bowtie analysis.................................................................112
7.8 Overall decision making..........................................................114
7.9 T
 aking overpressure scenarios to a layer of protection
analysis����������������������������������������������������������������������������������� 124

CHAPTER 8 Process pressures...............................................................127

8.1 Introduction.............................................................................127
8.2 Definitions, design, and sizing terms......................................128
8.3 The relief design procedure....................................................137

CHAPTER 9 Effects of backpressures on relief ­devices.........................141

9.1 Introduction.............................................................................141
9.2 Types of backpressure.............................................................142
9.3 Safety relief valve selection.....................................................148
9.4 Sizing with backpressures......................................................152
9.5 The issues with backpressure.................................................156

CHAPTER 10 Chatter in relief valves and the 3% rule..............................161

10.1 Introduction...........................................................................161
10.2 Design effects on chatter......................................................162
10.3 Types of chatter.....................................................................165
10.4 The 3% rule: fiction or reality................................................173

CHAPTER 11 Installation of pressure relief devices.................................183

11.1 Introduction...........................................................................183
11.2 General installation recommendations................................183
11.3 Types of discharge.................................................................187
11.3.1 Open discharge..........................................................187
11.3.2 Closed discharge.......................................................192
11.3.3 Exit conditions affecting hazard zones.....................195
11.4 Special code requirements...................................................199
viii Contents

CHAPTER 12 Overpressure scenarios......................................................203

12.1 Introduction...........................................................................203
12.2 Understanding overpressure scenarios................................204
12.2.1 R
 ole of the systems or process engineer in the
PHA/LOPA����������������������������������������������������������������� 205
12.2.2 U
 sing PRDs or independent protection levels in
PHA/LOPA����������������������������������������������������������������� 205
12.2.3 T
 aking overpressure scenarios to a layer of
protection analysis��������������������������������������������������� 213
12.2.4 PRDs used as an independent protection level........213
12.2.5 R
 isk reduction credits for overpressure
scenarios������������������������������������������������������������������ 214
12.2.6 Overpressure IPL solutions other than PRDs...........215
12.2.7 Double jeopardy in relief scenarios..........................216
12.3 Scenario calculations............................................................217
12.3.1 Blocked discharge.....................................................217
12.3.2 Gas blowby.................................................................229
12.3.3 Fire case....................................................................231
12.3.4 Thermal effects—cooling or reflux failure................251
12.3.5 Thermal expansion....................................................253
12.3.6 Chemical runaway reactions.....................................255
12.3.7 Heat exchangers........................................................257
12.3.8 Equipment, instrument, or automatic
control failure............................................................259
12.3.9 Blocked filters and strainers....................................261
12.3.10 Utility or power failure............................................262
12.3.11 Entrance of volatile media or abnormal
fluid input��������������������������������������������������������������� 264
12.4 Scenario examples................................................................264

CHAPTER 13  ecommended and generally accepted good

R
engineering practices.........................................................271

CHAPTER 14 Relief system sizing and design..........................................277

14.1 Introduction...........................................................................277
14.2 Use of shutdown devices.......................................................278
 Contents ix

14.3 What do codes say?...............................................................278

14.4 P
 ros and cons of taking credit for emergency
shutdown devices����������������������������������������������������������������� 280
14.5 Types of emergency shutdown devices.................................281
14.5.1 Safety instrumented systems...................................281
14.5.2 Auto lockout devices..................................................281
14.5.3 Auto start devices......................................................281
14.5.4 Shutdown systems for fired heaters.........................281
14.6 Various methods of credit taking..........................................282
14.7 H
 igh integrity emergency shutdown devices versus
reliability of pressure relief valves��������������������������������������� 284

CHAPTER 15 Overpressure protection on low-pressure storage tanks......287

15.1 Introduction...........................................................................287
15.2 Recommended guidelines and practices..............................292
15.3 Selecting conservation vents................................................296
15.4 T
 echnology and principle of operation of conservation
vents������������������������������������������������������������������������������������� 297
15.5 Sizing for normal operation..................................................301
15.6 Sizing for emergency relief...................................................307
15.7 Setting conservation vents....................................................309
15.7.1 Set pressure tolerances............................................310
15.7.2 Leakage tolerances...................................................311

CHAPTER 16 Tank blanketing...................................................................313

16.1 Introduction...........................................................................313
16.2 Why and where to use tank blanketing.................................314
16.3 General description of the blanketing process.....................317
16.4 Types of blanketing systems.................................................320
16.5 Sizing blanketing systems.....................................................322
16.5.1 Inbreathing requirements.........................................322
16.5.2 Outbreathing requirements.......................................324
16.6 Blanketing methods and requirements................................325
16.7 Setting and use of blanketing systems.................................327
16.8 International guidelines and recommendations...................329
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x Contents

CHAPTER 17 Learning from accidents/incidents and study cases..........331

17.1 Introduction.........................................................................331
17.2 Accident 1: Texas city refinery explosion............................333
17.3 Accident 2: hydrocracking unit UK......................................337
17.4 Accident 3: storage tank explosion.....................................339
17.5 Accident 4: tank explosion..................................................342
17.6 Accident 5: the Seveso disaster..........................................345
17.7 Accident 6: LNG plant Russia..............................................348
17.8 
Accident 7: chemical runaway accident the
United States���������������������������������������������������������������������� 349
17.9 Accident 8: The Piper Bravo offshore rig............................350
17.10 Miscellaneous accidents.....................................................351
17.11 Pressure relief case studies...............................................357
17.11.1 New installations...................................................357
17.11.2 Existing installations.............................................361
17.12 Incidents due to small modifications..................................364

Abbreviations and acronyms......................................................................... 367

Further reading.............................................................................................. 371
Index................................................................................................................ 373
About the Author

Marc Hellemans: Currently Managing Partner of VhC where

he works as a Senior Consultant specializing in overpressure
protection in the process industry and Pressure Relief Devices
and Systems. He has a master in electro-mechanics from
the University Antwerp and holds a degree in Strategic Mar-
keting from the Rice University in Houston. He started his
career at the end of the 1970s in the Flow Control business
and remained in this field his whole career. He was with Tyco
Flow Control until 2009, where he held various senior management positions
and where he was Vice President of Sales & Marketing for the Engineered Prod-
ucts group, a 350M€ business. Prior he was a Managing Director for the Euro-
pean Safety Relief Valve manufacturing plant of Anderson Greenwood Crosby,
a 50M€+ plant employing over 170 employees. Further, he managed various
companies throughout Europe, Africa, & Middle East and has set up sales orga-
nizations from scratch with own offices & agents worldwide. During his 40+
years career, he continued to train & coach people all over the world: technical,
commercial, & marketing and lately in particular on his core business: over-
pressure protection and safety relief devices. He is a worldwide leading expert
in the design, manufacturing, engineering, sales, and marketing of Safety Relief
Devices and Systems and is the author of the book: “The Safety Relief Valve
Handbook” published by Elsevier.

xi
Acknowledgments

I wish to acknowledge all my previous colleagues who gave me insight in the

topics that ruled the majority of my career. Appreciative thanks are due to
all those who trained me or shared their knowledge in so many interesting
symposiums, presentations, and conferences I attended. Although many com-
panies changed ownership during my 40+ years of career and many old col-
leagues and friends changed positions and companies all around the world or,
as many amongst us, retired I wish them all the best in their current endeavors
and thank them for their collaboration.
I also want to acknowledge Tim Fung from YF Asia who gave me the oppor-
tunity to have a very detailed exposure to all my South East Asian and Middle
Eastern customers which I was proud to consult, advise, and train during the
last 15 years of my career and who provided me with an in-depth field experi-
ence in the world of overpressure protection in the process industry.
While every effort has been made to trace copyright in all material in this book,
the author apologizes if he has inadvertently failed to credit any such ownership.
Furthermore, also these companies for their competency in overpressure pro-
tection and their attempt to produce equipment or knowledge that make the
current process industry safer:
Anderson Greenwood, Crosby
Varec - Whessoe
Sarasin – Weir group
Fike
Emerson process management
Leser GmbH & Co
Spirax Sarco
Bopp & Reuther, Manheim
Karlsruhe Institute of technology
Curtis Wright – Farris
Quest Consultants Inc.
xiii
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