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Overpressure Protection
A paramount safety consideration is the prevention of loss of containment due to vessel or pipeline overpressure situations.
Loss of containment can result in impact to human life and the environment, when flammable, explosive, hazardous, or toxic chemicals are released to the p atmosphere. Loss of containment can also result in economic impact due to production unit replacement/repair costs and production losses.
Over-Pressure Protection
Wherever pressure equipment and piping systems are used, continuous vigorous effort is required throughout the plant life cycle to safeguard such equipment and avoid overpressure-related ruptures.
Failures happen when the internal pressure of a vessel exceeds its maximum allowable working pressure (MAWP), often from a build-up of heat or materials.
Ruptures p of vessels, , boilers, , piping, p p g, seals, , and connections, can lead to fire and explosion, and the loss of liquids and vapors, all of which threaten personnel safety and the environment, and could result in significant asset losses.
Increases in process pressures beyond safe levels, potentially t ti ll resulting lti in i OVERPRESSURE due to a RELIEF EVENT
16%
21%
50%
90%
Minimum yield strength (dependent on materials of construction) Ultimate tensile strength (dependent on materials of construction)
300%
Passive Control
Overdesign of process equipment
Active Control
Install Relief Systems
Equipment
Relief Devices
Overpressure Scenarios
Primary objective: Ensure that all equipment has the necessary overpressure protection
Overpressure Protection
Industry standards from the American Petroleum Institute (API) and American Society of Mechanical Engineers (ASME) provide criteria for the design and protection of vessels and pipelines from rupture or damage caused by excess pressure. In conventional designs, pressure relief devices (PRD), such as pressure relief valves, rupture discs, etc. are used as the primary means of pressure protection. The design of each pressure relief device is based on the assessment of overpressure scenarios, such as typically experienced with the total loss of cooling or power supply, external fire, etc.
Rupture Disc
Conventional Balanced
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NOTE: The stop valve must have a full port area greater than or equal to the inlet size of the pressure relief valve. The stop valve should be used only as permitted by applicable codes.
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Reactor
Heater HP Separator
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Steam
Previous Appendix M
Stop valves could always be installed on the upstream and downstream of a relief valve to permit inspection, testing and maintenance if the following conditions are met 1 Administrative 1. Ad i i i Controls C l are provided id d to prevent unauthorized closure of the valve 2. Mechanical locking devices are installed on the valves 3. Valve failure controls are provided to prevent accidental closure 4. Procedures are in place to provide other pressure relief when the relief valve is out of service
An authorized person shall continuous monitor the pressure condition and be able to respond promptly by opening other valves or by closing the source of overpressure Person shall be dedicated with no other duties Person shall have documented procedures and training System should be isolated only for the time required Time required should be kept to an absolute minimum
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Mechanical Locking Elements are physical barriers to valve operation and they must be deliberately removed to close the valve valve, e e.g. g chain locks locks, plastic or metal straps, straps car seals, etc. Valve Failure Controls are measures taken in the design and installation of a valve to assure that it does not fail closed
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Description
Maximum allowable relieving gp pressure for fire contingencies g Maximum allowable relieving pressure for multiple pressure relief devices (except fire) Maximum allowable relieving pressure for single relief device (process contingencies) Maximum allowable set pressure for supplemental valves (fire contingencies) Maximum allowable set pressure for additional valves (process contingencies) Maximum Allowable Working Pressure (MAWP) Maximum allowable set pressure for single valve Typical maximum operating pressure
105
100 85 - 90
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Item 9 10 11 12 13 14 15 16
Overpressure Cause
Failure of automatic control Abnormal heat or vapor input Split exchanger tube Internal explosions Chemical Reaction Hydraulic expansion Exterior fire Power failure (steam, electric, other)
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Based on a 2002 study by Berwanger Inc. covering approximately 420 processing units, 42,000 pieces of equipment, and 25,000 relief devices in oil and gas, refining, petrochemical, and chemical facilities.
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PRD Documentation
Records of all inspections, testing and maintenance of f pressure relief li f devices d i should h ld be b maintained i i d for f the life of the system. They form the historical record of the conditions and services under which the valve operated. These are critical in demonstrating compliance with regulatory requirements and in adjusting the frequencies of inspections and testing to ensure the relief devices will provide overpressure protection.
Moderate
Severe
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Safeguarding Systems
The term safeguarding is used to describe the process of identifying and mitigating Process hazards to prevent uncontrolled loss of containment that could result in injury to personnel and release of toxic or harmful substances. Safeguarding Systems consist of pressure relieving devices (PRD (PRDs) s), instruments instruments, valves valves, insulation, insulation size restrictions on specific equipment, metallurgy, procedures, etc. Therefore, it includes all the protective devices and systems installed to protect against loss of containment.
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3 2 1 0
Event Frequency F
1 per 250 years 1 per 100 Years 1 per 10 years 1 per 10 years 1 per 100 Years 1 per 10 years 1 per 12.5 years 1 per 10 years
IEFi (events/year) ( t/ )
0.004 0.01 0.1 0.1 0.01 0.1 0.08 0.1
R f Reference
9.7 9.11 9.11 97 9.7 Assumed same as Blocked Discharge Assumed same as Blocked Discharge 9.7 9.1
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Design
Execute Design
Document
Verify
Document
OK
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