OVERPRESSURE

PROTECTION

Eka Rianita Saputri Bakri – Process Engineer

March, 4th 2014
 Table of Contents
1. Introduction
√ Work Process for Relief System Design
√ Codes and Standards
2. Pressure Relief System
√ Pressure Relieve Contingencies
√ Relieving Pressure
√ Pressure Relief Type Selection
√ PSV Inlet and Outlet Line Size

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 Introduction

 The design of oil and gas processing facilities must

include the safety concern in it. As the consequence, there
must be several layers of protection found in the design.
These layers of protection are aimed to mitigate the level
of severity resulting from the unintended conditions

 PSV are used to protect piping and equipment against

excessive overpressure. Proper selection, use, location,
and maintenance of relief devices are essential to protect
personnel and equipment as well as to comply with code
and standard.

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 Introduction
Work Process for Relief System Design

Relief system design is a two step process.

1. Evaluation of overpressure contingencies
(Process analysis)
2. Calculation of relief loads
(Sizing)
Required data:
Heat and Material Balances
Process Flow Diagrams (PFD’s)
Piping and Instrumentation Drawings (P&ID’s)
Equipment Load Sheets & Mechanical Data Sheets
Instrument Data (Control valve detail, RO sizes, etc.)
Plot plan/Equipment Layout

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 Introduction
Codes and Standards

 API

API STD 520 Part I & II - Sizing, Selection, and

Installation of Pressure Relief Valves
API STD 521 – Guide for pressure relief &
depressuring systems
API STD 526 – Flanged steel safety relief valves for
petroleum refineries

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 Introduction
Allowable Overpressures (set pressure 100 psig)

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 Pressure Relief System

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 Pressure Relief System
 Blocked Outlet/Blocked Discharge Case

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 Pressure Relief System
 External Fire Case

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 Pressure Relief System
 External Fire Case (cont’)
Single Flashing
Sr 5
Sr 2
Copy of Sr 2
Sr 4
Sr 1
Sr 7
Copy of Sr 3

Q1

Sr 3 Sr 6

ADJ

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 Pressure Relief System
 External Fire Case (cont’)
Multi stage Flashing

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 Pressure Relief System
 Control Valve Failure Case
HP LP

When Control Valve Stuck open, fluid will flow

through the outlet line, resulting overpressure at the
downstream equipment

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 Pressure Relief System
 Gas Blowby Case

When control valve stuck open,

loss of liquid will occur in vessel and
gas will flow through the liquid outlet line.
Cause over pressure at the downstream equipment
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 Pressure Relief System
 Thermal Expansion Case

Thermal expansion can caused by fire, direct

solar radiant, blocked in of heat exchanger on
the cold side with flow in the hot side

Full of liquid
equipment

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 Pressure Relief System
 Tube Rupture Case

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 Pressure Relief System
Pressure Relief Type Selection

Relief device selection is primarily based on:

 Back pressure allowance  calculated using rated capacity

 Client preferences
 Service (fluid, relieving temperature, operating pressure, etc.)

Conventional Balanced Bellows Pilot Operated

By Default √
Backpressure ≤ 10% ≤ 30% ≤ 50%
Max Operating Pressure ≤ 90% of Set P ≤ 90% of Set P > 90% of Set P
Remote Sense √
Plugging/Polymerizing Do not use Do not use

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 Pressure Relief System
Conventional Spring Loaded Safety Relief Valve

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 Pressure Relief System

Conventional
PRV

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 Pressure Relief System

Balanced Bellows Spring Loaded Safety Relief Valve

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 Pressure Relief System

Bellows PRV

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 Pressure Relief System
Piston Type Pilot Operated Safety Relief Valve

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 Pressure Relief System

Piston Type Pilot

Operated PRV

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 Pressure Relief System
Chatter

■ Chattering is the rapid, alternating opening and closing of a

PR Valve.
■ Resulting vibration may cause misalignment, valve seat
damage and, if prolonged, can cause mechanical failure of
valve internals and associated piping.
■ Chatter may occur in either liquid or vapor services

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 Pressure Relief System
Chatter Mechanism Excessive Inlet Pressure Drop

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 Pressure Relieve System
PSV Orifice Area and Designation
After relief area and capacity has been determined, minimum orifice
area and the designation shall be selected based on the standard sized
listed in API 526

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 Pressure Relieve System
PSV Inlet and Outlet Line Size
 PSV Inlet Line Size
 The pressure drop of the inlet piping and fittings shall not exceed 3% of the valve
set pressure (this is to avoid chatter, which will result in significant seat damage and
loss of capacity).
 Inlet line must be at least equal to PRV inlet flange.
 Inlet piping should slope continuously upward to avoid traps.
 PSV Outlet Line Size
The design of these lines shall comply with the following:
 Minimum line size 2".
 Back pressure to be compatible with the installed relieving device
 Velocity and ρV2.
 Generally Mach Number is less than 0.7.
 Discharge line must be at least equal to PRV outlet flange.
 No check valves, orifice plates or other restrictions permitted.
 Closed discharge piping should slope continuously downward to header to avoid
liquid traps.
The Final check of PSV tail pipe size and configuration will be performed using
simulation (FlareNet)

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 Pressure Relieve System
PSV Checklist
Item Description Status Remarks

1 Project Document Formatting

1.1 The document size is A4. Yes  No 

1.2 The document number and revision number (in all sheets) is as per the Yes  No 
approved Project Coordination Procedure.
1.3 The document template is as per the Project Co-ordination Procedure. Yes  No 

1.4 Any change in the document compared with the previous revision, Yes  No 
should be highlighted as per Project Coordination procedure (Revision
system).
1.5 The calculation sheet is taken from NRB template. Yes  No 
1.6 The PSV tag number and tag name are based on the approved Project Yes  No 
Coordination Procedure.

2 Standard / Document Reference

2.1 Calculation for Effective discharge area of Gas/Liquid/Gas-Liquid Relief Yes  No 

is as per API Std 520 latest revision.
2.2 Calculation of PSV Relief Rate and Overpressure Scenario are as per Yes  No 
API Std 521 latest revision.
2.3 Selection of orifice type is as per API Std 526 latest revision. Yes  No 
2.4 Heat and Material Balance Yes  No 
2.5 PFD & P&ID Yes  No 
2.6 Equipment layout plan/ elevation drawing/Plot Plan Drawing Yes  No 
(Basic/FEED Stage)
2.7 Isometric Drawing (Detailed Engineering Stage) Yes  No
2.8 Is there a Company Guideline for Relief / Disposal System? Yes  No 
2.9 If there is no Company Guideline for Relief System, prepare the basis Yes  No 
and assumption and request for Company’s Approval in the early stage
of Project.

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 Pressure Relieve System
PSV Checklist (continuous)
3 General Basis, Assumption and Input Data

3.1 Determine the applicable overpressure scenario

Applicable scenario for sizing the PSV is based on API Std 521, as follows; Yes  No
-Cooling or reflux failure Yes  No
-Absorbent flow failure Yes  No
-Accumulation of non-condensable Yes  No
-Entrance of volatile material into the system Yes  No
-Failure of process stream automatic controls Yes  No
-Abnormal process heat input Yes  No
-Internal explosion Yes  No
-Chemical reaction Yes  No
-Hydraulic expansion Yes  No
-External pool fires Yes  No
-Jet fires Yes  No
-Opening manual valves Yes  No
-Electric power failure
-Heat-transfer equipment failure

3.2 PSV Set Pressure is equal to design pressure or maximum allowable working Yes  No
pressure
3.3 Determine the operating device installation (Single device or Multiple device) Yes  No

3.4 Determine the allowable over pressure based on the operating device Yes  No
installation and scenario as mentioned in API Std 520 Table 1, section 5.4.1.5.

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 Pressure Relieve System
PSV Checklist (continuous)
3.5 Define the type of PSV based on the back pressure criteria. Yes  No
Type of PSV needs to be assumed in the beginning of calculation and the
assumption shall be discussed and agreed by Company. Selection of PSV
type and back pressure are based on API Std 520 section 5.3.3 or Project
Design Basis or Company Guideline. Common type of PSV and the back
pressure as follows;
-Conventional Type with PSV Back pressure is < 10% of PSV Set Pressure
-Balance Type with PSV Back pressure is < 30% of PSV Set Pressure
-Pilot Type with PSV Back pressure is < 50% of PSV Set Pressure

3.6 Specify the total back pressure includes superimposed and built-up Yes  No
back pressures to be considered or assumed at start of the project.

3.7 Define the equipments information;

-Equipment dimensions Yes  No
-Vessel type Yes  No

-Level settings Yes  No

Yes  No
-Insulation
Yes  No
-Dish ends details

3.8 Specify the cd, kb and kc correction factors to be considered. Yes  No

3.9 Specify the sizing methodology to be adopted for two-phase eg. Yes  No
Omega or DIERS Method.
3.10 Determine the PSV inlet and outlet flange size and rating as per API Yes  No
526 MAWP flange limits.

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 Pressure Relieve System
PSV Checklist (continuous)
4 External Fire/Thermal Expansion

4.1 Define the External Fire case is for wetted fire or un-wetted fire Yes  No
4.2 Check the impact of adequate fire fighting and drainage facilities exist Yes  No
or doesn't exist?

4.3 If the wetted fire case is applicable for PSV sizing, check whether the
calculation procedure is one-step flashing or multi-stage flashing based on
Project Design Basis or Company Guideline

4.4 Determine the dimension, volume and wetted area of vessel based on Yes  No
equipment sizing calculation. Wetted area shall be calculated for LAH and
LAL level setting (for intermittent liquid flow from vessel) or NLL level setting
for continuous liquid flow from vessel

4.5 Determine the diameter and length, volume and wetted area of piping based Yes  No
on P&ID and plot plan or isometric drawing.
Wetted area on piping shall be calculated based on liquid mass fraction in the
piping

4.6 Determine the latent heat of vaporization if liquid phase Yes  No

4.7 Define the PSV initial condition.
•Pressure Yes  No 
•Temperature Yes  No 

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 Pressure Relieve System
PSV Checklist (continuous)
4.8 If PSV sizing for wetted fire is calculated based on the multi-stage flashing,
determine the following basis from Project Design Basis or Company Yes  No 
Guideline;
Yes  No 
•The volumetric rate (Total volume of equipment + piping per hour)
Yes  No
•The increment temperature rise
•The basis of maximum fire duration and maximum temperature

4.9 Define the PSV relief condition.

•Pressure Yes  No
•Temperature Yes  No
•Fluid phase (Gas or Liquid or Gas-Liquid) Yes  No
•Molecular Weight Yes  No
•Mass Density Yes  No
•Cp/Cv Yes  No
•Specific heat of liquid Yes  No
•Heat transfer Yes  No
•Specific volume Yes  No
•Environment factor Yes  No

4.10 Determine the required orifice area Yes  No

4.11 Determine the selected orifice area and rated flow rate Yes  No

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 Pressure Relieve System
PSV Checklist (continuous)

5 Blocked Discharge

5.1 Define one phase or two phase relief Yes  No

5.2 Define the PSV initial condition.
•Pressure Yes  No
•Temperature Yes  No
•Flowrate Yes  No

5.3 Define the PSV relief condition. Yes  No

•Pressure Yes  No
•Temperature Yes  No
•Fluid phase (Gas or Liquid or Gas-Liquid) Yes  No
•Molecular Weight Yes  No
•Mass Density Yes  No
•Cp/Cv Yes  No
•Specific heat of liquid Yes  No
•Heat transfer Yes  No
•Specific volume Yes  No
•Specific volume @90% of the orifice inlet pressure at multiphase (if relieving Yes  No
condition is two phase)

5.4 Determine the required orifice area Yes  No

5.5 Determine the selected orifice area and rated flow rate Yes  No

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 Pressure Relieve System
PSV Checklist (continuous)
6 Heat Exchanger Tube Rupture

6.1 Tube Rupture case is evaluated due to design pressure and piping rating at the Yes  No
tube side is higher than the shell side
6.2 Determine the leak flowrate in the tube side based on following input;
•Tube ID & length Yes  No
•Molecular Weight Yes  No
•Pressure from High pressure side & Low Pressure side Yes  No
•Temperature from shell and tube Yes  No

6.3 Based on API Std 521 section 5.19.3, the required relieving rate of PSV is
determined based on following basis; Yes  No
a)The tube failure is a sharp break in one tube Yes  No
b)The tube failure is assumed to occur at the back side of the tube Yes  No
c)The high-pressure fluid is assumed to flow both through the tube stub Yes  No
remaining in the tube sheet and through the other longer section of tube.
A simplifying assumption of two orifices may also be used in lieu of above
method, since this produce larger relief rate than the above approach of a long
open tube and tube stub.

6.4 Determine the specific volume @90% of the orifice inlet pressure at multiphase. Yes  No 

6.5 Determine the required orifice area Yes  No

6.6 Determine the selected orifice area and rated flow rate Yes  No

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 Pressure Relieve System
PSV Checklist (continuous)
7 CV Failure/Gas Blowby

7.1 Control valve failure / gas blow by case is evaluated due to design pressure and Yes  No
piping rating at downstream system is less than the upstream system of Control
valve
7.2 Determine the control valve Cv at normal operating condition with 80% opening Yes  No
valve
7.3 Determine the upset condition at the upstream of Control valve (e.q PAHH) based on Yes  No
Project Design Basis or Company Guideline / Specification

7.4 Determine the PSV set pressure and relief pressure Yes  No
7.5 Determine the maximum flowrate through the Control valve during upset condition (at Yes  No 
the upstream of control valve) and relieving pressure (at the downstream of control
valve) at the 100% opening valve with the specified Cv calculated on point 6.2.

7.6 Define the PSV relief condition.

•Pressure Yes  No 
•Temperature Yes  No 
•Fluid phase (Gas or Liquid or Gas-Liquid) Yes  No 
•Molecular Weight Yes  No 
•Mass Density Yes  No 
•Cp/Cv Yes  No 
•Specific heat of liquid Yes  No 
•Heat transfer Yes  No 
•Specific volume Yes  No 
•Specific volume @90% of the orifice inlet pressure at multiphase (if relieving Yes  No
condition is two phase)

7.7 Determine the required orifice area Yes  No

7.8 Determine the selected orifice area and rated flow rate Yes  No

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 Pressure Relieve System
PSV Checklist (continuous)

8 Calculation Results

8.1 Define the Relief load Yes  No

8.2 Define the required orifice area Yes  No

7.3 Define the selected orifice area Yes  No

7.4 Define the PSV selected size Yes  No

7.5 Define the Rated load Yes  No

7.6 Define the PSV Type Yes  No

7.7 Define the upstream and downstream flange rating Yes  No

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Thank you

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