Relief System Adequacy a step towards SAFER

operations
by
Deepak Padwal, Ingenero, Mumbai, India

Prepared for presentation at the

AspenTech
Engineering Solution Seminar, Mumbai
February 23, 2016

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Presentation Outline
Brief Introduction to Ingenero
Introduction: Pressure Relief System
Adequacy of Pressure Relief System
Equipment based PRA
Role of simulation
Safety Analysis Environment in Aspen Hysys
Case Example Ethylene Plant

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Ingenero Overview
A High End Engineering Services Company
Supporting Operating Companies and Service
Providers

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Global Business Profile

We serve customers in multiple continents with
key offices in USA, India, KSA and Qatar

Chicago

Benelux
Germany

Houston

Tokyo,
Japan

(Headquarters)

Nigeria

Doha,
Qatar
KSA

Ingenero Tech (I) Pvt Ltd,

Mumbai

(Technical Ops & Delivery Center)

Johore,
Malaysia

South Africa

Client Sites
Offices
Target clusters

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Ingenero Key Service Areas

Ingenero combines extensive knowledge with
process expertise and operations experience to
deliver highly specialized 3600 engineering solutions

Focus area for this

presentation

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Pressure Relief Analysis Capability

We have been involved with several Pressure
Relief Systems projects for refiners in the USA,
Europe, Southeast Asia and the Middle East
covering the following activities:
Equipment or Relief Device based revalidation for the existing
facilities as well as new designs
Process design basis development
Flare header, Radiation & Dispersion analyses
Network equipment rating
Dynamic simulation & QRA
Risk categorization and cost effective mitigations for the
identified deficiencies

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Broad Experience Of Our PRA Team

Ingeneros extensive experience with pressure
relief systems and engineering allows for superior
delivery
More than 30,000 PSVs analyzed/designed
Broad spectrum of industries analyzed
Refineries and Oil & Gas ~50
Petrochemicals ~16
Specialty Chemicals - ~12

Over 80 process engineers with PRA experience

Engineers are familiar with and apply all relevant
international codes and standards
Leverage on operation and engineering expertise
Rigorous evaluations to uncover design deficiencies
Focus on cost-effective solutions

Work-Processes and Quality Management Systems

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Introduction : Pressure Relief System

Pressure relief is a dedicated system to protect life
and property from the dangers of overpressure
Overpressure is result of an imbalance or disruption of the
normal flows of material and energy that causes the
material or energy, or both, to build up in the system
Overpressure is prevented by relieving fluid from an overpressurized equipment or equipment system
The pressure relief system comprises of physical relief
device & the associated downstream disposal system (KO
drum, Flare) to safely handle the material relieved

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When is Pressure Relief Required?

In processing plants, overpressure can happen due
to various individual or combined triggers
Blocked outlet
Control valve failure
Exposure to fire
Utility failure
Exchanger Tube rupture
Thermal expansion
Operational errors, etc

The overpressure can lead to a major incident if

the pressure relief system is not in place/not
functional/not adequate
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Layers of Protection
Relief system is the last line of preventive defense
against catastrophic failure of equipment
Reference :
2006 ISA Safety
Division
Symposium
Houston TX

The physical relief devices should be capable of

operating at all times
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Adequacy of Pressure Relief System

Relief system needs on-going revalidation to
ensure overpressure protection
In general, for design capacity & composition, pressure
relief systems of processing plants are adequately
designed to handle overpressure contingencies
However, process plants go through continuous
modifications to enhance efficiency or capacity, often
without due attention being given to existing safety system
This increases the risks of major accidents.

Unforeseen incidents in the process industry in the recent

past have prompted many facilities to undergo adequacy
checks of their relief devices
To reduce the likelihood of damage to their assets and
surrounding environment

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Industry Incident Example 1

Unforeseen incidents have caused damage to
assets and surrounding environment
Refinery in Texas (USA)
March 23, 2005
Vessel overfilling, vapor
cloud
through atmospheric
blowdown system
Fifteen fatalities, 170 injured
Key findings: Various pressure relief system related
citations (inadequate relief system, Inadequate header
design info, equipment not protected..)
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Industry Incident Example 2

Unforeseen incidents have caused damage to
assets and surrounding environment
Processing Plant , Louisiana
(USA)
March 4, 1998
Catastrophic
Vessel over-pressurization
Four fatalities

Key findings: Third stage separator was not equipped with

any pressure relief device as mandated by API specification

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Revalidation of Relief System

Changes in process plants warrant immediate
revalidation of existing Pressure Relief system

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Rate change
Composition change
Change in Unit or Equipment operation mode
Rotating or fixed equipment change
Piping change
Change in vessel or flange ratings
Utility conditions change
Electrical Redistribution (New
Transformer/MCC/Substation)
Change in relief device set pressure/size/type/discharge
location
Vessel or relief device relocation or new service
Changes in flare header size/Knock Out Drum/Flare Tip
Outcome of studies such as PHA , HAZOP or Incident
investigation
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Equipment based Pressure Relief Analysis

Pressure Relief Analysis (PRA): Key Steps
1) Identify applicable Codes, Laws, Standards & Practices
ASME BPVC / NBIC / API standards & RP/ ANSI Standards / NFPA

Standards /
guidelines.

Best Design Practices / Local regulatory laws &

2) Data collection & validation

P&IDs, PFDs, Isometrics / Process basis (H&MB) / Equipment data (drawings,
U-1 forms)

Rotating & control equipment data (performance curves, Control valve

datasheets, orifice sizes etc.) /
Details of latest changes & modifications / Operating & Emergency
procedures

3) Supporting tools & programs

PPM,PSPPM (Siemens)/ Salus (Smith & Burgess) /
PSVplus(AspenTech)/ iPRSM(Farris) / SuperChems (iOMosaic)
Aspen/ Hysys/ PROII/ FlareNET(for flare hydraulic study)/ DNV
Phast (for Dispersion analysis / Internal programs & spreadsheets

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Equipment based Pressure Relief Analysis

Pressure Relief Analysis (PRA): Key Steps
4) Detailed Pressure Relief Analysis
Overpressure scenario identification.
Required relief rate calculations.
PRV sizing, adequacy & reliability checks,
Risk ranking/categorization
Advise on mitigation of identified concerns
Finalization of strategy & actions in consultation
with Client
Final documentation.

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PRA Phase -1

PRA Phase -2

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Role of simulation
Relief load determination requires rigorous
simulation for global scenarios
Simplified calculations can often result in overdesign
Global scenarios include utility failures
Total & Partial Power Failure
Steam failure
Cooling Water failure
Instrument air failure etc

Global scenarios often dictate the flare header sizing,

network equipment sizing and individual relief system
sizing
Determine global scenario load from various systems
using a simulator

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Steady state simulations

Steady state simulation is used for conservative
estimation of relief loads
Faster compared to dynamic simulations
Critical step for most of the systems is the reduced duty
calculations at elevated pressure
Snapshot from HYSYS:

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Relief simulation : Column system

Steady State set up for a typical column system
Snapshot from HYSYS for a typical column system:

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Relief simulation : Column system

Multiple flash drum set up for a high level partial
power failure scenario
Snapshot from HYSYS for a typical column system:

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Dynamic simulation
Dynamic simulation is selectively performed for
critical systems, for better estimate of relief loads
Time dependent analysis
Time intensive
Pressure relief is unsteady event with continuous
changes in various process parameters
Accounts for liquid hold-up
Better estimate of relief rates
Estimates time for the system to reach relief pressure

HYSYS Dynamic simulations results used effectively to:

Address flare adequacy issues due to expansion

Address flare flexibility during TAR

Avoid installation of additional relief capacity in HF Alky
unit for an isostripper based on steady state estimations

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Case Example Ethylene Plant

Revalidation of pressure relief system needed for
Ethylene plant due to changes in feed and capacity
A detailed pressure relief analysis for Ethylene plant was
performed in safety analysis environment, integrated
within latest versions of Aspen Hysys software
API overpressure scenarios were documented within Hysys
& sized with rigorous sizing methods in the software
The safety analysis environment enabled efficient analysis
and eliminates the manual data transfer & the errors
associated with it
The relief sizing results were effectively utilized for
mitigation and flare analysis
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Case Example Ethylene Plant

Equipment based PRA performed for Ethylene
plant involving variety of equipment
Total equipment systems ~ 200 ; Total equipment ~ 300
12

Column
Vessel
Heat
Reactor
Fired Heater
Compressor
Pump
Turbine
Piping
Tank
Sphere
Filter

60
149
4
3
12
9
6
49
3
2
1
0

25

50

75

100

125

150

Equipment count

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Case Example Ethylene Plant

PRA performed based on respective applicable
standards and codes
Applicable Standards and
Codes
Equipment
Pressure
Vessels
Piping System
Low Pressure
Storage Tanks
Power Boilers
Fired
Heaters
Exchanger
Tubular
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Design
ASME sec VIII
ASME B31.3
API STD 620, API STD
650, API 12
ASME sec I
API STD 530, API STD
560
API STD 660, API STD
661, TEMA

Relief analysis
ASME sec VIII, API STD 520,
API STD 521
API STD 520, API STD 521
API 2000, NFPA
ASME sec I
API STD 520, API STD 521
API STD 520, API STD 521
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Case Example Ethylene Plant

PRA study reported relief device inadequacy
concerns for 78% of total equipment systems
Total equipment systems ~ 200 ; Total concerns ~ 250
Outlet Piping
Pressure Loss
18%

Miscellaneous
4%
Inlet Piping Pressure
Loss
38%

Installation concerns
7%

Undersized
29%
In appropriate Set
Pressure
1%

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Relief Temp Concerns

3%

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Safety Analysis Environment in Hysys

PRA performed using Safety Analysis Environment
within Aspen Hysys
Snapshot from Hysys : Deethanizer Column System

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PRA Result for Deethanizer column

Existing PSV (4L6 & Conventional type) on
Deethanizer found to be inadequate Capacity &
Outlet Pressure Drop concerns
Snapshot from Hysys : Rating of existing PSV

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Mitigation for PSV Inadequacy

It was recommended to replace existing PSV with
new PSV (4N6 size & Balanced Bellow Type)
Snapshot from Hysys : New PSV Data

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Mitigation for PSV Inadequacy

New PSV provides adequate capacity
Snapshot from Hysys : Rating of New PSV

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Mitigation for PSV Inadequacy

No inlet and outlet piping pressure drop issues
reported for New PSV recommended
Snapshot from Hysys : Line sizing for New PSV

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Documentation Builder

(1)

Microsoft access based Documentation Builder is

available in Hysys for relief sizing documentation
Snapshot from Hysys : Documentation Builder

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Documentation Builder

(2)

Documentation Builder generates calculation

summary for each of the PSVs analyzed
Snapshot from Hysys : Calculation Summary

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Documentation Builder

(3)

Documentation Builder also generates summary

of relief loads for each of the PSVs analyzed
Snapshot from Hysys : Relief Device Summary

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Documentation Builder

(4)

Process Datasheet of New PSV generated by

documentation builder
Snapshot from Hysys : Process Datasheet of New PSV

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Documentation Builder

(5)

Mechanical Datasheet (ISA form) of New PSV

generated by documentation builder
Snapshot from Hysys : Mechanical Datasheet of New PSV

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Integration with Flare analysis

Relief loads of PSVs can be easily imported for
Flare analysis in Aspen Flare System Analyzer
Snapshot from Hysys:Importing relief loads for flare analysis

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Conclusion
Process safety (relief system) information is key
element of Process Safety Management
Ensure all equipment within the facility are protected for
various overpressure scenarios per standards and codes
Commercially various tools are available to document
overpressure scenarios, estimate relief rates, relief
device sizing and flare header sizing
Effectively utilize tools in the design of relief systems to
ensure safer plant operation and economical design at
the same time reducing the capital expenditure
Robust Management of Change (MOC) process must be
in place to keep relief systems documentation updated

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References
1.

Sizing, Selection and Installation of Pressure-relieving Devices, API

Standard 520, Part I 9th edition.

2.

Pressure-relieving and Depressuring Systems, API Standard 521, 6th

edition.

3.

Jung S K, Heather J D, Dr. N.R.Singh Proper relief-valve sizing

requires equation mastery Hydrocarbon Processing, Dec 2011.

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Thank You

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Author
Deepak Padwal is a Assistant General Manager Process
Engineering at INGENERO. He is currently managing multiple teams
for process development, simulation & optimization and process
safety related work.
He received his Bachelor in Chemical Engineering degree from
Institute of Chemical Technology (ICT), Mumbai, India, and Executive
MBA from S.P. Jain Institute of Management and Research, Mumbai,
India.
Before joining Ingenero, he worked for Reliance Industries Ltd, India
and Tata Enterprise, India.

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