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Required Data
Procure latest PIDs Heat and Mass Balance Report Rotating Equipment Datasheet (performance curves, etc.) Vessel and Heat Exchanger Datasheets (drawings) Operating/Emergency procedures Review current project specific document-Relief & Blowdown Philosophy
Industry Guidelines
API RP 521 API 2000
API RP 521
1. Fire 2. Closed outlets (Vapor BO or Liquid BO) 3. Failure Opening/closing of Control Valve
4. Thermal Expansion
5. Tube rupture 6. Check Valve Leakage 7. Reflux failure 8. Abnormal heat input 9. Power Failure 10. Utility failure (CW+IA+FG+Steam)
External Fire
Causes: 1.Explosion caused by the ignition of a flammable leaking gas 2. Leakage of flammable hydrocarbon inventory
Applicability Guidelines
Equipment must be located with in a fire zone Some portion of the equipment must be located below the maximum fire height (API RP 521 uses 25 feet) In some cases, the time required to reach relief pressure may render the scenario not credible
Sizing EquationQ=21000*F*A^0.82 (Btu/hr) Q=34500*F*A^0.82 (Btu/hr) Wetted Surface Area Liquid full such as Treaters: 100%
Air Coolers
Condensing versus liquid cooling services may be treated differently (see API RP 521 Section 3.15.7) Many air coolers are located above the maximum fire height API has special equations for air coolers Exact treatment of fire case for air coolers should be defined in the Project Guidelines
Determining Applicability
Trace all inlet lines to vessel to identify inlet control devices Trace upstream from any control devices to determine maximum expected upstream pressure Upstream pressure will be normal or maximum operating pressure Can selected upstream pressure exceed downstream equipment design pressure? Consider relative vessel volumes when the upstream volume is much less than the downstream volume
Glycol Contactor
PSV-1 @ 750 psig Dry Gas
Vapor
Vapor
LC
Liquid
LC
Liquid
LV
LV
Rich Glycol
Glycol Contactor
PSV-1 @ 750 psig Dry Gas
Vapor
Vapor
LC
LC
Liquid
LV
Fails Open
Liquid
LV
Rich Glycol
Glycol Contactor
PSV-1 @ 750 psig Dry Gas
Vapor
Vapor
LC
LC
Liquid
LV
Fails Open
Liquid
LV
Rich Glycol
The scenario to consider is that one inlet valve will be in a fully opened position regardless of the control valve failure position. Therefore, the required relief capacity is the difference between the maximum expected inlet flow and the normal outlet flow adjusted for relieving conditions and considering unit turndown
Normal Level
LV
High Pressure
Low Pressure
High Pressure
Low Pressure
Corrosion of Tube
High Pressure
Low Pressure
High Pressure
Low Pressure
Low Pressure
High Pressure
Determining Applicability
1. Determine maximum high-pressure side pressure (Phi) Design Pressure
2. Determine low-pressure side test pressure along with associated equipment and piping (Plow) Compare the two pressures If (Phi) > (Plow) then tube rupture relief is required
Not generally applied to double pipe exchangers or other types of exchangers with schedule pipe for tubes
Additional Considerations
Relief fluid properties are generally not the same as those upstream of the tube rupture:
Mechanical failure may occur due to -Stem breakage -Plug jamming -Manual valve mal operation
May result in control valve/block valve to move in closed position.
Fails Close
Vapor
LC
Liquid
LV
Often not considered for columns and vessels with no normal liquid inflow (suction scrubbers, etc.)
Vapor
LC
Liquid
LV
Fails Close
Thermal Expansion
Causes:
Hydraulic expansion can result from several causes, the most common of which are the following:
a. An exchanger is blocked-in on the cold side with flow in the hot side.
b. Piping or vessels are blocked-in while they are filled with cold liquid and are subsequently heated by heat tracing, coils, ambient heat gain, solar radiation or fire.
Cold Side
Hot Side
o 220 F
o 110 F
Cold Side
Hot Side
o 220 F
o 110 F
o 170 F
Cold Side
Hot Side
o 220 F
Locking open a block valve and posting signs may be adequate protection
-The reverse flow rate through a single check valve can be determined using the normal flow characteristics (i.e., forward-flow Cv) of the check valve. Leakage rate can be assumed to be 10 % forward flow Cv.
Overhead Condenser Failure, Reflux Failure, Abnormal Heat Input Or Power Failure
CausesUtility Failure, Mechanical failure of rotary equipments, Shutting down of utility compressor, Failure opening of control valve, Pumps or fail closure of control valve on supply line may result in complete loss of a utility or the partial loss of a utility, Instrumentation failure or loss of transformer/MCC/Busbar
Condenser
PC
Accumulator
LC
Feed (F)
Column
Heat in (Q)
Reboiler
LC
Bottoms (B)
Condenser
Overhead (V) Reflux (R)
Accumulator
LC
Feed (F)
Column
Heat in (Q)
Reboiler
LC
Bottoms (B)
Condenser
PC
Reflux (R)
Accumulator
LC
Feed (F)
Process
Column
Heat in (Q)
Reboiler
LC
Determining Applicability
In general, loss of cooling (from condenser or pump-around exchanger) will result in overpressure for distillation systems Loss of reflux can also result in flooding of condenser
In Conclusion
Collect information required to perform analysis Review relevant guidelines Determine all overpressure scenarios that apply to each piece of equipment Analyze required relief rates using standard methods Be conservative at first
Thank You