EG310 - Pressure Relief Systems

Occidental Oil and Gas Corporation
Engineering Guide
Title Document No.
PRESSURE RELIEF SYSTEMS

Revision No. Approved Effective Date
EG-310
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Please refer to EG-300 General to place this guide in context and for overall purpose and scope, general requirements, applica ilit!, variances, and glossar! of terms"
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THIS GUIDE IS U(DERG)I(G *DDITI)(*L RE+ISI)(, BUT SH)ULD BE USED I( THE PRESE(T F)RM. S-)PE This document provides assistance on the design and selection of the pressure relief system for onshore oil and gas production and processing facilities hile providing for the safe and rapid disposal of aste gas under controlled conditions so that personnel and ad!acent facilities are not e"posed to ha#ards. This document includes vapor discharge to the atmosphere$ vapor discharge to a closed pressure system and flare$ and vapor depressuring and li%uid &lo do n systems for nonto"ic hydrocar&ons. Pressure relief systems for to"ic vapors and venting atmospheric are not covered.
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PURP)SE The intent of the design philosophy is to produce the most economical pressure relief system that ade%uately disposes of all emergency releases from safety relief valves$ vapor depressuri#ing and &lo do n systems$ process stream diversion$ e%uipment drainage$ etc.
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DESIG( -RITERI* Overpressure is the result of an un&alance or disruption of the normal flo of material and energy that cause material or energy$ or &oth$ to &uild up in some part of the system. The pressure relief system should &e designed to protect the e%uipment and piping from pressures outside the operating limits and therefore$ the appropriate means of relief must then &e selected and the system discharged to a safe place. Although efforts have &een made to cover all ma!or circumstances$ the conditions descri&ed herein should not &e considered as the only causes of overpressure. Any circumstance that reasona&ly constitutes a ha#ard under the prevailing conditions for a system should &e considered in the design. Overheating a&ove design temperature may also result in overpressure$ due to the reduction of allo a&le stress. A pressure relief valve cannot protect against this type of contingency.
PROPRIETARY INFORMATION For Authorized Company Only
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The &asis for design overpressure is related to the American 'ociety for (echanical Engineers )A'(E*$ Boiler and Pressure Vessel Code and the American National 'tandards +nstitute )AN'+* ,-..-$ Code for Petroleum Refinery Piping. Compliance ith these codes is a re%uirement$ or is recogni#ed as the e%uivalent of a re%uirement in many locations. /here codes that are more stringent apply$ the local re%uirements must &e met. 0.. Pressure Relief (ethods There are three different methodologies to dispose aste gases and li%uids1 )a* vapor discharge directly to atmosphere$ )&* discharge to a closed pressure system and )c* discharge to a lo er pressure system or vessel. The most economical method of discharging vapors or li%uids from pressure relief devices is to discharge vapors to the atmosphere$ nonvolatile li%uids to a se er$ and volatile li%uids to other e%uipment operating at a lo er pressure. 2i%uids shall not discharge to the vapor disposal system. These methods are preferred to the closed pressure relief system or li%uid &lo do n system$ provided such disposal is not in conflict ith or restricted &y1 E"isting and anticipated regulations concerning air or noise. Prevailing meteorological conditions. Properties of the vapor that is discharged$ such as to"icity$ volatility$ flamma&ility$ entrained li%uid$ and molecular eight. Disposal re%uirements planned. hen the addition of a ne process unit is ater %uality and
'pecial consideration should &e given if there is concern that tu&e rupture in heat e"changers may cause release of volatile or to"ic hydrocar&ons to the atmosphere.
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Contingency ,asis All contingencies hich may result in e%uipment overpressure should &e considered$ this include e"ternal fire e"posure$ utility failure$ e%uipment failure and malfunctions$ a&normal processing conditions$ thermal e"pansion$ startup and shutdo n$ and operator error. 4or each contingency$ the resulting overpressure should &e evaluated and the need for appropriately increased design pressure )to ithstand the emergency pressure* or pressure relieving facilities to prevent overpressure ) ith calculated relieving rates* should &e esta&lished. Every emergency arises from a specific cause or contingency. The simultaneous occurrence of t o or more contingencies should &e considered unli5ely. 6ence$ an emergency$ hich can arise only from t o or more
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unrelated contingencies$ is normally not considered for si#ing safety e%uipment. 2i5e ise$ a simultaneous &ut separate emergencies are not considered if the contingencies causing them are unrelated. Contingencies$ including fire e"posure$ are considered as unrelated if there is no process$ mechanical$ or electrical relationship &et een them$ or if the length of time elapsing &et een possi&le successive occurrences of these contingencies is sufficient to separate their effects. Every e%uipment item must &e studied individually and every contingency must &e evaluated. The safety e%uipment for an individual item should &e si#ed to handle the largest load resulting from any possi&le single contingency. /hen analy#ing any single contingency$ one must consider all directly related effects that may occur from that contingency. 2i5e ise$ if a certain emergency ould involve more than one item$ then all affected items must &e considered together. The e%uipment !udged to &e involved in any one emergency is termed a 7single ris57. The single ris5 hich results in the largest load on the safety facilities in any system is termed the 7largest single ris57 and forms the design &asis for the common collection system$ such as the flare header$ 5noc5out drum and flare. The emergency$ hich results in the largest single ris5 on the overall &asis$ may &e different from the emergency that forms the &asis for each individual item of e%uipment. /hile generally only a single contingency is considered for design purposes$ there may &e situations here t o or more simultaneous contingencies should &e ta5en into account8 e.g.$ if there is some remote relationship &et een them$ and pressures and temperatures developed could result in catastrophic failure. Overpressure that may occur at normal or &elo normal pressures$ as a result of reduced allo a&le stresses at higher than design temperatures should also &e evaluated and appropriate protective features applied in the design. 4or e"ample$ such conditions may arise from startup or upset conditions. 2i5e ise$ lo metal temperature must also &e considered$ such as from autorefrigeration$ to ma5e sure that &rittle fracture conditions do not develop. 0.Pressure Relief Devices The function of a pressure relief device is to protect pressure vessels$ piping systems$ and other e%uipment from pressures e"ceeding the ma"imum allo a&le or5ing pressure )(A/P* &y more than a predetermined amount in order to avoid ris5 to personnel and e%uipment. The permissi&le amount of overpressure )a&ove (A/P* is covered &y various codes and is a function of the type of e%uipment and the conditions causing the overpressure.
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+ndividual pressure relief devices and system depressuring loads should &e calculated for each applica&le failure$ in accordance ith American Petroleum +nstitute )AP+* Recommended Practice 93.$ Guide for Pressure-Relieving and Depressuring Systems and American Petroleum +nstitute )AP+* Recommended Practice 93:$ Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries. The essential steps in the design of protection against overpressure hich are covered in other parts of this Guide$ or referenced documents as indicated$ are summari#ed &elo 1 4rom the range of availa&le pressure relief valves and other devices$ selection should &e made of the appropriate type for each item of e%uipment su&!ect to overpressure. +nstrumentation$ chec5 valves$ and similar devices are generally not accepta&le as means of overpressure protection. 'tandard calculation procedures should &e applied to determine the si#e of the pressure relief device re%uired for the ma"imum relieving rate$ together ith other information necessary to specify the valve. The pressure relief valve installation shall &e designed in detail$ including location$ si#ing of inlet and outlet piping$ valving and drainage$ selection of open or closed pressure relief$ and design of the closed pressure relief system. The design specification should include a ta&ulation of all contingencies considered$ together ith their relief re%uirements.
Pressure relief devices should &e located to discharge from the vapor space or overhead line of the protected vessel to minimi#e li%uid entrainment in the relief vapors. Pressure relief devices can &e classified as follo s1 0.-.. 'afety ;alves
An automatic$ spring<loaded device actuated &y the static pressure upstream of the valve and characteri#ed &y rapid$ full opening or pop action. +t is used for steam$ gas and vapor service. This valve should not &e used if the varia&le &ac5 pressure e"ceeds .: percent of the set pressure. 0.-.3 'afety Relief ;alves
A spring<loaded device characteri#ed &y rapid pop<open action in gas=vapor service or &y opening proportionally to the increase in inlet pressure over the opening pressure for li%uid service. The valve may re%uire ad!ustment to %ualify for specific service. This valve should not &e used if varia&le &ac5 pressure e"ceeds .: percent of the set pressure.
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'afety relief valves are further su&divided in1 #onventional $afet! %elief &alve > this type of valve has its spring housing vented to the discharge side of the valve. The operational characteristics )opening pressure$ closing pressure and relieving capacity* are directly affected &y changes in &ac5 pressure on the valve. 'ello(s $afet! %elief &alve > this valve incorporates a means of isolating the process fluid from the &onnet$ spring$ stem$ and stem &ushing. The &ello s is vented through the &onnet to atmosphere$ and in ha#ardous or to"ic service$ the vent must &e piped to a safe location. The &ello s design is recommended hen the process stream ould effect the moving parts causing a &inding &et een the stem and the stem &ushing. A valve ith a ruptured &ello s ill have a reduced capacity and a higher reseat pressure. 'alanced 'ello(s $afet! %elief &alve > a variation of the &ello s valve that minimi#es the effect of &ac5 pressure on the operational characteristics )opening pressure$ closing pressure and relieving capacity*. The opening and closing pressures are maintained ith increasing &ac5 pressure &y using a pitch diameter of the &ello s e%ual to the seat diameter of the valve. The &ello s is vented to the atmosphere and must &e piped to a safe location for ha#ardous and to"ic materials. A valve ith a ruptured &ello s ill have a reduced capacity and a higher reseat pressure. 0.-.2i%uid Relief ;alves
A spring<loaded device that opens in proportion to the increase in inlet pressure over opening pressure. +ts primary use is for li%uid service. This type of valve should not &e used if the &ac5 pressure e"ceeds .: percent of the set pressure. 0.-.0 Pilot<operated Pressure Relief ;alve
A valve having the set pressure and &lo do n control located in a separate pilot system. These can &e used to either pop or modulate the main valve. This type of valve uses the line pressure through the pilot valve and maintains a high degree of seat tightness$ especially as the set pressure is approached. This type ill permit &lo do n as lo as 3 percent. All are highly vulnera&le to dirt in the fluid stream and pilot line free#ing pro&lems. 'ome are not recommended for li%uid service. 0.-.9 Rupture Discs
A rupture disc is a thin diaphragm$ designed to &urst at a designated pressure. ?nli5e pressure relief valves$ a rupture disc does not re<close. Rupture discs may &e the only protection devices in the system$ or it may &e used together ith pressure relief valves in parallel or in series.
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Guidelines for ?se of Pressure Relief Devices Application guidelines are as follo s1 Conventional pressure relief valves should only &e used hen the &uilt< up &ac5 pressure or the varia&le superimposed &ac5 pressure in the piping do nstream of the valve ill not e"ceed .: percent of the set pressure. ,alanced pressure relief valves should &e used in vapor or gas service in hich the &uilt<up &ac5 pressure or the varia&le superimposed &ac5 pressure ill e"ceed .: percent of the set pressure. /hen &ac5 pressures e"ceed -: percent of the set pressure$ the valve si#ing ill &e &ased on the manufacturer@s data for the specific valve. Pilot<operated pressure relief valves should &e used henever the set pressure must &e ithin 9 percent of the ma"imum allo a&le or5ing pressure of the protected item or henever the &ac5 pressure e"ceeds -: percent of the set pressure. /hen &ac5 pressures e"ceed 9: percent of the set pressure$ the valve si#ing ill &e &ased on the manufacturer@s data for the specific valve. Rupture discs should &e used as a secondary pressure relief device )in parallel ith pressure relief valves* for remote contingencies re%uiring large relief areas. Their installation is also recommended upstream of pressure relief valves to minimi#e fugitive emissions of to"ic or valua&le materials$ or to protect a pressure relief valve from corrosion$ either upstream or do nstream.
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'ystem Piping The design of the pressure relief piping should conform to the re%uirements of American National 'tandards +nstitute )AN'+*=American 'ociety of (echanical Engineers )A'(E* ,-..-$ Code for Petroleum Refinery Piping . +nstallation details should conform to those specified in American Petroleum +nstitute )AP+* Recommended Practice 93:$ Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries$ Part ++. The &asic criterion for si#ing the discharge piping and relief manifolds is that the &ac5 pressure$ hich may e"ist or &e developed at any point of the system$ does not reduce the relieving capacity of any of the relief devices &elo that re%uired to protect e%uipment from overpressure. +t is necessary to define$ for each relief device$ the ma"imum allo a&le &ac5 pressure under each contingency. The allo a&le &ac5 pressure is a function of ).* the type of relief valve$ )3* the set pressure of the valve$ and )-* the relieving rate re%uired for each contingency. The effect of superimposed or &uilt<up &ac5 pressure on the operating characteristics of the valves must &e carefully e"amined. The discharge piping system must &e designed so that the &uilt<up
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&ac5 pressure caused &y the flo through the valve under consideration does not reduce the capacity or opening pressure of any pressure relief device that may re%uire to relieve simultaneously. Re%uirements for pressure relief piping are as follo s1 2eads )individual discharge lines* should &e si#ed for the ma"imum individual discharge rate as indicated 'ection -.- of this Guide. 2eads should &e no smaller than pressure relief valve outlet si#es. 2ateral )com&ined leads* should &e si#ed for the ma"imum individual lead load or the simultaneous discharge rate from one cause$ hichever is greater. 2aterals should &e no smaller than the largest lead they serve. 6eaders should &e si#ed for the ma"imum individual or simultaneous relief load generated ithin the section served as a result of a single failure$ hichever is greater. (ain headers$ vent or flare headers as ell as vents and flare stac5s should &e si#ed for the ma"imum emergency discharge rate.
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Bnoc5out Drums 6eaders to flare stac5s from relief$ depressuring and &lo do n valves are first run to a 5noc5out drum to strip the flare stream of any li%uid phase and thus$ prevent li%uid carry<over from the flare. +t is desira&le that header lines should &e run overhead to the top of the drum and they must slope at a minimum of . in 0:: so that all condensate runs into the drum and does not collect in the lines or around the outlet side of the valve. +f necessary$ the header lines may &e heated to prevent condensation. The 5noc5out drums are to &e located near the stac5$ immediately upstream of the seal$ to avoid condensation of li%uid &et een the drum and the stac5. +n some cases$ it ill &e proven necessary to supply 5noc5out drums at lo points in the flare header or at individual process units. The num&er of 5noc5out drums shall &e determined &y the volume of li%uids in the header$ the distance from the process unit to the flare$ and the configuration of the header. Design procedures for the 5noc5out drums shall &e &ased on the methodology suggested &y American Petroleum +nstitute )AP+* Recommended Practice 93.$ Guide for Pressure-Relieving and Depressuring Systems and should &e in compliance ith American 'ociety of (echanical Engineers )A'(E , Boiler and Pressure Vessel Code$ 'ection ;+++. The vesselCs ma"imum allo a&le or5ing pressure )(A/P* should &e set at -00.D0 5Pa )9: psig* as a minimum. The margin &et een the design pressure and the (A/P should &e given &y American 'ociety of (echanical Engineers )A'(E*$ Boiler and Pressure Vessel Code$ 'ection ;+++$ Division ..
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The 5noc5out drum should also &e a&le to ithstand an internal e"plosion ithout rupturing. The ma"imum allo a&le stress used for design$ the minimum tensile strength of the metal$ the operating a&solute pressure and the reactivity of the fluids &eing handled should &e considered. The design temperature should &e esta&lished from the e"pected ma"imum=minimum temperature in the header=drum. Autorefrigeration$ if a factor$ should &e considered. (aterial of construction shall &e compati&le ith the e"pected contents. Car&on steel is the most common used material. 'pecial alloys may &e re%uired hen the service includes or5ing conditions such as lo temperature$ high temperature$ highly corrosive li%uids or gases$ etc. ;ital instrumentation to &e provided on each drum includes1 Temperature indicator. 2evel and pressure gages. 2evel s itches. 6igh and lo <lo level alarms )local and control room*.
The 5noc5out drums should &e si#ed to handle the ma"imum li%uid accumulation from any scenario and$ generally$ designed for any of the follo ing t o conditions1 )r! load > vapor ith entrained li%uid$ in hich case the drum is si#ed to 5noc5out droplets a&ove 09: microns ).E: mil* for all flo rates$ including the ma"imum emergency discharge rate. *et load > vapor ith li%uid$ in hich case the drum hold<up is designed to cope ith the ma"imum e"pected li%uid release rate in certain amount of time. The time to &e ta5en into consideration shall depend on the instrumentation provided to arn operators to react. Normally a period of .9 to -: minutes is provided for li%uid accumulation in the drum.
Depending on the amount of li%uid to &e handled$ the 5noc5out drum could &e either hori#ontal or vertical. 'ince many li%uid relieves are large$ the most common orientation used is hori#ontal. The presence of three phases )product vapors and li%uid$ and ater* also influences the configuration of the drum depending on the t o li%uids. +f the amount of the heavier phase is small$ then a &oot is often used to provide for surge for removing the heavier li%uid. +f the amounts of the t o phases are e%ual$ then a eir is placed so that the light phase may spill over to a separate compartment for ithdra al. Alternatively$ the eir is designed so that the heavier phase underflo s to a separate compartment. +f the volume
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of the light phase is very small$ then manual drain coc5s are sometimes provided. Prevention of li%uid entrainment usually is accomplished &y straight in and outlet no##les designed for relatively lo velocities F3: to 0: m=sec )A9.A ft=s to .-..3 ft=s*G. Application of demister mats should &e avoided$ as they are suscepti&le to fouling. +t is normal practice to provide automatic li%uid pump<out facilities so operators do not have to go into a high thermal radiation area. Pumps should &e a&le to pump out the ma"imum li%uid hold<up of the drum in one to t o hours. Cold li%uid &lo do n drums are usually provided ith vapori#ing facilities designed such that the ma"imum e"pected li%uid accumulation could &e removed in t o to four hours. The cold li%uids are vapori#ed and discharged to the flare for com&ustion. +t should &e reali#ed that automatic starting of a pump$ hich transfers the li%uid into an atmospheric slop tan5$ might cause heavy vapori#ation in this tan5 if the atmospheric &oiling point of li%uid is &elo the tan5 content temperature. (anual starting should &e considered if such condition cannot &e precluded. As the 5noc5out drum may contain considera&le amounts of ater$ hen needed or at the designer criteria$ the drum shall &e provided ith heating coils to prevent free#ing$ to sta&ili#e volatile li%uids$ or hen re%uired &y process and=or environmental conditions. 0.D ;ents and 4lares The vent or flare line diameter should &e e%ual to the main header diameter and should &e designed in accordance ith 'ection -.9 of this Guide. 0.D.. ;ent 'tac5
The purpose of the vent stac5 is to provide a proper means to dispose release gases to a safe location under adverse ind conditions. Radiant heat intensity at critical points of the facility should &e chec5ed and evaluated to ensure personnel safety in the event that the vent &ecomes ignited. 0.D.3 4lare 'tac5
The immediate purpose of a flare is as a safety device$ here potentially e"plosive mi"tures are disposed of &y &urning$ to prevent fires or e"plosions. 4lares are designed to handle the aste gas load of a facility. As such$ the proper design of flare systems is contingent upon the optimi#ation of three varia&les1 flame temperature$ retention time$ and tur&ulence. ?nli5e other destruction systems$ here regulated amounts of 5no n aste material are fed at a fi"ed rate into enclosed systems$ flaring occurs in the open and is e"pected to &urn vastly different types of %uantities of material.
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+n flare systems$ the main flare header should slope to ards the li%uid 5noc5out drum to drain li%uid into it. 2o points in the flare header should &e avoided as li%uid and solid materials tend to collect at these points and may hamper the safe operation of the e%uipment connected to the system. +f a lo point is unavoida&le$ great care should &e ta5en to drain the li%uids either automatically or manually at regular intervals. +f there is any chance of li%uid solidification )e.g.$ free#ing*$ facilities are to &e provided to prevent such occurrence. The li%uid collected in the 5noc5out drum may &e returned to a slop tan5 from here it can &e reprocessed or used as fuel. De atering facilities may have to &e provided as the li%uid can contain su&stantial amounts of ater. After li%uid droplet 5noc5out$ the vapors are discharged into a flare at hich the vapors are ignited &y the pilot &urners. Preventive measures are to &e ta5en to preclude any possi&ility of flame flash&ac5 into the stac5 and the piping system. 0.D.Types
Typically$ flaring is performed in an unconfined area$ remotely situated from other processing e%uipment or plant personnel. Depending on the amount of space availa&le and the physical layout of the facility$ one or a com&ination of the follo ing flare types may &e used. 0.D.-.. Elevated 4lares
Despite its relatively high capital and operating cost as ell as plant area that may &e rendered unavaila&le for plant e%uipment$ the elevated flare is the preferred choice either for total flare loads or the handling of overcapacity releases in con!unction ith an enclosed ground flare. 4or most applications$ the elevated flare type is the only accepta&le means of flaring astes such as gases ith high contents of unsaturated hydrocar&ons or hydrogen sulfide$ or hich have highly to"ic com&ustion products. There are three types of stac5s utili#ed for elevated flares$ these are1 Guyed Stac! > usually the least e"pensive to &uild &ut in some cases the guy ires result in restrictions on the use of ad!acent land$ in addition to normal spacing restrictions. Derric! Stac! > ell suited for tall structures su&!ect to strong 6o ever$ they are the most e"pensive to erect and maintain. inds.
Self-supporting Stac! > designed so that the flare riser pipe has no lateral support structure support. 4or short flares$ this type is the least e"pensive to erect and maintain.
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Ground flares are partially enclosed &urners that are mainly utili#ed hen luminosity and noise have &ecome o&!ectiona&le. Radiation energy is minimi#ed &y the retaining structure and$ smo5eless operation can &e achieved provided the design gas rate to the flare is not e"ceeded. 6o ever$ since the flame is near ground level$ dispersion of flared gases may result in severe air pollution or ha#ard if com&ustion products are to"ic or in the event of a flame<out. Capital and maintenance re%uirements are usually high &ut the advent of more efficient &urners can contri&ute to reduce operating costs. 0.D.-.,urn<Pit 4lares
The &urn<pit flare is of simple construction$ generally ith lo capital and operating costs and can handle li%uid as ell as vapor hydrocar&ons. +ts use is usually limited &y spacing re%uirements and smo5e formation$ and it is applied to remote locations here there are essentially no opacity restrictions. The use is normally dictated &y periodic li%uid %uantities re%uiring disposal. Typical installation is hori#ontal mount. 0.D.0 0.D.0.. Design Considerations 'pacing$ 2ocation and 6eight
The spacing$ location and height$ the latter in case of an elevated flare$ are determined &y consideration of the follo ing factors1 %adiant +eat > the accepta&le level of radiant heat intensity for personnel e"posure. The allo a&le radiation level is a function of e"posure duration. +n an emergency$ personnel may ta5e from t o to five seconds to react$ and another five seconds to see5 for cover or leave the area. 'olar radiation should &e ta5en into consideration unless overcast conditions are predominant and there is little chance of flare and sun &eing sufficiently in line to ma5e their radiation additive. 'olar radiation values vary &ut ..:0 5/=m 3 )--: ,T?=ft3=hr* is a reasona&le design &ase.
Allo a&le e"posure levels guidelines derived from various sources are summari#ed &elo . The practical escape time should &e considered in selecting the level. +t is recommended that specialists &e consulted. 2ocal regulation must &e follo ed hen more restrictive.
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Ta34e 1a 5 *44%6a34e T!erma4 Radia7i%n E8 %"ure Le9e4" :;<#m $= EHPO'?RE T+(E A22O/A,2E PER'ONNE2 EHPO'?RE 2E;E2 'till Air 9 seconds -: seconds . minute 9 minutes .: minutes . hour Continuous J.0A 3.3. < A.A3 3.3. < 9.AE 0..: < 0.D-.A- < 0.D3.93 :.J9 < ..EJ Normal /ind J.0A 3.3. < D..: 3.3. < A.-. 0.D0..: < 0.D-..9 :.J9 < 3.93 6igh /ind J.0A 3.3. < D.0. 3.3. < A.DE 0.D- < 9.-A 0.D-.DE :.J9 < -..9 .9.DD .9.DD .9.DD N=A N=A N=A -..9 < .9.DD A22O/A,2E EI?+P(ENT EHPO'?RE 2E;E2
Ta34e 13 5 *44%6a34e T!erma4 Radia7i%n E8 %"ure Le9e4" :BTU#&7$#!r= EHPO'?RE T+(E A22O/A,2E PER'ONNE2 EHPO'?RE 2E;E2 'till 9 seconds -: seconds . minute 9 minutes .: minutes . hour Continuous -$::: D:: < 3$.:: D:: < .$E:: .$-:: <.$9:: .$.9: <.$9:: E:: -:: < A:: Normal /ind -$::: D:: < 3$39: D:: < 3$::: .$9:: .$-:: < .$9:: .$::: -:: < E:: 6igh /ind -$::: D:: < 3$-9: D:: < 3$.9: .$9:: < .$D:: .$9:: .$3:: -:: < .$::: 9$::: 9$::: 9$::: N=A N=A N=A .$::: < 9$::: A22O/A,2E EI?+P(ENT EHPO'?RE 2E;E2
+n most cases$ e%uipment can safely tolerate higher heat intensity than those defined for personnel. 6o ever$ if anything vulnera&le to overheating pro&lems is involved$ such as lo <melting point construction materials )e.g.$ aluminum or plastics*$ heat sensitive streams$ flamma&le vapor spaces$ or electrical e%uipment$ then the effect of radiant heat on them may need to &e evaluated. /hen this evaluation is re%uired$ the necessary heat &alance should &e performed to determine the resulting surface temperature for comparison ith accepta&le temperatures for the e%uipment. ,iquid #arr!over -all-.ut > the possi&ility of li%uid carryover fall<out from an elevated flare$ if li%uid hydrocar&ons should &e entrained into it.
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Environmental ,imitations > emissions such as smo5e formation$ malodorous$ or to"ic com&ustion products$ noise$ hich may &e &ased on statutory and=or pu&lic relations re%uirements. /aintenance 0ccess > for multiple flares$ maintenance access to elevated platforms or grade located e%uipment may affect spacing and height. rate$
The flare operating performance is in turn determined &y the flo material properties$ and smo5ing characteristics of the flame. 0.D.0.3 Construction
There are three &asic construction types of flares$ and they should &e selected &ased on the follo ing guidelines1 Elevated -lares > the most common method of reducing e"posure to thermal radiation and concentration of com&ustion products. They re%uire little real estate and are relatively ine"pensive. Ground -lares > also 5no n as com&ustor cham&ers. Ground flares are special types of ground &urners used primarily for continuous vent streams. They are enclosed to eliminate noise and thermal radiation. Typically$ they have e"tensive smo5e<reduction e%uipment. They are used hen the flare must &e located close to e%uipment or population. Their primary disadvantage is cost. 'urn-Pit -lares < their use is not recommended in areas pu&lic e"posure may &e of concern. Capacity and 'i#ing here the
0.D.0.-
The flare capacity is a function of flo rate and material properties$ environmental regulations$ type of assist gas$ e"istence of multiple header systems$ and num&er of flares or the staging of the flare and turndo n ratio. 4lare systems shall &e designed to safely discharge the %uantities of gas relieved under all normal and emergency operating conditions. 4lares may &e either of continuous or limited duration. #ontinuous -laring > during normal operation there may &e a continuous re%uirement to relieve gas to the flare system. +f associated gas is not flared$ the continuous load could &e made up of off< specification gases unsuita&le for use in the fuel system$ e"cess gas &lan5et and lea5age losses through valves. $hort Period -laring > occurs hen there is a sudden release of large %uantities of gas into the relief system. Typically$ ith short duration flaring$ there is a rapid increase to a pea5 follo ed &y a larger period of
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flo decay. 'hort periods of high flaring flo s normally occur as a result of plant shutdo n or emergencies. Normally$ the largest %uantity from a single contingency &asis is used and shall &e esta&lished after determining the ma"imum relief condition of each safety valve and the %uantities to &e relieved in each of the general emergency cases of cooling ater failure$ po er failure$ instrument air failure$ steam failure$ and fire conditions cited in American Petroleum +nstitute )AP+* Recommended Practice 93:$ Sizing, Selection, and Installation of PressureRelieving Devices in Refineries. ?nder fire conditions$ calculations of pressure relief loads should &e &ased on a minimum fire area of 3E: m3 )-$::: ft3* and a minimum height of D.A m )39 ft* a&ove any level at hich the fire may &e &ased$ in conformance ith American Petroleum +nstitute )AP+* Recommended Practice 93:$ Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries, Part . and American Petroleum +nstitute )AP+* RP 93.$ Guide for Pressure-Relieving and Depressuring Guides. 0.D.0.0 ,ac5 Pressure and Pressure Drop Considerations
4lare selection and si#ing of flare systems for lo pressure plants such as sta&ili#ers$ spheroids and 2PG tan5s need special considerations. 2i%uid accumulation in flare lines$ especially in vertical sections$ should have special attention &ecause of a possi&le pressure &uild<up in the flare system$ e"ceeding safe plant operating conditions. 0.D.0.9 4lash&ac5 Protection
4lare systems are su&!ect to potential flash&ac5 and internal e"plosion since flamma&le vapor and air mi"tures may &e formed in the stac5 or inlet piping &y the entry of air into the system. 'ince a pilot system constitutes a continuous ignition source$ flares should al ays &e provided ith flash&ac5 protection in the form of a li%uid seal or controlled air entry. This ill prevent a flame front from traveling &ac5 to the upstream piping and e%uipment. 0.D.0.A Emissions
A properly designed and maintained flare should not flameout. 6o ever$ flameout condition should &e modeled over the range of e"pected release rates using reasona&le adverse and orst<case meteorological conditions. Prefera&ly$ the release should not produce to"ic concentrations of concern or 9:K of the lo er e"plosive limit at the ground or elevated areas. 4lare height considerations should ta5e into account these results so that the residual ris5 of flare emissions is consistent ith environmental regulations and undesira&le effects from a flameout
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Purging and sealing are necessary to prevent air penetration in the header and flare stac5 to avoid flash&ac5 and the possi&ility of e"plosions. Purging and sealing provide complementary functions. Purging is used either in lieu of a seal or as a supplement to the seal. Purging &y itself may prevent air infiltration &ut is e"pensive due to the volume of purge gas re%uired. Therefore$ the purge rate may &e reduced &y a seal depending on the seal design and its location. 'ome seals are effective for most circumstances ith little or no purge gas$ hile other seals re%uire a fi"ed purge rate to &e effective. 'ealing is provided &y mechanical e%uipment that prevents air ingress. The type of seal is determined &y its location in the system. Purging and seals are further discussed in 'ections E and J respectively. 0.D.0.E 2i%uid 6andling
+f large amounts of li%uid are present in the flare stream$ li%uid carryover can result in ha#ardous conditions. Thus$ the flare header shall &e provided ith a 5noc5out drum to remove li%uid surges in the flare header so as to prevent li%uid slug damage to piping and vessels and 5noc5out li%uid droplets hich ould other ise proceed to the flare tip$ ignite and may create a ha#ard &y falling as &urning hydrocar&on droplets onto the plant area. 0.D.0.J Noise
Noise can &ecome a pro&lem$ particularly at high flo rates and if steam or another medium is &eing used to ma5e it smo5eless. Noise is not a safety pro&lem8 ho ever$ pu&lic concerns may &e a pro&lem. 0.D.0..: +gnition 'ystems
An ignition system to light the pilot$ or re<light the pilot if the flame is lost should &e provided. Three typical systems are descri&ed &elo . Preference is to have more than one method to prevent common cause failure of the flare flame. +gnition heads and piping to the igniter and pilot )up to - m ).: ft* &elo the pilot* are typically constructed of heat<resistant alloys. -lame -ront Generation > compressed air and fuel gas are added through a mi"ing tee to a line leading to the igniter tip$ hich is located &eside the pilot at the tip of the flare. A spar5ing device at grade ignites the mi"ture$ and the flame front travels up the line into the igniter tip and lights the pilot. The spar5ing device may &e located some distance from the flare. 4lame front generators are relia&le and proven$ &ut a relia&le source of air must &e availa&le. ,ac5up air shall &e provided from a different system or from compressed gas. 4lame front generators
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are either automatic or manual. /ith the latter$ the operator must monitor the pilot for re<lighting. 0ir 0spiration 1gniter > fuel gas is added to the line leading to the igniter tip$ hich is located &eside the pilot at the tip of the flare. An eductor in the line aspirates air that mi"es ith the fuel gas$ such that a source of compressed air is not re%uired. A spar5ing device after the eductor ignites the mi"ture$ and the flame front travels up the line into the igniter tip$ and lights the pilot. The eductor is located a&out -: m ).:: ft* from the pilot. Air aspiration igniters are either automatic or manual. /ith manual igniters$ the operator must monitor the pilot for re<lighting. Electric 1gniter > compressed air and pilot fuel gas are added to the pilot$ here it is ignited &y an electric igniter device located at the flare pilot. The flare pilot may &e operated in a continuous mode or an intermittent mode$ if permitted &y regulations. +n the continuous mode$ the pilot &urns continuously$ &ut is re<lighted automatically on failure$ hich is sensed &y the pilot monitor and the control panel. The control panel may &e located locally or in the control room. Relia&ility must &e evaluated and a source of air must &e availa&le$ although some designs use air that is self aspirated and mi"ed ith the fuel gas at the igniter. 4or compressed air systems$ &ac5up air is provided$ often as cylinders. Com&ustion Characteristics
0.D.0...
The characteristic of a properly designed and operated flare is that it ill &urn ith JEK or &etter com&ustion efficiency$ produce little No "$ and have a sta&le flame. 4lares may &e classified as smo5eless$ non<smo5eless$ or endothermic. 'mo5eless flares are further classified &y the type of assist fluid. 2on-smo3eless -lares > used for fluids readily &urna&le ithout smo5ing such as methane$ hydrogen$ and car&on mono"ide. 6o ever$ since most units encounter a mi"ture of hydrocar&ons$ non<smo5eless flares are not fre%uently used. Additionally$ regulations often specify strict emission and &urning efficiency levels on flares that usually preclude using this type of flare for most hydrocar&ons. $mo3eless -lares > used for all olefins$ aromatics$ and paraffins a&ove methane. +n general$ olefins and aromatics smo5e more than paraffins$ possi&ly due to more crac5ing and polymeri#ation. Com&ustion efficiency is improved &y outside momentum sources$ hich provide gas=air mi"ing tur&ulence. Typical sources of outside momentum are compressed air$ &lo er<forced air stream$ high ,T? fuel gas$ or ater spray.
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'mo5e is reduced &y higher com&ustion efficiency and chemical means. 'team and ater spray reduces smo5e chemically &y com&ining ith car&on to form car&on mono"ide$ car&on dio"ide$ and hydrogen. /ater may also reduce smo5e caused &y crac5ing and polymeri#ation &y cooling and adding a source of o"ygen. These methods are augmented &y flame retention rings that promote tur&ulence and 5eep the flame erect8 thus ma5ing the flame more sta&le at higher tip velocities. /ind guards placed around the tip can reduce ind<induced flame &ac5flo into the tip. 6igh<pressure tips also reduce smo5ing. 4lares utili#ing the Coanda effect )a method of ad!usting no##le or !et velocity and angle of entry to ma"imi#e surface area to promote mi"ing* may also reduce assist gas or stream re%uirements. 6o ever$ an offset disadvantage is that the system re%uires ad!usta&le clearances$ hich introduces more maintenance re%uirements at the flare tip. 4lare tips often foul ith un&urned products$ re%uiring fre%uent cleaning. The tips must &e designed to &e capa&le of easy cleaning. Endothermic 4-ired5 -lares > are used for lo ,T? gases or for gases that re%uire high temperatures or good com&ustion efficiency.
6igh flare com&ustion efficiency is achieved hen &urning hydrocar&ons such as natural gas$ ethane$ propane$ and &utane. 6ydrocar&ons such as ethylene and propylene have similar efficiencies$ if smo5eless operation is achieved &y steam$ air &lo er$ or multi<tip designs. The com&ustion efficiency ill &e lo er for gases having a lo er heating value from a high content of nitrogen$ car&on dio"ide$ ater vapor$ or other inert media. +f the heating value is &elo 0.- (L=m - )..9 ,T?='C4*$ some au"iliary fuel such as natural gas or propane must &e utili#ed to increase the heating value to the minimum level. +n some applications$ particularly if 63' is present$ the heating value must &e increased further. The magnitude of the needed increase is a function of flare tip design and e"it velocity. /here a gas contains considera&le amounts of hydrogen and car&on mono"ide that are fast &urning$ the minimum heating value for complete com&ustion can &e as lo as -.0 (L=m- )J: ,T?='C4*. +f a flare re%uires assist gas$ the use of an enclosed flare should &e considered. An enclosed flare ill allo complete com&ustion of a gas at a lo er calorific content ithout the use of assist gas. An enclosed ground flare can handle gases ith a heating value as lo as 3.3 (L=m- )A: ,T?='C4*. 6o ever$ if there are high levels of 6 3' or CO3 present$ the heating value must &e higher. As the CO 3 content increases$ assist gas must &e added to maintain a -.D (L=m - ).:: ,T?='C4* average heating value. /hen using an enclosed ground level flare for gases containing 6 3'$ a
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ha#ardous condition can result if a flameout occurs. 4laring of gases 63' level should &e done in an elevated flare. 0.D.0..3 ;elocity 2imitations for 4lare Tips
The criterion for flare tip velocity is a function of assist gas and net heating value. The criteria must &e met during periods of start<up$ shutdo n$ and malfunction of the process$ for the stated periods. 4or design purposes$ the e"it velocity should &e assumed to &e (ach :.9 or .AD.A0 m=sec )99:.:: ft=sec*. +t may &e possi&le to use a higher (ach num&er if recommended &y the vendor and if the re%uired &ac5 pressure is not unreasona&ly high. Proprietary flare tips shall &e si#ed &y the vendor at the appropriate ma"imum velocity. 0.E 'eals 0.E.. Gas 'eals at Top of 4lare
Gas seals are installed at the flare tip to prevent air from entering the stac5 and causing an e"plosion. Air can enter the stac5 from high inds that create a do ndraft$ gas shrin5age due to cooling after a hot release$ and loss of integrity of flare system such as opening a man ay at the stac5 &ase. Gas seals installed at the tip of the flare re%uire purge gas. The t o most common types of flare tip gas seals are1 0ir -lo( %eversing $eal > this seal is very light hen compared to a molecular seal ).=.: to .=3: the eight*$ has a minimum pressure drop F..-E < -.09 5Pa ):.3 < :.9 psi*G$ and uses little purge gas F..3 < 0.A cm=sec ):.:0 < :..9 ft=sec*G. These device routes the air infiltrating do n the side of the stac5 to ards the center of the stream here it is carried out &y the purge gas$ thus$ the seal partially protects from connective currents. 2oss of seal may &e through convection and diffusion. /olecular Gas $eal > &asically an inverted can that traps the flared gas so that air cannot infiltrate. +t protects fully against connective current and the seal is lost only &y diffusion. This type of seal has the disadvantage that is heavy$ re%uires a higher pressure drop F-.09 < A.EJ 5Pa ):.9 < ..: psi*G$ and is more e"pensive than the airflo reversing seal. The molecular seal re%uires less purge gas F-.. < J.. cm=sec ):.. < :.- ft=sec*G.
The choice &et een seals depends on the cost$ hether the flare stac5 can support the eight$ the pressure drop constraints of the system$ the cost and availa&ility of purge gas$ the possi&ility of the complete loss of purge gas to
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the seal$ and the type of air assist. 4orced air assist$ can no accommodate a molecular gas seal.
A properly designed seal at the tip of the flare stac5 protects &oth the flare header and the flare stac5. Therefore$ it is recommended that all flare stac5s &e protected ith a seal at the top of the flare$ ith the follo ing e"ceptions1 +f sufficient purge )minimum velocity* gas is provided to prevent air infiltration for the flare scenarios and material. +f the stac5 is designed to e"plosion. ithstand a credi&le design scenario the flare tip and &elo the
+f provided$ the seal is to &e located &elo refractory used to protect the tip. 0.E.3
'eals at 4lare 'tac5 ,ase )2i%uid 'eal*
'eals placed at the flare stac5 &ase protect the header &ut not the flare stac5s. They are located at the &ase since they are too heavy to place at the flare tip. The typical li%uid used is ater. The general principle is that the gas must pass through the li%uid seal as a series of &u&&les$ each separated &y ater. The ater &arrier acts to cool the gas and prevent flame flash&ac5 into the header. 2i%uid seals offer protection from air infiltration and e"cellent protection from flash&ac5. The seal internals must &e designed for pressure surges. Disadvantages of li%uid seals are e"pense and lac5 of protection for the flare stac5. There are several configurations for li%uid seals8 the follo ing are e"amples of them1 'eals are most commonly separate vessels located after the 5noc5out drum and &efore the flare stac5. They are located as close to the flare stac5 possi&le. They may &e vertical or hori#ontal depending on the amount of seal li%uid re%uired. 'eals are sometimes com&ined ith vessel to avoid the design of t o piping. +n this design$ the seal is the piping may &e designed as a seal designed as the 5noc5out drum. the 5noc5out drum in a hori#ontal separate vessels and connecting first compartment so that the inlet leg. The second compartment is
2i%uid seals are often com&ined ith the 5noc5out drum in proprietary cyclone designs. These designs incorporate t o cham&ers in one structure. The flare gas enters the 5noc5out drum$ and passes through the ater seal into the flare stac5.
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A li%uid seal should &e considered
There is a high possi&ility that the purge gas may fail. A li%uid seal provides positive header protection even ithout purge gas. 6o ever$ provision for retention of the seal must &e provided for scenarios such as cooling of the flare header. Detonating gases e"ist in the flare stream. Gases that are suscepti&le to detonation )e.g.$ ethylene o"ide$ hydrogen$ etc.* may not &e protected &y a seal at the tip of the flare since flare<tip seals also re%uire purge gas flo that may &e less than the speed of detonation. Gases that do not detonate often use only a seal at the tip of the flare stac5. 4or e"ample$ installations such as natural gas metering stations$ 2PG facilities$ and offshore flaring of produced aliphatic hydrocar&on gases use only a seal at the tip of the flare and do not use a li%uid seal.
The material to &e flared has a ide range of gases. +f the composition is not assured$ a li%uid seal may &e specified since it protects against detonating gases. Other 'eals
0.E.-
(echanical seals and flame=detonation arrestors are also other types of seal. 'ome mechanical seals use a flapper to prevent &ac5flo &ut the flappers are prone to failure and should not &e used. 4lame=detonation arrestor type seals operate &y providing a heat sin5$ to dissipate the heat of the flame. The most common design is a la&yrinth of metal plates$ hich offers a large area as a heat sin5. These types are suscepti&le to fouling and should not &e used ith plugging or corrosive vapors. +n addition$ purge gas is still re%uired to prevent a vacuum in the system due to cooling of the arm gases. 4or these reasons$ these seals are rarely used and are not recommended. 6o ever$ hen its use is considered unavoida&le$ the designer should consider a parallel installation so there is al ays a spare hen the other is &eing maintained. 0.J Purging Purging is defined$ as the minimum flo of gas re%uired to prevent the &ac5flo of air into the flare system. Purge gases must meet the follo ing re%uirements1 Non<corrosive nature. Non<reactive to any other gases in the system.
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6ave a de point &elo the lo est e"pected temperature. 'team and gases heavier than &utane are seldom used &ecause of their high de point. Contain insufficient o"ygen to support com&ustion.
Typically$ the purge gas is fuel gas or nitrogen. 6igh molecular eight gases encounter less mi"ing ith air than lighter gases$ essentially acting as a purge piston$ and thus re%uires a lo er purge rate. A seal may re%uire purge gas here air may &e dra n into the flare stac5 &elo the tip. The minimum purge gas re%uirements for different types of seals$ thus the seal manufacturer should &e consulted for the stac5 velocity design rate. Ta34e 3.2-1 5 S7a>; +e4%>i7y De"ign Ra7e
'tac5 velocity 'tac5 velocity 'tac5 velocity ithout a seal ith air reversing seal ith molecular seal A.. cm=s to J..0 cm=s ):.3 ft=s to -.: ft=s* ..3 cm=s to 0.A cm=s ):.:0 to :..9 ft=s* :.- cm=s to :.J cm=s ):.:. ft=s to :.:- ft=s*
(inimum velocity should &e maintained for all a&ove scenarios. ,esides the minimum purge rate$ facilities to add supplementary purge gas are often provided. Purge gas may &e added at any location upstream or do nstream of the seal. 6o ever$ the typical location is at the &eginning of the header so it may s eep it completely. Purge gas lines are often fitted ith lo flo alarms to arn of lac5 of sufficient purge gas. This is particularly true if the purge gas is used as a diluent for flared material. /. *TM)SPHERI- +E(TI(G The most economical method of discharging vapors from pressure relief devices is to discharge to the atmosphere. This method is preferred to the closed pressure relief system$ provided such disposal is not in conflict ith or restricted &y the follo ing1 Present and anticipated regulations concerning air %uality and noise. Prevailing meteorological conditions. Properties of vapor discharged$ such as to"icity$ volatility$ flamma&ility$ entrained li%uid and molecular eight.
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Discharges to the atmosphere should &e in the vapor state and &elo the autoignition temperature. The discharges should also meet one of the follo ing property re%uirements$ su&!ect to air %uality control regulations1 4lamma&le vapors are either e%ual or lighter than air. 4lamma&le vapors are heavier than air$ molecular eight is less than E: and the minimum velocity at discharge is .93 m=s )9:: ft=s*$ &ased on the ma"imum capacity of the relief valve. (a"imum velocity should not e"ceed E: percent of sonic velocity ):.E (AC6*. 4lamma&le vapors have a molecular eight greater than E:. ;elocity at discharge is as specified in the a&ove item$ su&!ect to management approval. ;apors$ of any molecular and non<condensa&le. eights$ hich are non<flamma&le$ non<to"ic
9..
Pressure Relief Devices Pressure relief devices shall &e selected in accordance Guide. ith 'ection -.- of this
9.3
;ent Piping ;ent pipe re%uirements are as follo s1 Atmospheric vent pressure drop shall &e designed using the relief loads for each applica&le failure case in accordance ith the American Petroleum +nstitute )AP+* Recommended Practice 93:$ Sizing, Selection, and Installation of Pressure-Relieving Devices in Refineries $ Part + and American Petroleum +nstitute )AP+* Recommended Practice 93.$ Guide for Pressure<Relieving and Depressuring 'ystems. The discharge velocity of the vapor is to &e maintained at .93 m=sec )9:: ft=sec* or higher. The end diameter of the vent pipe should &e reduced for a length e%ual to three pipe diameters$ if re%uired$ to achieve this velocity. 'tandard concentric reducers shall &e used. Discharge velocity shall not e"ceed E: percent of sonic velocity. Atmospheric vent pipes shall &e designed to prevent pipe failure caused &y 5inetic forces developed during a discharge. +f the vent system is not self<draining$ a drain shall &e provided at lo points to prevent the collection of li%uid in the discharge pipe. The drain shall &e piped to safe disposal so that the opening ill not endanger personnel or$ in case of a fire$ impinge on ad!acent surfaces. The drain must &e regularly emptied to prevent the system from filling ith li%uids and cause a high &ac5 pressure.
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4lame arrestors shall not &e installed on atmospheric vents &ecause arrestor elements may &ecome plugged ith atmospheric dust$ process products$ corrosion$ or ice during cold eather. The system shall &e designed to preclude internal &urning and=or e"plosions. Atmospheric vents shall terminate at least1 ..E m )A ft* a&ove the highest ad!acent structure or e%uipment. 0.A m ).9 ft* a&ove a dec5 or a&ove grade. .9 m )9: ft* or .3: pipe diameters$ hichever is greater from the nearest structure or e%uipment hen located at an elevation lo er than the structure or e%uipment. Any flamma&le material should &e discharged at more than -: m )JE.0 ft* hori#ontal distance from heaters$ air inta5es$ hot spots$ etc.
Atmospheric vents should &e si#ed to handle the ma"imum individual relief load. /here more than one pressure relief valve lead is connected to a vent$ the vent should &e si#ed for the largest anticipated individual relief load or for the simultaneous loads from one cause$ hichever is greater. 'pecial consideration should &e given to purging or design the entire system to handle flash&ac5s in case of ignition. Thermal radiation levels should also &e considered in case of ignition )i.e.$ lightning$ static electricity$ etc.*. 0. -L)SED PRESSURE RELIEF SYSTEM /here the atmospheric discharge is not permissi&le or practica&le$ vapor should &e discharged to a closed pressure relief system that terminates in a vent or flare. The design of the closed relief system should meet the re%uirements of air %uality regulations as ell as$ the release of com&ustion products to a safe location. Closed vent systems should &e used only for emergency relief and &lo do n. Closed flare systems should &e used for continuous discharge from pressure control systems. Consideration should &e given to grouping high pressure and lo pressure relief into t o separate systems. This may reduce piping costs and ensure &etter operating conditions for venting and flaring. A typical closed pressure relief system consists of1 A.. Pressure Relief ;alves Pressure relief devices shall &e selected in accordance Guide. ith 'ection -.- of this
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'ystem Piping 'ystem piping should &e designed in accordance ith 'ection -.9 of this Guide. +n addition$ the follo ing considerations should &e made1 The inlet piping &et een the protected e%uipment and the inlet flange of the pressure relief valve should &e designed so that the total pressure loss does not e"ceed - percent of the set pressure of the valve. Closed system piping should &e anchored and designed to resist the for ard$ lateral and up ard dynamic forces developed at &ends due to the high velocity vapors and condensed li%uids. The piping should include e"pansion loops to accommodate sudden thermal e"pansion or contraction. E"pansion !oints should not &e used. Pressure relief piping shall &e free of poc5ets and shall slope do n ard to ard the scru&&er or 5noc5out drum for good draina&ility. The total drop in elevation &et een any t o<pipe supports shall &e at least 3 mm in . m ).=0 in. in .: ft* plus the calculated deflections of empty pipe &et een t o supports. /here it is not practica&le to design the lines ith a continuous slope$ changes in elevation may &e made &y the use of scru&&ers. +nsulation of pressure relief headers shall &e provided here necessary for personnel protection$ noise or process reasons. The use of insulation and heat tracing to avoid ice accumulation ithin the pressure relief headers should &e considered. MNotch ToughN. or suita&le alloy steel should &e used in applica&le portions of pressure relief systems$ including pressure relief valves$ if auto<refrigeration of the gases can result in free#ing and ruptures at metal temperature of O3E.JC )<3:4* or lo er. 6eating of relief valves should &e considered here auto<refrigeration is e"pected.
A.-
'cru&&ers or Bnoc5out Drums 'cru&&ers or 5noc5out drums should &e designed in accordance ith 'ection -.A of this Guide. +n addition$ the follo ing considerations should &e made1 The scru&&er or 5noc5out drum should &e si#ed to separate droplets 09: microns ).E: mil* and greater for all flo rates$ including the ma"imum emergency discharge rate. +f the scru&&er is si#ed for venting rather than flaring$ it should &e designed to remove .9: microns droplets. Design procedure for gravity separators should &e &ased on the method recommended &y the American Petroleum +nstitute )AP+* Recommended Practice 93.$ Guide for Pressure-Relieving and Depressuring Systems .
Notch Tough is a term relating to the Charpy V-Notch impact test required to prove the resistance of carbon steel to brittle fracture.
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The use of cyclone or inertial type separators$ and serpentine or other internals$ may only &e considered ith management approval. (ist eliminators and other internals should generally not &e used unless the savings in space and eight are significant. 'afety authorities may see these internals as potential o&structions. 'pecial precautions may have to &e made to ensure that &loc5age of the internals cannot occur. 'cru&&ers should &e provided ith heating coils to prevent free#ing$ to sta&ili#e volatile li%uids$ or hen re%uired &y process and=or environmental conditions.
A.0
4lares 4lares should &e designed in accordance ith 'ection -.D.3 of this Guide. +n addition$ the follo ing considerations should &e made1 The flare stac5 is generally si#ed on a velocity &asis$ although pressure drop should &e chec5ed. The flare stac5 location should &e determined &y allo a&le radiant heat intensities at critical points of the facility. Additionally$ flares should &e chec5ed to ensure that sulfur dio"ide concentration levels from the flare do not e"ceed pollution restrictions. The ma"imum &urner tip e"it velocity for pipe tip flares should not e"ceed :.9 of sonic velocity at ma"imum emergency relief load flaring. The &urner tip should &e designed to prevent flame lic5 or e"cessive heat radiation to the tip assem&ly during periods of lo e"it gas velocity. Prevailing ind direction should &e considered hen locating the stac5.
The stac5 and stac5 structural support mem&ers should &e designed in accordance to appropriate codes and criteria to ithstand environmental and e%uipment loading conditions. The effects of radiant heat on the structure and shielding should &e considered. 6igh temperature materials should &e specified for the flare &urner tip and pilot assem&ly to ensure long service life. /here practical and considered economical$ radiant heat shielding may &e installed at selected points to protect personnel and e%uipment from radiant heat intensities.
A.9
'eals 'eals should &e designed in accordance ith 'ection -.E of this Guide.
A.A
Purging 4lares should &e designed in accordance ith 'ection -.J of this Guide.
Engineering Guide
Title Document No.

EG-310
Page No.
1 1. D..
Bryan D. Hum !rie"
1#1#$001
$0 %& $'
+*P)R *(D LI?UID DIS-H*RGES T) * L)<ER PRESSURE SYSTEM )R +ESSEL ;apor Discharge D.... Pressure Relief ;alves
+ndividual pressure relief valves may discharge to a lo er pressure process system or vessel capa&le of handling the discharge. Although this type of disposal system is infre%uently used for pressure relief in the vapor state$ it is recommended for discharges that contain corrosive materials$ hich may damage a closed pressure relief system$ or materials that should &e recovered. Care should &e ta5en to ensure that high<velocity stream from a pressure relief valve does not impinge on internal vessel fittings or displace trays or other internal e%uipment. D...3 Piping ith 'ection -.9 of this Guide.
Piping should &e designed in accordance D.3 2i%uid Discharge D.3..
2i%uid Discharge to an Onsite Bnoc5out Drum
Onsite 5noc5out drums shall have an effective li%uid reservoir si#ed to retain the re%uired li%uid relief discharge rate for a minimum period of .9 minutes. A vapor discharge line to the flare and a vapor space shall &e provided to handle that portion of the li%uid discharge e"pected to vapori#e. D.3.... Pressure Relief ;alves
Relief valves shall &e selected to meet the re%uirements of 'ection -.- of this Guide. D.3...3 Piping
Piping shall &e designed to meet the re%uirements of 'ection -.9 of this Guide. D.3...4lashed ;apor Disposal from the Onsite Bnoc5out Drum
The onsite 5noc5out drum shall &e provided ith a vapor line to a closed pressure relief system. The vapor line shall include a car<sealed open &loc5 valve and a &lind. The drum and piping shall &e designed to ithstand the ma"imum &ac5 pressure of the closed pressure relief system under ma"imum emergency relief conditions. The vapor space shall &e designed to separate the li%uid from the entrained vapor of the material that is discharged into the drum.
Engineering Guide
Title Document No.

EG-310
Page No.
1 D.3...0
Bryan D. Hum !rie" 2i%uid Disposal
1#1#$001
$1 %& $'
Onsite li%uid 5noc5out drums shall &e provided ith a pump and a spare each si#ed to empty a half<full drum in t o hours. The pump shall discharge to a suita&le slop line or slop tan5. D.3.3 2i%uid Discharge to a 2o er Pressure Process 'ystem or ;essel
A lo er pressure process system or vessel shall &e capa&le of handling the re%uired li%uid relief discharge rate. 4lashing at the lo er pressure should &e ta5en into consideration. D.3.3.. Pressure Relief ;alves
Relief valves shall &e selected to meet the re%uirements of 'ection -.- of this Guide. D.3.3.3 Piping
Piping shall &e designed to meet the re%uirements of 'ection -.9 of this Guide. D.3.2i%uid Discharge to an Oily /ater 'e er
2i%uid discharge to an oily ater se er shall &e via a &lo do n drum and shall &e non<volatile and non<to"ic. The re%uired li%uid relief rate shall &e ithin the oil removal capa&ility of the oily ater treating system. D.3.-.. Pressure Relief ;alves
Relief valves shall &e selected to meet the re%uirements of 'ection -.- of this Guide. D.3.-.3 Piping
Piping shall &e designed to meet the re%uirements of 'ection -.9 of this Guide. D.3.0 2i%uid Discharge to a Pump 'uction
+t is preferred that the re%uired li%uid relief &e discharged to the upstream reservoir from hich the pump ta5es suction. The li%uid relief may discharge directly into the pump suction line. 6o ever$ sufficient cooling shall &e provided to prevent a temperature rise of the li%uid recycled through the pump hen the relief valve opens.
Engineering Guide
Title Document No.

EG-310
Page No.
1 D.3.0..
Bryan D. Hum !rie" Pressure Relief ;alves
1#1#$001
$' %& $'
Relief valves shall &e selected to meet the re%uirements of 'ection -.- of this Guide. D.3.0.3 Piping
Piping shall &e designed to meet the re%uirements of 'ection -.9 of this Guide. Primar! %eferences are directly relevant to the design. "t#er References are documents hich are either referred to &y Primary References or hich only parts of may &e applica&le. The applica&le document)s* should &e consulted for specific applications. Primary References AP+ 93: AP+ RP 93. AP+ 'td. 3::: Other References A+ChE A+ChE AN'+ ,-..AN'+ ,-..E AP+ 'td. 93A AP+ 'td. 93D A'(E 'ection ;+++ 'i#ing$ 'election$ and +nstallation of Pressure<Relieving Devices in Refineries Guide for Pressure<Relieving and Depressuring 'ystems ;enting Atmospheric and 2o <Pressure 'torage Tan5s1 Nonrefrigerated and Refrigerated Guidelines for 6a#ard Evaluation Procedures$ 3nd Edition Guideline for Evaluating the Characteristics of E"plosions$ 4lash 4ires and ,2E;E Chemical Plant and Petroleum Refinery Piping Gas Transmission and Distri&ution Piping 'ystems 4langed 'teel 'afety Relief ;alves Commercial 'eat Tightness of 'afety Relief ;alves (etal<to<(etal 'eats ,oiler and Pressure ;essel Code ith

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Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie"

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie"

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie"

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie"

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie"

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie"

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie"

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie"

' %& $'

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie"

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie"

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie" Ground 4lares

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie"

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie"

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie"

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS

Bryan D. Hum !rie" Air +ngression Prevention

PROPRIETARY INFORMATION For Authorized Company Only

Occidental Oil and Gas Corporation

PRESSURE RELIEF SYSTEMS