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RELIEF SCENARIOS
Equipment failure, operator error or environmental conditions may led to an increase in
pressure , temperature or liquid level in the vessel/ process system , when these parameters
exceeds the safe working level of the system, there is a chance for the pipelines, vessels
and/or other components to rapture and release the process fluid/other flammable chemicals.
This may lead to huge accident with high consequences. So it is very important to identify the
possible relief scenarios of process system at the design stage itself and add all possible layer
of protection to avoid the same.
Some of the possible cause of relief includes,
Heating up of the vessel, this may be due to some external fire or any other possible
source of heat radiation on to the vessel surface. When vessel gets hated up the
flammable hydrocarbon in the pressurised vessel gets vapoured and thus leads to an
increase in pressure in the vessel.
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Operator error, it basically includes the failure in valve operation. Improper opening
or closure of value may lead to ,
1. If any valve in the liquid outlet line (upstream or downstream to pump P-101)
system is closed, the liquid level in the vessel will be increase this will lead to
the overpressure in the vessel and other associated components.
2. If the valve in the vapour outlet line is closed, the gas flowing out gets blocked
and thus leads to an increase in pressure in the vessel.
Instrumentation and valve failure, this includes the failure in the automatics control
systems or the valves itself got stuck. There are many possible ways , which include ,
1. If the level control valve (LCV-1) fails or the level indicator controller (LIC)
fails, i.e., either the level of the liquid in the vessel rise up (if LCV-1 stuck
closed) leading to the entry of the liquid into the vapour/gas line or more
amount of liquid gets out of the vessel (valve openings not controlled), which
may lead to the entry of the hydrocarbon gas into the outlet line causing
cavitation in pump,P-101.
2. If the temperature control valve (TCV-1) or the temperature indicator
controller (TIC) fails, i.e., the steam flow in the line got stuck (TCV-1 stuck
closed) leading to the decrease in the rate of vaporisation of the hydrocarbon
liquid due to insufficient heat .This can lead to a increase in the hydrocarbon
liquid level and causes same as the LCV-1 stuck close.
3. The failure of pressure control valve can be of,
a. PCV-2 stuck close, restricting the out flow of the hydrocarbon gas
from the vessel. This will lead to an increase in pressure in the vessel.
b. The pressure indicator controller (PIC) fails, so that PCV-2 remains
closed/open lead to an increase /decrease of pressure within the vessel.
Equipment failure, this includes the failure of the pumps and the pipe rapture. With
failure of the pump,P-101 the liquid outlet line gets stuck , leading to the increase in
the level of the liquid in the vessel and causes same as the LCV-1 stuck close. The
pipe rapture can be due to the external fire or due to the overpressure within the line.
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Utility failure, this include the failure of electric power, instrument air etc.
1. The electric failure will lead to the failure of the pump, instrumentation ands
the motor operated valves .If there is local power failure in which a single
component or system is effected the consequences will same as those
discussed above. But if there is a total power failure there is a possible chance
of double jeopardy.
2. The failure in supply of instrument air will lead to the failure of the all
controllers and transmitters and pressure regulating valves.
Double Jeopardy means if two or more events can be related to a common cause, the
combined effect is considered as a relief scenario. An example for the possible
scenario of for the given system is the total power failure to the entire system will lead
to the stoppage of the feeding of the liquid into the vessel and at the same time the
liquid taken out will also be stopped. But there is possible chance for the TCV-1 to be
in open position which will allow the steam to flow and thus resulting in an increase
in temperature of the liquid in the vessel and thus leading to over pressure. At the
same time the operating position of the PCVs will also have an impact on the
pressure in the vessel.
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2. By pass system with a double block valves and a bleed valve for each control
valve will help in the maintenance of the valves without shut down.
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release. But for considering the system/plant and workers safety as a whole these two
should be considered.
CONCLUTION
There are many possible relief scenarios for the given system which are discussed above. But
the maximum relief load is expected with the impact of the external fire on the vessel and
other components. At the same time probability of that event to happen is very low. Some of
the other possible scenarios are much likely to happen within the process but their
consequence is less. So while considering the overall risk each case is having its on important
in safe and reliable operation of the system.
The best possible layers of protections as discussed above will definitely help to improve the
safety and reliability of the system. But to attain the best result out of the system with all
mentioned layers of protection, the system components or equipments should be well
maintained. Each component should undergo periodic maintenance and since the system is
pressurised proper inspection must be carried out for all joints.
There can be more layers of protection to the system, like rapture disc at relief, flow control
valve to control the feeding rate of fluid, double block and bleed valve as a single unit etc.. ,
these being very expensive are not considered here. A stand by arrangement for both the
pumps will be as best arrangement, which helps in maintenance of the pumps and also the
failure of a pump wont be interrupt the process system. All these further recommendations
can only be implied after a cost effective analysis of the impact of these add-ons on the
process system.
REFERANCERS
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