GBH Enterprises, LTD.: Process Engineering Guide

GBH Enterprises, Ltd.
Process Engineering Guide:

GBHE_LEP_0214
Pressure Systems, Pressure Relief Streams

& Protective Devices, Pressure Vessels
Process Information Disclaimer
Information contained in this publication or as otherwise supplied to Users is

believed to be accurate and correct at time of going to press, and is given in
good faith, but it is for the User to satisfy itself of the suitability of the Product for
its own particular purpose. GBHE gives no warranty as to the fitness of the
Product for any particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability for loss, damage or personnel injury
caused or resulting from reliance on this information. Freedom under Patent,
Copyright and Designs cannot be assumed.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
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Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com

Process Engineering Guide: Pressure Systems, Pressure Relief
Streams & Protective Devices,
Pressure Vessels
CONTENTS
1 PRESSURE SYSTEMS
1.1 INTRODUCTION/SCOPE
1.2 GENERAL REFERENCES
1.3 RESPONSIBILITIES
1.3.1 SITE RESPONSIBLE ENGINEER

1.3.2 PRESSURE SYSTEMS INSTRUCTIONS
2 PRESSURE RELIEF STREAMS AND PROTECTIVE DEVICES
2.2 ADDITIONAL RESPONSIBILITIES
2.2.1 FORMAL DESIGN REVIEW OF PRESSURE RELIEF

STREAMS (& ASSOCIATED RELIEF EQUIPMENT)
2.2.2 REGISTRATION
2.2.3 PERIODIC INSPECTION
3 PRESSURE VESSELS
3.2.1 FORMAL DESIGN REVIEW OF PRESSURE VESSELS

3.2.2 REGISTRATION

1 PRESSURE SYSTEMS
1.1 Introduction/Scope
A local procedure is required for the design, manufacture, installation,

Registration, commissioning, Periodic Inspection, repair, modification, re-
rating and operation of all the site's Pressure Equipment and Systems.
Additional working instructions may be required to support this procedure.
All site, facility and project appointments as well as responsibilities for

commissioning, operating and inspection must be listed.
1.2 General References
National and local regulations for Pressure Systems
1.3 Responsibilities
1.3.1 Site Responsible Engineer
The Site Responsible Engineer is required to read and understand the

documents listed in clause 2 and to carry out the engineering
responsibilities listed below. Carrying out the responsibilities may require
support from a Responsible Mechanical Engineer or Functional Advisor.
The Site Responsible Engineer is to make sure that:
(a) Pressure Systems are designed, approved, manufactured,

installed, maintained, repaired, modified and re-rated in accordance
with national and international standards.
(b) Inspection during manufacture, repair or modification is by the

relevant national or local authority or by an inspection service
approved by the Site Responsible Engineer or Project Manager as
appropriate.
(c) Pressure Systems and Equipment is given either Registered or

non-Registered status.

Registered Pressure Systems equipment is to include:
• all equipment covered by national or local legislation;
• all pressure vessels except those listed as exempt from Registration;
• atmospheric pressure Storage Tanks which are in a location where a leak

or failure could cause an Unacceptable Situation;
• all Pressure Relief Streams and associated relief equipment with the
possible exception of items listed as exempt from Registration;
• piping systems which are outside site boundaries or in a location that a

leak or failure could cause an Unacceptable Situation;
• equipment other than the above such as silos, hoppers, furnaces and
components of non-registered piping systems such as bellows, piped-in
flexibles, non-return valves and spray injection desuperheaters /coolers,
which for particular reasons the site consider appropriate for Registration.
(d) The design of new, modified or re-rated Pressure Systems

equipment which is registered is verified by a knowledgeable and
independent Design Authority to make sure that the design is
satisfactory for the specified conditions of use.
Note: Some items listed may be exempted from verification of

design at the discretion of the Responsible Mechanical Engineer or
Project Manager as appropriate.
(e) Registered Pressure Systems equipment is Periodically Inspected

by a competent inspection service within an agreed period.
Note: The Site Responsible Engineer or nominee is to sign

or countersign a written report of the inspection and any
repairs.
(f) Formal appointments are made of the engineers and organizations

responsible for Registration, design verification and Periodic
Inspection of Pressure Systems equipment.

1.3.2 Pressure Systems Instructions
Pressure Systems instructions for a site or facility may be issued as part of

documentation on site engineering, site operation or site safety, but
wherever they are included there is to be references to make sure
responsible people are aware of them.
The Site Responsible Engineer (where appropriate together with the

Operating Manager) is to issue, and make sure they conform with site
working instructions, Pressure Systems instructions that include the
following key topics in single or combined documents:
• Registered Piping Systems;
• Pressure Relief Streams and Protective Devices;
• Testing of relief devices;
• Pressure vessels;
• Atmospheric pressure Storage Tanks;
• Silos, Hoppers, Furnaces, etc.;
• Transport Containers and other portable tanks / vessels;
• Flexible Pipes or Hoses on Hazardous Duties;
2 PRESSURE RELIEF STREAMS AND PROTECTIVE DEVICES
This section includes particular requirements for the Formal Design

Review, Registration and Periodic Inspection of Pressure Relief Streams
and Non-pressure Protective Devices which are additional to the
management systems required in all Critical Pressure Systems, and the
appointments and general responsibilities listed.

2.2.1 Formal Design Review of Pressure Relief Streams (&

Associated Relief Equipment)
(a) For all new Pressure Relief streams the following information is
submitted to the Design Authority for Formal Design Review
• Engineering line diagram(s) showing all relevant details.
• Process engineering documents on protection against over and

under pressure.
• Protective Device data sheet(s), sizing calculations (including inlet

& outlet piping pressure drops), and blow off test certificates.
• Data sheets and/or drawings of Associated Relief Equipment.
• Detailed piping drawings of the Pressure Relief Stream with

information on discharge reaction forces, and piping flexibility loads
on the Protective Devices for systems subject to significant
variation from ambient temperature.
• Data sheets or drawings of equipment protected by the Pressure

Relief Stream.
• As appropriate, reports on in-service testing and inspection of

Protective Devices.
(b) The Design Authority gives written approval of the design of all new
Pressure Relief Streams (e.g. Design Verification Certificate) before
use of the equipment.
(c) If there should be doubts about the suitability of an Existing

Pressure Relief Stream then a Formal Design Review is requested.
(d) For Modifications to Pressure Relief Streams the requirements of

(a) and (b) apply irrespective of whether the Pressure Relief Stream
has been previously reviewed.

2.2.2 Registration
(a) Pressure Relief Streams and Associated Relief Equipment are

Registered and Periodically Inspected as required.
(b) Documentation is provided in the Registration file as listed in

registry.
(c) The identification of Pressure Relief Streams for the purpose of

Registration is initially via the schedule of Protective Devices.
(d) For each Pressure Relief Stream and its Associated Relief
Equipment, components are identified and numbered separately
wherever it is necessary to have different schemes and intervals for
Periodic Inspection.
Note: (Figures 1 and 2) for simple and complex

arrangements
(e) Pressure Relief Streams / Protective Devices on non-pressure

equipment such as silos are registered. Vents or panels to protect
against dust explosion are examples of this type of equipment.
(f) Instrumented devices and systems providing protection against

excess high or low pressure (such as those which isolate
equipment from the source of pressure) are registered as Pressure
Relief Streams.
(g) Registration is provided for non-pressure Protective Devices and

systems which protect the pressure envelope of equipment against
high or low excess temperatures, high or low fluid levels (e.g. boiler
plant) or adverse fluid composition which would cause rapid
corrosion, erosion or cracking.
Note: Other devices may control the course or rate of a

chemical reaction, and where such devices and systems
make use of instrumentation, reference should be made in
the register.

2.2.3 Periodic Inspection
(a) Periodic Inspection is considered during Registration for all

components of Pressure Relief Streams and Associated Relief
Equipment.
(b) Pressure Relief Streams are categorized according to the risk of

blockage or fouling due to the system contents:
• Category 1 - Clean, non-corrosive duty.
• Category 2 - Blockage or fouling possible but not likely.
• Category 3 - Vulnerable to blockage or fouling.
(c) GBHE guidance on inspection intervals for the different Categories

is considered when deciding on the maximum intervals between
Periodic Inspections.
Note: GBHE gives detailed guidance on inspection intervals for

each of the following parts of Pressure Relief Streams. - Protective
Devices; Pressure Relief Stream Piping; Associated Relief
Equipment; Non-pressure Protective Devices; Other Equipment.
(d) Periodic Inspection of Protective Devices includes the following:
 Examination of the condition of Safety Valves and Bursting

Discs as-removed and before cleaning, and judgment of how
they would have behaved on-line.
 Testing of Safety Valves and other reseatable devices in-situ

or on removal (as far as is practicable) as a guide to the
pressure at which they would have operated in service. If
any device fails to operate within acceptable limits, the
cause should be investigated.
 All devices are cleaned, examined, shop reconditioned, and

tested.

 Maintaining Records of all observations, testing,
maintenance and replacement in the Registration file.
 the Periodic Inspection interval should be reviewed based on

the observations and test results.
Note: See GBHE "Periodic Testing, Examination and

Reconditioning of Safety Valves"
(e) Details of the routine testing, calibration and maintenance of any

Instrumented Protective Systems for Pressure Protection are
available to the Inspection Authority, and records of these are
placed in the Registration file.
(f) Pressure Relief Stream Piping is examined for blockage of the main
flow passages and accumulation of debris and it is ensured that
any drains, purge connections and instrument tappings are clear.
The pipework and its supports and restraints should also be
inspected.
(g) All other equipment such as scrubbers, separators, flare stacks and
relevant ancillaries to these items are to be inspected and tested to
ensure their continuing ability to meet the design requirements of
the Pressure Relief Stream.
(h) Associated Relief Equipment is inspected to check that orifice sizes

have not enlarged by such means as erosion or corrosion that
unauthorized changes in equipment have not been made and that
the design basis of the Pressure Relief Stream has not been
otherwise altered.
(j) The complete Pressure Relief Stream is inspected before

commissioning (or re-commissioning after overhaul) to check that it
has been assembled as designed. A record that this inspection
should be kept in the registration file.

3 PRESSURE VESSELS
This section includes particular requirements for the Formal Design

Review, Registration and Periodic Inspection of Pressure Vessels which
are additional to the management systems required, for all Critical
Pressure Systems, and the appointments and general responsibilities.
For more detailed guidance contact GBHE: ’Pressure Equipment’
3.2.1 Formal Design Review of Pressure Vessels
(a) For new and Modified Pressure vessels the following information is
submitted to the Design Authority for Formal Design Review:
• A complete set of design calculations. Calculations

should include for cyclic duty and state design life if
calculations exist.
• A complete set of drawings.
• Other documents required to complete the description

of the design.
• A mechanical data sheet, where applicable.
• Documentation (for example a Design Verification

Certificate) listing the design conditions, with
references to other relevant documents.
(b) The Design Authority carries out a Formal Design Review of the
Pressure Vessel to confirm that it is suitable for the conditions given in
(a), and in particular that:

• the appropriate code design procedures have been followed.
• any non-code design procedures are appropriate and

correct.
• appropriate non destructive testing and pressure testing has

been specified.
• no essential design requirements have been omitted.
Note: Formal Design Review is primarily concerned with the

integrity of the pressure envelope, but may by agreement be
extended to cover other aspects (such as the loads imposed
on the shell from internal trays of distillation columns).
(c) Formal Design Review certification is issued before any new, Modified,
re-rated, or replacement Registered Pressure Vessel is returned to
service (for Modifications, the review need cover only those parts
affected by the changes).
Note: Repairs to Pressure Vessels should restore them to

their original design and specification using original or
equivalent materials, fabrication & welding standards,
heat treatment, etc. Otherwise the work is treated as a
Modification.
(d) Formal Design Review is waived for small low pressure vessels
(where stored energy is the only hazard) only if all of the following
apply:
• the contents are non-flammable, non-toxic gases and/or

liquids.
• the design pressure does not exceed 15 bar g.
• the product of design pressure (bar g.) and gross volume
(m3) does not exceed 25 bar m3.
• exemption is approved by the Site Responsible Engineer (or
Project Manager) after careful consideration of all relevant
factors.
• details are recorded in the Registration file.

(e) A Formal Design Review is considered if there are doubts about the
suitability of an existing Pressure Vessel, such as where the
Registration file does not contain adequate information.
(f) Adequate documentation and design confirmation is obtained for

proprietary Pressure Vessels. Formal Design Review is required for
vessels with potential hazards because of pressure and/or the nature
of their contents, but alternatives may be considered for small series or
regularly produced equipment such as intercoolers, aftercoolers and
line filters on low hazard duties. (see GBHE Ordering and Design
Verification of Proprietary Vessels)
3.2.2 REGISTRATION
(a) All Pressure Vessels (with the possible exception of those listed in
Appendix A) are Registered and Periodically Inspected as required
by GBHE, and also that:
• Pressure Vessels are identified from flowsheets, line diagrams and

equipment lists, taking care not to overlook additions arising from plant
modifications.
• used Pressure Vessels designed for other duties are not Registered and
put into service until they have been:
- approved by the Design Authority with a Formal Design Review;
- thoroughly inspected and approved by an inspection authority.
(b) Documentation is provided in the Registration file as listed in

registry.

(a) Periodic Inspection is considered during Registration.
(b) Pressure Vessels and associated equipment should be allocated inspection

grades based on the ability to predict behavior in service and / or the
expected rate of deterioration.
(c) GBHE guidance on inspection intervals for the different grades is considered
when deciding on the maximum intervals between Periodic Inspections.
(d) Periodic Inspection of Pressure Vessels includes:
• checking the condition by visual inspection, supplemented as

necessary by other techniques and measurements to determine
fully the extent of loss of thickness, pitting, cracking or other
defects;.
• consideration of both internal and external features;
• internal inspection by entry where access is possible, except where

satisfactory alternative means of internal examination are available
and where the Site Responsible Engineer waives entry;
• Hydraulic (not pneumatic) pressure testing when it is the only

practical way of demonstrating integrity (e.g. for complex tubular
arrangements). Pressure testing only confirms the ability of the
equipment to hold pressure at the time of the test and does not
provide equal reassurance of long term integrity to that gained from
thorough examination of surfaces. As such it is not a generally
preferred means of examination for any equipment.
Note: The in service pressure testing of equipment instead

of inspection requires a written procedure and Risk
Assessment.

(e) Pressure Vessels which have limited life (due to high temperature creep,
or to fatigue cracking due to pressure cycling or frequent start up and shut
down) are categorized and inspected as advised.
(f) All non-registered Pressure Vessels are inspected externally at

appropriate intervals. Adequate inspection and maintenance should take
place to ensure their continuing fitness for purpose.
(G) Specialist advice is sought for Pressure Vessels of particular construction

and / or containing certain types of chemicals.


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GBH Enterprises, Ltd.

Process Engineering Guide:

Pressure Systems, Pressure Relief Streams

Process Information Disclaimer

Information contained in this publication or as otherwise supplied to Users is

Web Site: www.GBHEnterprises.com

1.3.1 SITE RESPONSIBLE ENGINEER

2 PRESSURE RELIEF STREAMS AND PROTECTIVE DEVICES

2.2.1 FORMAL DESIGN REVIEW OF PRESSURE RELIEF

3.2 ADDITIONAL RESPONSIBILITIES

3.2.1 FORMAL DESIGN REVIEW OF PRESSURE VESSELS

Web Site: www.GBHEnterprises.com

A local procedure is required for the design, manufacture, installation,

All site, facility and project appointments as well as responsibilities for

1.2 General References

National and local regulations for Pressure Systems

1.3.1 Site Responsible Engineer

The Site Responsible Engineer is required to read and understand the

The Site Responsible Engineer is to make sure that:

(a) Pressure Systems are designed, approved, manufactured,

(b) Inspection during manufacture, repair or modification is by the

(c) Pressure Systems and Equipment is given either Registered or

Web Site: www.GBHEnterprises.com

• all equipment covered by national or local legislation;

• all pressure vessels except those listed as exempt from Registration;

• atmospheric pressure Storage Tanks which are in a location where a leak

• piping systems which are outside site boundaries or in a location that a

(d) The design of new, modified or re-rated Pressure Systems

Note: Some items listed may be exempted from verification of

(e) Registered Pressure Systems equipment is Periodically Inspected

Note: The Site Responsible Engineer or nominee is to sign

(f) Formal appointments are made of the engineers and organizations

Web Site: www.GBHEnterprises.com

Pressure Systems instructions for a site or facility may be issued as part of

The Site Responsible Engineer (where appropriate together with the

• Registered Piping Systems;

• Pressure Relief Streams and Protective Devices;

• Testing of relief devices;

• Atmospheric pressure Storage Tanks;

• Silos, Hoppers, Furnaces, etc.;

• Transport Containers and other portable tanks / vessels;

• Flexible Pipes or Hoses on Hazardous Duties;

2 PRESSURE RELIEF STREAMS AND PROTECTIVE DEVICES

This section includes particular requirements for the Formal Design

Web Site: www.GBHEnterprises.com

2.2.1 Formal Design Review of Pressure Relief Streams (&

The Site Responsible Engineer is to make sure that:

• Engineering line diagram(s) showing all relevant details.

• Process engineering documents on protection against over and

• Protective Device data sheet(s), sizing calculations (including inlet

• Data sheets and/or drawings of Associated Relief Equipment.

• Detailed piping drawings of the Pressure Relief Stream with

• Data sheets or drawings of equipment protected by the Pressure

• As appropriate, reports on in-service testing and inspection of

(c) If there should be doubts about the suitability of an Existing

(d) For Modifications to Pressure Relief Streams the requirements of

Web Site: www.GBHEnterprises.com

The Site Responsible Engineer is to make sure that:

(a) Pressure Relief Streams and Associated Relief Equipment are

(b) Documentation is provided in the Registration file as listed in

(c) The identification of Pressure Relief Streams for the purpose of

Note: (Figures 1 and 2) for simple and complex

(e) Pressure Relief Streams / Protective Devices on non-pressure