Design for

Overpressure and
Underpressure
Protection

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Design for
Overpressure and
Underpressure
Protection
SLIDE PRESENTATION
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Outline
Introduction

Reliefs

Runaways

Safeguards

Introduction
Causes of Overpressure and
Underpressure
Reliefs
Effluent Handling Systems for
Reliefs
Runaway Reactions
Overpressure Protection for
Internal Fires and Explosions

For Further Information:

Refer to the Appendix
Supplied with this Presentation

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Causes of Overpressure
Operating Problem
Equipment Failure
Process Upset
External Fire
Utility Failures
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Causes of Underpressures
Operating Problem
Equipment Failure

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Presentation 1 of 3: Reliefs

Causes of
Overpressure/Underpressure
Presentation 1: Reliefs

Presentation 2: Runaways
Presentation 3: Safeguards

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Pressure Relief Devices

Spring-Loaded Pressure Relief Valve
Rupture Disc
Buckling Pin
Miscellaneous Mechanical
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Spring-Loaded
Pressure Relief Valve

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Rupture Disc

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Buckling Pin Relief Valve

Closed
Pressure Below
Set Pressure

Full Open
Pressure at or Above
Set Pressure

(Buckles in Milliseconds at a Precise Set Pressure)

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Simple Mechanical
Pressure Relief

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Types of Spring-Loaded
Pressure Reliefs
Safety Valves for Gases and Vapors
Relief Valves for Liquids
Safety Relief Valves for Liquids
and/or Gases
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Types of Safety Valves

Conventional
Balanced Bellows, and
Pilot-Operated

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Conventional Safety Valve

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Balanced Bellows Safety Valve

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Pilot-Operated Safety Valve

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Types of Relief Valves

Conventional
Balanced Bellows

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Types of Rupture Discs

Metal
Graphite
Composite
Others
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Rupture Disc and Pressure

Relief Valve Combination

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Vacuum Relief Devices

Vacuum Relief Valves
Rupture Discs
Conservation Vents
Manhole Lids
Pressure Control
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Conservation Vent

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Pressure or Vacuum Control

Add Air or Nitrogen
Maintain Appropriately

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Relief Servicing
Inspection
Testing

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Relief Discharges
To Atmosphere
Prevented
Effluent System

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Effluent Systems
Knock-Out Drum
Catch Tank
Cyclone Separator

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Effluent System (continued)

Condenser
Quench Tank
Scrubber
Flares/Incinerators
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Effluent Handling System

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Design for
Overpressure and
Underpressure
Protection
SLIDES WITH TEXT
Introduction
Reliefs
Runaways
Safeguards

This presentation includes technical information

concerning the design for overpressure and
underpressure protection. The presentation is designed
to help students and engineers to:

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Design for
Overpressure and
Underpressure
Protection
Introduction
Reliefs
Runaways
Safeguards

Understand the technologies, special engineering

devices, and methods that are used for the protection
against overpressure and underpressure (vacuum)
incidents,

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Design for
Overpressure and
Underpressure
Protection
Introduction
Reliefs
Runaways
Safeguards

Understand the root causes of overpressure and

underpressure incidents, and
Design plants with the appropriate features to protect
against overpressure and underpressure incidents.

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Six Sections
1. Introduction
2. Causes of Overpressure and
Underpressure
3. Reliefs
4. Effluent Handling Systems for Reliefs
5. Runaway Reactions, and
6. Overpressure Protection for Internal Fires
and Explosions
Introduction
Reliefs

This presentation is divided into six sections:

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Safeguards

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Six Sections
1. Introduction
2. Causes of Overpressure and
Underpressure
3. Reliefs
4. Effluent Handling Systems for Reliefs
5. Runaway Reactions, and
6. Overpressure Protection for Internal Fires
and Explosions
Introduction
Reliefs
Runaways
Safeguards

The Introduction button on your left will lead you to this

introduction and an explaination of the Causes of
Overpressure and Underpressure

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Six Sections
1. Introduction
2. Causes of Overpressure and
Underpressure
3. Reliefs
4. Effluent Handling Systems for Reliefs
5. Runaway Reactions, and
6. Overpressure Protection for Internal Fires
and Explosions
Introduction
Reliefs
Runaways
Safeguards

The Reliefs Button sends you to Sections 3 and 4,

covering Reliefs and Effluent Handling Systems for
Reliefs

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Six Sections
1. Introduction
2. Causes of Overpressure and
Underpressure
3. Reliefs
4. Effluent Handling Systems for Reliefs
5. Runaway Reactions, and
6. Overpressure Protection for Internal Fires
and Explosions
Introduction
Reliefs

The Runaways Button leads to a discussion on

Runaway Reactions, and . . .

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Safeguards

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Six Sections
1. Introduction
2. Causes of Overpressure and
Underpressure
3. Reliefs
4. Effluent Handling Systems for Reliefs
5. Runaway Reactions, and
6. Overpressure Protection for Internal Fires
and Explosions
Introduction
Reliefs
Runaways
Safeguards

The Safeguards Button will take you to a section on

Overpressure Protection fot Internal Fires and
Explosions

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Appendix Contains
Detailed Information

Introduction
Reliefs
Runaways
Safeguards

This design package includes an appendix with detailed

information for each of the sections of this presentation.
The appendix also includes an extensive list of relevant
references.

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Causes of Overpressure
Operating Problem

Introduction
Reliefs
Runaways
Safeguards

The major causes of overpressure include:

Operating problems or mistakes such as an operator mistakenly
opening or closing a valve to cause the vessel or system pressure to
increase. An operator, for example, may adjust a steam regulator to
give pressures exceeding the maximum allowable working pressure
(MAWP) of a steam jacket.

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Causes of Overpressure
Operating Problem

Introduction
Reliefs
Runaways
Safeguards

Although the set pressure is usually at the MAWP, the design safety
factors should protect the vessel for higher pressures; a vessel fails
when the pressure is typically several times the MAWP.

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Causes of Overpressure
Operating Problem
Equipment Failure

Introduction
Reliefs
Runaways
Safeguards

Equipment failures; for example a heat exchanger tube rupture that

increases the shell side pressure beyond the MAWP. Although the set
pressure is usually the MAWP, the design safety factors should protect
the vessel for higher pressures; a vessel fails when the pressure is
typically several times the MAWP.

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Causes of Overpressure
Operating Problem
Equipment Failure
Process Upset
External Fire
Utility Failures
Introduction
Reliefs
Runaways
Safeguards

Process upset; for example a runaway reaction causing high

temperatures and pressures.
External heating, such as, a fire that heats the contents of a vessel
giving high vapor pressures, and
Utility failures, such as the loss of cooling or the loss of agitation
causing a runaway reaction.

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Causes of Underpressures

Introduction
Reliefs
Runaways
Safeguards

The causes of underpressure or the inadvertent creation of a

vacuum are usually due to operating problems or equipment
failures.

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Causes of Underpressures
Operating Problem

Introduction
Reliefs
Runaways
Safeguards

Operating problems include mistakes such as pumping liquid

out of a closed system, or cooling and condensing vapors in a
closed system.

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Causes of Underpressures
Operating Problem
Equipment Failure

Introduction
Reliefs
Runaways
Safeguards

Equipment failures include an instrument malfunction (e.g.

vacuum gage) or the loss of the heat input of a system that
contains a material with a low vapor pressure.

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Part 1 of 3: Reliefs

Introduction
Reliefs

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Safeguards

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Pressure Relief Devices

Introduction
Reliefs
Runaways
Safeguards

Pressure relief devices are added to process equipment to

prevent the pressures from significantly exceeding the MAWP
(pressures are allowed to go slightly above the MAWP during
emergency reliefs).

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Pressure Relief Devices

Spring-Loaded Pressure Relief Valve
Rupture Disc
Buckling Pin
Miscellaneous Mechanical
Introduction
Reliefs
Runaways
Safeguards

The pressure relief devices include spring-loaded pressure relief

valves, rupture discs, buckling pins, and miscellaneous
mechanical devices.

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Spring-Loaded
Pressure Relief Valve

Introduction
Reliefs
Runaways
Safeguards

This is a sketch of a spring-loaded pressure relief valve. As the

pressure in the vessel or pipeline at point A exceeds the
pressure created by the spring, the valve opens. The relief
begins to open at the set pressure which is usually at or below
the MAWP; this pressure is usually set at the MAWP.

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Rupture Disc

Introduction
Reliefs
Runaways
Safeguards

This is a sketch of a rupture disc. In this case the disc ruptures

when the pressure at A exceeds the set pressure. Recognize,
however, that it is actually the differential pressure (A-B), that
ruptures the disc.

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Buckling Pin Relief Valve

Closed
Pressure Below
Set Pressure

Full Open
Pressure at or Above
Set Pressure

(Buckles in Milliseconds at a Precise Set Pressure)

Introduction
Reliefs
Runaways
Safeguards

This sketch shows a buckling pin pressure relief valve. As

shown, when the pressure exceeds the set pressure, the pin
buckles and the vessel contents exit through the open valve.
The rupture disc and the buckling pin relief valves stay open
after they are opened.

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Buckling Pin Relief Valve

Closed
Pressure Below
Set Pressure

Full Open
Pressure at or Above
Set Pressure

(Buckles in Milliseconds at a Precise Set Pressure)

Introduction
Reliefs
Runaways
Safeguards

The spring operated valves close as the pressure decreases

below the blowdown pressure. The blowdown pressure is the
difference between the set pressure and closing pressure.

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Simple Mechanical
Pressure Relief

Introduction
Reliefs
Runaways
Safeguards

A simple mechanical pressure relief is a weighted man-way

cover as shown in this sketch. Another mechanical relief is a Utube filled with water (or equivalent).

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Types of Spring-Loaded
Pressure Reliefs
Safety Valves for Gases and Vapors
Relief Valves for Liquids
Safety Relief Valves for Liquids
and/or Gases

Introduction
Reliefs
Runaways
Safeguards

There are three types of spring-loaded pressure relief valves:

Safety valves are specifically designed for gases.
Relief valves are designed for liquids, and
Safety relief valves are designed for liquids and/or gases.

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Types of Safety Valves

Conventional
Balanced Bellows, and
Pilot-Operated

Introduction
Reliefs
Runaways
Safeguards

There are three types of safety valves; that is:

Conventional,
Balanced bellows, and
Pilot-operated.

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Conventional Safety Valve

Introduction
Reliefs
Runaways
Safeguards

A conventional safety valve is designed to provide full opening

with minimum overpressure. The disc is specially shaped to
give a pop action as the valve begins to open.

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Balanced Bellows Safety Valve

Introduction
Reliefs
Runaways
Safeguards

A balanced bellows safety valve is specially designed to reduce

the effect of the back pressure on the opening pressure. As
illustrated in this sketch the differential pressure that is required
to open the valve is the pressure inside the vessel minus the
atmospheric pressure.

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Balanced Bellows Safety Valve

Introduction
Reliefs
Runaways
Safeguards

The bellows design allows the outside air and pressure to be on

the downstream side of the valve seal. Once the relief is open,
then the flow is a function of the differential pressure A-B.

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Pilot-Operated Safety Valve

Introduction
Reliefs
Runaways
Safeguards

A pilot-operated safety valve is a spring-loaded valve. As

illustrated, the vessel pressure helps to keep the valve closed.
When the pressure exceeds the set pressure (or the spring
pressure), the pressure on top of the valve is vented and the
valve opens.

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Pilot-Operated Safety Valve

Introduction
Reliefs
Runaways
Safeguards

The set pressure of this type of valve can be closer to the

operating pressure compared to conventional and balanced
bellows valves. The disadvantages, however, are (a) the
process fluid needs to be clean, (b) the seals must be resistant
to the fluids, and (c) the seals and valves must be appropriately
maintained.

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Pilot-Operated Safety Valve

Introduction
Reliefs
Runaways
Safeguards

These disadvantages are also true for spring operated reliefs.

Pilot-operated valves are not used in liquid service; they are
normally used in very clean and low pressure applications.

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Types of Relief Valves

Conventional
Balanced Bellows

Introduction
Reliefs

Relief valves (for liquid service) are either the conventional or

the balanced bellows types.

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Types of Rupture Discs

Metal
Graphite
Composite
Others
Introduction
Reliefs
Runaways
Safeguards

As illustrated, there are many different types of rupture discs.

They are especially applicable for very corrosive environments;
for example: discs made of carbon or Teflon coating are used
for corrosive service.

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Types of Rupture Discs

Metal
Graphite
Composite
Others
Introduction
Reliefs
Runaways
Safeguards

A rupture disc that is used for pressure reliefs may need a

specially designed mechanical support if it is also used in
vacuum service.

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Rupture Disc and Pressure

Relief Valve Combination

Introduction
Reliefs
Runaways
Safeguards

Rupture discs, as illustrated, are sometimes used in

combination with a spring operated relief device. In this case
the disc gives a positive seal compared to the disc-to-seal
design of a spring operated valve.

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Rupture Disc and Pressure

Relief Valve Combination

Introduction
Reliefs
Runaways
Safeguards

This is useful when handling very toxic materials where even a

very small release (through the seal) may be hazardous, or
when handling materials that polymerize.
The spring operated relief following the rupture disc reseats
when the pressure drops below the blow-down pressure.

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Rupture Disc and Pressure

Relief Valve Combination

Introduction
Reliefs
Runaways
Safeguards

This design, therefore, stops the discharge from the vessel.

The discharge is not stopped if only a rupture disc is used. This
design (rupture disc followed by a spring-operated relief) is
discouraged by some practitioners.

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Rupture Disc and Pressure

Relief Valve Combination

Introduction
Reliefs
Runaways
Safeguards

In this design, as illustrated, a pressure detection device (per

ASME Code), e.g., a pressure indicator, needs to be placed
between the disc and the spring-operated valve. This pressure
reading is checked periodically to be sure the rupture disc has
its mechanical integrity.

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Rupture Disc and Pressure

Relief Valve Combination

Introduction
Reliefs
Runaways
Safeguards

A pin-hole leak in the rupture disc could increase the pressure

on the discharge side of the disc. This is a major problem
because it increases the relief pressure, that is: the differential
pressure across the disc is the rupturing mechanism.

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Rupture Disc and Pressure

Relief Valve Combination

Introduction
Reliefs
Runaways
Safeguards

Another major problem with this design is the possibility that a

piece of the rupture disc could plug the discharge orifice of the
spring operated relief. This problem is prevented by specifying
a rupture disc that will maintain its integrity when it is ruptured;
that is, non-fragmenting.

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Vacuum Relief Devices

Vacuum Relief Valves
Rupture Discs
Conservation Vents
Manhole Lids
Pressure Control
Introduction
Reliefs
Runaways
Safeguards

Vacuum relief devices are: vacuum relief valves, rupture discs,

conservation vents, manhole lids designed for vacuum relief,
and pressure control.

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Conservation Vent

Introduction
Reliefs
Runaways
Safeguards

A conservation vent is illustrated in this sketch. As shown, it is

designed to relieve a pressure usually for pressures in the
region of 6 inches of water. It is also designed to let air into the
vessel to prevent a vacuum, usually a vacuum no more than 4
inches of water.

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Pressure or Vacuum Control

Add Air or Nitrogen
Maintain Appropriately

Introduction
Reliefs
Runaways
Safeguards

Sometimes pressure or vacuum control systems are used to add air or

nitrogen to the vessel to maintain a slight pressure. In this case, the
system needs to be appropriately maintained because a malfunction
could result in an overpressure or underpressure. In either case the
consequence could be a ruptured vessel.

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Relief Servicing
Inspection
Testing

Introduction
Reliefs
Runaways
Safeguards

Every relief device needs to be inspected and tested before

installation and then at predetermined intervals during its
lifetime. The interval depends on the service history, vendor
recommendations, and regulatory requirements, but it is usually
once a year.

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Relief Servicing
Inspection
Testing

Introduction
Reliefs
Runaways
Safeguards

Operating results and experience may indicate shorter or longer

intervals.
Records must be carefully maintained for every inspection and
test, and for the entire life of the plant.

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Relief Discharges
To Atmosphere

Introduction
Reliefs
Runaways
Safeguards

Discharges from pressure relief devices may be sent directly to

the atmosphere if they are innocuous, discharged in a safe
manner, and regulations permit it.

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Relief Discharges
To Atmosphere
Prevented

Introduction
Reliefs
Runaways
Safeguards

An additional option is to prevent releases by (a) designing

vessels with high MAWPs to contain all overpressure scenarios,
or (b) add a sufficient number of safeguards and/or controls to
make overpressure scenarios essentially impossible.

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Relief Discharges
To Atmosphere
Prevented
Effluent System

Introduction
Reliefs

The third option is to design an effluent system to capture all

nocuous liquids and gases.

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Safeguards

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Effluent Systems
Knock-Out Drum
Catch Tank
Cyclone Separator

Introduction
Reliefs
Runaways
Safeguards

An effluent system may contain a

Knock-out drum
Catch tank
Cyclone separator

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Effluent System (continued)

Condenser
Quench Tank
Scrubber
Flares/Incinerators
Introduction
Reliefs
Runaways
Safeguards

Condenser
Quench tank
Scrubber, and/or
Flares or incinerators
An effluent handling system may have any combination of the above unit
operations.

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Effluent Handling System

Introduction
Reliefs
Runaways
Safeguards

One effluent handling system is illustrated in this sketch. Every

element of an effluent system needs to be designed very
carefully. The design requires detailed physical and chemical
properties, and the correct design methodology for each unit
operation.

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Effluent Handling System

Introduction
Reliefs
Runaways
Safeguards

It should also be recognized that it is important to size the relief

appropriately, because the size of the entire effluent system is
based on this discharge rate. The design methodology is in the
references noted in the Appendix of this package.

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