CODES, LAWS, STANDARDS AND PRACTICES Process Equipment ‘Pressure Vessel Codes American Society of Mechanical Engineers (ASME) ASME VII Div. 1 Most common (Div. 2 for more sophisticated design approaches) ASME Section 1 for boilers and super-heaters ‘Other countries have their own codes (Britain, Germany, Holland, France, Japan). All have similar design equations and stress limits. Codes: Provide design equations for minimum thickness of different sections of vessol Provide Tables of allowable/design stresses for many materials as a funetion of temperature Provide methodologies to include for corrosion allowance, manufacturing tolerances, welding, testing, atc, etc. Pressure vessel code applies to all equipment under pressure (towers, tanks, heat exchangers, etc.) Piping Code similar to Pressure Vessel Code, but some slight differences in equations, streaa levels etc. cagmacev mas — oe rsaus Pant Dain CODES, LAWS, STANDARDS AND PRACTICES Code Requirements The ASME Boiler and Pressure Vessel Code divides pressure vessel into two classes Section I of the Code deals with fired boilers, steam. generators and heat transfer fluid vaporizers. Section VIII of the code deals with non-fired pressure vessels Pressure relief system and pressure relief device requirements are quite different depending upon which section of the Code applies to a particular installation Mechanical equipment, piping, low-pressure vessels and tanks, and other equipment items not covered by the ASME Code also require overpressure protection Cagesagen vas eat ieCODES, LAWS, STANDARDS AND PRACTICES ASME Seetion 1 Section I of the ASME Code applies to Rollers and Fired Steam or Vapor Generators 2 Section I does not apply to process heaters Scction I clearly statos where safety valves are required, what capacity they should have relative to the boller output, and how they ehould be installed Paragraphs PG-67 through PG-73 contain the relief system requirements | PG-67.1 defines the basic requirement that boilers be equipped with one or more eafety valves Paragraph PG 68 covers pressure relief system requirements for super- heaters and re-heaters Paragraph PG-71. Section I does not allow any block valves to be installed under the safety valves and requires the safety valve be installed directly on the steam drum or super-heater Cagenaacen os aaa a | oe HALL PERE oF WARM LONNIE YORHBG PRESUME | HUGE) 1 Thus gure conorm with the requirements ofthe ASHE Power Hoder Code Sect 1. 2 The peenane consitons shown ave So ey (ste) wmv isin on pene BOB | 2B Alowali at pensive laerances will ln accordance wih He appeals cle. | Sulnweaigate opal ae ecuer prea: are meneieeeaeenee | STs ewer sr vs en Se -SEsa Desire 90% of . set pressure Unica vosrae wed uppoved Dy Wsruiment eon 6, Desi pressure may be lamer tan SOAWF | CaRnaaGeN ma TS Serie rrseuns Plant DesigsCODES, LAWS, STANDARDS AND PRACTICES ASME Section VIII Section VIII of the ASME Code deals with unflred pressure vessels. ‘The sections of the Code which address pressure relief systems are Paragraphs UG-125 through UG-194, mandatory Appendix 11, and non mandatory Appendix M Section Vill of the code is much more gencral its basic requirements than is Section I. Since Section VIII is nonspecific, the user must often employ some degree of judgment or interpretation in complying with the code in a given situation. ‘The key code provisions are as follows: Paragraph UG-128a states that all pressure vessels shall be provided with pressure relief devices Paragraph UG-125b unfired steam generators should be equipped with pressure relief devices in accordance with Section I. However, this must be read in conjunction with Paragraph U-1G of the Section VIII introduction. This indicates that on fired steam generators may be constructed to cither Section I or Section VII, and specifically requires that heat exchangers employed for steam generation in conjunction with petroleum processing must be constructed according Section VII. 5 cemiges tegmcerig cogmagey vam Coats Sees 1710 Process Pat Design Notes 1 Yam LON HORII EEL OE aes —| EE 1, This figure conforms with the requirements of he ASME Hodes ard Pressure Vernal Cade Sect. VI, Preszure Vesela, “The prestire conditions shaw are fr pres vllef wales intalle gn a preseare vessel, Allowable vot premcure tolerates will be in accordance with the applicable codes MAW? ia equal to or greater than ie design pressure for a enmncident design tempersture. “Th serig oma ayes ihr ore presse. Opertng panic ont i eed OO fet pressure unless reviewed and aypovved ly instrument engineer. Bee ASME Boiler and Pressure Veasel Code Sect. VII Dis. 1 Appendix M for guidance an Siamdowm and pressure dillerendals Desi pressure may be lower than BMACODES, LAWS, STANDARDS AND PRACTICES ‘The key code provisions are as follows (continucd) Paragraph UG-125h states that when overpressure is external to a vessel and under such positive control that overpressure in the vessel cannot occur, the pressure relief device need not be directly installed on the vessel Paragraph UG-133c states that it interconnected vessels connected by adequate piping valves with no valves may be treated as one ‘vessel for pressure relief purposes - Paragraph UG-135¢ allows use of block valves between a vessel and it takes pressure relief device if the valves are interlocked so that relief capacity cannot be reduced below the required capacity or if the conditions defined in Appendix M are met Appendix M-5 states that a block valve may be installed betweon the vessel and ite pressure relief device for the sole purpose of maintenance and repair. This block valve must be attended. whenever it is closed and must be locked or seal opened at all other times org Retin, CagaaAGeN waa “nme Seren 1210 jaeCODES, LAWS, STANDARDS AND PRACTICES Storage Tanks. Storage tanks with design pressures exceeding 15 psig are subject to ASME Section VIII. requirements for both construction and overpressure protection. Tanks with design pressure but less than 15 psig are usually built in accordance with API and Standards 620 or 650. Normal and emergency venting requirements for low pressure storage tanks are discussed in API Standard 2000. In some applications the sizing of pressure relief devices for fire exposure is governed by OSHA or NFPA procedures. cagagEeNn wuss raat pe CODES, LAWS, STANDARDS AND PRACTICES Adherence to Codes It is cometimes a matter of judgment az to what minimum pressure relief requirements must be met to be in compliance with code. It must be clearly understood however that a pressure relief system does not satisfy code requirements unless all the associated clements (pressure relicf device, sct pressure, installation, etc.) are in compliance with the applicable sections of the code for that particular service. _ ASME Section I is very specific and leaves little room for interpretation of pressure relief aspects. wy Section VIM is not necessarily so clear. For example, if the basic statement of UG-125a that all code vessels must have their own pressure relicf devices were Hterally followed, many redundant pressure relief valve would have to be installed. This question has been addressed in the subscquent paragraphs that modify the basic statements of paragraph UG- 1253. * Sa we cageageN woe cane Some neCODES, LAWS, STANDARDS AND PRACTICES The ASME Code is a new construction code. This means that an installation must be in accordance with the, version of the code in effect at the time it was built, but does not need to be retrofitted if the code changes unless local laws require otherwise. This issue is straightforward for pressure vessels. themselves. However, new pressure relief devices are often required, due to changes in process conditions or throughput, and the question arises as to what version of the code then applies. Generally with the exception of Liquid trim pressure relief valves, the portion of the Code applicable to pressure relief systems has been fairly stable over the past 20 te 50 years. For any future reviews the following criteria should be followed cageagen : : vas omstgaresense Preses Pht Posen CODES, LAWS, STANDARDS AND PRACTICES Existing Systems - Replacement in Kind When there is a maintenance or replacement of an existing pressure relief device with another of identical capacity and set pressure, an upgrade to current code is not required. Obviously, any deficiencies, if found, should be corrected. Existi stems - in Pressure Relief Device Size or Service When changes in process operation arc made which required a different size of pressure relief device, or a change in the relieving fluid, the new pressure relief device should be specified and installed in accordance with current code, laws, and company standards New Services For new services, the latest edition of the code should be applied CARMAGEN 3 seeruuaesees 310 Proce Haat DeionCODES, LAWS, STANDARDS AND PRACTICES Definitions Sot Pressure . ‘Set pressure is the inlet gauge pressure at which a pressure rellef s designed or adjusted to start operating under service Souditions ‘Accumulation ‘Accumulation is the pressure increase over the maximum allowable ‘working pressure of a vesscl while its pressure relief devices are eperating. Generally this is expressed us a percentage of the vessel ‘Overpressure ‘Gverpressure is the pressure increase over the set pressure of a pressure relief device when the device is operating seed asa Pera hee erence, ios the prom ler series set to overpressure and accumulation are the same. Blowdown ‘Blowdown is the difference between the set preesure and the re- seating pressure of 4 pressure relleve valve expressed as 8 percentage of set pressure. Cold Differential Test Pressure Cold differential test Pressure is the pressure at which a pressure relief walve is set to open when it is adjusted on a test stand. This value includes any corrections which must be made for service conditions such as high service temperature or back-pressure. ‘Often this value is the same as the ect preseure, but may be masts cageagen wn Soa nonmetnae CODES, LAWS, STANDARDS AND PRACTICES ASME Section I Paragraph PG-67.3 details pressure scttings of safety valves. One or more safety valves om the boiler proper shall be sct at or below the MAWP. If additional safety valves all used, the highest pressure setting shall not exceed the MAWP by more than 3%. The complete range of pressure settings of all the saturated steam safety valves on a boiler shall not exeeed 10 percent of the highest pressure of which any valve is set. Pressure setting of safety relief valves om high temperature water boilers may exceed this 10 percent range. PG-67.2, details accumulation pressures. ‘The safety valve or safety relicf valve capacity for each boiler shall be such that the safety valve will discharge all the steam that can be generated by the boiler without allowing the pressure to rise more than 6% above the highest pressure at which any valve is set and in no case to moze than 6% above the maxitnum allowable working Pressure. Althongh the code appears to allow 6% accumulation, the interpretation of mest safety valve manufacturers and state inspectors is that the code allows safety valve sizing only fo 3% accumulation. cCagmaGen vias eine cn rast BeCODES, LAWS, STANDARDS AND PRACTICES ASME Section I PG-72.1, details blow-down requirements All safety valves shall close at a pressure not lower than 96% of their set pressure, except that all drum safety valves installed on a single boiler may be set to reseat at a pressure not lower than 96% of the set pressure of lowest set drum safety valve. For boilers whose maximum allowable working pressure is less than of 100 psig, the safety valves may be set to reseat at a pressure 4 psi less than their set pressure. The minimum blow-down in any case shall be 2 psi. For spring loaded pop safety valves with set pressures between 200 hundred and 300 psig, both inclusive, the blow-down shall not be less than 1 percent of the set pressure. At (Commer Hnpneenng ine. Cagpeaqgev war ‘Course Sees 1210 someman mgt CODES, LAWS, STANDARDS AND PRACTICES ASME Section VII UG-134, details pressure settings of pressure relief devices, When a single pressure relieving device is used, it shall be sct to operate at a pressure not exceeding the MAWP of the vessel ‘When multiple pressure relieving devices are used, only one device need be set at or below the MAWP. The additional _ device may be set to open at higher pressures, not excceding 105% of the MAWP of the vessel Supplemental devices permitted as protection against ‘excessive pressure caused by exposure to fire or other unexpected sources of external heat may be set to operate at pressure not in excess of 110 percent of the MAWP of the vessel. This does not apply when the vessel is also used to protect against contingencies other than fire, in which case ‘the upper limit reverts to 105%. cAgnaAGEN ms ora as - Procace Plant DesignCODES, LAWS, STANDARDS AND PRACTICES. ASME Section VII UG -125 details accumulation pressures, : All pressure vessels other than unfired steam boilers shall be protected by pressure relicf device that shall prevent the pressures from rising more than 10% or 3 psi, whichever is greater, above the MAWP, except as noted below When multiple pressure relieving devices are provided, they shall prevent the pressure from rising more than 16% or 4 psi, whichever is greater above the MAWP Where an additional hazard can be created by exposure of the pressure vessel to fire or other unexpected sources of external heat, supplemental pressure relief devices may be installed to protect against excessive pressure. Such supplemental pressure relieving devices shall be capable of Preventing the pressure from rising more than 21% above the MAWP. If the same pressure relief device is used to protect against both fire and non fire cases, the allowable accumulation is 21% for the fire case, and 10% (16% for multiple valves) for ather contingencies. ASME Section VIII does not specify blow-down tolerances. Most manufacturere adjust blow down to approximately 7% of set pressure. Blowdown may be specified for other values, but in practice is difficult, if not impossible todo. (Come Fapiering ne cagmagen vat Cau Serie 170 Seocuae Poe Beige CODES, LAWS, STANDARDS AND PRACTICES Won ASME Equipment Atte er ce promi ier eer poettaton ofaan ASAE: spond aciding fed Heatere ag z ae EE cnet eee ae eq iy MAWE for an ASME Vessel. Nameplates and Code Stamps In order for pressure relief system to comply with the ASME code, the pressure relief devices must also comply with ASME construction and testing Fequirements and bear the official code stamp. When pressure relief devic are manufactured, the manufacturer attaches the nameplate with the appropriate V (Section I}, UV (Section VIII ), and NB (National Board of Boiler and Pressure Vessel Inspectors) stamps embossed on it. The code stam] shows that the Device as been constructed, tested and certified to criteria. The NB stamp certifies that capacity test have been reviewed and approved by the National Board of Pressure Vessel Inspectors. Depending on not have to be'p pplicable state laws, the ASME and NB stamps may or may iysically present on the existing pressure relief device It is the purchaser's responsibility to request code stamps on pressure relicf devices who's service requires them. Manufacturers will not autpmatically provide ASME and NB stamps and scc ASME required nameplate, even though the pressure relief valve being supplied has been tested and certifiedCODES, LAWS, STANDARDS AND PRACTICES Code Application Guidelines Paragraph UG-125a of Section VIII effectively says that all ASME vessels must be protected from overpressure by ASME approved pressure relief devices. The basic requirement of the code is that overpressure protection must always be present. ‘Therefore, for all ASME vessels, there must be a pressure relief device on the vessel or installed on other piping or equipment which can be identified as protecting a vessel from overpressure. cagrsagen — ee —eeeas eee CODES, LAWS, STANDARDS AND PRACTICES Interconnected Vessels ASME Code allows pressure relief devices mounted on one vessel to be used to protect other vessels if some basic conditions are met Isolation From Sources Of Overpressure Vessels Open to Atmosphere Vessels With No Relief Case a cagraagen vas amare 130 eooan Fest BeesCODES, LAWS, STANDARDS AND PRACTICES Block Valves n ASME Section I states that no block valves are allowed in Section I services. Section VIII, paragraph 135¢ allows the use of block valves under pressure relief valves for inspection and repair purposes provided adequate sparing and administrative procedures exist so the vessel is always protected. The use of a single pressure relief valve with a block as described in Section VIII, Appendix M, is not usually considered desirable and should only be used when there is no practical alternative. An ¢ffective block valve administration policy is an extremely important part of the ownership of pressure relieving systems. . comer tegen oe cagnsagen vss ene rs ce reo best CODES, LAWS, STANDARDS AND PRACTICES Multiple Pressure Relief Valve Applications Both Section I and Section VII. of the ASME Code state conditions under which multiple pressure relief valves may be used. Each section of the code also states the allowable set pressures and overpressures. Interconnected Vessels Section VIII. of the ASME code allows interconnected vessels to be protected by a single pressure relief valve provided the vessel or are connected by adequate piping not containing valves. However, Paragraph UG-135¢e of Section VIII allows block valves for maintenance if the installation procedure and criteria required in Appendix M, is met.CODES, LAWS, STANDARDS AND PRACTICES Process Line Block Valves Generally no block valves are allowed between two or more process vessels rotected by a pressure sellef device mounted on one of the vessels. In some Einited cases, process line block valves may be allowed as follows: — Block valves may be in a line connecting vessels protected by the same Bresiure soief device ifthe biock valves are Yor equipment maintenance purposes only If closure of any one block valve could cause an overpressure case in any vessel in the 5 tha block valve must be lecked or sealed open or pressure relief devices protecting against closure of the block valve must be provided. ~ Any Block vaive which is locked or scaled open must be attended when ‘closed and the procedures outlined in Appendix M of ASME Section VIIT must be followed ~ Potential overpressure in n systeim which might occur if 4 locked or sealed open block valve was improperly closed should be zeviewed. If there is a potential for pressurizing the equipment to a pressure of 1.5 times its MAWP, separate pressure relief should be provided and locked open block valves should not be relied upon For liquid filled systems, situations where locked or sealed block valves may not be required if blocked in fire is the only viable relief ease are discussed later ee mage Ragnering te cagmagen veer ‘Course Serer 1310 srecu Pie bere CODES, LAWS, STANDARDS AND PRACTICES Equipment Blockage for Maintenance In many units, block valves are provided for maintenance isolation. These valves are closed only when piece of equipment is being prepared for maintenance. Normally securing a piece of equipment for maintenance requires venting and draining and purging or steaming out the equipment and is generally a plant operator attended operation. Each piece of equipment does not necessarily need to be individually protected for the contingency of being locked in by two or more block valves. i many emcee ne CaRageNn a meaCODES, LAWS, STANDARDS AND PRACTICES Pressure Profiles When a single pressure relief device installation protects two or more interconnected vessels, the effects of flowing and static pressure losses must be considered. Hydraulics Blockage In designing pressure relief systems for interconnected vessels, care must be taken to ensure that the connecting piping is adequate for relief conditions. Plugging If the service is subject to sudden plugging or reduction in flow arca in the piping connecting a vessel to the vessc! which has the pressure relief device, then providing pressure relief devices for both vessels should be considered. cAgMaGgEN ws ten : nate ene aoeemee et EMERRGEEENE < ee = erento scna ola Sembee ange rene Dore Beng I et >See sir es eam PelesCODES, LAWS, STANDARDS AND PRACTICES Non ASME Equipment - Fired heaters Heater tubes are generally protected by pressure relief valves located elsewhere in the system. These valves should be set to open before the short term design pressure (elastic design pressure] is exceeded, with due allowance for the system pressure profile. Non ASME Equipment - Centrifugal Pumps Pumps shall be protected from overpressure if the maximum discharge Pressure exceeds the pump casing design pressure, the pump’s discharge Piping design pressure, all the MAWP of any vessels in the discharge piping system. Noa ASME Equipment - Centrifugal Compressors Centrifugal compressors must be protected with pressure zelief devices in all cases where the maximum discharge pressure exceeds the maximum casing design pressure defined by the compressor vendor. cCagmagen ves a Gane ameriTe : recta bees CODES, LAWS, STANDARDS AND PRACTICES Non ASME Equipment - Positive Displacement Equipment With few exceptions, positive displacement pumps and compressors require discharge pressure relief devices. Their set pressure is normally governed by the need to protect Piping or downstream equipment, although in isolated cases the cylinder or casing desiga all the machine itself may be limiting. . Non ASME Equipment - Steam Turbines Frotection requirements for steam turbine casings are dependent both on the inlet steam pressure level and the type of service. NEMA standards recommend full flow pressure relief valves on all turbines, however, there are no laws requiring it. + cagnaagen we Sos eeCODES, LAWS, STANDARDS AND PRACTICES Noa ASME Equipment - Piping Within process units, most piping is protected against overpressure by pressure relief valves installed on the process vessels. Systems consisting entirely of piping, where the piping is the component with the lowest design pressure, and which can be over pressurized, must be protected by pressure relief valves. The set pressure must not cxcced the pipe design pressure, with an allowable accumulation of 20 percent, corresponding to the ANSI piping code short term conditions. If there is also an ASME vessel in the system, the allowable ASME accumulation must not be exceeded. On.plot piping which cannot be over pressurized does not require pressure relicf valves. Off-plot piping, which can be isolated and left quid ful, should be equipped with pressure relicf valves to protect against thermal expansion due to solar radiation or heat input from tracing. Off-plot piping should also be protected against inadvertent valve opening if the piping is connected to high pressure systems. Off-plot piping does not require thormal relicf if administrative procedures are used to ensure the piping is drained, prior to being blocked in. To minimize disposal problems when thermal relief valves are installed, it ig recommended that the relief valve discharge be connected to the other side of one of the piping block valves. caresam rng cagagen vasa Couey 10 resent Peet utp CODES, LAWS, STANDARDS AND PRACTICES ‘Non ASME Equipment - Surface Condensers ‘The protection of steam turbine service condensers against ‘overpressure duc to loss of cooling should follow guidelines contained in the Heat Exchanger Institute (HERI) standards for steam surface condensers. The pressure rellef valve is sized to pass the full throttle steam to the condenser under normal operation. The maximum sct pressure is 10 psig., with allowable accumulation of 10%. ‘Non-ASME Vessels By definition, vessels which fall outside the jurisdiction of the ASME ‘Code include the following Mechanical equipment casings, such as for pumps, compressors, ete. * Vessels whose operating pressure is less than 15 psig ~ Vessels with a diameter of 6 in. or less ‘carmaven agree tn CagennaGeNn snes ure seen iio papa BactCODES, LAWS, STANDARDS ae AND PRACTICES ‘The ASME Code does not require process vessels be designed to withstand vacuum. However there are applications where a vesscl in normal pressure service may be submitted to vacuum. Preasures veszels in these applications should either be designed to withstand a full one all be suitably protected. Vessels which may be subjected to vacuum only as a result of steam-ont do not necessarily need to be provided with vacuum protection, Procedures may be uscd as a safeguard. However, such procedures have the same importance as block valve lockout procedures, should clearly state the requirements and be rigorously enforced ‘Vesscls which may be subjected to vacuum due to process causes should have somes form of vacuum protection, Conventional vacuum breakers often rely upon opening to atmosphere to provide vacuum protection. In process applications, this is often unacceptable, and high-quality vacuum regulators which would provide fuel gas or an inert gas to the vessel should be considered. If a vacuum regulator is used, it should be inspected and maintained as if it was a pressure relief device. For services for which it regulate alone is not considered sufficient, a backup vacuum breaker, set to open a higher vacuum than the regulator may be provided. 4 ‘comms nec, CARMAGEN vss ‘Courve Senex 1210 recess Past Deteh CODES, LAWS, STANDARDS AND PRACTICES ‘The Code is clear in requiring that an in the service vessel either have a pressure relief davice in service, or be continuously attended while it's relief device 1s being serviced. Some considerations which may lead to recommending a spare pressure relief valve include = Operating experience with a service or similar services that has shown, that pressure relief devices require maintenance at shorter intervals than the time between unit turnarounds ~ An operating situation in which failure of a particular pressure vessel rellef valve could itself force the shutdown of x major unit. - Knowa of suspected conditions which could contribute to pressure relicf valve damage or failure to res Appendix M of Section VIII permits removal of pressure relicf valves for inspection and repair while operation continues, provided that an operator remains in attendance for the peried in which the vessel is unprotected. With installed spare pressure relief valves provided, the use of a three-way switch rather than separate block valves is recommended. Alternatively, the use of a key lock system to ensure that at least onc block valve is always open under a relief valve is a system that has beea used~ successfully. st neems me cagnsagen ome ace ee Sparing PhilosophyCODES, LAWS, STANDARDS AND PRACTICES Administrative Procedures ‘Some areas where administrative procedures may be applicable are — Lock and car seal procedures for block valves associated with pressure relief valve: — Requirements that certain equipment be vented in drained when the equipment is removed from service — Requirements that equipment be continuously attended during certain operations ~ Limitations on modification of equipment without the proper engineering review of the effect on the pressure relief system. - Establishment of operating procedures for shutting down the unit under pre-identified failures or upset conditions Plant management has direct responsibility for accepting the risks that can be associated with administrative procedures and for assuring that administrative procedure policies are established and enforced coronene cageagen wmsr cots oasis : ‘Process Plat Design