Introduction to Reliefs

Prevention of accident
• Mainly 3 strategies:
1. Inherent safety
2. Better process control
3. Install relief systems (avoid pressure buildup)
• Relief concepts
1. to protect personnel
2. to minimize chemical losses
3. to prevent damage to equipment
4. to prevent damage to adjoining property
5. to reduce insurance premiums
6. to comply with governmental regulations
Relief Design Procedure
Concept of Runaway Reaction

In the chemical process industry, raw materials are converted into

commercial products.

Exothermic chemical reactions can lead to a thermal runaway if the

heat generation rate exceeds the heat removal rate.

The runaway itself is characterized by an exponential increase in the

rate of heat generation, temperature and pressure.

Pressure build-up during the runaway is caused by an increasing vapor

pressure of liquid components and by the production of non-
condensable gases.
Pressure versus time for runaway reactions: A) relieving
vapor B) relieving froth and C) closed reaction vessel
 What is Relief System?

The network of components around a relief

device, including the pipe to the relief, the
relief device, discharge pipelines, knock –
out drum, scrubber, flare or other types of
equipment which assist in the safe relief
process.
 Specifying relief locations
• Steps are:
1. Review every unit operation and
processing step.
2. Must anticipate potential problem that
result in increased pressure.
3. Install relief system at every potentially
hazardous point.
 Review process
• Example of questions asked:
What happens with loss of cooling,
heating, agitation etc.?
What happens if process is contaminated?
What conditions cause runaway
reactions?
What happens if operator makes an error?
What happens if a line fails (blockage
etc.)?
Guidelines for specifying relief location
• All vessels need reliefs, including reactors,
storage tanks, towers & drums.
• Blocked-in sections of cool liquid-filled lines that
are exposed to heat (eg. sun) or refrigeration
need reliefs.
• Positive displacement pumps, compressors, and
turbines need reliefs on the discharge side.
• Storage vessels need pressure & vacuum reliefs
to protect against pumping in or out .
• Vessel steam jackets are installed with reliefs to
prevent excessive steam pressures due to
operator error or regulator failure.
 Relief Types
The type of relief device is specified on the
basis of the details of the relief system,
process conditions and physical properties
of the relieved fluid.

Two general categories of relief devices:

- Spring Operated
- Rupture Discs
Two major types of spring operated valves:
- Conventional
- Balanced bellows
Major types of relief devices
Concepts of Conventional and balanced bellows Relief

On spring operated valves, the adjustable spring tension offsets the

inlet pressure.
The relief set pressure is usually specified at 10% above the normal
operating pressure.
Conventional type of valve is acceptable only when backpressures are
minimal.

The balanced bellows design is used for process situations where

substantial backpressures are present.
This type of valve keeps atmospheric pressure on the discharge side
of the relief.
Spring operated reliefs in series with rupture discs

Rupture discs are frequently installed in series to a spring loaded

relief

- To protect an expensive spring loaded device from a corrosive

environment

- To give absolute isolation when handling extremely toxic

chemicals

- To give absolute isolation when handling flammable gases

- To protect the relatively complex parts of a spring loaded

device from reactive monomers which could cause plugging

- To relieve slurries which may plug spring loaded devices.

 “Tell – tale gauge”

When rupture discs are used before a spring loaded relief,

a pressure gauge is installed between the two devices.

This “Tell –tale gauge” is an indicator which shows when

the disc ruptures.

The failure can be the result of a pressure excursion, or the

result of a pin hole due to corrosion.

In either case, this telltale indicates that the disc needs to

be replaced.
 Subcategory type of spring-loaded
relief
• Relief valve is primarily for liquid
service
• Safety valve is for steam, gas and
vapor service.
• Safety relief valve is used for liquid
and vapor service.
 Data for Sizing Reliefs

Physical property data and sometimes reaction rate

characteristics are required for making relief sizing
calculations.

When designing reliefs for gas or dust explosions, special

deflagration data for the scenario conditions is required.

A runaway reaction is another scenario which requires

special data.

Runaway reactions nearly always result in two phase flow

reliefs.
Vent Sizing Package (VSP)

The data required for making two phase flow relief calculations are
determined with a specially designated calorimeter called a Vent Sizing
Package (VSP).
Runaway reaction temperature data acquired
using the VSP
Runaway reaction pressure data acquired
using the VSP
 Relief Systems

After the relief type is chosen and the relief size is

computed, the engineer takes the responsibility for
completing the design of the relief system, including

- Deciding how to install the relief in the system

- Deciding how to dispose of the exiting liquids and
vapors.
Some Relief Installation Guidelines
Relief Design Consideration

A designer of relief systems must be familiar with governmental codes,

industrial standards and insurance requirements.

Another important consideration is the reaction forces generated when

the relieved materials flow through the relief system at high speed.

It is also important to recognize that company philosophy and the

regulatory authorities have a significant influence on the design of the
final disposal system, primarily from the standpoint of pollution. For this
reason reliefs are now rarely vented to the atmosphere.
 Knockout drums

• Knockout drums are sometimes called catch tanks or

blowdown drums.
• Serve as a vapor-liquid separator or holdup vessel for the
disengaged liquid.
• Vapor-liquid enters at one end vapor leaves at the
opposite end.
• Figure shows the relief containment system with
blowdown drum
• The blowdown drum separates the vapor from the liquid.
Dropout Velocity

The design method for sizing relief containment system with blow down
drum is based on the maximum allowable velocity for minimizing liquid
entrainment. The dropout velocity of a particle in a stream is
 Containment systems

Flares/Scrubbers
• Sometimes used after knockout drums
• Flares are used to burn combustible or toxic gas
to produce harmless combustion products.
• Scrubbers can also be used to scrub toxic vapor
into diluted solution or entrapped in a column.
Condenser
• If vapor is of high boiling point and value, it can
be condensed back to liquid.
• Simple, less expensive and minimize volume of
material for post-treatment.
 Question # 01
Give four examples of situations requiring a
combination of spring-operated reliefs in
series with rupture discs.
Question # 02
Refer to the of extraction systems and do the following:
Determine the locations of relief devices, the types of relief valve that
should be used at each location, the relief scenarios for each relief
devices and make recommendations for total containment systems.