1.

SELECTION OF DESIGN CODE & STANDARDS

The codes used in our country for the UFPV ( Unfired Pressure Vessels) are:
2. OVER PRESSURE PROTECTION
Safety by Pressure Relief Devices
A) General
All pressure vessels, irrespective of size or pressure, shall be provided with over pressure
protection in accordance with the requirements as per the code and system design
In addition following shall apply:
(1) It is the user’s responsibility to identify all potential over pressure
and the method of overpressure protection used to mitigate over pressure
(2) It is the responsibility of the user to ensure that the required over pressure
protection system is properly installed prior to initial operation.
(3) It is the responsibility of the user or his/her designated agent to size and select
the pressure relief device(s) based on its intended service.
The Intended service considerations shall include the following:
(a) normal operating and upset conditions
(b) fluids
(c) fluid phases

(4) The overpressure protection system need not be supplied by the vessel Manufacturer

(B) SET PRESSURE LIMIT

(a) When a pressure relief device is provided, it shall prevent the pressure from rising
more than 10% or 3 psi (20 kPa), ( whichever is greater) above the M.A.W.P.
 2. OVER PRESSURE PROTECTION
b) When multiple pressure relief devices are provided they shall prevent the pressure from
rising more than 16% or 4 psi ( whichever) is greater above Max Allowable Press

(c) When a pressure vessel can be exposed to fire or other unexpected sources of external
heat, the pressure relief device shall be capable of preventing the pressure rise more than
21% above Max Allowable pressure

(C) LOCATION
Pressure relief devices shall be constructed, located, Installed such that they are readily
accessible for testing, inspection, replacement & repair and so that they do not
become inoperative

D) Type of Pressure Relief Valves

All Safety relief valves shall be of the direct spring loaded type.
a) Pressure relief valve
It is a pressure relief device which is designed to re ‐close and prevent the further flow of fluid
after normal conditions have been restored
b) Non‐reclosing pressure relief device
It is a pressure relief device designed to remain open after operation.
c) Safety valve
It is a pressure relief valve actuated by inlet static pressure and characterized
by rapid opening or pop action ( Example‐Boiler)
2. OVER PRESSURE PROTECTION

d) Relief valve
It is a pressure relief valve actuated by inlet static pressure which opens in proportion to
the increase in pressure over the opening pressure.

e) Pilot operated pressure relief valve

It is a pressure relief valve in which the major relieving device that
combined with and controlled by a self‐actuated auxiliary press relief valve

D. Safety Valve Tolerance :

The set pressure tolerances, plus or minus, of pressure relief valves shall not exceed
2 psi (15 kPa) for pressures less than 70 psi (500 kPa) and 3% for pressures above 70 psi
(500 kPa)
2. OVER PRESSURE PROTECTION

E. No reclosing Pressure Relief Devices

(A) RUPTURE DISK DEVICES
A rupture disk is the pressure sensitive activation device and component that
breaks/open up at over pressure

SHAPE : Rupture disks may be designed in several configurations such as plain

flat,
prebulged, or reverse buckling.

HOLDER A rupture disk holder is the structure that encloses and clamps the
rupture disk in position.( Flange End, Screw etc.)

TOLERANCE : The burst pressure tolerance at the specified disk temperature

shall not exceed ± 2 psi (±15 kPa) for marked burst pressure less than 40 Psi
(300 kPa) and ± 5% for marked burst pressure above 40 psi (300 kPa)
2. OVER PRESSURE PROTECTION
INSTALLATION/Location :
When the rupture disk device discharges directly to the atmosphere then
(a) It is installed within eight pipe diameters from the vessel nozzle entry
(b) Length of discharge pipe not greater than five pipe diameters from the
rupture disk device; and
(c) the nominal diameters of the inlet and discharge piping are equal to or greater
than the stamped value on the device
d) The calculated relieving capacity of a pressure relief system shall not
exceed a value based on the applicable theoretical flow equation
at coefficient of discharge K equal to 0.62
(e) A rupture disk device may be used as the sole pressure relieving device on a vessel.
(f) A rupture disk device may be installed between a pressure relief valve & the vessel
Provided
* the combination of the pressure relief valve and the rupture disk device has enough
capacity to meet the following requirement:
*The marked capacity of a pressure relief valve (nozzle type) shall be 0.9 times rated
relieving capacity of the valve alone when installed with a rupture disk between
the inlet of the valve and the vessel

SET PRESSURE/Burst Pressure :

Not more than 105% of the allowable working pressure in any case
2. OVER PRESSURE PROTECTION

b) Pin Devices ( Obsolete and not in use now a days )

(a) A pin device may be used as the sole pressure relieving device on a vessel
* It can be installed between the vessel and pressure relief valve
In a manner same as rupture disc and capacity with all its limitation

Overpressure Protection by System Design ( Using Instrumentation)

We all are aware that the design, installation of the over protection system is a solely
responsibility of the pressure vessel user, they can either design the pressure vessel at
higher working capacity or adopt pressure relieving device by proper selection and
installation of instruments over pressure protection system. It ma be in combination of
both devices
I would like to recommend a High‐Pressure _Trip Systems for the pressure vessel
protection when run away reaction occurs .
The oxidation , Hydrogenation , polymerisation etc are few examples
It will be difficult to install relief valves that are large in size and to be open quickly enough
to avoid over pressuring the equipment.
2. OVER PRESSURE PROTECTION

THE TRIP CAN ISOLATE THE SUPPLY OF ONE OF THE REACTANT OR

HEATING SYSTEM AND OPEN UP COOLING CYCLE TO MINIMISE OVER
HEATING DUE TO REACTION FAILURE

It is to be noted here that Fire Relief vent protection is to be kept as it is when

replacing the conventional pressure relieving system, by trip system,

BASIC COMPONENTS OF A TRIP SYSTEM

The basic minimum requirements are :

a)Design, Select & Install A High ( rising) pressure sensor & Pressure
switch on the overhead Gas/Vapour /Vent line to operate and activate a relay
contactor
b) The relay contactor should stop the power supply line connected with the
heating device either by hot water pump or Hot oil pump
c) Select and install a solenoid valve associated with trip valve installed on the
steam/Hot water/Hot oil supply line use to heat Pressure Vessel or Reactor