CHAPTER 9

9-1. Relief Concepts

Problem:
Can gate valves be placed between a vessel relief and its vessel?
Answer:
Only when tied to another relief, so the vessel always
Has active relief.

This design may be necessary if relief line plug frequently.

9-2. Definitions2
Problem:
Describe the process of creating a vacuum in a storage vessel as a result of condensation.
Develop an example to illustrate the potential magnitude of the vacuum.
Answer:
Example of process conditions
creating a vacuum in a storage
tank:
Ambient temperature
320 F

a)Open v-1 and v-2

b)Connect steam line to
v-2 to steam out volatiles

9-3. Location of Reliefs

Problem:
In the future it is anticipated that insurance rates will be set as a function of the safety of a plant.
Illustrate the kinds of plant statistics that you would cite to reduce your insurance costs.
Answer:
Data which should demonstrate the effectiveness of a company
safety program may include:
a)OSHA recordable accidents per year
b)Lost time accidents per year

c)Insurance claims due to injury or

plant damage.
d)Effectiveness of safety program
(i)Special safety features in plant
(ii)Maintenance program to ensure safety
features work adequately
(iii)Audit results from surprise safety audits
9-4. Relief Types and Characteristics
Problem:
Give four examples of situations requiring a combination of spring-operated reliefs in series
with rupture discs.
Answer:
When to use this type of relief system:
a)When handling very toxic vapor,
when minor weep through
spring loaded device could be
hazardous.
b)Very corrosive service where fumes
could easily damage the spring
loaded device.
c)When relief occurs at some pressure,
but it is desired not to relieved all
the way down to atmospheric pressure.
d)When vessel contents cannot be contaminated
with air, The rupture disk gives absolute
isolation from atmospheric contamination.
9-5. Relief Scenarios
Problem:
PSV-2 of Figure 9-6 is a relief to protect the positive displacement pump P-1. If the fluid being
handled is extremely volatile and flammable, what design modifications would you make
to this relief system?
Answer:

Use cooling water to volatization and the chance of ignition. Reliefs, even from pumps, may
require control devices such as condensers, scrubbers, flares, carbon adsorbsers, incineration, etc.
9-6. Data for Sizing Reliefs
Problem:
One defense against runaway reactions is better process control. Using the system illustrated
in Figure 9-6, what control features (safeguards) would you add to this reactor system?
Answer:
In this example, a runaway would occur if there were a loss
of cooling. Safeguards would ascertain the proper functioning
of the cooling system and/or mechanisms. For example:
a)A flow device to alarm when cooling water fails.
b)RPM indicator to alarm when agitator fails.
c)An interlock to ensure agitator and cooling water
is on before monomer is added
d)An alarm (also a monomer shut-down) when the
cooling water value is open 100%.
e)Temperature readouts throughout the reactor (top to bottom)
to ensure temperature profile is normal.
Note: Others may be developed by the students.
9-7. Relief Systems
Problem:
If a scrubber is installed after PSV-1b and it has a pressure drop of 30 psig, how would this
affect the size (qualitatively) of this relief system?
Answer:
It would increase the size of the relief value area needed,
because the the pressure drop across it is low. In this circumstance,
you would design for a P of only 5 psig from the scrubber to the vessel.
A balanced bellows might also be included.
9-8
Problem:
Referring to Problem 9-7, qualitatively describe the algorithm you would use to compute the
relief size for this system.
Answer:
An algorithm might be developed as follows:
a) Develop relief scenarios
(i) Full steam into the reactor
(ii) Full nitrogen into the reactor
(iii) Full cooling water into the reactor

(iv) Full pump capacity to the reactor

(v) A runaway reaction under worse case conditions
(vi) A fire around the vessel
b) Acquire appropriate data
c) Size reliefs for each scenario, choosing two phase
flow when appropriate (runaway).
d) Choose the worse case
9-9
Problem:
Review Figure 9-14, and determine the locations for relief devices.

Answer:
Relief locations for figure 9-14
a) PD pump discharges.
b) On cooling water lines (expansion) of l charge.
c) Distillation column, drum, and reboiler.
d) On steam limes (If low pressure steam developed via
regulator from higher pressure system)
9-10
Problem:
Review Figure 9-15, and determine the locations for relief devices.

Answer:
Relief locations for figure 9-15
a) On the two vessels
b) Discharge of the 2 PD pumps
c) On the cooling water line between the exchangers
d) Steam lines next to the vessels (If low pressure steam developed
via regulator from high pressure system)
9-11
Problem:
Review Figure 9-14 and Problem 9-9 to determine what types of relief devices should be
used at each location.
Answer:
a) Relief value (liquid service)
b) Relief value (liquid service)
c) Rupture disk followed by safety relief. Use
Balanced bellows if scrubber in-line.
d) Safety value for steam
9-12
Problem:
Review Figure 9-15 and Problem 9-10 to determine what types of relief devices should be
used at each location.
Answer:
a) Rupture disk followed by safety relief. Use
balanced bellows if scrubber in-line.
b) Relief value (liquid service)
c) Relief value (liquid service)
d) Safety value for steam
9-13
Problem:
Review Figure 9-14 and Problems 9-9 and 9-11, and make recommendations for total
containment systems.
Answer:
Total containment System for Distillation:
The type of containment depends on the toxicity and/or flammability
of the relief:

a) If non-flammable, non-toxic, and infrequently vented

(which is the normal case), vent to the atmosphere.
b) If flammable and/or toxic, then the system would be based
on the cost performance analysis of various types of
containment systems, i.e, catch tank, scrubber flare,
incinator, condenser, etc.
c) Water relief and steam relief would go to ground.
9-14
Problem:
Review Figure 9-15 and Problems 9-10 and 9-12, and make recommendations for total
containment systems.
Answer:
Total Containment System for Extraction:
The answer is roughly the same as for problem 8-13. A component change might
Be appropriate, however. The engineer could use a simple condenser and cooler
System, followed by catch tanks. Water and steam relief would go to ground.
Notice: try to design a simple, yet practical containment system. Dont make
The operation of the containment system too complex. It hazardous itself,
Possibly more hazardous than a simple catch tank containment system.
9-15
Problem:
Using the results of Problems 9-9 and 9-11, determine the relief scenarios for each relief
device.
Answer:
Relief scenarios for each device:
a) Size relief for pump on and block values turned off.
b) Size for following conditions:
(i)cooling coils are filled with water
(ii)cooling water values are both shut
(iii)steam added to reboiler and feed stream (under these
Conditions, the condenser is hit with a full stream of hot vapor.)
c) Check 3 scenario:
(i)No value is opened full, so column sees pressure
of source at rate computed by choked flow
(ii)Full heat on feed stream and reboiler wit
all exit lines blocked in
(iii)Fire
d) Steam feed values stuck full open, regulator fails so high
pressure steam enters system, and a block value or steam

trap is fully closed on the exit line. If the exchanger is pipe,

pressure will probably not burst the pipe, therefore relief
is not required. If steam goes to jacket, relief will be required
if Psteam > Pjacket.
9-16
Problem:
Using the results of Problems 9-10 and 9-12, determine the relief scenarios for each relief
device.
Answer:
Relief scenarios for each device:
a) Check 3 scenarios:
(i)Nitrogen value fails full open
(ii)Steam line breaks in vessel with value
full open
(iii)Fire
b) Full capacity of pump with discharge line blocked
via values.
c) Assume water is blocked into exchangers and the
exchange is hit with live stream
d) High pressure regulator fails and high pressure steam enters
the line (If this is pipe, the high pressure may not be high enough
to burst the pipe. Therefore, relief may not be necessary)
If steam goes into the reactor jacket, the high pressure will very likely
exceed the jacket pressure rating. Relief is necessary to protect the jacket.

9-17
Problem:
Develop sketches of reactor vent systems for the following four cases:

Answer:

918 p v=0.04 1b / ft

=0.02 cp

pv=64.5 1 b/ ft

dia= 400 microns

9-18
Problem:
Determine the vapor velocity inside a horizontal knockout drum for the following three
systems:

Answer:

Pv=0.03 lb/ft3
Pv=64.0 lb/ft3

0.01
dia=300 micron

a) The obscissa of figure 9-13 found using equation

9-2
C(Re)2= 0.95 x 108 cp2
pv d3 p (Pc-Pv)
(1b/fr3) fr3
=

(300 x

M2

10-6

3.28ft

= 9.84 x 10 -4ft

C(Re)2 =

0.95 x 108 cp2

(0.03) (1b/ft3) (9.84 x 10-4 ft)3 (64.0 0.03 1b/ft3

(1b/ft3)3 (ft3)

= 1.7 x 103

(0.01 cp )2

Using figure 9-13 the drag coefficient = 2.0

Equation 9-1 applies:

v v
gdp()
v C
ud=1.15
63.971 b/ ft 3

1.15 (32.17 ft /sec 2)(9.84 x 104 )

=

=6.68 ft/sec

b)

pv=0.04 1 b /ft

pv=64.5 1 b/ ft

=0.02 cp

dia = 400 microns

The abscissa of figure 8-11 is found using equation 9-2

C(Re)2=

0.95 x 108 cp2

v d3 p ( v

(1b/ft3) ft3

dp = (400 x 10-6)

v )

3.28 ft

= 1.31 x 10-3 ft
m
C(Re)2 = 0.95 x 108 cp2
(1b/ft3) ft3

=1380

(0.04 1b/ft3)(1.31 x 10-3)(64.5- .04 1b/ft3)

(0.02 cp2)

Using figure 9-13, the drag coefficient = 2.3

Equation 9-1 applies:
(32.17 ft / sec 2)(1.31 x 103 )(64.5.04 1 b /ft 3)
ud=1.15
( 0.04 1 b/ft 3 )(2.3)
= 6.25 ft/sec
c) v = 0.05 1b/ft3 =0.01 cp
v = 50 1b/ft3 dia = 350 microns
= 1.15 x 10-3 ft

C(Re)2 = 0.95 x 108 cp2

(0.05 1b/ft3)(1.15 x 10-3)(50- .05 1b/ft3)

(1b/ft3) ft3

(0.0 / cp2)

= 3600
Drag coefficient = 1.7
2
3
3
(32.17 ft / sec )(1.15 x 10 )(50.05 1 b/ ft )

ud=1.15
3

( 0.051 b / ft )(1.7)

= 5.36 ft/sec
9-19
Problem:
Determine the height of a flare, assuming various maximum heat intensities at ground level at
the specified distances from the flare, for the following three cases:

9-19 Equation 9-4 applies:

2
4
q X f 960 Qm M
120 df 2
qf

Hf =60 df + 0.5

Answer:

(Note: M should be considered dimensionless, 960 is actually a constant 960

btu/1b In this way, dimensions are correct.
(

Hf = ft -

BTU
BTU
) /( 2
)
2
f t hr
f t hr

5 (960)(60,000) 30

( 4 )(2000)
a) Hf = -60(2) + 0.5
( 120 )( 2 ) 2

Hf = -120 + 0.5 (328)

= 44.0 ft
2

10 (960)(70,000) 60

(4 )(3000)
b) Hf = -60(3) + 0.5
( 120 ) ( 3 ) 2

ft

Hf = -180 + 0.5 (429) = 34.5

5 (960)(80,000) 80

( 4 )(4000)
c) Hf = -60(5) + 0.5
( 120 )( 5 ) 2

Hf = -300 + 0.5 (636)

= 18.0 ft

9-20
Problem:
Describe the advantages and disadvantages of a buckling pin relief valve. See Grossel and
Louvar (2000).
Answer:
Advantages:
(a) The pin buckles at a precise pressure.
(b) Maintenance is simple, i.e. periodically check to see that the
pin is in place and that it is not corrodes.
(c) Pins are easy to replace, even if you need to change
The rating of the value.
Disadvantage:
(a) Once open the value stays open.
(b) When it opens first and completely (Under same circumstances
This may be a problem).
9-21
Problem:
Describe the advantages and disadvantages of a pilot-operated safety valve. See Grossel and
Louvar (2000).
Answer:
Advantages: The set pressure can be very close to the operating pressure compared
To conventional and balanced bellows values.
Disadvantages:
(a) The process fluid needs to be claim.
(b) The seals must be resistant to the fluids being handled.
(c) The seals and values must be appropriate maintained .
These disadvantages are also true for spring operated reliefs.

9-22
Problem:
Describe the advantages and disadvantages of a rupture disc followed by a spring-operated
relief valve. See Grossel and Louvar (2000).
Answer:

Advantages:
(a) The rupture disc gives a positive seal, therefore, used
When handling toxic materials.
(b) The spring-operated value closes when the pressure
decreases below the blow-down pressure, This
prevents the continued release when only using
a rupture disc.
Disadvantages:
(a) The pressure device between the rupture disc and the springOperated relief needs to be installed and checked frequently.
a pin-hole leak in the rupture disc double the required
relief pressure.
(b) When engaged a fragments of the rupture disc may plug the
Spring operated relief. A non-fragmenting rupture
Disc must be specified.

9-23
Problem:
When using a rupture disc followed by a spring-operated relief, it is important to periodically
check the pressure gauge to be sure that there is no pinhole leak in the rupture disc. Describe
several methods to satisfy this requirement.
Answer:
Solution:
(a) Add this required check to a daily operating check list.
Also add a management audit to be sure the check
Is conducted daily.
(b) Add an instrumented device, e,g. pressure indicator and alarm,
That is alarmed when the pressure increases.
9-24
Problem:
When designing the inlet piping to a relief valve, what pressure losses are recommended? See
API 520, Sizing, Selection, and Installation (1994).
Answer:
Solution: Not more than 3% of the set pressure.
9-25
Problem:
The outlet piping of a relief system is normally supported to resist two mechanical stresses.
What are these two stresses? See API 520, Sizing, Selection, and Installation (1994).

Answer:
Solution:
a) Support is needed to resist the weight of the relief system.
b) Support is also needed to resist time reaction forces during
the relief. This reaction force includes both static pressure
and momentum (sce API 520).

9-26
Problem:
Sometimes isolation valves are needed between the vessel and the relief. What management
system is recommended for isolation valves? See API 520, Sizing, Selection, and Installation
(1994).
Answer:
Solution:
a) Strict management procedures should be im place that prohibits the inedvertment closing
of isolation valves im relief piping.
b) The procedures should require that the opening and closing the valves be done by an
authorized person.
c) An updated list of all isolation valves should be maintained and managed.
d) Isolation valves should be periodically checked for proper positioning and management.

9-27
Problem:
Describe a runaway reaction scenario that is the result of a sleeper reaction. See Grossel and
Louvar (2000).
Answer:
Solution:
Sleeper reactions are usually the result of an operator error. Two examples are: a) the
addition of two immiscible reactant when the agigator mistakenly in the of position , and b) the
addition of the reactant to the reaction mass when the temperature is mistakenly lower than the
required to the imitiate by starting the agitator and adding heat respectively.

9-28
Problem:
Describe a tempered runaway reaction. See Grossel and Louvar (2000).

Answer:
A tempared runaway reacting maintain a cmatent temperature , when the energy exiting the
relief device is equal to the energy generated in the reactor due to the exothermic reaction. The
reaction heat is absorbed by the evaporation of th violatile components. The vapor pressured in
the tempered system can be typically characterized by an antoin type equation.
9-29
Problem:
Describe a runaway that is gassy. See Grossel and Louvar (2000).
Answer:
A system that is characterized as gassy has no volatile solvents or reactant. The pressure
buildup is due to the genearation of nonecondensible gas such as N2 or CO2 or HCL.
9-30
Problem:
Describe a runaway that is a hybrid. See Grossel and Louvar (2000).
Answer:
A hybrid system is the combination of a tempered and a gassy system. Under runaway
conditions, the pressure increases due to the vapour pressure of the volatile components as well
as from the generation of noncondensible gaseoves products.
9-31
Problem:
Identify the problems with the relief valve configurations shown in Figure 9-16.

Solution:

Problem 9-31 (Continued)

Problem 9-31 (Continued)

LOWAR & SEVILLA

BSIT-2A