Numberr 8 Major Accident

A H
Hazards B
Bureau
2018 MA
AHB
B Technoloogy Innovattion in Secuurity Unit

s e veso
co
ommon I PECT
INSP TION
N s e r i es
criteria
e

Presssure Relieef Systems

This publiication of the
t Europe
ean commu unity on CCommon In nspection Criteria
C is intended
i to
o
share knowledge abo out techniccal measure es and enfoorcement practices
p re
elated to major hazard d
control annd impleme entation off the Seve eso Directive. The crriteria havee been developed by y
Seveso insspectors to
o aid in disssemination of good en nforcementt and risk managemen
m nt practices
s
for the con
ntrol of majjor industriial hazards in Europe and elsewh
here.
This particcular issue highlights
s a numberr of issues s that are critical
c for successfullly reducing g
risks throough efficiient and correct pressure
p re
elief syste ems. Poorr design, inadequate e
maintenan nce and immproper ope eration andd training can
c all lead
d to the faiilure of pre
essure relie
ef
systems. Many majo or processs accidentss and inciddents have been cau used by re elief system
m
failures. N
Note that th
his docume ent is not in
ntended as a technica al standard nor as a summary
s or
replaceme ent of any existing
e standards on the matterr.

DEFINITION AND
D SCOPE
In this docuument, the term “Pressure Relief Sysstems”
is defined aas a combinaation of:
 One or more pressu ure relief devvices (PRD)
 The in nlet piping, i.e., the piping from m the
protectted vessel tot the inlett of the preessure
relief device
 The ou utlet or disccharge piping, i.e., the piping
from th he outlet off the pressurre relief devvice to
the atm mospheric venting
v poin
nt, the flaree, the
blow do own tank or any other syystem design ned to
handle the relief flo
ow
Pressure relief
r devicees protect a vessel against
a
overpressure. A presssure relief device can be a Figure 1. Reaactor with a pre
essure relief sysstem (U.S. Copyright © European Union, 2018
Chemical Saffety Board, 2018)
pressure reelief valve or a rupture diisk.
A pressure relief valvee is designed d to automaatically pressure rellief device actuated by
p b inlet static
reclose and d prevent thhe flow of fluuid when preessure p
pressure and d designed to b bursting the
o function by
has dropped below the t set preessure. Therre are r
rupture diskk that is insstalled in a rupture disk
various typpes of pressu ure relief valvves: spring‐loaded h
holder. The rupture disk
d device includes the
pressure reelief valves, safety
s (relief) valves, ballanced r
rupture disk and rupture disk holder.
pressure reelief valves, pilot‐operatted pressuree relief A pressure relief
r m may consisst of only one
system
valves. A deescription off these typess of pressuree relief p
pressure relief valve or rupture
r disk device, eith
her
valves is beeyond the sccope of this document
d an
nd can w or without dischargge pipe, on a single vesssel
with
be found iin literature. The criterria in this bulletin o line. A mo
or ore complex system mayy involve many
apply to all types of preessure relief valves. p
pressure‐relieving devvices disch harging in nto
A rupture disk device is a non‐recclosing differrential c
common heaaders to term
minal disposaal equipmentt.

Joint
Reesearch JRC 11456
67
Ceentre
Flare systems are not included as part of this CIC, The overpressure scenarios for which the PRS
even though they are normally regarded as a part of serves as a risk reducing measure should be listed.
the pressure relief system. For each scenario, the relief flow (to be
discharged) should be calculated. The PRS should
THE PURPOSE OF PRESSURE RELIEF be sized for the scenario with the largest relief
SYSTEMS flow.
A pressure relief system is normally installed where
it is necessary to avoid that the pressure in a plant, Using the largest relief flow, the minimal discharge
specific installations, or specific equipment exceeds area of the PRD is obtained. The PRD that are
limits for safe operation of the plant and affected installed should have an orifice area equal or larger
equipment. The system prevents escalation of than the minimal area required (for the ‘largest’
incidents by rapid pressure reduction and ensures scenario).
that released substances are removed from the Calculation should take into account phenomena
process in a safe manner without causing damage to such as the pressure losses in the inlet and outlet
personnel and equipment. Protection against piping and any backpressure present in the blow
overpressure is recognized as an important part of down system (if present).
process design.
Overpressure can occur due to any number of RISKS INTRODUCED BY THE PRESSURE
conditions. Inadvertent valve opening, closed or RELIEF SYSTEM
blocked outlets on vessels, utility failure, excess heat, When a pressure relief system discharges to the
transient pressure surges, and fire are all examples atmosphere, a hazardous situation can occur,
of situations that may cause overpressure. Pressure depending on the properties of the substances
relief valves are typically associated with boilers and released. For instance, a toxic or explosive cloud
pressure vessels and storage and transport tanks. can be formed. The operator should assess the
risks involved with potential substance releases.
IDENTIFICATION & DOCUMENTATION The analysis typically involves dispersion
For each pressure relief valve or rupture disk device calculations. If the risks are deemed unacceptable,
the operator should have a specification sheet. measures should be taken to reduce the risks, such
Templates of these specification sheets can be found as, discharging into a blowdown vessel or to a
in literature and typically contain information such flare, relocating the atmospheric venting point to
as: a safer location, implementing additional measures
to reduce the likelihood of the PRS being activated
 Identification of the components (item number)
(e.g., via safety instrumented systems), etc.
 Identification of each relief position (e.g., the tag
Another risk typically associated with PRS
number on a P&ID)
discharges to the atmosphere may be caused by
 The service conditions (liquid, vapour, two phase reaction forces imposed on outlet piping. The
flow, temperature, back pressure, …) calculation of these forces should be a part of the
sizing calculations. The operator should be able to
 Orifice area
demonstrate that the outlet piping (and more
 Operating pressures specifically, its supports) can withstand the
reaction forces.
 Design code
Discharging gases under high pressure or liquefied
 Construction materials
gases can lead to a considerable drop in
 Type of pressure relief valve or rupture disk temperature and hence, to brittle fracture in the
outlet piping and blow down system. The
EFFECTIVENESS, SIZE & CALIBRATION OF calculation of the pressure drop should be part of
THE PRESSURE RELIEF SYSTEM the sizing calculation. The operator should be able
The operator should be able to demonstrate that to demonstrate that the materials used for the
design and dimensioning of the pressure relief outlet piping and the blowdown system are suited
system is based on a pressure relief analysis. This to handle these low temperatures.
analysis should be appropriate for the expected fluid
phase (liquid, vapour, or two‐phase flow).

2
 PREVENTTION OFF DAMA AGE TO THE over the ruptture disk. Du
o ue to the bacckpressure, the
p
pressure diffferential at which the rupture disk
PRESSUR
RE RELIEF SYSTEM s
should bursst will not be attaineed when the
The pressure relief system also sho ould be prottected
m
maximum allowable
a p
pressure in
n the vesssel
from poten ntial damagge during no ormal operaations.
s
safeguarded by the PRS is reached.
For example, many pro ocess materiials often buuild up
and solidifyy on internaal surfaces. This can cre
eate a T
This phenomenon req quires instaallation of a
problem foor pressure relief system ms such that they p
pressure indicator thaat monitors the spaace
may becomme partially or
o completelyy blocked. b
between the
e rupture dissk and the pressure
p relief
v
valve. The pressure
p ind
dicator shou uld preferabbly
Corrosion ccan also com mpromise thee proper opeeration g
give an alarm m when backpressure is detected. If
of safety vaalve, causingg the disk to stick
s at the seat
s or n
not, the ind dicator should be regularly inspected
causing leaks between disk and seaat. (each shift). Operators must
m be awaare that a high
The operattor should have
h evaluatted whetherr such p
pressure read ding requires urgent actiion.
harsh operration condittions are prresent and should
s
D
DEACTIVA
ATION OF THE PRS
have taken n the appro opriate measures in plaace to
A vessel or pipe
p that is protected
p byy a PRS shou uld
guarantee the reliablee operation of the preessure
n
never be disconnected from
f the PRSS while it is in
relief device, such as:
o
operation (an
nd the risk of overpressu
ure is presentt).
 installingg heating orr tracing sysstems) to prrevent
TTo allow maiintenance annd inspection
n of PRD som
me
freezing o or solidification
p
pressure systtems are eqquipped withh two or moore
 protectio
on of a presssure relief valve
v by a ru
upture (redundant) PRD. This configuratio on allows one
disk P
PRD to rem
main in serrvice (connected to the
p
pressure systtem) while the
t other PR RD can be sh
hut
 installatio
on of pressuure relief devvices directlyy on a
o by a hand
off d valve or 3‐w
way valve.
vessel (elliminating th
he need for in
nlet piping)
A system sho ould be in place to guaraantee the rigght
 Increasing the insspection and mainteenance
p
position of the valve in the inlet or outlet pipinng,
intervals
m
making sure that at leasst one PRD is
i always lined
u with the pressure
up p systtem under protection.
PRESSUR
RE BUILD UP
U BETWEEEN THE
PRESSUR
RE RELIEF VALVE AN
ND RUPTU
URE INSPECTIO
ON AND MAINTENA
M ANCE
DISK odic inspection
TThe operatorr should estaablish a perio
When a prressure relief a
and mainteenance sysstem with all activity
valve and a rupturee d
documented . Each pre essure relieff valve shou uld
disk are installed in n u
undergo:
sequence, an enclosed d  n and mainteenance (testing
a periodiic inspection
space iss formed d and recalibration) of each pressure relief valvve
between th he (outlet of
the) burstiing disk and d  a visual on‐stream
o inspection
(the inlett of the) Periodic maiintenance of
P o a safety valve involvves
pressure rrelief valve e. r
removing it from
f the insstallation and transporting
Small leakss (pin holess, itt to a maintenance
m e shop. Itt is stronggly
cracks) in the rupturee r
recommende ed to test thee pressure reelief devices in
disk can lead to a t maintenaance shop before
the b disasssembly. In th his
pressure b build up in n w
way, it can beb tested whether the pressurep relief
this enclo osed space e. v
valve opens at the set pressure. (This is sometim me
The backpressure in n r
referred to as
a the ‘pretest’ or the ‘ass received pop
this space will render t
test’.) If a prressure relieef valve failss to open att a
the burstinng disk (that Figure 2. Diagramme sh howing p
pressure levvel above the set pressure (e. g., at
is still largely closed) the enclo
osed space betw ween 1
110% of the set pressuree), the pressu ure relief vallve
nonoperatiional. Thee the burstting disk and th
he iss considered d to have faiiled the test. An inquiry to
bursting disk iss pressure relief valve
t possible causes then should be executed. If the
the
activated by thee p
pressure relieef valve failss the test rep
peatedly, it iss a
pressure differentiaal

3
 strong indication of a structurall problem (e.
( g.,  Upstreamm and down nstream block valves are
a
corrosion, ssticking, etc.). sealed, or chained and locked, in the prop
per
After maintenance and d reassembly of the preessure position
safety valvve, the presssure safety valve is tested in  Dischargee piping is prroperly supported to avo
oid
order to veerify: breakage or leakage
 The open
ning pressuree (the pop teest)  Valve bod
dy drains and vent staack drains are
a
 The tighttness of thee seat of thee safety valve (to open
make surre it does nott leak while in
i service).  Any heat tracing or insulation critical to the
Visual on‐sstream inspeection (whilee the safetyy relief proper opperation of the
t relief syystem is intaact
valve is in sservice) shou
uld ensure th
hat: and operaating properlly

 The relieef device doe

es not leak  Any rupture disk is prroperly orien
nted

 Bellows vents are op

pen and clear TThe pressuree indicators and
a alarms monitoring
m the
s
space betweeen the rup pture disk and the safeety
v
valve should also be perio
odically inspected.

O
Other pub
blications
s in the Common
C n Inspecttion Crite
eria Serie
es

Proceess Safety Manaagement of Change

C EEmergency Isolation Process Haazard Analysis
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e Permit‐to‐W
Work Safety Insttrumented
Proccedures System Systems

HB publicationss can be found at https://minerva.jrc.ec.europa.eu/een/shorturl/minervaa/publications

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