Hydrocarbon Processing - May 2022 - 83

Valves, Pumps and
Turbomachinery
P. K. NAMILAKONDA, Samsung Engineering,
Houston, Texas
Considerations for not providing
a dedicated spare pressure-relief device
Pressure-relief devices (PRDs) play a critical role in the hydrocarbon
processing industry. They act as the last line of defense
in protecting plant equipment from overpressure and are
mandated by the American Society of Mechanical Engineers
(ASME). This article provides some key factors that process
engineers and plant operators must consider to determine if an
installed spare PRD is necessary.
Like many other plant components, relief devices require
routine maintenance to ensure safe and reliable plant operation.
While most of the PRDs in hydrocarbon processing plants can
be taken out for maintenance during plant turnarounds, certain
PRDs may require more frequent maintenance while the
plant is in operation (onstream). The term " onstream " refers to
the overall plant operation. Reasons for more frequent maintenance
could be due to safety requirements or possibly because
the PRD is installed in a fluid service where fouling, corrosion
or plugging could potentially impact PRD operation.
Onstream maintenance of a specific PRD in the plant can
be achieved by one of the following options:
1. Providing an alternate and adequate relief protection
to the protected equipment (e.g., a spare PRD, or an
alternate and adequate flow path to another PRD)
2. Isolating, draining and depressurizing the protected
equipment from all possible overpressure sources
(taking the equipment out of service)
3. Eliminating as many overpressure sources as feasible,
and implementing administrative controls
for monitoring the protected equipment
for the duration of the PRD maintenance.
Process engineers are required to review these options during
the front-end design development step, with input from
the plant operations team, to make an appropriate decision.
PRDs requiring onstream maintenance are, in general, provided
with isolation valves on inlet and outlet (if applicable)
pipelines. ASME code requires administrative controls to be
in place for proper operation of the isolation valves in the
relief path so the equipment's overpressure protection is not
compromised. These requirements include providing locks or
car seals in addition to administrative controls to prevent accidental
closure (for more information, refer to ASME BPVC
Section XIII Non-Mandatory Appendix B). Process engineers
and plant operators must be familiar with the ASME code requirements,
and Appendix B provides valuable guidance and
requirements for determining a need for installing a dedicated
spare PRD. The following will review the three options in further
detail.
Option 1. Providing an installed spare PRD is generally a preferred
way to provide adequate overpressure protection to the
process equipment. While this option involves initial capital
expenditure for the PRD and associated piping, it also provides
the safest way to keep the protected equipment in continuous
operation for the duration of the maintenance. Plant
operators are required to follow stringent administrative procedures
for isolating the PRD requiring maintenance.
In the absence of an installed spare PRD, there can be other
creative ways to achieve the same purpose. This includes utilizing
PRDs on nearby equipment to provide the necessary
protection by means of utilizing an existing pipe routing for
a temporary relief path. However, process engineers should
perform a thorough analysis to ensure that such a temporary
and alternate relief path is adequate in terms of hydraulic requirements
(inlet pipe pressure loss), PRD flow area and fluid
service compatibility.
Option 2. This option is best suited for equipment that can
be taken out of service while onstream plant production is
maintained. A spare PRD may not be required if the entire
protected system can be isolated during normal plant operation.
Equipment operating in intermittent service also may
not require a spare PRD. For example, consider a hydrocarbon
system containing multiple catalyst bed vessels in parallel,
where at least one vessel is always isolated for catalyst regeneration
and is in standby mode for a prolonged duration. A spare
PRD may not be provided for protecting such vessels, as maintenance
can be performed when the vessel is in standby mode.
In such cases, the duration of the maintenance should be given
careful consideration, as the vessel cannot be returned to service
without code-compliant relief protection. Plant operators
generally rely on administrative procedures to open and close
several valves for placing equipment back in service. Failure
to properly follow these administrative procedures can compromise
the overpressure protection mandated by the ASME
code. One such safety incident was the ruptured heat exchangHydrocarbon
Processing | MAY 2022 83

Hydrocarbon Processing - May 2022

Table of Contents for the Digital Edition of Hydrocarbon Processing - May 2022

Contents
Hydrocarbon Processing - May 2022 - Cover1
Hydrocarbon Processing - May 2022 - Cover2
Hydrocarbon Processing - May 2022 - Contents
Hydrocarbon Processing - May 2022 - 4
Hydrocarbon Processing - May 2022 - 5
Hydrocarbon Processing - May 2022 - 6
Hydrocarbon Processing - May 2022 - 7
Hydrocarbon Processing - May 2022 - 8
Hydrocarbon Processing - May 2022 - 9
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Hydrocarbon Processing - May 2022 - Cover3
Hydrocarbon Processing - May 2022 - Cover4
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