Chapter 1 - Overview

01-01 - Overview (13 min.) Sample Lesson

Chapter 2 - API Guidelines

02-01 - API 520, 521 & 2000 (10 min.) Quiz: 02-01 - API 520, 521 & 2000
02-02 - Other Related API Guidelines (9 min.) Quiz: 02-02 - Other Related API Guidelines

Chapter 3 - Relief Device Types & Their Operation

03-01 - Basics of Relief Device Operation (11 min.) Quiz: 03-01 - Basics of Relief Device Operation
03-02 - Basic Spring PSV Operation (15 min.) Quiz: 03-02 - Basic Spring PSV Operation
03-03 - Conventional Relief Valves (4 min.) Quiz: 03-03 - Conventional Relief Valves
03-04 - Balanced Relief Valves (8 min.) Quiz: 03-04 - Balanced Relief Valves
03-05 - Pilot Relief Valves (15 min.) Quiz: 03-05 - Pilot Relief Valves
03-06 - Buckling Pin Relief Device (5 min.)
03-07 - Rupture Discs (34 min.) Quiz: 03-07 - Rupture Discs
03-08 - Pressure/Vacuum Relief Devices (18 min.) Quiz: 03-08 - Pressure/Vacuum Relief Devices

Chapter 4 - ASM Certified Relief Devices

04-01 - The National Board (14 min.) Quiz: 04-01 - The National Board
04-02 - ASME Relief Device Markings (11 min.) Quiz: 04-02 - ASME Relief Device Markings
04-03 - ASME PSV Trims (10 min.) Quiz: 04-03 - ASME PSV Trims

Chapter 5 - Relief Device Set Pressures

05-01 - Set Pressure Deviations from MAWP (9 min.) Quiz: 05-01 - Set Pressure Deviations from MAWP
05-02 - Cold Differential Test Pressure (CDTP) (4 min.) Quiz: 05-02 - Cold Differential Test Pressure (CDTP)
05-03 - Pressure Accumulation Rules (13 min.)

Chapter 6 - Hydraulic Limitations of Relief Devices

06-01 - Basis of Hydraulic Calculations (6 min.) Quiz: 06-01 - Basis of Hydraulic Calculations
06-02 - Inlet Piping & PSV Stability (10 min.) Quiz: 06-02 - Inlet Piping & PSV Stability
06-03 - Discharge Piping (13 min.) Quiz: 06-03 - Discharge Piping
06-04 - Relief Valve Chatter (4 min.) Quiz: 06-04 - Relief Valve Chatter
06-05 - Discharge Piping Design (12 min.) Quiz: 06-05 - Discharge Piping Design

Chapter 7 - Sizing of Relief Devices

07-01 - Critical Flow (9 min.) Quiz: 07-01 - Critical Flow
07-02 - API Orifice Sizes (4 min.)
07-03 - Gas Service (7 min.) Quiz: 07-03 - Gas Service
07-04 - Liquid Service (4 min.) Quiz: 07-04 - Liquid Service
07-05 - Two-Phase or Flashing Flow (10 min.) Quiz: 07-05 - Two-Phase or Flashing Flow
07-06 - Sizing for Atmospheric Storage Tanks (22 min.) Quiz: 07-06 - Sizing for Atmospheric Storage Tanks
07-07 - Rupture Disc Sizing Methods (6 min.) Quiz: 07-07 - Rupture Disc Sizing Methods

Chapter 8 - ASME vs API Orifice Relief Areas

08-01 - ASME & API Orifice Relief Area Differences (13 min.) Quiz: 08-01 - ASME & API Orifice Relief Area Differences

Chapter 9 - Overpressure How's & Whys

09-01 - Basic Causes of Overpressure (21 min.) Quiz: 09-01 - Basic Causes of Overpressure
09-02 - Blocked Flow (8 min.) Quiz: 09-02 - Blocked Flow
09-03 - Compressors (5 min.)
09-04- Reflux failure (8 min.)
09-05- Hot Liquids Entering a System (4 min.) Quiz: 09-05- Hot Liquids Entering a System
09-06 - Liquid Overfill (3 min.)
09-07 - Failure of Controls (12 min.) Quiz: 09-07 - Failure of Controls
09-08 - Check Valve Leakage (9 min.) Quiz: 09-08 - Check Valve Leakage
09-09 - Thermal Expansion (7 min.) Quiz: 09-09 - Thermal Expansion
09-10 - (Part 1) - Fires (17 min.)
09-10 - (Part 2) - Fluids Relieved (18 min.) Quiz: 09-10 - (Part 2) - Fluids Relieved
09-11 - Failure of Heat Transfer Equipment (13 min.) Quiz: 09-11 - Failure of Heat Transfer Equipment
09-12- Utility Failure (5 min.)
09-13 - Other Overpressure Failures (5 min.)

Chapter 10 - PRD Maintenance

10-01 - PRD Maintenance (11 min.) Quiz: 10-01 - PRD Maintenance

Chapter 11 - Open Vents

11-01 - Open Vents (5 min.)

Chapter 12 - Spec Breaks

12-01 - Spec Breaks (7 min.) Quiz: 12-01 - Spec Breaks

Chapter 13 - Documentation

13-01 - Documentation (4 min.)

Chapter 14 - Overpressure Example Calculations

14-01 - Sample Calculation Exercise 1 (7 min.)
14-02 - Sample Calculation Exercise 2 (2 min.)
14-03 - Rupture Disk Design Example (5 min.)
14-04 - PVSV Example (5 min.)
14-05 - Multiple PSV Example (4 min.)
14-06 - Two Phase Flow Example (4 min.)
14-07 - Blocked Pump Discharge Example 1 (6 min.)
14-08 - Blocked Pump Discharge Example 2 (6 min.)
14-09 - Tank Vent Example (4 min.)
14-10 - Critical Flow Example (3 min.)
14-11 - Blowthrough Example 1 (4 min.)
14-12 - Blowthrough Example 2 (4 min.)
14-13 - Control Valve Failure Example (4 min.)
14-14 - Check Valve Leakage Example (4 min.)
14-15 - Thermal Expansion Example 1 (3 min.)
14-16 - Thermal Expansion Example 2 (2 min.)
14-17 - Fire Example 1 (5 min.)
14-18 - Fire Example 2 (4 min.)
14-19 - Depressurization Example (3 min.)
14-20 - Heat Exchanger Tube Failure Example (4 min.)
14-21 - PSV Reaction Force Example (3 min.)

Overpressure Protection / Chapter 1 - Overview

Lesson 01-01 - Overview

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Transcript

01. Lesson 1.01: Overview 02. Course Contents 03. Overview 04. Canada Safety Board (CSB)

01. Lesson 1.01: Overview

Hello, welcome to the SAGA Overpressure Protection course. My name is Keith Timms. I'm a professional engineer working in Alberta, Canada, and I've developed a great interest in safety. I do a lot of hazard facilitation, but I also do a great deal of overpressure protection consulting with many clients in Alberta.
And this is an opportunity for me to share my knowledge with you. And hopefully you'll find this helpful and useful. You can probably tell from my accent, I come from England, but that's many, many decades ago. I came to Canada in 1982. And I'm not going back to England. So let's get on with the course. Thank you very much again for choosing to attend the course.

02. Course Contents

So first of all, we're going to go off with an overview. So what is the course going to talk about? So there's a quick overview of the contents of the course.
First thing we're going to go over is API standards (American Petroleum Institute standards) that are very useful when considering overpressure protection. So we're going to have a quick trip through those. And throughout the whole course, I'll be referencing on many occasions the various sections in the API standards. And in fact, you'll see in the title pages on many of the chapters and sections, a reference to the appropriate section in the API standard. So you can dive in there and do a deeper dive if you want in your own time because this course can't possibly cover the entire contents of an API standard.
Then we're going to go and look at the types of relief devices and how they work plus their limitations. Nothing's perfect, so there are limitations with the various relief devices. So we're gonna have a little chat about that.
Then we're going to have a chat about how to determine set pressures of relief devices, which may seem pretty straightforward, typically the MAWP of the equipment. But there are occasions when we want to set it a little differently from that. So we're gonna have a little discussion about that.
Then we are going to talk about ASME and non-ASME relief devices. So there are two classes of relief devices out there in the world. Most companies, most jurisdictions in North America require to have an ASME relief device. But there are some exemptions to that where you can have a non-ASME relief devices and these are typically situations which aren't as high in risk as a relief valve that's needed for an ASME application.
Then we're going to talk about the National Board, who they are and why they're important. They're very, very important.
Then we can have a chat about how to resize relief devices. These are the equations that we can use to determine the relief area of a relief device.
Then another super important part of overpressure protection is the piping associated with the relief device because we have to really think of the relief device as one component of the relief system and the piping hydraulics into and out of the relief device are really important. The relief device does have some limitations if those hydraulics aren't right. And in fact if the hydraulics are not right, the relief device won't work as you want it to and you're not going to have appropriate relief protection.
Then we're going to deep dive into how many ways overpressure can occur, the various scenarios that typically you might come up in a HAZOP or discussions with your colleagues, and we want to go through a number of relief scenarios and how to determine the relief flow rate.
We can have an extensive review of API 520, 521 and 2000 in particular out of the API standards, although I will be talking about a few more standards, but we won't take a deep dive into those standards. But these 3 standards are your kind of go to API standards for overpressure protection. So we will be taking a good look at these.
And in particular, API 2000. Now, API 2000 covers atmospheric storage tanks. And we will be discussing this, but ASME does not require overpressure protection for vessels in terms of an ASME relief device for vessels with an MAWP below 15psig, but you still have to protect them from overpressure. So API 2000 is the one way in which we're going to talk about atmospheric storage tanks, which is in the next section of the slide, protection of atmospheric storage tanks from overpressure and vacuum in particular.
And then we're going to go to the last part of the course. We're going to take a look at several overpressure scenarios, how we determine relief flow rates, how we size the PSV. And there's going to be a number of examples that I'm going through at the end of the course.

03. Overview

So quick overview, I mean, I think probably you all know that loss of containment due tooverpressure is one of the main risks in many industries; oil and gas, chemical mining, oil sands, etc. So unfortunately, there have been many fatalities over the years because of a lack of overpressure protection. We've had explosions, loss of containment, fire, release of toxic chemicals. So this course is trying to help you to eliminate or at least significantly reduce the probability of that.
If equipment is exposed to a pressure, perhapsdesign pressure, then failure of that equipment is likely and you could release the contents of the vessel and the associated piping and that could in turn result in an explosion, a toxic emission, a flying debris. Obviously, if a pressure vessel ruptures, there's an enormous amount of stored energy that's released and that could cause equipment damage, harm to personnel, damage to the environment, damage to reputation. So we want to make sure that we minimize or even eliminate these possibilities.
This course cannot present all possible materials related to overpressure protection, but it's going to have a pretty extensive overview and references to further reading. This is a really big topic and this course can't possibly hope to cover everything, but hopefully you'll get a good flavor of overpressure protection and what you have to do and the various calculation methods and determination of relief flow rates.
In most jurisdictions, restrictions want to see how equipment is protected against overpressure and if such means meet local codes. Now this course isn't going to go over codes because they vary throughout Canada and the United States by state and province, so I'm not going to deep dive into the codes except where ASME codes have certain requirements because ASME Codes are applicable across Canada and the United States and most jurisdictions require you to follow ASME codes.
In most jurisdictions, regulators don't want to see the calculation, except some jurisdictions do. I know in particular Alaska requires a stamped calculation, but many other jurisdictions do not require a calculation. But this course is going to go through some examples.
And the last bullet point here is there is a wonderful, well, it's a very interesting website. It's www.csb.gov/videos. And this is the Chemical Safety Board website. So this is just a link that you can go to that website. And it has excellent videos analyzing, unfortunately, incidents that have happened over the years throughout North America. And so if you wanna go and educate yourself on some of the bad things that can happen, often from overpressure failure, then this is a good website to go to.

04. Canada Safety Board (CSB)

Yeah, so this is the website of the Chemical Safety Board, which is an excellent site. It's an organization that investigates incidents within the United States. And here you can see a number of videos and links to various instances that have happened over the years. I'm not going to show any one of them, it's just for your education that this website exists. And there's a lot of interesting lessons that can be learned from this as well.
And the next video I'm going to share with you is a MythBusters video of something that we all have in our house. It's a simple water heater. You might not think this is a high-risk item, but it certainly can be a high-risk item. So this video is going to show you some of the things that can go wrong and has gone wrong over the years in people's homes. And it's just to highlight the deadly nature of pressure.

05. Mythbusters Video

The buildup of steam under pressure can cause many things to go off. But how about a water heater bursting right through your house? To mimic a real-life situation, the roof of the house has been constructed to California Building Code specifications. And the water heater contains no explosives. They turn on the power, hunker down, and wait.
You feel ready? Everyone's in position? Cameras are all rolling?
Yeah. We've got a nice little red house out there, you know, like everything's rosy.
Rosie on the outside, but roasting on the inside.
Okay everybody. We're at 300 psi. That's twice the tank rating. Keep your eyes peeled.
As the pressure inside the tank mounts, so does Jamie and Adam's heart rate.
315 psi. Oh, this is killing me! 320. Any second. 325.
This is excruciating! This kind of stress on a regular basis can't be good.
Shortening our life span
We're gonna make it to 350.
Suddenly, the heater launches and tears through the roof like it's tissue. You could practically have a 3-course meal while you're waiting for it to come back down.
Look at the house!
What house? I don't see a house! I don't know what you're talking about!
This actually surprised me. The house was no hindrance whatsoever to the rocket. It probably would have gone through several houses like this before it stopped going.
It's like a fairy tale come true. The water heater huffed, it puffed and it blew the house down.
It just goes to show you. There's danger everywhere. Did you know what was lurking in your basement?
The guys inspect what's left of their once-charming home.
The bottom of the tank went from concave to convex, probably in a split second. There's a hole in the roof. It had to go through two layers of 2x4 trusses in order to make that hole, and yet it totally did. And it did it without breaking any of the 3 windows in here. That's a rocket, my friend, not a bomb.
The trajectory and form of the 500 ft high rocket-like blast is revealed on the high speed.
I gotta say, it's more interesting than an actual explosive explosion because this steam is just erupting everywhere and completely disintegrating. It's different. It's more elegant.
Yes, it was like a lovely, delicate water heater ballet, but deadly.
So there you can see, pressure is very frightening. It's very scary. There was a water heater as exposed to twice its designed pressure. In fact, this is slightly more than its designed pressure and you can see a tremendous release of energy. That water heater was going vertically through a house. It's gonna cause significant damage and potentially harm to people.
So that concludes Chapter 1. Thank you for listening. And in the next chapter, we're gonna have a little look at the various API standards, some of which we'll be discussing during the course. Thank you.