Overpressure protection is used to protect tubing, pipes, desiccators, filters, reactors, etc. from being over pressurized. Why use it? Serious or fatal accidents can occur if overpressure protection is not used when it is needed. Texas A&M Jan 29, 2006 Ruptured liquid nitrogen tank. (The pressure relief device had been removed) http://ucih.ucdavis.edu/docs/chemistry_301a.pdf Roughly 1200 psig passed through a regulated valve into downstream pvc piping. Overpressure protection had not been provided downstream from the valve. Overpressure protection is needed when a feeding system generates/stores pressure higher than the maximum working pressure rating of downstream pipes, tanks, and other components. Feeding system examples include compressors & compressed gas cylinders. The overpressure protection protects the downstream components from being over pressurized. If a regulator or pressure switch has been installed then overpressure protection is needed. Use overpressure protection to protect objects (pipes, reactors, dryers, etc.) that could develop pressures above their safe maximum operating pressure (e.g. for example runaway reactions). Overpressure conditions might arise due to: 1. Regulator failure (or other device failures) 2. Runaway Reactions 3. Operator Error 4. Fire 5. Utility Failure (e.g. water, steam, natural gas) Exothermic reactions produce heat and need to be cooled to be controlled. If cooling fails then a runaway reaction can occur. Increased heat will increase the speed of the reaction. Gases and vapors can over pressurize their containment leading to a catastrophic failure if overpressure protection isn’t provided. Use engineering and administrative controls to avoid overpressure accidents. This includes avoidance strategies as well as use of pressure relief devices. Avoidance Strategies 1. Design the system to withstand the maximum pressure that is present, or that can develop. 2. Use of redundant cooling systems. 3. Develop and use safe operating procedures and train operators properly. Pressure Relief Devices 1. Buckling pin relief valve 2. Rupture pin relief valve 3. Spring loaded pressure relief valve 4. Rupture disc You must utilize a form of pressure relief unless you will be utilizing the first avoidance strategy! To prevent accidents the Chemical Safety Board (CSB) recommends: 1. Identify & thoroughly evaluate reactive hazards for your process; 2. Implement appropriate emergency pressure relief systems and other design safeguards; 3. Develop effective operating procedures and training; 4. Carefully manage any changes to existing processes; and 5. Plan for possible accidents -1 fatality- 5 steps weren’t completely implemented. Exothermic runaway reaction and ensuing vapor cloud ignition. http://www.aristatek.com/Newsl etter/JAN08/TechSpeak.pdf If you find that pressure relief devices won’t work for your application then use series regulation. The risk of two regulators failing is very low. Drawback - it may be difficult to detect a regulator that has failed because there is another regulator masking the failure. Contact Airgas, or another specialty gas supplier for proper regulator selection. Steps for selecting relief devices: 1. 2. 3. Select the type of relief device you would like to use based upon their characteristics (see following slides); Create a schematic of your setup, identifying the maximum safe operating pressure for each component of your system; and Contact a manufacturer and have them help you select the proper pressure relief device. These valves can “simmer” (release gas) at 95% capacity. Spring Loaded Pressure Relief Valves Require annual inspection and bench top testing. Open at a specified set pressure and reseat after blow-down (2 to 20% below set-pressure). Outlet gases need to be channeled to an appropriate location. (diagram from Clarkson University) A disc’s stress at the burst point is much greater than the yield stress. http://oseco.com/na/home/ Rupture discs contain a one time http://www.zookdisk.com/ use membrane that ruptures near a specified set pressure. Discs need to be replaced once they are used. Rupture discs fatigue over time and need to be replaced according to manufacturer recommendations. Outlet gases need to be channeled to an appropriate location. (diagram from Clarkson University) Buckling pins buckle at a precise set pressure allowing the valve to isolate upstream pressure. Rupture pins buckle at a precise set pressure allowing the valve to relieve the pressure. The vented gases will need to be channeled to an appropriate location. Expensive, but there are no size or pressure limits for the design of the valve. Pins can be replaced while the valves are in service. Valves close/open within milliseconds. Install, test, and maintain pressure relief devices according to manufacturer recommendations. Pressure relief devices can fail if not properly installed and maintained.