Description
This webinar explains how to evaluate the safety implications of production rate increases, with a special focus on understanding the impact of tube rupture scenarios in heat exchangers. The presenters summarize key guidance from API 521 and the Energy Institute's tube rupture guidelines, then walk through common issues seen during relief system evaluations. The session includes examples, statistics, design considerations, and dynamic simulation case studies that show how increasing unit rates can influence exchanger protection, relief sizing, and overall system safety.
Key Topics Covered
- Overview of tube rupture risks in rate increase projects
- API 521 guidance on applicability, sizing assumptions, and required relief capacity
- Energy Institute recommendations for evaluating tube rupture behavior
- Differences between leaks, partial ruptures, and full bore ruptures
- Dynamic effects of pressure spikes and liquid displacement
- Importance of relief device type, set point, and response time
- Common design deficiencies such as unprotected piping, outdated assumptions, and missing devices
- Case studies showing tube rupture impacts on cooling water networks and exchanger headers
What You’ll Learn
- How rate increases can affect exchanger performance and relief requirements
- How to determine when steady state evaluation is sufficient and when dynamic modeling is required
- How tube diameter, volume, fluid phase, and pressure differential influence peak pressures
- How to assess whether downstream piping, valves, and equipment are adequately protected
- How to compare relief devices such as rupture discs, pilot devices, and relief valves for tube rupture service
- How to use API and Energy Institute guidance to make informed decisions about relief sizing and mitigation
Who This Webinar Is For
Process engineers, PSM specialists, project engineers, operations leaders, and anyone responsible for evaluating rate increases, heat exchanger safety, or relief and flare system design in refining, petrochemical, chemical, and midstream facilities.
Duration
70 minutes
Speakers (2)
Jason Spearow
Technical Lead Supervisor
Zubin Kumana
Principal Engineer
