A Novel Methodology for Maintaining Mechanical Integrity of High Pressure Relief Systems

Safe operation and maintenance of emergency systems are of primary importance to the process industries, including upstream oil and gas. The upstream production facilities are usually protected from overpressurization by HIPPS which shuts in the well when local pressure levels exceed a certain threshold. The pressure relief system is often installed as a last safety barrier, when HIPPS fails. One of the critical elements of emergency system is proper design, documentation and to maintain high reliability of this system. In particular, the pressure relief system is an integral part of upstream design and operation; prevention of an accidental release of toxic, flammable or noxious materials from a production facility requires correct design and construction, safe operation, and proper documentation of this system. This paper proposes a basic change in the way relief systems are documented - a requirement in order to comply with OSHA 1910.119 and thereby describes a new methodology and a change in documentation to meet OSHA requirements and other industry standards (such as API 520/521, API-RP 75, 14J). This paper also describes the steps involved in a high pressure relief system evaluation and introduces concept of ever-greening to maintain a high reliability of this system. The paper illustrates how an up-to-date relief system leverages management of change (MOC) and helps in setting up the foundation for a strong overall process safety management (PSM) program. The paper will identify the drivers and the benefits of having an evergreening program for pressure relief documentation as well as explore the interdependency of the proposed evergreening elements. The paper will assist upstream facility personnel to utilize good engineering practice in design and documentation of safety relief systems, to meet both onshore and offshore process safety requirements, and to develop consistent company best practices for process safety management. In addition the paper will describe a comprehensive equipment based analysis protocol, preparation of documentation sufficient for design, operational, and audit purposes, and discuss maintenance both of the physical system and design data.