Safety is not a luxury but an important concern in high-risk industries such as oil & gas; power generation; and chemical processing. One of the key components ensuring that the operation is safe is the safety valve, often referred to as a silent protector. The safety valve relieves excess pressure to avoid catastrophic failure. Thus, it plays a critical role in both protecting equipment and human life.
We'll discuss a real-world example from the United Arab Emirates that illustrates how the choice of a safety valve can mean the difference between failure of an entire production system and continued operation of the production system. As someone involved in industrial operations, you should understand that this case clearly demonstrates that choosing the proper safety valve is not only a technical decision, but also a strategic decision.
The Challenge: Pressure Build-Up That Would Blow the System
The operators of a large petrochemical facility in the United Arab Emirates identified that there was a gradual pressure increase within a critical processing unit. At first, the pressure increase was considered to be under control. Within hours, however, the pressure began to reach the maximum allowed threshold of the system.
The pressure increase was caused by a combination of high ambient temperatures and a temporary blockage in the pipeline. Without immediate intervention, the pressure could have created a system-wide failure with the very real risk of an explosion, equipment failure, and serious injury or death to employees.
The Safety Valve Function
Luckily for this facility, the recently-installed safety relief system included a high quality safety relief valve. This type of valve differs from standard safety relief valves as it was selected for the following reasons:
- Fast reaction to pressure variations
- High flow capacity
- Accurate setting at critical levels
- Can survive in extreme environment found in the UAE
Once the pressure level exceeded the safe range, the safety valve opened and relieved excess pressure which returned the system to an equilibrium state of operation.
What Factors Contributed to the Selection's Effectiveness?
Numerous factors need to be taken into account when selecting the right safety valve. In this instance, the engineering team also took several good design decisions with the following characteristics:
1. Accurate Pressure Rating
The safety valve that was ultimately selected is a proper match to the system’s pressure requirements. As a result, the valve is set up to actuate on time without premature discharge.
2. Material Strength and Compatibility
Construction materials for the valve were selected from very corrosion-resistant alloys to withstand the high-temperature and chemical environments typical of industrial sites in the UAE.
3. Compliance With International Standards
The selected safety valve conforms to both API and ASME stringent international safety standards; meaning that the valve is designed for maximum reliability and safety under very harsh or extreme operating conditions.
4. Immediate Response Mechanism
The safety valve was constructed using a spring-loaded mechanism providing immediate actuation during pressure spikes, therefore minimizing the risks of excess pressure to the system.
The Result: Disaster Averted, Workday Maintained
In response to a surge in excess pressure, the safety valve functioned as designed; i.e., excess pressure in the process was released within seconds with no damage to the processing unit.
The results were substantial:
- Prevented potential losses of approximately $12 million
- Eliminated any environmentally hazardous or safety-related situations
- Maintained an uninterrupted production flow
- Increased the life of critical equipment
As an operations engineer stated; "With this safety valve, the safety of our system was a key factor; the safety of our business was another."
Safety Valve Selection in the UAE is Important due to Extreme Temperature and Corrosion
Independent of the industrial facility or industry, adding to the challenges of temperature, there are also extreme environments due to corrosion present within the UAE. Likewise, the presence of both corrosive conditions and high temperature causes the need for high quality components that can withstand pressure – literally.
It’s estimated that improper pressure relief systems account for approximately 30% of industrial incidents worldwide (source: International Society of Safety Engineers). Therefore, ensuring that the right safety valve is selected for the intended application is critical.
Considerations for Selecting Safety Valve
In order to ensure safe and optimal performance, consider the following:
- Pressure requirements of the system: Must accurately match up with the valve setting.
- Temperature of the environment: Must select materials that will be able to withstand the environment of the UAE.
- Flow requirements: Must determine what will be the maximum discharge and should select a safety valve that will be able to handle this maximum discharge.
- International compliance: Always select safety valves that are compliant to International Standards.
- Reliability and maintenance: Select designs to minimize wear and downtime.
Investment in Safety Valves Should Be Viewed As A Strategic Investment In Safety
Investment in safety valve selection should not only be viewed as Compliance but as a way of protecting your employees, property and your reputation. Proactive measures of safety through the selection of safety valves is extremely important given that we are located in a high growth area where the amount of industrial growth is significant, and the stakes are high.
Conclusion
the safety valve is such a small piece of equipment, yet it has the potential to drastically affect your operation either positively, or negatively. This case study demonstrated how proper selection of a safety valve can make the difference between continued operation or catastrophic failure.
Now is the time to invest in improving your pressure management systems if you operate in the United Arab Emirates (UAE) . This will involve evaluating the state of your current pressure management systems and consulting with professionals who have experience in providing safe running systems.
If you are looking for reliable products and assistance, contact Al Zerwa Trading Company LLC for more information about how they can help you with your industrial valve requirements. Al Zerwa Trading Company LLC has been providing high-quality industrial valves for many years.
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