Emergency Relief System Design

Reducing costs and increasing accuracy in the design or revalidation of relief systems.

Effective Emergency Relief System (ERS) design helps companies meet risk-management goals, compliance requirements, and sound business practices. ioMosaic provides a total ERS solution with our comprehensive ERS design services, from reactivity testing for design basis determination to calculations for Z-axis deflection from dynamic loads.

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How We Can Help You

Our team has decades of experience performing PRFS analysis and design.

Our risk-based approach helps mitigate near-unventable scenarios to a tolerable level of risk.

Better evaluate hazards in your facility with an accurate process simulation.

Delivering properly designed pressure relief systems that save both money and time.

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Featured Resources

RAGAGEP Considerations for Overtemperature Protection in Relief Systems

How to Calculate ETTF or ETTY in Fire Exposure Scenarios

Reasonable estimates of the expected time to failure (ettf) or expected time to yield (etty) are required and necessary for effective risk management as well as effective emergency and fire protection and response. Read this paper for a demonstration of calculating ettf or etty in fire exposure scenarios with Process Safety Office® SuperChems™.

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The Importance of a Team Based Approach to Overpressure Scenario Development

With the increased regulatory focus on pressure relief and flare systems (PRFS) design basis, many companies are in the process of updating their existing relief systems design documentation. A very important aspect of any relief systems analysis is the correct identification of overpressure scenarios, and one way to ensure successful and accurate overpressure scenario development is to conduct this process as a team. This approach is currently in effect at many major oil and petrochemical companies including BP, Shell, Chevron Phillips, Bayer, etc., even though current relief systems recognized and generally accepted good engineering practice (RAGAGEP), does not call for this approach.

The benefits of a team-based approach to overpressure scenario development include participation and consensus from all affected disciplines: engineering, operations, instrumentation and control, maintenance, and process safety. Unique insights can be provided through operational experience, and there are opportunities to confirm correct operating and design conditions. In the same way that a process hazard analysis (PHA) is conducted using a team approach; so should the relief systems rationale.

This paper outlines the basic steps involved in overpressure scenario identification, the way that a team approach can be implemented, and the benefits of a team-based approach to overpressure scenario development.

Table 1. Common Contingencies Cross-Referenced to Type of Equipment.

Common Contingencies Cross-Referenced to Type of Equipment

Our Team

Georges A. Melhem, Ph.D., FAIChE

President & CEO The founder of ioMosaic and internationally renowned expert in the areas of pressure relief and flare systems design, chemical reaction systems, process safety and risk analysis. Read more...

Neil Prophet

Senior Vice President and Partner He brings over 20 years of experience in pressure relief and flare systems design project management and engineering expertise for chemical, pharmaceutical and petrochemical companies. Read more...

John Barker, Ph.D.

Director The head of our international offices in the U.K. and the Kingdom of Bahrain and an expert in risk management for oil, gas and transportation. Read more...

Marcel Amorós Martí

Director and Partner His expertise consists of a diverse range of industries from chemical and petrochemical to oil and gas and utilities. Read more...

Charles Lea, P.E.

Director, Minneapolis Office Lead He directs a number of large technical projects across multiple offices and is also responsible for all project management in our Minneapolis office. Read more...

Matthew LeVere, P.E.

Senior Safety and Risk Management Consultant Experienced in PRFS design and analysis for clients in the petrochemical, chemical, and pharmaceutical industries. Read more...

Neal Dahlheimer, CPPM

Senior Safety and Risk Management Consultant Technical lead on PRFS projects for chemical, petrochemical and oil facilities as well as QA/QC reviews and training on advanced techniques for complex systems. Read more...

James Close

Safety and Risk Management Analyst Mr. Close is focused on pressure relief and flare system design and analysis for large chemical and petrochemical companies in Europe and the United States. Read more...

Christian Sarno

Senior Safety and Risk Management Consultant Focuses on quantitative risk assessment (QRA), facility siting, pressure relief and flare system (PRFS) design and analysis for chemical and utility companies. Read more...

Featured Videos


Emergency Relief System Design Workflow

This PSE module performs efficient tracking of process safety related data and analysis. A customized workflow allows for a specific operating unit or the entire facility to be studied and evaluated for compliance.

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Featured Case Studies

Validate Relief System Performance and Flare System Capacity for Increased Unit Charge Rate

A major petroleum company recently increased production capacity and required an analysis of its existing relief systems to validate performance and design. As a result of increasing production capacity and debottlenecking studies, several refinery units were found to be operating at charge rates higher than the design basis for the relief systems documentation.

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A refinery approached ioMosaic for the purposes of ensuring that pressure relief capacity was adequate for the loss of liquid seal scenario in a high-pressure separator (2,000 psig). They were also concerned about the pressure waves that would occur in the high-pressure separator’s outlet lines on rapid closing of the isolation valves and sought our expertise.
A large oil refinery with a very complex flare network had become so complex that the tools the refinery was using to evaluate the flows through the flare network could not adequately model the system. Management no longer had confidence that their model results reflected the actual network performance and therefore, could not be sure the system would perform properly in the event of a global relief scenario at the facility.
A multinational energy company wanted to complete an evaluation of a pressure relief valve system in order to comply with the PSM standard OSHA 29 CFR 1910.119 which requires that employers compile information pertaining to the equipment in the process, including relief system design and design basis. 


Featured Services

Pressure Relief and Flare System Design

Our risk-based approach helps mitigate near-unventable scenarios to a tolerable level of risk and develop economical designs for more credible events. Read more...

Relief Header and Flare Analysis Systems

Delivering properly designed pressure relief systems for refineries and chemical plants that save both money and time. Read more...

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