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


Understanding MAWP and High-Pressure Vessel Design

Gain an Understanding of Maximum Allowable Working Pressure (MAWP)

Read this white paper to understand how and who determines the maximum allowable working pressure (MAWP), the relationship between MAWP and Design Pressure, and finally how high-pressure vessel is designed.

Read the White Paper

Two-Phase Flow Onset and Disengagement Methods

Two-phase flow is often considered in system hydraulics as well as the evaluation and design of pressure relief and effluent handling systems. A variety of scenarios can lead to two-phase flow under relief conditions.

In general, two-phase flow during relief can occur because of flow hydrodynamics and poor vapor/ liquid disengagement where (a) the liquid swells due to generation of vapor bubbles in the liquid 1, (b) fluid expansion occurs due to heating, and/or (c) the superficial vapor velocity is high enough through the pressure relief device. Oversized relief devices can induce two-phase flow because a large relief flow area yields a higher superficial vapor velocity. Runaway chemical reactions and/or chemical systems that are viscous and/or foamy almost always lead to homogeneous two-phase flow.

Two-phase flow can also occur by entrainment, for example, where gas is sparged at a high enough rate in the liquid. In some systems, condensation leading to two-phase flow in the discharge piping can also occur due to expansion cooling caused by pressure reduction through a control valve or a pressure relief device.

Numerous two-phase flow models have appeared in the literature. These models represent broad ranges of theory. Some are based on single-phase critical flow, others on homogeneous equilibrium flow, frozen flow, separated flow, slip flow, and/or non-equilibrium flow.

Homogeneous equilibrium flow models assume equal vapor and liquid velocities and calculate the change of quality with pressure using an isenthalpic or isentropic thermodynamic path. Homogeneous frozen models assume equal vapor and liquid flow velocities and that the quality is frozen along the flow path, i.e., no change with respect to pressure or temperature. The separated flow models assume different vapor and liquid flow velocities and account for mass, momentum and heat transfer between the separate phases.

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 Pressure relief and flare systems design project management and engineering expertise for chemical, pharmaceutical and petrochemical companies. Read more...

Daniel Nguyen, PE & PMP

Senior Vice President and Partner Responsible for a team of software engineers in the development of ioMosaic’s PSO software and manages pressure relief and flare systems evaluation and design projects. Read more...

John Barker, Ph.D.

Director The Director of our U.K. office and an expert in risk management for the international oil and gas and transportation industries. Read more...

Marcel Amorós-Martí

Director, California Office Lead His expertise includes pressure relief and flare systems design for large chemical and petrochemical companies around the globe and in the United States. 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...

Ying Zhang, P.E., PMP

Senior Safety and Risk Management Consultant Chemical engineer focused on pressure relief and flare system design and analysis for large chemical and petrochemical companies in the U.S. 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...

Featured Videos


PSE Emergency Relief System Design Workflow

Process Safety Enterprise Emergency Relief System Design Workflow performs efficient tracking of process safety related data and analysis. The customized workflow allows for a specific operating unit or the entire facility to be studied and evaluated to maintain compliance and ensures your facility remains protected.

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Featured Case Studies

Fire Exposure and Relief Protection for Vessels Containing Reactive Chemicals

The client was storing reactive materials in vessels that could be subject to fire exposure. They wanted to be sure that the relief protection on the vessels was correctly sized, or if not, what changes were necessary for an effective relief system.

View Case Study
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 PRV 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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