Designing Pressure Relief Systems for Heat Exchanger Tube Ruptures

Presenters: Phil Henry, P.E.
Date: July 17, 2025 | 11:00 AM EDT

When designing pressure relieving systems for heat exchangers, the potential for internal tube failure needs to be considered, particularly if there is a significant difference in design pressure between the shell-side and tube-side of the exchanger. As per API STD 521, Pressure Relieving and Depressuring Systems, if the operational pressure on one side exceeds the corrected hydrostatic pressure of the other side, it is necessary to size the overpressure protection system of the low-pressure side considering the possibility of a tube rupture scenario. Sizing for the tube rupture scenario leads to increased costs, whether it involves a new design or retrofitting existing systems. However, API 521 permits users to consider the tube rupture scenario as non-credible following a comprehensive assessment of the heat exchanger, known as the tube rupture credibility assessment (TRCA). This assessment encompasses various critical aspects related to the potential of tubes to withstand an instant full-bore rupture, such as vibration phenomena, required wall thickness, susceptibility to erosion, corrosion, or credible degradation mechanisms. Often, the TRCA results indicate that implementing a tube inspection program is a fundamental measure to mitigate and address damage mechanisms that could lead to a sudden tube break.

This webinar addresses the uncertainty and cost burden associated with designing for a tube rupture scenario in heat exchangers—especially when a significant pressure differential exists between the shell and tube sides. Without a structured assessment, designers are often forced to assume the worst-case scenario, leading to oversized relief systems and unnecessary capital expenditure. The presentation provides clarity on how to apply API 521's provisions to determine when a tube rupture scenario is truly credible and when it can be justifiably excluded.

What You Will Learn:

When and why a tube rupture scenario must be considered for pressure relief system design in heat exchangers
What constitutes a tube rupture credibility assessment (TRCA) and how it can be used to justify the scenario as non-credible
Key factors evaluated in a TRCA, including vibration, corrosion, erosion, and degradation mechanisms
The role of inspection programs in maintaining tube integrity and mitigating risk
Cost implications of tube rupture relief sizing versus risk-based engineering justification

Who Should Attend:

Process Safety Engineers
Mechanical and Reliability Engineers
Pressure Relief System Designers
PSM (Process Safety Management) Coordinators
Engineering Managers and Decision Makers involved in equipment design or modification
EPC Contractors and Engineering Consultants in the oil, gas, chemical, and refining industries

Register today and learn how to make informed decisions that align with API 521 while reducing the cost and complexity of relief system design.

Register Below:

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