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.

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