Compression system check-valve failure hazards

Processes that utilize multistage compression systems (olefins plant compression systems, gas processing, integrated refrigeration systems, etc.) have the potential for overpressure due to single or multiple check-valve failure. Catastrophic equipment failure resulting from overpressure can potentially occur due to compression system discharge, interstage, and/or suction check-valve failure, coincident with compressor shutdown. Depending on system design and application, overpressure values approaching or exceeding 300% of equipment design are possible, while for some equipment, even limited overpressure can result in catastrophic vessel failure due to brittle fracture. Additional hazards associated with compression system fail-to-check scenarios include risks associated with excessive flare loading and compressor rotor reverse rotation. In the case of an ethylene refrigeration compressor at a typical ethylene plant, rotor reverse rotation can potentially exceed overspeed limits.This paper provides risk assessment results based on analyses performed on the three primary compression systems in six ethylene plants. The methodologies used for risk identification screening, detailed risk assessment and evaluation of system dynamics are all presented. Alternative methods for mitigating risks are also discussed, along with check-valve reliability data. An overview of applicable overpressure protection requirements defined in the ASME Boiler and Pressure Vessel Code is provided. This paper will be of interest to anyone who designs or operates multistage compression systems in the chemical, petrochemical or refining industries.

► Ethylene plant compression system check-valve failure risks were evaluated.
► Check-valve failure can result in equipment overpressure exceeding 300% of design.
► Additional hazards include rotor reverse rotation and excessive flare loading.
► Expected check-valve failure frequency is between 1/10 and 1/100 years.
► Risk mitigation options with associated pros and cons are presented.