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Process Safety & Relief Systems Masterclass
Published 9/2026
Created by ProjectEngPro Engineering and Project Management
MP4 | Video: h264, 1920x1080 | Audio: AAC, 44.1 KHz, 2 Ch
Level: Intermediate | Genre: eLearning | Language: English | Duration: 40 Lectures ( 7h 38m ) | Size: 4.3 GB
Relief valve sizing, flare system design & radiation, disposal systems, blowdown, HAZOP & LOPA
What you'll learn
Size a relief device for gas, liquid, two-phase and fire case scenarios to API 520 Identify and select relieving scenarios, and determine the governing case for a system Calculate flare radiation and determine sterile area and stack height to API 521 Size relief headers for simultaneous relief and assess back pressure on every connected device Size knockout drums for droplet removal and specify liquid seals to prevent flashback Determine depressurisation rates and assess vessel wall temperature during fire case blowdown Recognise low-temperature embrittlement risk on blowdown and design around it Run a HAZOP and LOPA that produces credible relief scenarios and IPL credits Set relief device test intervals from as-found data rather than by habit Select and install rupture discs, including combination installations with relief valves Apply API 2350 overfill protection and specify independent protection layers for tanks Navigate PED conformity assessment, PSSR and the written scheme of examinationRequirements
No prior relief system experience is required - scenarios and sizing are built from first principles Any engineering or technical background is enough to follow the programme Comfortable with basic algebra - every sizing calculation is worked step by step No software or licence needed. The calculations are done by hand so the methodology is visible Helpful but not essential: familiarity with P&IDs and process plant operation Suitable both as a complete programme and as a reference to return to module by moduleDescription
A relief valve lifts. Where does the fluid go, how fast, and what happens to everything downstream of it?
Most engineers can size the valve. Fewer can size the header it discharges into. Fewer still can calculate the radiation at the flare tip, assess whether the knockout drum will actually remove the liquid, or determine whether the vessel will drop below its minimum design metal temperature during blowdown.
Overpressure protection is a chain, and it fails at whichever link nobody analysed.
WHAT THIS COVERS THAT A RELIEF COURSE DOES NOT
The relieving device is one component in a system that runs from the hazard identification study that established the scenario, through the sizing calculation, into the header, through the knockout drum and seal, up the flare stack, and out as thermal radiation over a sterile area.
Every one of those is a separate engineering discipline with its own standard and its own failure modes. This programme covers the whole chain, because a correctly sized relief valve discharging into an undersized header protects nothing.
WHAT IS INSIDE - TEN COMPLETE MODULESPressure Relief Systems (API 520, 521). Relief scenarios and their selection, sizing for gas, liquid, two-phase and fire case, conventional, balanced bellows and pilot-operated valves, set pressure, accumulation and overpressure, back pressure effects, inlet pressure drop and the three percent rule, and reaction force.
HAZOP & LOPA.Where the relief scenarios come from in the first place. Node selection and guide words, cause and consequence identification, independent protection layers and their credit values, initiating event frequency data, the risk gap and SIL determination, and two complete worked studies.
Flare System Design & Radiation. Flare tip selection and types, smokeless operation and assist media, radiation calculation and the API 521 method, sterile area determination, dispersion for unignited release, flare stack height determination, and pilot and ignition systems.
Disposal Systems, Knockout Drums & Liquid Seals.Header hydraulics and back pressure accumulation, header sizing for simultaneous relief, knockout drum sizing and droplet removal, liquid seal drums and flashback prevention, purge Requirements and air ingress, and low-temperature considerations in the header.
Blowdown & Depressurisation.Depressurisation philosophy and the API 521 rate, fire case blowdown and vessel wall temperature, low-temperature embrittlement on depressurisation, restriction orifice sizing, blowdown valve selection, and the interaction with relief system loading.
Flare & Vent Systems as Equipment.The flare as mechanical hardware - tips, stacks, derricks and guy wires, seals including molecular and velocity types, pilots and flame detection, purge gas systems, and the maintenance and inspection of equipment that cannot be taken offline.
Relief Device Testing & Management (API 576). Shop practice and as-found set pressure verification, disassembly and component inspection, seat lapping and reassembly, post-repair testing, interval setting from as-found data, and the management programme that keeps a population of hundreds of devices in date.
Rupture Discs & Non-Reclosing Devices.Disc types and their selection, burst tolerance and manufacturing range, combination installations with relief valves, the interface with the valve set pressure, and the failure modes specific to non-reclosing devices.
Tank Overfill Protection (API 2350). Tank categories and levels of concern, response time and the human factor, independent protection layers for overfill, alarm and automatic shutdown systems, and the Buncefield lessons that shaped current practice.
PED, PSSR & CE Marking. The regulatory frame - conformity assessment, categories and modules, the written scheme of examination, PSSR obligations, and the documentation a competent authority expects to see.
THE INTEGRATING ARGUMENT
The relief valve is sized from a scenario that came out of a HAZOP. Its set pressure and back pressure limits are set by the header, which is sized by the simultaneous relief case, which came from the same study. The header discharges into a drum sized for the largest liquid load, then to a flare whose height was determined by radiation at the fence line.
Change any one of those and the others move. That is the chain, and it is what no single course in the set can teach.
TWO FULL MOCK EXAMINATIONS
Timed, scored and retakeable, covering relief sizing and scenarios, flare and disposal systems, and hazard study and regulatory content.
WHO THIS IS FOR
Process and process safety engineers sizing relief devices and designing disposal systems. Project engineers responsible for flare and relief system design on capital projects. Operations and technical engineers managing existing relief and flare systems. Inspection and maintenance engineers running relief device programmes. HAZOP and LOPA participants who want to understand what their recommendations require. And anyone whose plant has a flare study they cannot fully defend.
WHAT YOU GET
Around 31 hours of structured video across 200 lessons and 50 sections, two full mock examinations, all presentations downloadable, lifetime access on mobile and TV and a certificate of completion.
No prior relief system experience is required - sizing and scenarios are built from first principles. Comfortable with basic algebra is enough; every calculation is worked step by step and no software is needed.
STILL GROWING
This masterclass is actively extended. New modules are added at no extra cost to everyone already enrolled.
Built by a practising Chartered Engineer (CEng MIMechE) with over fifteen years delivering safety-critical projects across oil, gas and energy infrastructure.
Enrol now and be able to defend the whole chain, not just the valve.
Who this course is for
Process and process safety engineers sizing relief devices and designing disposal systems Project and EPC engineers responsible for flare and relief system design on capital projects Operations and technical engineers managing existing relief, flare and blowdown systems Inspection and maintenance engineers running relief device testing and interval programmes HAZOP and LOPA participants who need to understand what their recommendations actually require Mechanical and equipment engineers specifying vessels protected by relief systems Compliance and safety case professionals responsible for overpressure protection demonstration Graduate and early-career engineers entering process safety rolesHomepage
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