PHPublished 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: 20 Lectures ( 3h 40m ) | Size: 2.1 GB
Header hydraulics and back pressure, KO drum sizing, seal drums, air ingress, flashback and cold relief
What you'll learn
Configure a disposal network and justify wet, dry, high pressure, low pressure and cold segregation
Establish the simultaneous relief case and accumulate load along a header section by section
Calculate compressible flow pressure drop and apply velocity, Mach and noise criteria to a header
Separate built-up from superimposed back pressure and check every relief device against it
Work the iteration between header sizing and relief device type instead of fixing either one
Size a knockout drum from droplet settling velocity, in horizontal or vertical configuration
Decide which internals belong in a flare drum and which will foul, plug or collapse
Design a liquid seal drum and explain the seal failures that allow flashback
Calculate purge, understand air ingress on cooling and low flow, and layer the defences against it
Handle cold, cryogenic, toxic and atmospheric disposal routes and their material and dispersion issues
Requirements
No prior disposal system experience is required — back pressure, compressible flow and droplet settling are built up from the start
Any engineering, technical or operations background is enough to follow the course
Comfortable with basic algebra — the sizing calculations are worked step by step, in full
Helpful but not essential: a relief load summary, a flare header line list or a drum datasheet from your own plant to work against
No software or purchases needed — no flare network package and no standard needs to be bought
Description
This course contains the use of artificial intelligence.
▸ Sizing the relief valve is the easy half. The hard half is where the discharge goes.
A relief valve is sized against an orifice area and signed off. Downstream of it sits a header that collects every other device on the plant, a knockout drum that has to take the liquid out, a seal drum that has to keep air from travelling back up, and a stack that has to carry it away. None of that is visible in the relief valve calculation, and all of it decides whether the relief valve will actually work when it is called.
The failures are quiet until they are not. A header sized on an optimistic simultaneous case, so the built-up back pressure pushes a conventional valve into chatter on the day it is needed. A knockout drum designed for a droplet size nobody recorded, sending liquid to the tip as burning rain. A liquid seal that has boiled dry or frozen. A pocket in a header that was never sloped, holding a slug that arrives at the drum as a plug of liquid. A cold header that goes below its minimum design metal temperature during a flashing relief and becomes a brittle fracture risk in the middle of an upset.
This course teaches the whole chain from relief device outlet to flare tip: segregation and header configuration, the simultaneous load, compressible flow and back pressure, knockout drum sizing from droplet settling, seal drums, purge and air ingress, and the cold, toxic and atmospheric routes that do not go to a flare at all.
▸ The system that is only tested in a real relief event
A disposal system is unusual among plant systems in that it does nothing on any normal day. It is not proved by operation, its faults do not show up in production data, and the first genuine test of the design is an event nobody wanted. That is why this course weights failure and diagnosis so heavily — the mechanisms have to be understood in advance, because there is no learning curve during a relief.
The iteration between header sizing and relief device selection is treated as the central problem it really is. Back pressure limits differ between conventional, balanced bellows and pilot-operated valves, so the header you can afford changes the valves you must buy, and the valves already installed change the header you are allowed to design. The course works that loop rather than presenting either end of it as fixed.
Five focused sections, worked through in an afternoon.
▸ What you will master
• Configure a disposal network — wet and dry, high and low pressure, warm and cold — and understand why the segregation decision governs everything downstream of it
• Establish the simultaneous relief case and accumulate load along a header to size each section on the load it actually carries
• Calculate compressible flow pressure drop in a relief header and apply velocity, Mach and noise criteria correctly
• Separate built-up from superimposed back pressure and check every device against the calculated value, for conventional, balanced bellows and pilot-operated valves
• Work the iteration between header size and relief device selection instead of treating either as fixed
• Size a knockout drum from droplet settling velocity, choose between horizontal and vertical configuration, and set diameter, length and hold-up volume
• Judge which drum internals belong in a flare knockout drum and which are a liability in a fouling, slugging service
• Design a liquid seal drum — seal depth, gas passage, seal liquid selection and freezing — and explain the seal failures that permit flashback
• Calculate purge requirement, understand the air ingress mechanism on cooling and low flow, and layer the defences that prevent a flammable mixture forming in the header
• Handle the awkward routes — cold and cryogenic relief and its material consequences, toxic and acid gas disposal, and atmospheric vents that need a safe location assessment
▸
Who this course is for
Process and process safety engineers designing or reviewing relief and disposal systems
Piping and layout engineers routing flare headers and managing slope, pockets and drainage
Mechanical and vessel engineers specifying knockout drums and seal drums
Operations and technical support engineers responsible for live flare header networks
Project engineers assessing existing disposal systems against increased relief load
Graduate engineers moving into relief systems, process safety or design roles
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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: 20 Lectures ( 3h 40m ) | Size: 2.1 GB
Header hydraulics and back pressure, KO drum sizing, seal drums, air ingress, flashback and cold relief
What you'll learn
Configure a disposal network and justify wet, dry, high pressure, low pressure and cold segregation Establish the simultaneous relief case and accumulate load along a header section by section Calculate compressible flow pressure drop and apply velocity, Mach and noise criteria to a header Separate built-up from superimposed back pressure and check every relief device against it Work the iteration between header sizing and relief device type instead of fixing either one Size a knockout drum from droplet settling velocity, in horizontal or vertical configuration Decide which internals belong in a flare drum and which will foul, plug or collapse Design a liquid seal drum and explain the seal failures that allow flashback Calculate purge, understand air ingress on cooling and low flow, and layer the defences against it Handle cold, cryogenic, toxic and atmospheric disposal routes and their material and dispersion issuesRequirements
No prior disposal system experience is required — back pressure, compressible flow and droplet settling are built up from the start Any engineering, technical or operations background is enough to follow the course Comfortable with basic algebra — the sizing calculations are worked step by step, in full Helpful but not essential: a relief load summary, a flare header line list or a drum datasheet from your own plant to work against No software or purchases needed — no flare network package and no standard needs to be boughtDescription
This course contains the use of artificial intelligence.
▸ Sizing the relief valve is the easy half. The hard half is where the discharge goes.
A relief valve is sized against an orifice area and signed off. Downstream of it sits a header that collects every other device on the plant, a knockout drum that has to take the liquid out, a seal drum that has to keep air from travelling back up, and a stack that has to carry it away. None of that is visible in the relief valve calculation, and all of it decides whether the relief valve will actually work when it is called.
The failures are quiet until they are not. A header sized on an optimistic simultaneous case, so the built-up back pressure pushes a conventional valve into chatter on the day it is needed. A knockout drum designed for a droplet size nobody recorded, sending liquid to the tip as burning rain. A liquid seal that has boiled dry or frozen. A pocket in a header that was never sloped, holding a slug that arrives at the drum as a plug of liquid. A cold header that goes below its minimum design metal temperature during a flashing relief and becomes a brittle fracture risk in the middle of an upset.
This course teaches the whole chain from relief device outlet to flare tip: segregation and header configuration, the simultaneous load, compressible flow and back pressure, knockout drum sizing from droplet settling, seal drums, purge and air ingress, and the cold, toxic and atmospheric routes that do not go to a flare at all.
▸ The system that is only tested in a real relief event
A disposal system is unusual among plant systems in that it does nothing on any normal day. It is not proved by operation, its faults do not show up in production data, and the first genuine test of the design is an event nobody wanted. That is why this course weights failure and diagnosis so heavily — the mechanisms have to be understood in advance, because there is no learning curve during a relief.
The iteration between header sizing and relief device selection is treated as the central problem it really is. Back pressure limits differ between conventional, balanced bellows and pilot-operated valves, so the header you can afford changes the valves you must buy, and the valves already installed change the header you are allowed to design. The course works that loop rather than presenting either end of it as fixed.
Five focused sections, worked through in an afternoon.
▸ What you will master
• Configure a disposal network — wet and dry, high and low pressure, warm and cold — and understand why the segregation decision governs everything downstream of it
• Establish the simultaneous relief case and accumulate load along a header to size each section on the load it actually carries
• Calculate compressible flow pressure drop in a relief header and apply velocity, Mach and noise criteria correctly
• Separate built-up from superimposed back pressure and check every device against the calculated value, for conventional, balanced bellows and pilot-operated valves
• Work the iteration between header size and relief device selection instead of treating either as fixed
• Size a knockout drum from droplet settling velocity, choose between horizontal and vertical configuration, and set diameter, length and hold-up volume
• Judge which drum internals belong in a flare knockout drum and which are a liability in a fouling, slugging service
• Design a liquid seal drum — seal depth, gas passage, seal liquid selection and freezing — and explain the seal failures that permit flashback
• Calculate purge requirement, understand the air ingress mechanism on cooling and low flow, and layer the defences that prevent a flammable mixture forming in the header
• Handle the awkward routes — cold and cryogenic relief and its material consequences, toxic and acid gas disposal, and atmospheric vents that need a safe location assessment
▸
Who this course is for
Process and process safety engineers designing or reviewing relief and disposal systems Piping and layout engineers routing flare headers and managing slope, pockets and drainage Mechanical and vessel engineers specifying knockout drums and seal drums Operations and technical support engineers responsible for live flare header networks Project engineers assessing existing disposal systems against increased relief load Graduate engineers moving into relief systems, process safety or design rolesYou do not have permission to view the full content of this post. Log in or register now.
You do not have permission to view the full content of this post. Log in or register now.
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