Chemical Engineering Safety Protocols

PRV vs PSV vs Rupture Disk: Critical Safety Devices in Pressure Systems In pressurized systems—across industries such as pharmaceuticals, chemicals, oil & gas, and power generation—overpressure protection is essential. The selection of the right device is not merely technical; it’s a life-safety and compliance-critical decision. Below is a refined comparison of three major types of overpressure protection devices: 1. PRV (Pressure Relief Valve) Function: Opens proportionally as system pressure exceeds the set point, allowing a modulated release of fluid. Best For: Liquids or incompressible fluids. Typical Use Cases: Systems requiring gradual pressure reduction to avoid fluid hammer or mechanical stress. Reset Mechanism: Self-reseating once pressure returns below the set point. Common Applications: Hydraulic systems, piping networks, liquid storage tanks. 2. PSV (Pressure Safety Valve) Function: Opens rapidly ("pop action") when the system reaches the set pressure, allowing full flow to relieve pressure. Best For: Gases and vapors. Typical Use Cases: Situations demanding quick pressure relief to avoid vessel rupture or catastrophic failure. Reset Mechanism: Self-reseating after pressure drops below the reseat level. Common Applications: Boilers, pressure vessels, gas pipelines, chemical reactors. 3. Rupture Disk (Burst Disk) Function: A non-reclosing, one-time-use membrane that bursts at a precise, predetermined pressure. Best For: Environments where instantaneous, full-flow relief is needed, or where valve leakage is not acceptable (e.g., sterile or corrosive processes). Typical Use Cases: Secondary relief (behind a PRV or PSV), high-purity or hazardous systems, or cost-sensitive protection. Reset Mechanism: Non-resetting — must be replaced after activation. Common Applications: Sterile pharma systems, explosive or corrosive atmospheres, chemical reactors. Why It Matters Selecting the appropriate overpressure protection device is crucial. A mismatch can lead to: Equipment damage Process interruptions Regulatory non-compliance Serious safety incidents Understanding the specific characteristics of PRVs, PSVs, and rupture disks ensures optimized protection, regulatory adherence, and safe operation of critical systems.

𝐁𝐚𝐬𝐢𝐜𝐬 𝐨𝐟 𝐚 𝐏𝐫𝐞𝐬𝐬𝐮𝐫𝐞 𝐑𝐞𝐥𝐢𝐞𝐟 𝐕𝐚𝐥𝐯𝐞 - 𝐂𝐨𝐦𝐩𝐨𝐧𝐞𝐧𝐭𝐬 𝐚𝐧𝐝 𝐅𝐮𝐧𝐜𝐭𝐢𝐨𝐧𝐢𝐧𝐠 A Pressure Relief Valve (PRV) is a safety device designed to protect equipment and systems from overpressure by automatically releasing excess pressure from a vessel, pipeline, or system when it exceeds a preset limit. Once the pressure returns to safe levels, the valve reseats and closes to prevent further fluid or gas loss. They are commonly used in boilers, pressure vessels, pipelines, chemical plants, oil & gas, and other pressurized systems. 🔹 Functions of a Pressure Relief Valve Safety protection – prevents catastrophic equipment failure, explosions, or rupture. Pressure regulation – maintains pressure within safe operating ranges. ✅ Working Principle: 🔹Normal condition: Spring force > System pressure → valve stays closed. 🔹Overpressure: System pressure > Spring force → disc lifts → fluid/gas escapes → pressure drops. 🔹Pressure normal: Spring pushes disc back → valve closes. Pressure Relief Valve Parts 1. Cap Protects the top of the valve and prevents dirt, moisture, and accidental tampering with the compression screw. 2. Stem A vertical shaft that transfers the spring force to the disc. It moves upward when pressure exceeds the set point. 3. Compression Screw Used to adjust the compression of the spring, thereby changing the valve’s set pressure. 4. Compression Nut Locks the compression screw in place to prevent unintended adjustment of the set pressure. 5. Bonnet Covers and houses the upper part of the valve components like the spring and stem. It also guides the stem’s movement. 6. Spring Provides downward force on the disc to keep the valve closed. Its compression determines the relief pressure. 7. Top Spring Step & Bottom Spring Step Support plates for the spring. Top Spring Step: Connects to the compression mechanism. Bottom Spring Step: Transfers spring load to the disc holder/guide. 8. Handle (Lever) Allows manual lifting/testing of the valve to ensure proper operation and prevent seizing. 9. Stud & Stud Nut Fasteners holding the bonnet to the valve body, ensuring structural integrity and sealing. 10. Guide A cylindrical guide ensuring proper alignment of the disc/stem movement, preventing side loads. 11. Disc The sealing element that blocks flow when seated. It lifts when pressure exceeds the set point to allow pressure relief. 12. Disc Holder Supports the disc and ensures correct seating. Helps center the disc on the nozzle. 13. Nozzle Inlet port where upstream fluid enters. It forms the seating surface for the disc and defines the flow area when the valve opens. 14. Point (Seat Contact Area) The sealing interface between disc and nozzle. Critical for achieving a tight shutoff. 15. Upstream (Inlet) Side of the valve where the system pressure is applied. This is the pressure being relieved. 16. Downstream Flange (Outlet) Outlet path for the relieved fluid once the disc lifts.

🎯Enhanced Due Diligence (EDD) When and Why It’s Applied? Enhanced Due Diligence (EDD) is a vital pillar of any Anti-Money Laundering (AML) framework. It goes beyond standard due diligence, applying deeper verification, thorough risk assessment, and ongoing monitoring to higher-risk situations. But when exactly should EDD be applied? Let’s explore the key scenarios: 📌1. High-Risk Customers Certain customer profiles inherently carry higher risks: ♦️Politically Exposed Persons (PEPs): Individuals in prominent public roles vulnerable to corruption. ♦️High-Net-Worth Individuals (HNWIs): Customers with significant financial resources requiring closer scrutiny. ♦️Customers from High-Risk Countries: Those from jurisdictions with weak AML controls or a history of financial crime. 📌2. High-Risk Transactions EDD is critical when transactions show unusual patterns or elevated risks: ♦️Large or Unusual Transactions: Deviations from a customer’s typical behavior. ♦️Cross-Border Payments to High-Risk Regions: Countries known for money laundering or terrorist financing activities. ♦️Transactions with Unclear Purposes: Activities lacking a transparent, legitimate rationale. 📌3. High-Risk Products or Services Some products or services are naturally more prone to misuse: ♦️Cash-Intensive Businesses: Casinos, convenience stores, and others dealing heavily in cash. ♦️Offshore Banking Services: Especially in jurisdictions with limited regulatory oversight. 📌4. New or Complex Customer Relationships When onboarding new customers especially those with complex corporate structures or limited historical data EDD ensures hidden risks are identified before they materialize. 📌5. High-Risk Geographies EDD becomes mandatory when dealing with: ♦️Sanctioned or Embargoed Countries: Jurisdictions restricted due to political, economic, or security concerns. ♦️Countries Identified by FATF: Locations flagged for strategic AML deficiencies. 📌Why EDD Matters? Enhanced Due Diligence isn’t just about ticking regulatory boxes, it’s about: ♦️Safeguarding financial institutions from financial crime. ♦️Building credibility and trust with regulators, stakeholders, and customers. ♦️Strengthening the integrity and resilience of the global financial system. In an ever-evolving threat landscape, EDD stands as one of our strongest defenses. #AML #EDD #Compliance #FinancialCrime #RiskManagement #DueDiligence

🔹 Layers of Protection Analysis (LOPA): A Structured Approach to Risk Reduction 🔹 In process safety, the goal isn’t to eliminate risk completely — it’s to reduce it to an acceptable level through multiple independent protection layers (IPLs). A LOPA is a semi-quantitative risk analysis method that bridges the gap between a qualitative HAZOP study and a fully quantitative risk assessment. It helps identify whether existing safeguards are sufficient — or if additional protection layers are needed. The diagram below illustrates the nine layers of protection, from the most inherent to the outermost response barrier: 1️⃣ Inherently Safer Design (ISD) 2️⃣ Basic Process Control System (BPCS) 3️⃣ Alarms & Operator Intervention 4️⃣ Safety Instrumented System (SIS) 5️⃣ Physical Protection (Relief Devices) 6️⃣ Physical Containment (Bunds, Dikes) 7️⃣ Fire & Gas System 8️⃣ Plant Emergency Response 9️⃣ Community Emergency Response Each layer must be independent, auditable, and effective in preventing or mitigating the consequence of a hazardous event. A typical LOPA workflow involves: ✔️ Identifying an initiating event (failure or human error) ✔️ Estimating its frequency (FOIE) ✔️ Defining the independent protection layers and their Probability of Failure on Demand (PFD) ✔️ Calculating the Mitigated Consequence Frequency (MCF) = FOIE × PFD ✔️ Comparing the risk against acceptable criteria Through this structured method, LOPA ensures that major accident scenarios identified in HAZOPs — such as overpressure, toxic release, or fire — are managed with sufficient, reliable, and independent barriers. ⚙️ Key takeaway: LOPA is not just a calculation — it’s a mindset of defense in depth that reinforces the integrity of every safeguard. #ProcessSafety #LOPA #RiskManagement #PSM #HAZOP #HSE #SafetyCulture #OilAndGas #ChemicalEngineering #CCPS

I thought I understood KYC, CDD, and EDD... until an interviewer asked me Can you explain when EDD is actually required — with examples? I froze. I had studied the theory. I knew the full form. But I couldn’t connect it to real-life risk. That day changed how I learned AML forever. Here’s the simplified, real-world version I wish someone had taught me earlier 👇 KYC vs CDD vs EDD — Explained Like You’re New 🔹 Simplified Due Diligence (SDD) 👉 For low-risk customers 🧾 Example: Salary account for a school teacher with full KYC 📌 Minimal ID verification only 🔹 Customer Due Diligence (CDD) 👉 For moderate-risk customers 🧾 Example: Indian freelancer receiving international payments 📌 You check PAN, Aadhaar, business nature, and source of income 🔹 Enhanced Due Diligence (EDD) 👉 For high-risk cases (yes, that includes crypto!) 🧾 Example: A politically exposed person (PEP) A customer routing funds through offshore entities 📌 You go deeper: source of funds, UBO, periodic review, negative news ⚠️ But when exactly is EDD required? These are your red flags 🚩👇 🔺 Customer is a PEP (or a close relative of one) 🔺 Using high-risk jurisdictions (FATF grey/blacklisted) 🔺 Crypto wallet usage, especially privacy coins 🔺 Large structured deposits just below reporting limits 🔺 Shell companies or layered transactions 🔺 Reluctance to disclose source of wealth 🧠 What helped me grow: Stop memorizing definitions. Start thinking like a risk analyst. Ask: Would I trust this customer without more info? If you’re a student, career switcher, or even an AML professional — you don’t need a ₹10,000 course. You just need the right context, the right practice, and someone to show you what matters in real interviews. 💬 Drop EDD in the comments or DM me for the next batch details.

High-Risk Customers How Enhanced Due Diligence (EDD) for High-Risk Customers is Conducted? Enhanced Due Diligence (EDD) is a stricter version of Customer Due Diligence (CDD) applied to high-risk customers such as politically exposed persons (PEPs), offshore companies, clients from high-risk jurisdictions, and cash-intensive businesses. 1. Identify High-Risk Customers  Factors That Trigger EDD -Customers from high-risk countries (FATF black/grey list) -PEPs (Politically Exposed Persons) or their associates -Businesses dealing with cash-intensive transactions (casinos, crypto, money service businesses) -Complex ownership structures (shell companies, trust funds) -Transactions that lack a clear economic purpose  Screen Against AML Watchlists -Sanctions Lists (OFAC, UN, EU, FATF) -PEP Lists -Negative Media Checks (Links to financial crime, fraud, money laundering) 2. Gather Additional Documentation  For Individuals -Source of Wealth (SoW): How was the wealth accumulated? (e.g., salary, business profits, inheritance) -Source of Funds (SoF): Where is the money coming from? (e.g., bank accounts, investments) -Proof of Address (Recent utility bill, lease agreement) -Enhanced Identity Verification (Biometric checks, additional government ID)  For Businesses -Detailed Ownership Structure (Ultimate Beneficial Owners – UBOs) -Business Purpose & Economic Justification -Financial Statements & Tax Records -Proof of Business Activities (Invoices, contracts, website, business registration) 3. Conduct In-Depth Risk Assessment  Assess Risk Level Based on Customer Profile & Transactions -Analyze transaction volume, frequency, and geographical locations Identify abnormal patterns (e.g., structuring, frequent international wire transfers) -Review past compliance history (e.g., previous AML flags, regulatory concerns)  On-Site Visits & Interviews (For Businesses) -Conduct physical verification of business operations -Interview key executives and verify legitimacy of business activities 4. Implement Ongoing Monitoring & Reporting  Continuous Transaction Monitoring -Real-time tracking of large or unusual transactions -Scrutinizing transactions linked to offshore accounts, high-risk countries  More Frequent KYC Updates -Update high-risk customer profiles every 6 months to 1 year (instead of the usual 1-2 years)  File Suspicious Activity Reports (SARs) -If there are red flags, report to regulators (e.g., FinCEN, FCA, FATF, AUSTRAC) -Maintain detailed records for compliance audits

Red Flags in Enhanced Due Diligence (EDD) Enhanced Due Diligence (EDD) is required for high-risk customers, including Politically Exposed Persons (PEPs), offshore entities, and clients from high-risk jurisdictions. Identifying red flags during EDD helps mitigate risks related to money laundering, fraud, and terrorist financing. 1. Identity & Documentation Red Flags • Discrepancies in identity documents (e.g., mismatched details, fake or altered IDs). • Use of multiple identities or aliases across various accounts. • Reluctance to disclose Ultimate Beneficial Owner (UBO) information. • Complex corporate structures with unclear ownership (e.g., shell companies, nominee directors). • Frequent changes in business registration details, such as address, directors, or ownership. 2. Source of Wealth (SoW) & Source of Funds (SoF) Red Flags • Unclear or unverifiable Source of Wealth (e.g., unexplained large assets). • Discrepancy between Source of Funds and customer profile (e.g., a low-income individual managing large sums). • Large cash deposits without a reasonable explanation. • High-value transactions that are inconsistent with declared income or business activities. • Frequent third-party payments or transactions with no apparent business relationship. 3. Transaction Behavior Red Flags • Rapid fund transfers across multiple accounts without a clear business purpose. • Transactions structured to stay just below reporting thresholds. • Large transfers to or from high-risk jurisdictions (e.g., FATF black/grey list countries). • Unusual cryptocurrency transactions (e.g., privacy coins, mixing services, unregulated exchanges). • Unexplained cross-border transactions involving offshore entities. 4. Business & Economic Justification Red Flags • Recently established businesses receiving unusually high transaction volumes. • Financial transactions inconsistent with business activity (e.g., a small retail shop processing millions). • Use of shell companies or offshore entities in tax havens. • Lack of online presence or physical business operations. • Frequent changes in business ownership, directors, or legal structure. 5. Politically Exposed Persons (PEPs) & Sanctions Red Flags • Customer is a PEP or closely associated with one (e.g., family members, business partners). • Negative media reports linking the customer to corruption or financial crimes. • Ties to sanctioned entities, blacklisted organizations, or terrorist groups. • Attempts to use intermediaries or proxies to conceal involvement. 6. Customer Behavior & Interaction Red Flags • Hesitation or refusal to provide additional information during EDD reviews. • Evasive, secretive, or defensive behavior when questioned about transactions. • Avoidance of in-person meetings or reluctance to provide verifiable contact details. • Requests to bypass compliance procedures or expedite onboarding.

Case Study: How an AML Professional Handled a High-Profile Individual Transaction to a High-Risk Jurisdiction Characters: Emma: AML Investigator John: Relationship Manager for High-Profile Clients Sophia: Compliance Officer Mr. Peterson: High-Profile Client Scene 1: Notification of the Transaction Emma receives an alert for a large transaction involving a high-profile client, Mr. Peterson. Emma: (reviewing the alert) Hmm, a $5 million wire transfer to a bank in a high-risk jurisdiction flagged by our monitoring system. Let’s dig into the details. Emma examines the transaction history and notices Mr. Peterson has no prior transactions of this nature. Emma: This is unusual. Mr. Peterson typically conducts business locally. I need more context. Scene 2: Initial Discussion Emma reaches out to John, the relationship manager for Mr. Peterson. Emma: Hi John, I noticed a significant transaction initiated by Mr. Peterson to a high-risk jurisdiction. Do you know the purpose of this transfer? John: Yes, he mentioned it briefly. He’s looking to invest in a real estate project in that region. It’s part of his portfolio diversification strategy. Emma: Did he provide any documentation or details about this project? John: Not yet, but I can request it if needed. Emma: Please do. I’ll also conduct some additional checks on the jurisdiction and counterparties involved. Scene 3: Enhanced Due Diligence Emma conducts enhanced due diligence (EDD) on the transaction. Emma: (thinking aloud) Let’s check the sanctions lists, politically exposed persons (PEP) databases, and adverse media for the beneficiary. Emma finds no sanctions issues but discovers the beneficiary has links to a company previously investigated for money laundering. Emma: This is concerning. Let me escalate this to Sophia in Compliance. Scene 4: Escalation and Decision-Making Emma presents her findings to Sophia. Emma: Sophia, I’ve flagged a $5 million transaction by Mr. Peterson to a high-risk jurisdiction. The beneficiary has ties to a company previously implicated in money laundering. Sophia: Good work. Let’s inform Mr. Peterson that additional documentation is required, including proof of funds, project details, and the relationship with the beneficiary. Scene 5: Client Communication John communicates with Mr. Peterson to gather the required information. John: Mr. Peterson, our compliance team has flagged your transaction for additional review. Could you provide the project agreement, your due diligence on the counterparty, and proof of funds? Mr. Peterson: Certainly. I’ll have my team send over the documents by tomorrow. "Curious about how this case study concluded? Check the comment section below for the final review and resolution—your insights and thoughts are welcome!" #AMLCaseStudy #ComplianceMatters #FinancialCrimePrevention #HighRiskTransactions #AMLInsights #RiskManagement #DueDiligence #FinancialIntegrity #AntiMoneyLaundering #PEPMonitoring

𝗘𝗺𝗲𝗿𝗴𝗲𝗻𝗰𝘆 𝗣𝗿𝗲𝘀𝘀𝘂𝗿𝗲 𝗥𝗲𝗹𝗶𝗲𝗳 𝗩𝗲𝗻𝘁𝘀: 𝗧𝗵𝗲 𝗟𝗮𝘀𝘁 𝗟𝗶𝗻𝗲 𝗼𝗳 𝗗𝗲𝗳𝗲𝗻𝘀𝗲 In storage tanks and process vessels, unexpected overpressure can occur due to fire exposure, runaway reactions, or even blocked vents. When all normal venting systems fail to maintain safe internal pressure, an Emergency Pressure Relief Vent (EPRV) becomes the final safeguard protecting both equipment and personnel from catastrophic rupture. An EPRV is designed to open only under extreme overpressure conditions, usually above the normal operating or conservation vent range. These devices play a critical safety role by: • Preventing structural damage or explosion of the tank • Releasing excess vapors to the atmosphere (or flare system) • Automatically reclosing once normal pressure is restored According to API 2000 and NFPA 30, every tank storing volatile liquids must be equipped with both normal and emergency venting provisions. If you’re dealing with tanks or process systems: 1. Verify vent sizing using API 2000 or ISO 28300. 2. Check the set pressure — it should be slightly higher than the normal vent but below the tank design pressure. 3. Inspect regularly for corrosion, blockage, and gasket wear. 4. Protect the vent outlet with flame arrestors where flammable vapors are involved. Have you ever encountered a case where an emergency vent activated unexpectedly? What was the root cause design error, blocked vent, or abnormal process conditions? #ProcessSafety #PressureVessel #PressureRelief #StorageTanks #HSE #MechanicalEngineering #OilAndGas #PlantDesign #HVAC

Managing Risk with Layers of Protection 🔹 In process industries, one of the biggest challenges is answering the question: “How safe is safe enough?” The Layer of Protection Analysis (LOPA), developed by CCPS and AIChE, offers a structured, semi-quantitative approach to risk assessment. Unlike subjective debates or emotional appeals, LOPA provides a consistent, risk-based framework that helps organizations: ✅ Identify accident scenarios and their potential consequences ✅ Evaluate the effectiveness of protection layers (engineering, procedural, or human) ✅ Decide whether risks are tolerable or need additional safeguards ✅ Document decisions clearly, improving both transparency and accountability What makes LOPA powerful is its balance—it’s more rigorous than qualitative methods (like HAZOP) but less resource-intensive than full quantitative risk analysis. This makes it an efficient tool for design, operations, and management of change across the process life cycle . 🌍 With increasing global emphasis on process safety, methods like LOPA are not just technical tools—they’re enablers of sustainable, responsible operations. 👉 Have you used LOPA in your risk management practice? What challenges or benefits did you observe? #ProcessSafety #RiskManagement #LOPA #ChemicalEngineering #SafetyCulture