This case study explains how a gas processing plant modernized aging pressure relief systems during an asset life extension project while avoiding expensive piping modifications. Several relief valves were identified as vulnerable to high inlet pressure loss and valve chatter. Instead of redesigning piping, the solution replaced conventional spring-operated relief valves with pilot-operated relief valves that could handle the challenging conditions using existing dimensions and layouts. The upgrade reduced shutdown complexity, eliminated potential reliability issues, and delivered substantial savings in labor, time, and modification costs while improving pressure relief performance.

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