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Process Plant Overpressure Risk Analysis

Contingency Analysis (often referred to as an Overpressure Protection Study) is the systematic engineering process of identifying every credible scenario that could cause the pressure in a vessel or piping system to exceed its Maximum Allowable Working Pressure (MAWP). In the context of relief system design (governed largely by API Standard 521), you cannot simply size a Pressure Safety Valve (PSV) for a generic flow rate. You must analyze various "contingencies"—deviations from normal operation—calculate the required relief load for each, and size the valve for the single scenario that requires the largest orifice area. This worst-case scenario is known as the Controlling Case.