The lessons learned are 1) that a burst disk that is properly designed into a hydrogen system will provide protection from over-pressurization, and 2) that refueling operations must be conducted carefully by attentive operators. These are. Rupture discs are critical instruments utilized so that companies can ensure process safety as set forth by the International Safety Standards (IEC 61508/61511). . Inferior rupture discs often cause unnecessary and expensive production shutdowns due to the lack of quality testing and expertise in manufacturing. Those blowers use rotating vanes or blades that are driven by large motors. The PTFE film is scored along the outer edge of the rupture disk to facilitate failure of the film upon rupturing of the disc. Once the drain is opened, how do you know when the bowl is full? The most common symptom of a piping problem is rupture disc leakage due to uneven loading of the metal-to-metal sealing surfaces. If the relief fluids are vented in the common header vented media can result in either corrosion or polymerization. Consider the following example: If plugging two waffle irons into an electrical outlet will blow a fuse (a safety device), the solution is not to switch to a bigger fuse. Rupture Disc. For further information on how we how we use cookies and how to change your browser settings, please read our, New Product Improves Process Performance, Reliability, and Safety, Continental Disc Corporation Appoints Mike Waters as New CEO, Introducing: TSL Engineered Products, Global Manufacturer of Specialized Solutions. The system then heats the oatmeal for 20 minutes and finally drains the oatmeal into a bowl. Disc manufacturers caution the user to periodically check their discs for fatigue. The rupture element of the disc is equipped with breaking points that are normally created by means of lasers. Consider the ramifications of a personal computer maker revealing that their computers were designed to crash. If Purchaser decides not towitness the relevant feature, production can proceed without permission of Purchaser. Some involved failures from multiple pressure-relief events. | Privacy Policy This independent evaluation demonstrates our commitment to unmatched safety and top-of-the-line quality. This website is my first venture into the world of blogging with the aim of connecting with other piping engineers around the world. More than 600 Articles! It is normally, above the working pressure during normal operation and below the maximum allowable working pressure) and corresponding temperature. Usually we should but in some instances the data can mislead us. The Resistance to Flow Method analyzes the flow capacity of the relief piping and accounts for the frictional losses of the relief piping and all components. It sounds preposterous! They are designed to act in tension. He received a B.S. This paper attempts to numerically simulate the deformation and failure behaviour of forward domed rupture disc, with rectangular scores at a high impulse loading rate of 500 MPa/s, adopting a visco-plastic, and . While being filled with hydrogen, a small gas cylinder was over-pressurized due to a faulty pressure transducer and failed catastrophically. The burst causes were investigated. This isnt always the case, though. A very thin membrane will be quite responsive to small changes in pressure, deflecting a large amount (typically in a less-than-linear fashion). While this may offer more assurance of avoiding catastrophe, it also may prompt unnecessary and costly shutdowns, slowdowns, etc. Fail. However, thats not always the case. An improperly installed or designed burst disk system can result in a greater risk than the hazard for which it was installed. The shell's volume is 7.5 m 3. Overall an interesting article as per me. Your email address will not be published. Pre-torque style holders are frequently used in applications where physical inspection and re-use of the rupture disc is desired as the holder maintains load on the disc even after removal from the pipe flanges. This is usually the case with storage vessels for non-refrigerated liquefied compressible gases at ambient temperatures. | 3160 W. Heartland Drive | Liberty, MO 64068-3385 | Privacy Policy, This website uses cookies to enhance and improve your browsing experience. Common solutions to this problem include the following: Use of heat tracing or steam jacketing around the vessel nozzle and rupture disc holder, Use of a viscous tee style holder (Figure 1), which continually wipes the disc surface, preventing product buildup, Use of a flush-mount-style rupture-disc assembly, which eliminates any dead space in the vessel nozzle that could accumulate solidified materials. 1995 - 2007, All Rights Reserved. best wishes, sshep Reply To This Thread This puts lives and assets at greater risk. Changes occurring faster than the sensor can read will produce skewed results or an average rather than true data. In one case, multiple burst disks were installed in a holder where only one was supposed to be used. Signal processing really comes down to how many points we get, how accurate they are and what we do with the space in between them. In this study, the results of tensile tests, failure modes, failure characteristics, and failure mechanisms were analyzed in detail for two fabric structures, namely, plain-weave and. This problem occurs as a result of improper piping-design and rupture disc selection. prior to rupturing of the metallic disk. Highly corrosive atmospheres can also significantly damage the materials that the discs are made out of. Burst disks used in a hydrogen system should be manufactured from a material compatible with hydrogen service and sized and pressure-rated to the system they are protecting. In most cases, the disc actually has operated as intended to relieve an overpressure event but the available data arent good enough for us to see that such an event occurred. When confronted with a signal spike (high intensity, short duration), averaging will smooth relevant magnitudes out of the graph, causing under-reported values. So, it has to be replaced after the burst. The use of a ruptured disc as primary relief is attractive if the relieving fluids are non-toxic, non-hazardous, and the system stop and the loss of fluids is not an issue. Domes are typically supported on the outlet side to prevent movement of the dome prior to reversal. The key lesson learned is that even though there is no specific industry guidance on burst disk materials, some materials provide improved performance characteristics. << Workers could also over-torque the mounting service, which can cause leaks and premature failure. /Length1 24592 This is the rupture disks minimum cross-sectional area needed to meet the required flow. The inlet lets the fluid into the system. Anal. ERIC GOODYEAR is a senior engineer at Oseco, Broken Arrow, Okla. Email him at egoodyear@oseco.com. GB567-2012, Bursting disc safety devices. Averaging often is used to filter out electrical noise. 2) Type of Inspection byRupture Disc Purchaser may be changed according to equipment criticality and vendor QC evaluation at job stage. Then, how do you tell when the tank is full? H. J. Lee, Y. R. Kim, S. H. Kim, et al, Experimental investigation on the self-ignition of pressurized hydrogen released by the failure of a rupture disk through tubes, P. Combus. The emergency responders cooled the tube trailer with water and closed the isolation valves to extinguish the fire without further incident. Both disk and disc are commonly used spellings of the word in industry. lining on the discs are discontinuous and of no practical value for corrosion Copyright 2012-2013 Inspection-for-Industry.Com, Rupture Disc Mill test reports for body and trim, Rupture Disc Checking of Characteristics (Effective Pressure, Disc Diameter ), Rupture Disc Performance including set pressure test, Rupture Disc Final visual / Dimension Inspection, Rupture Disc Documentation review prior to release(Final activity of Technical Inspection). The typical rupture disc begins to respond to pressure in excess of the burst pressure in less than 1 millisecond. (Notification req'd), S: Witness, but spot check basis. These lessons learned are followed by brief accounts of the 12 burst disk safety event records in the database, with links provided to each record. Although the vent line was procured from a commercial source, it was not of sufficient strength to contain the hydrogen gas pressure relief. 2023 Endeavor Business Media, LLC. A quick way to check for holder damage due to over-torque is to put a straight edge along the gasket face and look for signs of significant bending (Figure 5). Several safety systems are examined, such as gas cleanup systems and plasma shutdown systems. So be with me for the next couple of years! Another limiting factor of many sensors is accuracy, i.e., the closeness of the reported value to the true one. It can get incredibly complex very quickly. Many process materials are also prone to building up and solidifying on internal surfaces. This plot indicates a much less severe pressure spike. NFPA 37 vs NFPA 110 (PDF). Loss Prevent Proc. Moreover, interpreting these data requires properly accounting for significant interactions that can impact engine rpm; small changes in conditions can affect the reported values drastically if sample rates arent taken into account. 2) Type of Inspection by Rupture Disc Purchaser may be changed according to equipment criticality and vendor QC evaluation at job stage. Kindly find below the operating parameters and suggest if a change in rupture disc design would rectify the problem So, adequately monitoring the engine involves analyzing a massively greater volume of data. In one incident, water freezing on a burst disk surface caused it to fail. SO, I can take a couple of approaches: I could just drill a few holes in the sides, but that destroys the water tight characteristics of the container. One of these standards is NFPA 37: Standard for the Installation Hi There! Once data are sampled, the reporting signal itself may exhibit some cyclic characteristics. EPA Orders Chemours to Address PFAS Pollution. Recall the scenario weve already covered where the tank pressure rose at a high rate but the data recorder showed pressure lower than the actual. The maximum-value retention scheme is more common in testing and laboratory setups. This means that a short-duration pressure spike that is not detectable by normal process instrumentation can and will affect the rupture disc. 5 below: The flow area calculated is known as the Minimum Net Flow Area (MNFA). Rupture Disk is basically a non-reclosing type of pressure relief safety device that protects equipment or system during overpressure situations or potentially damaging vacuum conditions. When opening the fill valve, you must make sure the drain is closed and the vent is open, otherwise the oatmeal wont go into the tank because the air cant displace. The following items form a good starting point for data collection: Actual normal and maximum operating pressure, Actual normal and maximum operating temperature, Discharge to atmosphere, pressure relief valve or header, Rupture-disc performance history in this location, Photos of rupture disc, holder, installation, Signs of abnormal operation: for example, pin-hole opening, partial opening, slippage and corrosion products. Provide both overpressure protection and depressurizing. When an explosion event occurs, how quickly can you get the replacement parts that you need? So, pay attention to the sensors accuracy specification if one is provided, and note whether it relates to the entire range or the reading. The greater the difference (error) is, the faster the event (recall the averaging discussion above) becomes. Pressure spikes and water hammer generated by rapid opening or closing of valves somewhere in the process frequently do affect the rupture disc. Partnering with your rupture disc supplier to investigate and evaluate these situations will promote opportunities to improve rupture disc performance, extend maintenance cycles and reduce long-term costs. Currently there is no specific industry guidance related to burst disk material, however, materials with improved resistance to degradation when exposed to hydrogen should be used. The rupture disc used for safety in Chemical & Petro-Chemical Industries is one of the critical components where the design has to be done for failure of thematerial than the usual design problem of Engineering Design which is designing for strength. In such a case, a sampling rate of a few times per minute may suffice. Rupture discs are commonly found throughout many facilities around the world that utilize high-pressure vessels, systems, or equipment. Engineering for failure, simply put is not a sound business strategy, except when it comes to rupture discs (also known as bursting discs) used in process safety systems. Something must sample the signal generated by the sensor and record the data values. Process Safety: Avoid Big Trouble from Little Changes, Part 2, Poor Training Caused Workers' Deaths at BP, Steps To Meet Environmental, Social and Governance Reporting Challenges, Training on Digital Twins Reveals Performance Gaps, Opportunities, Congress Strengthens Cosmetics Regulations. Burst disk vent stack discharge was inadequate and/or poorly located. Disc inspection: The value of rupture disc inspection is limited to signs of damage, corrosion, or product buildup. It is a one-time-use device that is either destroyed or permanently deformed in response to over pressurization and then must be replaced. As the rupture disc is a one-time-use device. The fill system had a burst disk that failed to protect the cylinder because it was rated at too high a pressure. So, a shutdown may be required to refit. When it comes to safety, there is no room for compromise or margin for error. Contact us today to discover more about our extensive offerings, or to help you choose the right disc to fit your needs, use ourDisc Selection Form here. Suppose that the well in the figure has been analyzed for the potential of an APB failure, and the analysis indicates the . The performance of bursting at the predetermined pressure is. Morphologies of the fracture were observed by scanning electron microscope and the relatively chemical compositions were analyzed by energy dispersive spectrometer. react quickly enough to relieve the excess pressure quickly. What we can do is put well-specified devices into place that, in the event of a systems failure, will protect the plant and the people inside it, no matter what data are reported. Bear in mind that design engineers when configuring most systems to monitor and record processes only consider conditions deemed reasonably likely. That would put the system at risk of an overload that could have catastrophic consequences. ?g30/%p Cn0K]{([o Eg ~}Bex~ The resulting pressure in the ammo can may cause it to explode violently. | Diversity Inclusion & Equity, Install these rupture discs where atmospheric discharge occurs, Runaway Reactions:Ignore the Chemistry at Your Peril, Test Your Knowledge: Focus on Jacketed Vessel Heating, Gear and Mechanical Drivetrain Engineer - Crown Equipment Corporation - New Bremen, OH, Inspector - 1st Shift - AMETEK Aerospace & Defense - Garden City, NY, Welder - 1st Shift - AMETEK Aerospace & Defense - Garden City, NY, Project Manager / Senior Project Manager - Watry Design, Inc. - Long Beach, CA. Such information alone can be quite illuminating because only a limited number of overpressure events can happen. |. The score lower cycle life due to the generation of tensile stresses that promotes crack propagation. As such, they are fragile and require careful installation so as not to damage them. Some gaskets may have a higher required load than that of the rupture disc. A failure analysis was requested to determine if the discoloration was due to corrosion and if so, the cause. Three basic methodologies are followed for sizing rupture disc devices. Additionally, the welding joint is another unwanted influencing factor. As discussed above, the sensor itself constrains the sampling rate. For instance, take a system that must open a valve to relieve pressure in a tank. So they offer standard burst strengths that are high by common standards [~30 W.C. (~1 psi)]. A burst disk associated with a tube on a hydrogen tube trailer failed below design pressure during a fill operation and vented hydrogen through a vent tube. When reviewed later, the record would indicate a pressure significantly under the rated working limits of the tank. At Continental Disc Corporation, we specialize in engineering and manufacturing the highest caliber rupture discs on the market. However, ASME Section VIII, Division 13 states that a Kr of 2.4 shall be used. [5] On the other hand, if the pressures are very different (~20% or more), this means that whatever activated the valve did so quickly. Some of the vent systems were not adequately restrained and could not accommodate the expected maximum flow and pressure conditions after a burst disk ruptured. Consider corrosion, operating pressure, cyclic duty and so on. 2023 Continental Disc Corporation , LLC. Indications that you may have an over-loaded rupture disc include the following: Torque: All rupture discs have a recommended torque provided by the manufacturer. care to be exercised during installation not to damage the rupture disc. Indications that you have an under or unevenly loaded rupture disc include the following: Leakage between the rupture disc and holder. The hydrogen gas and the autoclave system were turned off immediately, but fire continued to burn in the autoclave cell. high reliability to prevent unnecessary downtime of the system. When a safety device activates, in our experience its useful to assume it worked as intended and then follow that logical assumption to its conclusions. Upgrade: Are there other disc materials or newer disc technologies that will allow the maintenance interval to extend beyond current limitations? They are mostly made of metals or plastics (Inconel, Hastelloy, or Tantalum, plastic liners such as PTFE or FEP.). Such devices should only be installed when necessary to prevent a serious overpressure hazard. In 2015, a failed rupture disc caused a 90-m3 vertical cylindrical steel tank to fail catastrophically. The typical rupture disc begins to respond to pressure in excess of the burst pressure in less than 1 millisecond. In such a configuration, the design considers a double jeopardy scenario and gives protection with both the vessel overpressure and the pressure relief valve failure. In such cases, the Rupture disc would isolate the vented media from the relief valve. It was burst after only 2000 times of operational circles. Coincidently, all existing research on failure of rupture discs assumed the four-petal pattern without stating any specific reason. They are: In the coefficient of discharge model, The rupture disk is considered as a relief valve, and the flow area is estimated using relief valve formulas with a fixed coefficient of discharge, Kd of 0.62. For example, consider a pressure sensor that has a membrane whose deflection is measured to indicate pressure. with a plastic disk glued on the outside of the container, i.e. The rupture disc must be marked at a pressure within the manufacturing range. The HPRD high pressure rupture discs can be used for pressures up to 5000 bar and temperatures up to 400C. A new test-section equipped with state-of-the-art instrumentation is used to deliver . C. Sudha, P. Parameswaran, S. Kishore, et al, Microstructure and deformation mode of a stainless steel rupture disc exposed to sodiumwater reaction, Mater. The rupture disk discharge should be directed to the atmosphere. shall be done by Purchaser during inspection visit. An outside liquid hydrogen storage vessel slowly heated over time, causing an over-pressurization that was relieved by a burst disk rupturing with a loud noise. There is no one, right answer regarding replacement frequency, but common considerations include the following: Severity: What is the severity of the service the rupture disc is subjected to?