rupture disc failure analysis

I could rig a pressure relief valve, but they cost more than the can and batteries combined! The exchanger contains 100 tubes each 3 meters long with an inner diameter of 10 mm. It is recommended that a hazard analysis be performed to assure that all effluent vent operations are discharged to a safe location that is remote from people and property, since discharge fires are common. need replacement every time it ruptures. is being permeated by the ozonated sulfuric acid. 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). Initial operation will be witness point and subsequent operation will be witnessed at discretion of Purchaserconsidering the results of previous inspection. While seemingly simple, consider for a moment all the complexities that occur very quickly. Todays processing plants generally include complex networks of sensors, monitors and computer processors. When an explosion event occurs, how quickly can you get the replacement parts that you need? This is usually the case with storage vessels for non-refrigerated liquefied compressible gases at ambient temperatures. Sampling rate is simply the number of times a signal is read and recorded over a certain interval. Analysis outlines hydrogen requirements in the chemical industry. We will be updating and growing this site with more and more of industrial inspection related articles. is being permeated by the ozonated sulfuric acid. The PTFE film Rupture discs are typically used to protect this high pressure process itself, as well as the . Figure 3. 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. Due to the metal-to-metal sealing surfaces, any re-installation of a rupture disc is likely to seal less effectively. He has technical responsibility for a variety of products including rupture discs, explosion vents, and mechanical explosion and fire-protection products. Figure 2 results from averaging the same ten data points per second. The key lesson learned is that even though there is no specific industry guidance on burst disk materials, some materials provide improved performance characteristics. A hydrogen delivery tube trailer filling a hydrogen storage tank experienced a premature burst disk failure, allowing hydrogen gas to escape. In this case, the burst disk may have functioned properly as designed, but the vent stack design and the emergency response actions did not allow the vent stack to function. The key lesson learned was that the vent stack design should be re-evaluated. Provide both overpressure protection and depressurizing. high reliability to prevent unnecessary downtime of the system. The rupture element of the disc is equipped with breaking points that are normally created by means of lasers. However, under abnormal circumstances, say in the event of a runaway reaction or fire, a much faster rate of pressure rise may occur. I am very much passionate about blogging and always tried to do unique things. The results show that the bursting of the rupture disc was caused by fatigue fracture. 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. There are also specific places and industries where you shouldnt use rupture discs, such as those that tend to have significant pressure fluctuations. | 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. Welcome to my space, I am Anup Kumar Dey, an experienced piping engineer for the last 19 years. a one-time-use membrane that ruptures at a pre-decided pressure difference between the inlet and outlet of the device (i.e, defined breaking point), either positive or vacuum, thus releasing the pressure. The PTFE film is scored along the outer edge of the rupture disk to facilitate failure of the film upon rupturing of the disc. Rupture disc life is generally tied to the stress history (pressure and temperature) applied to the disc. The vessel discharge port could then become partially or fully blocked, resulting in higher than expected burst pressures and limited discharge flow. Additionally, when designed into the system from the outset, they often can simplify control systems and passively protect equipment and personnel. %PDF-1.4 It took off like a rocket into the air, landing on a nearby van and crushing it completely. The vent stack design was reviewed, and as an additional safety measure to protect nearby people and property, the vent stack height was extended. Figure 1 shows the true pressure values for a system measured over a period of time. As shutdowns for maintenance activities are stretched further and further apart, it is not unusual to expect 3 to 5 years of service from the rupture disc. the failsafe performance of rupture discs. As stated earlier, rupture discs and pressure relief valves can be used in parallel. In such a case, a sampling rate of a few times per minute may suffice. This plot indicates a much less severe pressure spike. On the other hand, if the pressures are very different (~20% or more), this means that whatever activated the valve did so quickly. In reality, the device may have activated precisely when it should have. A pressuretransmitter and local gauge are installed between the two rupture discs to notify operators of failure or leakage of one or both of the rupture discs. Material selection is important to reduce hydrogen embrittlement failures. As discussed above, the sensor itself constrains the sampling rate. The burst disks were replaced with an alloy 20 nickel-chromium-molybdenum stainless steel material that is less susceptible to stress corrosion cracking than alloy 600 nickel-chromium-iron. The greater the difference (error) is, the faster the event (recall the averaging discussion above) becomes. In 2015, a failed rupture disc caused a 90-m3 vertical cylindrical steel tank to fail catastrophically. Did you find this article useful? In such cases, the Rupture disc would isolate the vented media from the relief valve. Rupture discs are not standardized products. In one case, multiple burst disks were installed in a holder where only one was supposed to be used. Rupture discs are critical instruments utilized so that companies can ensure process safety as set forth by the International Safety Standards (IEC 61508/61511). The major differences between the above-mentioned rupture disk types are tabulated below: Refer to Fig. Both disk and disc are commonly used spellings of the word in industry. Burst disks prematurely failed below their rated pressure. 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. After the first burst disk failure occurred, the vent line was not sufficiently attached to take the thrust force from the hydrogen release and bent outward violently, damaging some adjacent vent system components. A carbon steel shell and tube exchanger has methane in the tube-side and cooling water in the shell-side. Rupture discs cause all sorts of problems- detection, frequent replacement, cost, drips from the excess flow check, etc. However, thats not always the case. Thepresent paper considers discs that fail because of Tensile stresses. A burst disk (or rupture disk) is a common pressure-relief device that is designed to break at a predetermined pressure. Potential causes include cycling, corrosion or simple wear-and-tear from exposure to the elements. Highly corrosive atmospheres can also significantly damage the materials that the discs are made out of. 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. It can also be dened as a thin metal membrane designed to burst at a certain pressure and temperature to prevent overpressurization of the attached vessel. 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 . [11] For instance, remember the valve and tank discussed above. The goal of the flange connection is to apply the proper amount of clamping load for the rupture disc and holder to function correctly. Consider corrosion, operating pressure, cyclic duty and so on. Also, some rupture disc types may exhibit increased burst pressure variability when re-installed. Consider the ramifications of a personal computer maker revealing that their computers were designed to crash. Read on to learn more about several other rupture disc problems. 2023 Endeavor Business Media, LLC. Attributing the bursting of a rupture disc to "premature failure" exemplifies this. This is the rupture disks minimum cross-sectional area needed to meet the required flow. [2] Burst disks are sometimes required by code, but other times are specifically excluded from installation (e.g., where the premature release of a toxic or flammable gas might be a higher risk than a vessel failure). A failure analysis was requested to determine if the discoloration was due to corrosion and if so, the cause. improper bolt torque during installation may also affect the disc burst pressure. Company > News & Events > Engineered to Fail. high reliability to prevent unnecessary downtime of the system. Currently, I work in a reputed MNC as a Senior Piping Stress Engineer. 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. It took off like a rocket into the air, landing on a nearby van and crushing it completely. Anal. By quantifying this performance characteristic, rupture disc devices may be selected. The burst causes were investigated. Morphologies of the fracture were observed by scanning electron microscope and the relatively chemical compositions were analyzed by energy dispersive spectrometer. H: Hold Point implies that relevant production activities shall not proceed until the continuation of work is permitted by Purchaser. Various factors affect its performance. 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. [10] Such information alone can be quite illuminating because only a limited number of overpressure events can happen. Inferior rupture discs often cause unnecessary and expensive production shutdowns due to the lack of quality testing and expertise in manufacturing. When the pressure rise is so large and rapid that extremely fast-acting is required to prevent catastrophic failure. A hydrogen explosion occurred at a plant, damaging a wall adjacent to the hydrogen storage assembly. Heavy corrosion of the rupture disc holder can result (Figure 2). As the rupture disc is a one-time-use device. An important lesson learned is that burst disks should be properly installed. Something must sample the signal generated by the sensor and record the data values. Routing Of Flare And Relief Valve Piping: An articleVarious types of pressure relieving devices required for individual protection of pressure vessels in process plantsModeling Relief Valve (Pressure Safety Valve) Thrust forceStress Analysis of PSV connected Piping Systems Using Caesar II. However, the device doing the sampling, such as an analog/digital converter, also imposes constraints, both mechanically and due to downstream devices such as controllers or recorders and their associated needs. So be with me for the next couple of years! T. More, K. Johnson, A simple, low-cost burst disc for use at cryogenic temperatures, Cryogenics 38 (1998) 947-948. The device may be re-installed if desired as long as the disc hasnt been removed from the holder. (Notification req'd), S: Witness, but spot check basis. However, doing so multiplies the amount of data captured and, in many cases, can be expensive. << The fill system had a burst disk that failed to protect the cylinder because it was rated at too high a pressure. (Notification req'd), W: Witness point implies that Purchaser intends to witness the designated inspection feature. The result is that a short period of time after applying the correct load, the gasket will have further compressed and released most of the load. Site Copyright 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. The investigation revealed that the explosion was the consequence of the failure of a burst disk at a pressure much lower than its rating. In addition, you must consider the way in which the data are compiled, graphed and analyzed. Abstract The objective of the current work is to model a stainless steel (SA 316L) autoclave explosion and rupture that occurred during a Keywords Finite element analysis Failure locus Blast load Rupture Overpressure Pressure vessel 1. Dean Miller is the manager of mechanical engineering with Fike Corp. (704 SW 10th St., Blue Springs, MO 64015; Phone: 816 655-4729; Email: dean.miller@fike.com). 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. In this case the disc is subjected to transverse load. One key lesson learned is to consider the use of spring-style pressure-relief valves instead of burst disks. GB567-2012, Bursting disc safety devices. used for both gas and liquid handling application. Due to their very nature, rupture discs are fragile and can easily break if removed to poke the debris from the duct stub. Many process materials are prone to building up and solidifying on internal surfaces. Once full, you have to close the vent and fill tap before heating the tank. Most systems will round the value to the nearest significant number to prevent false interpretations.. 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. Since the vent stack was open, some water entered and froze, plugging the stack and sealing off the only hydrogen pressure-relief exit path. | 3160 W. Heartland Drive | Liberty, MO 64068-3385 | Privacy Policy, This website uses cookies to enhance and improve your browsing experience. Investigation on the degradation and opening behavior of knife blade burst disks, J. Operators should always be attentive to the fill operation and make sure that it takes place in a safe location. Rupture disc has been one of the most effective equipment to prevent overpressure from explosion for the pressure equipment. They also require complete replacement before machines can be put back online, thereby increasing the overall downtime. Meanwhile, metallographic. |. The shell's volume is 7.5 m 3. After installation the applied pressure is nearly fully-loaded on the welding joint. Bad things are going to happen, even to our best systems. The rupture disc manufacturer publishes the actual Net Flow Area (NFA) for each model and size. This identifies uniquely the disc type, its equipment number and batch, the rated bursting pressure and temperature, the design code and also indicates the vent side of the 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. Scientific.Net is a registered brand of Trans Tech Publications Ltd Many manufacturers who are looking for a more permanent safety solution often opt for explosion doors. To that end, we partnered with Intertek Consulting Services, the leading provider of safety system assessment and verification. Burst disks have finite lifetimes, and routine replacement should be planned. Rupture discs work by using thin metals that are scribed or scored to burst at predefined pressures. Figure 2. The resulting pressure in the ammo can may cause it to explode violently. This content provides you a sample rupture disc inspection and test plan. Over time, pipelines can What is NFPA 37? The rupture toleranceat thespecified disc temperature shall not exceed 2 psi for marked pressures up to and including 40 psiand 5% for marked burst pressures above 40 psi. One conventional domed slotted rupture disc, which was fabricated with Inconel 600 alloy, was used in reaction kettle. Some of those parameters for the proper selection of a rupture disc are: The main components of a rupture disk are: Rupture Disc Sizing for a particular application is done following the standard methodologies described in ASME Section VIII Div. These failures may have been prevented with closer attention to the design and maintenance of the burst disks and their integration into the hydrogen storage and piping systems. If the cause is not apparent, it is time to engage the manufacturer to assist in troubleshooting the problem. Return from Rupture Disc Inspection and Test Plan to Inspection and Test Plan, Return from Rupture Disc ITP to Inspection for Industry Home. R. Rivera, A. Chiminelli, C. Gmez, et al, Fatigue failure analysis of a spring for elevator doors, Eng. For over 50 years, Continental Disc Corporation has manufactured premier rupture disc products for a variety of process industries. The vent pipe exhausted the hydrogen gas mixture into the autoclave cell, where it ignited in a fireball and then ignited nearby combustibles. So, it has to be replaced after the burst. If the relief fluids are vented in the common header vented media can result in either corrosion or polymerization. The fire heated a small compressed gas cylinder (lecture bottle) until it exploded with enough force to cause an estimated $55,000 in facility structural damage and burns to one employee. This issue can usually be resolved with strategic placement of piping supports. These events arent expected but potentially can destroy the equipment. [4] However, pasteurization can also be used for foods and Read More, If you have older equipment with explosion relief doors it may be time they are replaced. 4) Monitoring/Observation ofRupture Disc Vendor shop daily routine works (i.e.Storage of materials, Adherence to approved procedures,Testing tool calibration check, workmanship, cleanliness and etc.) 6)Unless otherwise specified in REQ., theRupture Disc sampling Q'ty of " S (Spot Witness Check) " shall be as follows: 3 to 203Pcs(all if total 2 and less) , 21 to 505Pcs, 51 to 10010Pcs,101 to 20020Pcs, 201 to 30030Pcs, 301 to 50050Pcs. with a plastic disk glued on the outside of the container, i.e. In time, the tank warmed, became over-pressurized, and ruptured. Frequent inspection of the hydrogen system would likely have prevented some failures, since deteriorated or missing components, especially those exposed to weather conditions, were found in post-incident inspections. rupture disc downstream (outlet) of the relief valve. Firefighters responding to the hydrogen release sprayed water on the tank and vent stack. Remember too, these events shouldnt happen but we are forced to prepare because they could and do. Depending on the applications and suitability, rupture discs can be of different types. The rupture discs can be classified as tensional loaded discs, Compressive loaded discs and shear type that fail in pure shear. So, lets quickly review some key facts about the sensor, sampling and resolution, and data reporting. Some gaskets may have a higher required load than that of the rupture disc. A mechanic working under the tube trailer was slightly injured when the loud noise from the burst disk rupture caused him to bump into the trailer several times while quickly exiting the area. Our networks are powerful but bad things still happen to good systems. The PTFE film If Purchaser decides not towitness the relevant feature, production can proceed without permission of Purchaser.

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