Pressure Rupture Discs Replacement
Pressure Rupture Discs Replacement
What are the best practices to replace pressure rupture discs?
Re: Pressure Rupture Discs Replacement
As per API 576 para 6.8.2.6, rupture disks cannot be nondestructively tested and should be replaced on a regular schedule based on their application, the manufacturer’s recommendations, consequences of nuisance releases, and/or past experience.
Re: Pressure Rupture Discs Replacement
Looking forward to have something developed for our use at site.
What I understand from here is to take a start with the manufacturer's recommendation and build upon that connecting with consequences and operating /maintenance history.
What I understand from here is to take a start with the manufacturer's recommendation and build upon that connecting with consequences and operating /maintenance history.
Re: Pressure Rupture Discs Replacement
One thing here for sure is that even not all series of rupture discs by any manufacturer would be having one single replacement frequency.
Somewhere, when defined as 10 years (as I have observed) may not be a good guideline to just apply over all the population until or unless the provided recommendation of replacement frequency by all manufacturer of all discs (yes every disc is required to be checked for that) at site is not frequent than 10 years or any other number for that case.
The service life of a rupture disc is influenced by various factors that can lead to premature failure or degradation, necessitating replacement even if the disc has not burst:
Operating Pressure and Cycling:
Rupture discs have an "operating ratio," which is the percentage of the maximum operating pressure relative to the disc's burst pressure. Operating too close to the burst pressure, especially with pressure cycling or pulsations, can cause fatigue and weaken the disc over time, potentially leading to premature failure.
Taking the case of a manufactuere, Fike's G2 technology discs, for instance, offer high cycle life profiles, but demanding cyclic conditions can still impact longevity.
For systems with low pressures and static conditions, disc life is generally longer, whereas cyclic conditions approaching the burst pressure result in shorter life.
Take the case of AD series, we have their replacement frequency of one year.
Temperature Effects:
Temperature variations can affect the burst pressure of a rupture disc. If ordered at a specific pressure and temperature, any variance in process conditions will alter the burst pressure. Higher temperatures tend to weaken the disc, while lower temperatures strengthen it.
Corrosion: The material of the rupture disc must be compatible with the process medium. Corrosion of the disc membrane can significantly affect its burst pressure and overall integrity.
Improper Installation:
Incorrect torque applied during assembly, misalignment, or damage during handling and installation can lead to leakage, slippage, or premature bursting.
Piping Loads and Downstream Conditions: Excessive piping loads transferred to the disc, or downstream issues like back pressure, condensation, or debris, can also affect performance and lifespan.
If confident on the practices being followed with regards to the installation, you may not consider this as a vital factor but one cannot ignore the piping loads transferred.
Aging:
Even without activation, materials can age, potentially affecting the disc's integrity.
That would help in just having an understanding the variables affecting to have defined frequency depending on the application.
Somewhere, when defined as 10 years (as I have observed) may not be a good guideline to just apply over all the population until or unless the provided recommendation of replacement frequency by all manufacturer of all discs (yes every disc is required to be checked for that) at site is not frequent than 10 years or any other number for that case.
The service life of a rupture disc is influenced by various factors that can lead to premature failure or degradation, necessitating replacement even if the disc has not burst:
Operating Pressure and Cycling:
Rupture discs have an "operating ratio," which is the percentage of the maximum operating pressure relative to the disc's burst pressure. Operating too close to the burst pressure, especially with pressure cycling or pulsations, can cause fatigue and weaken the disc over time, potentially leading to premature failure.
Taking the case of a manufactuere, Fike's G2 technology discs, for instance, offer high cycle life profiles, but demanding cyclic conditions can still impact longevity.
For systems with low pressures and static conditions, disc life is generally longer, whereas cyclic conditions approaching the burst pressure result in shorter life.
Take the case of AD series, we have their replacement frequency of one year.
Temperature Effects:
Temperature variations can affect the burst pressure of a rupture disc. If ordered at a specific pressure and temperature, any variance in process conditions will alter the burst pressure. Higher temperatures tend to weaken the disc, while lower temperatures strengthen it.
Corrosion: The material of the rupture disc must be compatible with the process medium. Corrosion of the disc membrane can significantly affect its burst pressure and overall integrity.
Improper Installation:
Incorrect torque applied during assembly, misalignment, or damage during handling and installation can lead to leakage, slippage, or premature bursting.
Piping Loads and Downstream Conditions: Excessive piping loads transferred to the disc, or downstream issues like back pressure, condensation, or debris, can also affect performance and lifespan.
If confident on the practices being followed with regards to the installation, you may not consider this as a vital factor but one cannot ignore the piping loads transferred.
Aging:
Even without activation, materials can age, potentially affecting the disc's integrity.
That would help in just having an understanding the variables affecting to have defined frequency depending on the application.
Re: Pressure Rupture Discs Replacement
In this case, we need to look for the recommendations provided by each manufacturer on replacement and follow that.
I need to check with my maintenance counterparts if they have run a similar exercise ever before.
All I could see was that a blanket frequency of 10 years replacement has been set and that also once triggered is not done for all cases. That then trigerred this necessary discussion.
Mechcolor, the scenarios which you have described largely affecting the replacement frequency helped.
I need to check with my maintenance counterparts if they have run a similar exercise ever before.
All I could see was that a blanket frequency of 10 years replacement has been set and that also once triggered is not done for all cases. That then trigerred this necessary discussion.
Mechcolor, the scenarios which you have described largely affecting the replacement frequency helped.