OVERPRESSURE PROTECTION -- USING RUPTURE DISCS FOR PRESSURE RELIEF

Tappi PLC Conference August 2000 Fike Corporation

Cross Sectional View

Screwdriver Slot Configuration

Hex Head Configuration

Hex Head with Threaded Outlet

Wrench Flat Configuration

Typical Installations

Typical Installations

Sizing Considerations
Account for rupture disc assembly length Viscosity of the fluid Sizing for fluids with viscosity > 10 cP
calculate min. diameter using the flow through an orifice calculation Poiseuilles viscosity equation min. flow diameter = larger of the two

Poiseuilles Viscosity Equation

D = [128 LQ / P]1/4 where: P = (Po)(1.10) - Pe
D = pipe or inside diameter = absolute or dynamic viscosity L = pipe or tube length Po = relieving pressure Pe = exit pressure

Flow through an Orifice

A = Q/37.98K S/P (sizing for Liquids equation)
A = cross-sectional flow area (in2) Q = volumetric flow rate (gpm) K = 0.62 (per ASME)

Rupture Disc Sizing Methods

Coefficient of Discharge Method KD Resistance to Flow Method - KR

Coefficient of Discharge Method

UG-127(a)(2)(a)

Methodology for simple systems Coefficient of discharge KD = 0.62 KD is applied to the calculated theoretical flow capacity of the device based on the certified minimum net flow area MNFA Q = Qcalc * KD

Coefficient of Discharge Method - Guidelines for Usage UG-127(a)(2)(a)

Disc must discharge to the atmosphere Disc must be installed within 8 pipe diameters of the vessel nozzle Length of discharge piping not greater than 5 pipe diameters Certified MNFA includes vessel exit effects and the 8 & 5 piping losses

Resistance to Flow Method

UG-127(a)(2)(b)

Sizing is done on a relief system basis not by capacity of individual components Rupture disc is treated as another component in the relief system that provides some resistance to flow System relief capacity must be multiplied by a factor of 0.90 to allow for uncertainties inherent with this method

Resistance to Flow - Cont.

Based on Darcy formula (Crane 410) hL = f L/D v2/2g K ~ f L/D API recommendation for rupture discs has been L/D = 75 K = .02 (75) = 1.5

Proper Specification
Standard burst diameters from 3/16 to 1-3/4 Larger sizes up to 6 Max burst pressure is 12,000 psig @ 800 F for soldered Higher burst pressures for welded designs

Materials of Construction
Stainless steel body Inconel rupture disc Conventional prebulged type Standard manufacturing range of +6% to -3% Rupture tolerance of +/-5%

Common Questions
Q: What is the difference between the burst tolerance and the manufacturing range? A: The burst tolerance is the variation around the stamped burst pressure in which the individual rupture disc burst pressures in a lot are required by the ASME code to fall.
5% of marked burst pressure for pressures above 40 psi 2 psi of marked burst pressure for pressures 40 psi and below

Common Questions
A: The manufacturing design range is a range of pressure within which the average burst pressure of the test discs must fall to be acceptable as agreed upon between the manufacturer and the user.

Common Questions
Q: What manufacturing ranges are available? A: Standard -- +0 to -10%
Maximum Stamped -- All values below Minimum Stamped -- All values above Reduced-- +0 to -5% Special Min/Max -- All tolerances included Zero -- no range

Common Questions
Q: How do I choose the proper burst pressure? A: As the primary relief device, the disc shall be set to operate at a pressure not exceeding the MAWP.

Common Questions
Q: How does the operating ratio help me decide what burst pressure I should use? A: The operating ratio is the ratio of the operating pressure to the stamped burst pressure. Each family of discs will have a maximum recommended operating pressure that will ensure good service life for that disc.

Common Questions
Q: How do I calculate the operating ratio? A: Divide the operating pressure by the minimum possible burst pressure
Requested B.P.: 900 psig Manufacturing Range: 954 to 873 psig Operating Pressure: 600 psig 600 psig/873 psig= 68.73% Maximum Operating Ratio: 70%

Common Questions
Q: How many discs are burst tested from each lot? A: The number increases with the lot size.
Lot Size 1 or 2 3 to 15 16 to 25 26 to 40 41 to 65 66 to 100 Sample Size 2 3 4 5 7 10

Rupture disc tooling

Common Questions
Q: How does temperature affect the burst pressure of the disc? A: There is an inverse relationship -- as the temperature increases the burst pressure decreases
For Inconel material
Burst pressure 900 psig 915 psig 925 psig 935 psig Temperature 72 F 250 F 500 F 750 F

Common Questions
Q: So how do I choose the correct coincident temperature? A: Use the maximum normal operating temperature.
Since there is an inverse relationship -- if the temperature continues to rise, the disc will burst at a lower pressure

Installation, Operation, and Maintenance Procedures

Stop the screw and allow pressure to bleed off Remove the rupture disc while the polymer is above the melt temperature Wipe the polymer off the disc body with a soft cloth to protect the tip from damage Clean the rupture disc seat with the appropriate tools

Proper Installation
Apply Never-Seez (pure nickel type) to the threads of the new assembly Insert by hand Tighten to the specified torque with a torque wrench CAUTION: over-tightening can affect the burst pressure Attach the tag to the assembly or to the housing

Safety Considerations
Verify that the rupture disc matches the tag Check that the disc has a safe, unblocked point of discharge Do not add extra piping to the disc other than specified Assume that there is always pressure behind a rupture disc Use protective gloves, sleeves, and a face shield when changing discs

Questions?????

Agenda
Causes of high pressure build-up Safety considerations for polymer transfer piping Rupture discs and the ASME code Rupture disc design Sizing considerations Proper specification Installation, operation, and maintenance

 Packing

Causes Of High Pressure Build-up

LDPE expands 30% from 72 to 300 F Cooling creates voids to allow space for expansion Transfer pipes can cool faster creating a vacuum to draw in polymer from the die and extruder Pipes heat more quickly, so packed pipes can overpressurize during heat-up

Causes of High Pressure Build-up

Decomposition
Extreme temperatures resulting from failed controller, excessive set points, improper use of heaters At elevated temperatures, LDPE produces gases generated by decomposition Trapped gases can cause overpressure that can lead to expansion and rupture

Safety Considerations in Designing Polymer Transfer Piping

Use high pressure pipe design and welded fittings Divide the pipe into multiple zones to minimize hot spots Use heating methods that assure uniform heating along the pipe Use low-watt density heaters Use high temperature shutdown safety devices Install pressure relief devices such as rupture discs

Rupture discs and the ASME Code

Definition: RD device is a non-reclosing pressure relief device actuated by inlet static pressure and designed to function by the bursting of a pressure containing disc RD is the pressure containing and pressure sensitive element of the RD device

Related ASME Code Sections

Section VIII Div. 1
1995 Edition, 96 Addenda: UG-125 through UG-136 1995 Edition, 97 Addenda: UG-125 thru UG137 Published January 1, 1998. Mandatory for new construction beginning January 1, 1999 1998 Edition: UG-125 through UG-137 Published July 1, 1998. No changes to rupture disc requirements

Definitions
General: Every RD shall have a marked burst pressure established by the rules of UG-137(d)(3) within a manufacturing design range at a specified disc temperature and shall be marked with a lot number. Manufacturing design range is a range of pressure within which the marked burst pressure must fall to be acceptable for a particular requirement.

Definitions
The specified disc temperature shall be the temperature of the disk when the disc is expected to burst. A lot of rupture discs is those discs manufactured of a material at the same time, of the same size, thickness, type, heat, and manufacturing process including heat treatment.

Rupture Disc Applications

Primary Secondary (Multiple) Combination Fire

Primary Relief UG-125(c)

The rupture disc is the only relieving device provided on the vessel.
ASME: Overpressure Allowance: 110% of MAWP or 3 psig, whichever is greater Marked Burst Pressure: not to exceed 100% of MAWP

Secondary or Multiple Relief

UG-125(c)(1), UG-134(a)

The rupture disc may be used to provide secondary relief to other rupture disc or pressure relief valve.
ASME: Overpressure Allowance: 116% of MAWP or 4 psig, whichever is greater Marked Burst Pressure: not to exceed 105% of MAWP

Rupture Disc / PRV Combination

UG-127(a)(3)(b)

The rupture disc is used in combination with a pressure relief valve.

ASME: Sizing and marking requirements determined based on whether combination is primary or secondary device

External Fire UG-125(c)(2), UG-134(b)

A supplemental relief device may be installed to protect against excessive pressure caused by unexpected source of external heat such as fire.
ASME: Marked Burst Pressure: not to exceed 110% of MAWP Overpressure Allowance: 21% above MAWP

Rules to Determine the Rated Flow Capacity of a System UG-127(a)(2)

Use the coefficient of discharge method
discharges directly to atmosphere -- 8 & 5 rule inlet and discharge = or > NPS of the device theoretical flow for the media times K (0.62)

By analyzing the total system resistance to flow

consider the flow resistance of disc device, piping, etc. certified flow resistance factor KR to calculate velocity head loss calculated capacity times factor of 0.90

Manufacturer Authorization to Use the UD Code Stamp U D

UG-137(c)

Conduct flow testing to have the capacities certified at an ASME accepted test facility Demonstrate that its manufacturing, testing, and quality assurance systems will insure agreement between production units and certification units Comply with periodic inspections by an ASME representative

Requirements for Certifying the Capacity of the Device

Certified flow resistance KR = 2.4 or as determined through testing Tests shall be conducted with air or gas Tests at inlet pressure not to exceed 110% of device set pressure KR for devices tested with nonpressure containing items (seals, support rings, and vacuum supports) is applicable to those without

Flow Resistance Certification Testing UG-131(o)

One size method Three size method

One Size Method UG-131(o)(1)

For each disc type, 3 discs are burst tested at the minimum B.P. for that size Same 3 discs are then flow tested to determine KR value Burst and flow values are averaged
All individual flow resistances shall fall within the avg. flow resistance by an acceptance band of plus or minus 3 times the average of the absolute values of the deviations of the individual flow resistances from the avg. flow resistance

Three Size Method UG-131(o)(2)

Same as One Size Method Exception: done over a range of 3 sizes Resulting KR value can be used for entire family of devices (applies to all sizes and pressures of the design tested)

Inspection of Manufacturing
UG-137(c)(1)(2)

Demonstrate that its manufacturing, production, testing, and quality procedures will insure close agreement between the performance of random samples and those submitted for Certification Agree to allow inspections at any time by an ASME designee

Production Audit UG-137(c)(3)(a&b)

After one size or three size testing is successfully performed, 2 sample discs are selected by ASME for final verification These discs are burst and flow tested in an accepted flow laboratory Must meet or exceed the performance requirements

Performance Requirements UG137(c)(3)(a&b)

Burst pressures must be within the burst tolerance specified in UG-127(a)(1) Discs must exhibit a KR value that does not exceed the claimed value Discs must meet the minimum net flow area (MNFA) when installed on an 8 & 5 rig Success = permission to use the UD Code Symbol valid for 5 year periods

Production Testing UG-137(d)(3)(a) / UG-127(a)(1)

(a) at least 2 burst tests per lot Burst tests performed at the specified disc temperature The marked B.P. shall be determined so that the sample disc burst pressures are within the B.P. tolerance of UG-127(a)(1):
5% of marked burst pressure for pressures above 40 psi 2 psi of marked burst pressure for pressures 40 psi and below

More Production Testing UG137(d)(3)(b)&(c)

(b) At least 4 sample discs burst tested at 4

different temperatures Data used to make a smooth curve of BP vs. temperature Value for the BP derived from the curve

(c) At least 4 sample discs using 1 size of disc

from each lot of material shall be burst at 4 different temperatures data used to make a curve of percent change of BP vs. temperature

Rupture Disc Marking UG-129(e)

Old Requirements Manufacturers Name Model or Part Number Lot Number Disc Material Nominal Size Stamped Burst Pressure Specified Disc Temperature Capacity New Requirements Manufacturers Name Model or Part Number Lot Number Disc Material Nom. Size (NPS of holder) Marked Burst Pressure Specified Disc Temperature Minimum Net Flow Area Cert. Flow Resistance KR year built ASME symbol

UD

1998 Ed. Rupture Disc Tag

Rupture Disc Design for Plastic Extrusion Processes

Rupture Disc Design for Plastic Extrusion Processes

Rupture Disc Design for Plastic Extrusion Processes

Cross Sectional View

Cross Sectional View

Cross Sectional View