How long does a blast disk last?

The blast disks are carefully selected and made of very thin materials, using real trial methods, not calculation methods. In the end, durability is exactly what is needed and this does not include the effect of corrosion margin or other safety factors. The healthy working life of the disk depends on many factors that can cause the disk to prematurely explode. Some of these are:

Operational Pressure (Operational Ratio)

All bursting disks have a so-called operating ratio (the specified OR percentage is used to calculate the maximum operating pressure). This ratio varies for different disk designs and can be between 50% and 95%.

To give an example, if the bursting pressure is set at 10 Barg for a bursting disc with a 90% operating ratio and a bursting tolerance (margin of error) of +/- 10%, in order to obtain a long service life, the bursting disc should not be subjected to an operating pressure obtained by multiplying the minimum nominal bursting pressure of the bursting disc (10barg*%90=9barg) and the 10% bursting tolerance (9 barg*%90=8.1 barg). If the bursting disk is exposed to pressures above this value (8.1 barg), it may stress the bursting disk membrane causing metal fatigue and premature rupture.

Vibrating Environment

Rupture disks can fatigue in conditions of intense vibration. Some types of rupture disk designs are better suited for these types of environments than others. For example, “Reverse Buckling” type rupture disks.

Temperature Effect

Temperature can affect the burst pressure of the rupture disk. For example, if the rupture disk is ordered for a certain pressure and temperature, a possible temperature difference in the process conditions will affect the rupture pressure of the disk. Due to the structure of metals, as the temperature increases, the strength will gradually weaken, and as the temperature decreases, the strength will gradually increase. The effect will vary depending on the rupture disk design and material of construction.

Corrosive Environment

It is very important to check whether the production material of the rupture disk is compatible with the process need. Even the slightest corrosion of the rupture disk will affect the burst pressure of the rupture disk. Rupture discs can be made of 316SS, Nickel, Inconel, Monel, Aluminum, Hastelloy-C276, Tantalum, Graphite etc. according to need. It can be manufactured from various materials such as.

Random Installation or Over-Torquing of the Rupture Disc Assembly

Applying a torque to the rupture disk assembly (disc and holders) that is different from the torque values given in the technical specification document may cause the rupture disk not to burst within the specified burst range and/or damage the rupture disk.

Installation Direction of Rupture Disc Assembly

It is very important to install the rupture disk and arrester assembly in the correct flow direction. If the rupture disc or complete assembly is installed in the wrong flow direction, the opening pressure of the rupture disc may be several times higher than the nominal burst pressure indicated on the rupture disc label. The consequences of a rupture disk that does not burst/rupture when needed can be disastrous. In order to perform correct and error-free installation, there are arrows indicating the flow direction on both the rupture disk label and the holder labels, and these arrows must be followed during installation.

Transportation and Storage

It is very important that rupture discs are stored and used correctly. The surfaces of rupture disks are very sensitive. For this reason, the slightest damage to the dome of the rupture disk while maintaining or assembling it will affect the burst pressure. Many rupture disk designs are designed to be “fail safe” and will explode at less than the rated burst pressure if the dome is damaged. Additionally, some single-layer design rupture disks manufactured to withstand full vacuum conditions will fail under vacuum conditions if the membrane/dome of the rupture disk is damaged during containment or assembly.

The cost of replacing a prematurely ruptured rupture disk can be very expensive, especially if it requires a system shutdown to replace the rupture disk. For this reason, we recommend that all rupture discs be replaced at regular intervals, even if they appear to be in good condition, at periodic intervals determined according to process conditions. The best time to do this is when the system/process is down for planned maintenance.

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