Rupture Disks For Process Engineers

Rupture Disks for Process Engineers - Part 1
This is a real story. A rupture disk manufacturer presented a seminar to a group consisting of
junior and more senior level process design engineers (yours truly included) with a few
instrument engineers thrown in. After about an hour of hearing terms such as bursting pressure,
tolerance, manufacturing range, etc., and discussions on the mechanical aspects that differentiate
the various types of rupture disks, the seminar ended with many of those attending just shaking
their heads. Most of the attendees just wanted to learn how to specify this item so the instrument
engineer can buy one or the manufacturer can tell you what is needed.
I eventually put together a
ads not by this site
seminar on rupture disks for process design engineers that went over very well. This series of
articles is taken from that seminar. Part 1 covers the whys and when to use a rupture disk. Part 2
covers how to size the rupture disk. Subsequent parts will include how to set the burst pressure,
the Relief Valve/Rupture Disk combination, how to specify the device and some discussion on
the type of rupture disks you can purchase.
Before I begin, let me point out that most of what is included in this series of articles can be
found in API RP5201 and API RP5212, and ASME Section VIII, Division 13. Much of what is
found in these documents can also be found in vendor literature.
Why and When to Use Rupture Disks
Why Do We Use a Stand-Alone Rupture Disk?
A rupture disk is just another pressure relieving device. It is used for the same purpose as a relief
valve, to protect a vessel or system from overpressure that can cause catastrophic failure and
even a death.
When Do We Use a Stand-Alone Rupture Disk?
Some of the more common reasons are listed below. You may think of others.
1. Capital and Maintenance Savings:

Rupture disks cost less than relief valves.
They generally require little to no
maintenance.
2. Contents will be lost, but who cares? A
rupture disk is a nonreclosing device,
which means once it opens, it doesn't
close. Whatever is in the system will get
out and continue to do so until stopped by
some form of intervention. If loss of
contents is not an issue, then a rupture
disk may be the relief device of choice.
Figure 1: Basic Components of a Rupture Disk
3. Benign service: It is preferable that the
relieving contents be non-toxic, non-hazardous, etc. However, this is not a requirement when
deciding to use, or not use, a stand-alone rupture disk.
4. Rupture disks are extremely fast acting: Rupture disks should be considered first when there is
a potential for runaway reactions. In this application, relief valves will not react fast enough to
prevent a catastrophic failure. A relief valve may still be installed on the vessel to protect against
other relieving scenarios. Some engineers prefer to use rupture disks for heat exchanger tube
rupture scenarios rather than relief valves. They
are concerned that relief valves won't respond fast
enough to pressure spikes that may be experienced
if gas/vapor is the driving force or liquid flashing
occurs.
5. The system contents can plug the relief valve
during relief: There are some liquids that may
actually freeze when undergoing rapid
depressurization. This may cause blockage within
a relief valve that would render it useless. Also, if Figure 2: Rupture Disk Mounted on a Vessel
the vessel contains solids, there is a danger of the
relief valve plugging during relief.
6. High viscosity liquids. If the system is filled with highly viscous liquids such as polymers, the
rupture disk should seriously be considered as the preferable relieving device. Flow through a
relief valve will be very difficult to calculate accurately. Also, very viscous fluid may not relieve
fast enough through a relief valve.
Cost Comparison Between Comparable Stand-Alone Rupture Disk and Relief Valve
Rupture disk manufacturers burst at least two disks per lot before shipping them to a customer.
As a consequence even if you want just one rupture disk you will be buying three. Therefore, the
first usable rupture disk is comparatively expensive. Also for new installations, each installed
rupture disk must be purchased along with a holder. However, the same holder may be used for
replacement purchases as long as you buy the exact same rupture disk from the same
manufacturer.
Below is a capital cost comparison between Continental Disc Corp. (www.contdisc.com) 3"
Ultrx Hastelloy C rupture disks with holders and Farris Engineering (www.cwfc.com) 2600
series relief valves, based on a budget estimate in year 2001 dollars.
Table 1: Cost Comparison - Rupture Disk vs. Relief Valve

Basis: Continental Disc
Basis: Farris Engineering
st
3" Ultrx Hast C Disc = $2,600 for 1 usable 3" x 4" Hast C 26KA10-120 = $13,400
disk, then $870 each
3" Ultrx Hast C Holder = $3,300 ea.
TOTAL for one pair = $5,900
TOTAL for three pair = $14,240
TOTAL for three = $40,200
This capital cost comparison will vary considerably with size and material of construction but
you get the point. However please note that everything has a value and the loss of contents
should be considered in the overall cost difference between a rupture disk and a relief valve.
When Do We Use a Rupture Disk-Relief Valve Combination?
Rupture disks are often used in combination with and installed just
upstream and/or just downstream of a relief valve. You may want to
choose the combination option if:
1. You need to ensure a positive seal of the system (the system

contains a toxic substance and you are concerned that the relief valve
may leak). Application: rupture disk installed upstream of the relief Figure 3: Rupture DiskRelief Valve Combination
valve.
2. The system contains solids that may plug the relief valve over time. Remember, the relief
valve is continuously exposed to the system. Application: rupture disk installed upstream of the
relief valve.
3. TO SAVE MONEY! If the system is a corrosive environment, the rupture disk is specified
with the more exotic and corrosion resistant material. It acts as the barrier between the corrosive
system and the relief valve. Application: rupture disk installed either upstream and/or
downstream of the relief valve.
Below is a capital cost comparison between combination Hastelloy C rupture disks with stainless
steel relief valves and three stand-alone Hastelloy C relief valves. Again, this is based on a
budget estimate in year 2001 dollars using Continental Disc Corp. rupture disks and holders and
Farris Engineering relief valves.
Table 2: Cost Comparison for Rupture Disk-Relief Valve Combinations
Basis: Continental Disc
Basis: Farris Engineering
3" Ultrx Hast C Holder = $3,300
3" x 4" Hast C 26KA10-120 = $13,400
st
3" Ultrx Hast C Disc = $2,600 for 1 usable 3" x 4" SS 26KA10-120 = $4,300
disk, then $870 each
Combination of Hastelloy C Disk and SS Relief Valve
Single Installation Total = $10,200
Total for three installations = $27,140
Three stand-alone Hastelloy C relief valves = $40,200
Summary
A stand-alone rupture disk is used when:
1. You are looking for capital and maintenance savings
2. You can afford to loose the system contents
3. The system contents are relatively benign
4. You need a pressure relief device that is fast acting
5. A relief valve is not suitable due to the nature of the system contents
A rupture disk / relief valve combination is used when:
1. You need to ensure a positive seal of the system
2. The system contains solids that may plug the relief valve over time
3. TO SAVE MONEY! If the system is a corrosive environment, the rupture disk is
specified with the more exotic and corrosion resistant material
References
1. API (www.api.org) Recommended Practice 520, "Sizing, Selection, and Installation of
Pressure-Relieving Device in Refineries, Part 1-Sizing and Selection", 7th Edition

(January 2000)
2. API (www.api.org) Recommended Practice 521, "Guide for Pressure-Relieving and
Depressuring Systems", 4th Edition (March 1997)
3. ASME (www.asme.org) "Boiler and Pressure Vessel Code, Section VIII, Division 1"
(1998)
Chemical and Process Engineering Resources

Nov 08 2010 01:30 PM | pleckner in Safety and Pressure Relief
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Part 1 of this series on rupture disks for Process Engineers covered why you use a rupture disk
and when you might want to use this device. This part will discuss how to size the rupture disk.
Subsequent parts will include how to set the burst pressure, the Relief Valve/Rupture Disk
combination, how to specify the device and some discussion on the type of rupture disks you can
purchase.
found in these documents can also be found in vendor literature
Sizing
Sizing the rupture disk is a two-part procedure. First, determine how much flow the rupture disk
needs to pass. Then determine how big it needs to be.
How much flow does it need to pass?
Answering this question is the same as determining the required relieving rate for the system.
There is no difference between determining the relieving rate for a rupture disk and a relief
valve. They both require a set pressure (burst pressure for rupture disk), an allowable
overpressure, an evaluation and calculation of the required relieving rate for each credible
scenario and then choosing the flow rate associated with the worst-case scenario. Determining
the controlling relieving rate is a paper in of itself and I will not attempt to get into details here.
How Big?
There are two recognized methods that can be used to answer this question, the Resistance to
Flow Method or the Coefficient of Discharge Method.
Resistance to Flow Method
The Resistance to Flow Method analyzes the flow capacity of the relief piping. The analysis
takes into account frictional losses of the relief piping and all piping components. Calculations
are performed using accepted engineering practices for determining fluid flow through piping
systems such as the Bernoulli equation for liquids, the Isothermal or adiabatic flow equations for
vapor/gas and DIERS methodology for two-phase flow.
Piping component losses may include nozzle entrances and exits, elbows, tees, reducers, valves
and the rupture disk (note that the rupture disk and its holder are considered a unit). Let me
emphasize that in this method, the rupture disk is considered to be just another piping
component, nothing more, and nothing less. Therefore the rupture disk's contribution to the over
all frictional loss in the piping system needs to be determined. This is accomplished by using
"Kr", which is analogous to the K value of other piping components. Kr is determined
experimentally in flow laboratories by the manufacturer for their line of products and is certified
per ASME Section VIII, Division 13. It is a measure of the flow resistance through the rupture
disk and accounts for the holder and the bursting characteristics of the disk.
Below is a list of some models of Continental Disc Corporation rupture disks with their certified
Kr values4.
Table 1: Rupture Disks from Continental Disc Corp.
Rupture Disk (and holder) Type
Media
Size Range
ULTRX
Gas, Liquid 1" - 12"
ULTRX
Gas only
1" - 12"
MINTRX
Gas, Liquid 1"- 8"
STARX
Gas, Liquid 1" - 6"
SANITRX
Gas, Liquid 11/2" - 4"
Kr
0.62
0.36
0.75
0.38
3.18
For comparison, the following is a list of some models of Fike rupture disks with their certified
Kr values5.
Table 2: Rupture Disks from Fike
Media
Size Range
SRX
1" - 24"
SRL
1" - 8"
SRH
1 1/2" - 4"
HO / HOV
1" - 24"
Kr
0.99
0.38
1.88
2.02
PV, CPV, CP-C, CPV-C
1/2" - 24"
3.50
If at the time of sizing the manufacturer and model of the rupture disk are unknown, there are
guidelines to help you choose Kr. API RP5212 recommends using a K of 1.5. However, ASME
Section VIII, Division 13 states that a Kr of 2.4 shall be used. Which one? Remember that ASME
is Code (meaning LAW for the most part) and API is a recommended practice. In addition, as can
be seen in the tables above, even ASME may not be as conservative as you may think. Therefore,
it is in the engineer's best interest to determine ahead of time the manufacturer and model of the
rupture disk that eventually will be purchased. This can be done without knowing the exact size,
as Kr is more manufacturer and model specific than size specific (see above tables). If a number
of manufacturers are on the allowable purchase list, then at the very least choose the most likely
models you would buy from each manufacturer and use the largest Kr from that list. This will be
a significantly better guess than just using guidelines.
Once the piping system is laid out and all the fitting types are known, including the rupture disk,
the engineer can proceed with the calculations in the following manner (presented here as a
suggestion, there are many ways to do it).
1. Known are the two terminal pressures, these being the relieving pressure (upstream) and
the downstream pressure (a knock-out pot, atmosphere, etc.).
2. Also known are the fluid properties and required relieving rate (the flow the rupture disk
needs to pass).
3. Choose a pipe size. This will be the size to use for all components, including the rupture
disk.
4. For vapor/gas or two-phase flow, use one of the accepted calculation methods to
determine the maximum flow through the system. The maximum flow through the system
is commonly known as critical flow or choked flow. For liquids, use the Bernoulli
equation to calculate the flow that will balance the system pressure losses.
5. Per ASME Section VIII, Division 1, multiply this flow by 0.9 to take into account
inaccuracies in the system parameters. Compare the adjusted calculated flow to the
required relieving rate. If it is greater, then the calculation is basically done. However, the
next smaller line size should also be checked to make sure the system is optimized; you
want the smallest sized system possible. If the adjusted calculated flow is less than the
required relieving rate, the pipe is too small, choose a larger size and repeat the
calculations.
Why not just choose a large Kr? Isn't that more conservative?
Many times, relief is not to atmosphere but to some downstream collection and treatment system,
e.g. knockout drums and flares or thermal oxidizers. These are more often than not specified at a
time period in the design that predates the actual purchase of the rupture disk. The flow used to
size this equipment will be based on the capacity of your relief system as determined above.
If the rupture disk contributes a significant portion of the frictional losses to the system, a
fictitiously large Kr might result in an oversized piping system. Sounds all right on the surface
but once the actual rupture disk is chosen, the calculation must be repeated with the "real" Kr and
this may be a much lower value than originally used. More fluid will flow through the system
than previously determined because there will actually be less resistance to flow. The result is
that the downstream processing equipment may have been undersized.
The opposite is also true. An initial guess of a fictitiously small Kr might ultimately result in
oversized downstream equipment and the excessive expenditure of a significant amount of
money.
Atmospheric discharge must also be similarly analyzed because the flow capacity determined
after rupture disk selection may have a major impact on the emissions reported for permitting if
they were based on the initial value of Kr.
Coefficient of Discharge Model
The second calculational method is the Coefficient of Discharge Method. The rupture disk is
treated as a relief valve with the flow area calculated utilizing relief valve formulas and a fixed
coefficient of discharge, Kd', of 0.62. This method does NOT directly take into account piping
so there are restrictions in its use. These restrictions are known as the "8 & 5 Rule" which states
that in order to use this method to
size the rupture disk ALL of the following four conditions MUST be met3:
The rupture disk must be installed within 8 pipe diameters of the vessel or other overpressure
source.
1. The rupture disk discharge pipe must not exceed 5 pipe diameters.
2. The rupture disk must discharge directly to atmosphere.
3. The inlet and outlet piping is at
least the same nominal pipe size
as the rupture disk.
A sketch of the "8 & 5" rule starting with
a 2" nominal sized pipe is shown at the
below.
The flow area calculated with this
method is called the Minimum Net Flow
Area or MNFA. The MNFA is the rupture
disk's minimum cross
sectional area required to meet the
needed flow.
Figure 1: Diagram Showing the "8 & 5" Rule
This is not the area (and thus the size) you specify. Just like a pipe with a nominal size and an
actual inside diameter, the rupture disk has a nominal size and an actual Net Flow Area or NFA.
The rupture disk purchased must have a NFA equal to or greater than the MNFA. The
manufacturer publishes the NFA for every rupture disk model and size they sell. The NFA also
accounts for bursting characteristics of the disk and the holder.
Below is a list of some Continental Disc Corporation rupture disks with their NFA4.
Table 3: Continental Disc Corp Disks with NFA

Nominal Size,
NFA,
inches
in2
ULTRX
1-1/2"
2.04
ULTRX
3"
7.39
SANITRX
1-1/2"
1.18
SANITRX
3"
5.49
Once the actual NFA of the rupture disk is determined, the calculations must be repeated,
basically for the same reasons discussed above for the Resistance to Flow Method.

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Why I Don't Like the Coefficient of Discharge Model
It's too restrictive! During the basic design phase of a project, actual piping configuration
is unknown. You may think you are within the "8 & 5" rule at first but may not be when
the final details are worked out. Remember, the "5" means 5 pipe diameters. For a 3" line,
that is only a nominal 15". For a 6' vertical vessel with a rupture disk discharge being
piped to a drain hub on the floor, the 15" maximum length is exceeded without even
thinking.
Using the Resistance to Flow Method is valid for all cases. All sizing calculations can be
standardized.
The Kr used in the Resistance to Flow Method is obtained by actual flow data for a given
model of rupture disk and holder. Its use will provide a much more accurate calculation.
The 0.62 coefficient of discharge used in the Coefficient of Discharge Method is very
general and independent of rupture disk manufacturer model and type, holder, disk
bursting characteristics and flow restrictions of the total relief system.
Two-phase flow can be a major concern when using this method. The coefficient of
discharge was established mainly for true vapors. Its application to liquids is questionable
and its application to two-phase flow is totally fictitious. Granted, for the Resistance to
Flow Method the Kr is not particularly applicable to two-phase systems either but one
can easily compensate for this in the system calculations. Also, the rupture disk is only a
part of an entire piping system and its overall contribution to the system frictional losses
may not be greatly significant. Therefore, errors in Kr may not be very significant. In the
Coefficient of Discharge Method, it is the only device considered. If the coefficient of
discharge is grossly in error, the MNFA calculated will also be grossly in error.
The same argument can be made for highly viscous liquid systems such as polymers.
In Summary
Obtain the required relieving rate using good sound "what can go wrong" scenario
analysis.
Use the Resistance to Flow Method to calculate the size of the rupture disk (use the
Coefficient of Discharge Method if you really must and you fall within the "8 & 5" rule).
For the Resistance to Flow Method, try to choose the manufacturer and model of rupture
disk you intend to purchase ahead of time or at least have a list of acceptable
manufacturers and a good idea of the model you intend to use from each.
For the Resistance to Flow Method use the ASME Kr value of 2.4 if you have no idea
who the manufacturer(s) will be at the time of sizing.
References
(January 2000)
(1998)
4. Continental Disc Corporation (www.contdisc.com), CertiflowTM Catalogue 1-1112
5. Fike (www.fike.com), Technical Bulletin TB8104, December 1999
6. Another good rupture disk manufacturer to investigate would be Oseco
(www.oseco.com).
7. A good reference source for calculating flow through the system for liquids and
gas/vapors is CRANE Technical Paper 410, "Flow of Fluids Through Valves,
Fittings, and Pipe"
8. A great source and one that I feel should be the bible on two-phase flow is: Leung, J.C.
"Easily Size Relief Device and Piping for Two-Phase Flow", Chemical Engineering
Progress, December, 1996

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and when you might want to use this device. Part 2 discussed how to size the rupture disk. In this
part, I will cover how to set the burst pressure. Subsequent parts will include temperature and
backpressure affects, the Relief Valve/Rupture Disk combination, how to specify the rupture disk
and some discussion on the type of rupture disks you can purchase.
Problem
1. What is the maximum allowable specified burst pressure?

2. What should the expected stamped (rated) burst pressure of the rupture disk be?
3. At what pressure(s) can we expect the delivered rupture disk to actually burst at?
4. What is the maximum allowable operating pressure in the vessel?
All these questions must be considered in order to properly set the burst pressure of a rupture
disk.
What is the Maximum Allowable Specified Burst Pressure?
Burst Pressure
What do we mean by burst pressure? This is the pressure at which the rupture disk will open or
burst. It is analogous to the set pressure of a relief valve and is specified by the process engineer.
Design Pressure
To find the maximum allowable specified burst pressure, the process engineer first needs to
define a vessel design pressure. The design pressure is an arbitrary value above the vessel
maximum operating pressure. One guideline used by many process design engineers is to
increase the maximum operating pressure by 25 psig or 10% whichever is greater. For example,
if the maximum operating pressure is 70 psig, then 25 psig should be added to arrive at the
design pressure since 10% is only 7 psig. The design pressure would then be set at a nice round
100 psig. Other criteria to determine design pressure may be used but I recommend that the
margins never be less than what I described above (the reason will become apparent later).
Maximum Allowable Working Pressure (MAWP)
The next step is to determine the Maximum Allowable Working Pressure (MAWP) of the vessel.
A vessel specification stating design pressure, the coincident design temperature and other
parameters is sent to the manufacturer. The manufacturer performs a series of calculations
utilizing these parameters, amongst others, to determine material thickness for use in vessel
fabrication. A standard material thickness (greater than or equal to what was calculated) is
chosen. With the actual material thickness known, the true MAWP is calculated. The vessel
design documents are then stamped (certified) at this pressure in accordance with code.
However, for one reason or another, the MAWP calculation is not always done and the vendor
will just stamp the vessel at the specified design pressure.
The Maximum Allowable Specified Burst Pressure
So, what is the maximum allowable specified burst pressure? Theoretically it is the MAWP.
However, rupture disks are typically specified during basic engineering, which is performed way
before the vessel is mechanically designed. This, combined with the fact that the true MAWP
may never really be known (as mentioned above), the maximum allowable specified burst
pressure will more typically be the vessel's design pressure.
Note if the rupture disk is to be used in conjunction with another relief device to fulfill the total
required relieving capacity, the maximum allowable specified burst pressure could be 5% or even
10% greater than the design pressure (or MAWP). See ASME Section VIII, Division 1
paragraphs UG-125 and UG-134.
Also note that the specified burst pressure can be lower than the maximum allowable. Indeed,
this is often the case if the rupture disk is used to protect reactor vessels against over pressure
due to run-away reactions.
Stamped Burst Pressure
What should the expected stamped (rated) burst pressure of the rupture disk be?
What do we mean by "stamped or rated" burst pressure? Per code, the rupture disk vendor must
provide a tag containing, amongst other things, the rated or what is typically called the stamped
burst pressure. This is a guaranteed value so the user knows (within an allowable tolerance; more
on this later) the exact bursting pressure of the rupture disk. Also this stamped burst pressure
must never exceed the design pressure (or MAWP); except for the special case mentioned above.
So, the rupture disk vendor stamps the disk with the burst pressure specified by the process
engineer? Not necessarily!
Manufacturing Range (MR)
Figure 1: Graphical Representation of the Manufacturing Range

A rupture disk is made out of a sheet of material, e.g. stainless steel, high alloys, ceramics, etc.
Like all things in this world, this sheet of material is not perfect. To quantify the inaccuracies in
sheet material thickness, the vendor uses what is called the Manufacturing Range (MR).
The MR is expressed as % of the

specified burst pressure. It determines the
highest pressure above the specified burst
pressure or the lowest pressure below the Figure 2A: Specified and Stamped Burst Pressure
specified burst pressure that the disk can be stamped at. This is shown graphically in Figure 1.
Figure 1 shows the two extremes, a MR of 0% and a MR of some value%. Note that other
combinations may be used such as + 0% and - some value% or - 0% and + some value%.
Let's look at an example. If the specified burst pressure is 100 psig with a MR of 0%, the
stamped or rated burst pressure will be 100 psig (see Figure 2A). However, if the MR is +5% and
- 10%, the disk can be delivered with a stamped burst pressure of 105 psig, 90 psig or anywhere
in between (see Figure 2B). That's right, if the MR is anything but 0%, the user won't know the
stamped burst pressure until the rupture disk is ready for shipment!
Figure 2B: Differences in Specified and Stamped Burst Pressures

Do you see anything wrong with this rupture disk as specified?
Remember, the stamped or rated burst pressure must never exceed the vessel's design pressure or
MAWP (assumes a single device, no special cases). Since the specified burst pressure is the
design pressure, this particular rupture disk is not acceptable because the delivered rupture disk
may have a stamped burst pressure of 105 psig or 5 psig greater than design!
How can we avoid this problem? There are a number of ways.
The process engineer specifies the Manufacturing Range, not the manufacturer. You can ask for
any range within the capability of fabrication including 0%. Considering the potential
problems, why specify anything other than 0%? Cost. A MR of +5% and -10% can save as
much as 40% off the cost of a similar rupture disk with a MR of 0%. Even if you demand +0%
(which you should), you can still realize some cost savings if a stamped burst pressure lower
than specified is acceptable (not always a good idea as will be discussed later). Note that code
only affects the upper stamped limit, not the lower.
Another way to avoid the potential violation of code and still get a cheaper rupture disk is to
specify a burst pressure that will be lower than the vessel design pressure. Thus, when the MR is
added the stamped burst pressure will not exceed the design pressure. The maximum allowable
specified burst pressure could be determined in the following manner:
Pspec_max = (DP) - (+MR/100) x (Pspec_max)
Where DP = Design pressure
So:
Pspec_max = (DP) / [1+(+MR)/100]
Since DP = 100 psig and the upper value of MR = +5%,
Pspec_max = 100 /[1+(+5/100)] = 100/(1+0.05) = 100/1.05 = 95.2 psig
This rupture disk would be specified with a burst pressure no higher than 95.2 psig while the
stamped burst pressure may be as high as 100 psig.
Note that the standard Manufacturing Range for most manufacturers is 0% and this is reflected
in the base price you will be quoted.

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Where Will the Disk Burst?
At what pressure(s) can we expect the delivered rupture disk to burst at?
Trick question? The answer should be the stamped burst pressure. But again the world isn't
perfect.
Burst Tolerance
The Manufacturing
Range is applied to the
specified burst pressure
but there is yet another
unknown due to
imperfections in the
material used to fabricate
the rupture disk. This is
accounted for in the
burst tolerance. Burst
tolerance is applied to the
stamped burst pressure
and is set by code. For
Figure 3A: Burst Tolerance
stamped burst pressures
of 40 psig and lower, the burst tolerance is 2 psi. For stamped burst pressures above 40 psig,
the burst tolerance is 5%.
Let's look at the examples again but apply the burst tolerance. For this discussion, I'm changing
the specified burst pressure for the case of a rupture disk with a Manufacturing Range of +5%
and -10% to 95.2 psig (see Figure 3B) so the stamped burst pressure can't exceed code.
The important thing to notice is that in both Figures 3A and 3B, the upper limit of the stamped
burst pressure is equal to the design pressure but the maximum bursting pressure is 105 psig, or 5
psig over design pressure. Unlike the stamped burst pressure, which by code cannot exceed the
design pressure (or MAWP), the maximum expected burst pressure can if it is caused by the
burst tolerance.
Figure 3B: Specified, Stamped, and Maximum Burst

Maximum Allowable Operating Pressure
What is the maximum allowable operating pressure in the vessel?
Up to now, the discussions focused on the upper limit of the stamped burst pressure because this
is governed by code. But the lower limit is extremely important to consider as well because of
the possible affect it has on the maximum allowable operating pressure in the vessel.
Operating Ratio (OR)
The operating ratio is defined as the ratio of the maximum operating pressure to the lowest
stamped burst pressure. The OR is used to protect against premature bursting of the rupture disk.
If the operating pressure is too close to the lowest stamped burst pressure, or the system pressure
cycles (pressure rises and falls during operation) too close to the stamped burst pressure, the
material will fatigue and can
eventually loose its structural integrity. This is a classic reason for premature bursting of a
rupture disk.
The manufacturer publishes the Operating Ratio for every rupture disk model they sell. For
example, the Continental Disc Corporation's ULTRX rupture disk has an operating ratio of 90%4.
This means the system pressure can operate to within 90% of the lowest stamped burst pressure
without the fear of premature bursting. However, it's always best to operate as far away from the
lowest stamped burst pressure as you can to avoid material fatigue.
From Figure 3B above, the lower limit or minimum stamped burst pressure is 85.7 psig:
Pstamped_min = (Pspec) - ABS [(-MR/100)] x (Pspec)
Where ABS' stands for Absolute Value.
So:
Pstamped_min = (Pspec) x {1- ABS [(-MR/100)]}
Since Pspec = 95.2 psig and the lower value of MR = -10%,
Pstamped_min = 95.2 x {1 - ABS [(-10/100)]} = 95.2 x {1-ABS [(-0.1)]} = 95.2 x (1-0.1) = 95.2 x 0.9
= 85.7 psig
Therefore based on an OR of 90%, the maximum allowable operating pressure should not be
greater than:
Pop = Pstamped_min x OR = 85.7 x 0.9 = 77 psig.
Since our discussions have been based on a maximum operating pressure of 70 psig, this rupture
disk is acceptable. But note that this 10% cushion exists only because of the design pressure
margin used (25 psig). Had the margin been less, say only 10%, the rupture disk we would want
to use would be unacceptable.
How to avoid this problem?
Set the design pressure appropriately

Choose a rupture disk with a MR of 0%
Choose a rupture disk with a OR of 90% (they don't really go much higher)
There is one more point to consider. Although I have never seen any mention of checking the
maximum allowable operating pressure against the minimum expected burst pressure (arrived at
by taking into account the burst tolerance), I think it only makes good engineering sense to do so.
After all, if the disk can burst at this lower pressure, one certainly does not want to operate too
close to it!
Getting back to our question, what is the maximum allowable operating pressure in the vessel? In
this case, it is 77 psig.
ummary
What is the maximum allowable specified burst pressure?
- Design Pressure or MAWP if the rupture disk is the only relief device
OR
- For special cases, 105% (or even 110%) of design pressure or MAWP if the rupture disk is a
secondary device
What should be the expected stamped (rated) burst pressure of the rupture disk?
- As specified by the process engineer for a Manufacturing Range of 0%

OR
- As specified by the process engineer but could be adjusted per the Manufacturing Range if
other than 0%
At what pressure(s) can we expect the delivered rupture disk to actually burst at?
- 5% of stamped burst pressure for stamped pressures greater than 40 psig

OR
- 2 psi for stamped pressures 40 psig and lower
What is the maximum allowable operating pressure in the vessel?
- Specified by the process engineer based on operating need but must be checked against the
Operating Ratio of the rupture disk
- I strongly suggest you also check against the minimum expected burst pressure as well.
Manufacturing Range is applied to the specified burst pressure

Burst Tolerance is applied to the stamped burst pressure
Set the design pressure appropriately
Choose a rupture disk with a MR of 0%
Choose a rupture disk with a OR of 90%
WARNING!
Don't go running out and specifying a rupture disk just quite yet! We still need to consider the
affects of temperature and backpressure and the relief valve-rupture disk combination.
References

(January 2000)
(1998)
4. Continental Disc Corporation, ULTRX Catalogue 3-2210-3

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and when you might want to use this device. Part 2 discussed how to size the rupture disk. Part 3
discussed how to set the burst pressure. In this part, I will discuss how temperature and
backpressure affects the rupture disk design. Subsequent parts will include the Relief
Valve/Rupture Disk combination, how to specify the rupture disk and some discussion on the
type of rupture disks you can purchase.
Temperature and Backpressure Considerations
In Part 3, I discussed how to set the burst pressure of the rupture disk. However, the discussion is
not complete without considering the affects of temperature and backpressure on the bursting
pressure.
Temperature
The rupture disk manufacturer uses both the specified burst pressure and the specified
temperature when designing and stamping the disk. (In this instance, I use the term design to
mean arriving at the correct burst pressure, not mechanical integrity). However, it is more than
likely that the temperature of the rupture disk will not be at the specified temperature when it is
called into service. Why is this so?
The temperature most commonly specified is that of the relieving fluid coincident with the burst
pressure, i.e. relieving conditions. Sounds logical, but remember that the disk is continuously
exposed to the process stream for hours, days, weeks or even months before it may ever be
needed. Or, the disk may be exposed to ambient conditions. Therefore, expect the disk
temperature to be approximately equal to its environment during normal operation of the system.
When a process upset occurs, system pressure rises until it reaches relief (burst). The temperature
of the relieving fluid also rises per thermodynamics. However, the time interval between normal
system operation and relief is usually so small that the rupture disk's temperature hardly has time
to come to equilibrium with the higher process fluid temperature. Therefore the disk can actually
be colder than it's specified temperature. The affects?
In general, burst pressure varies inversely with temperature. For some rupture disks, the burst
pressure can be as much as 15 psi greater than stamped if the actual temperature is 100oF lower
than specified, e.g. a disk specified with a burst pressure of 350 psig at a temperature of 400oF
will actually burst at 365 psig if its temperature is only 300oF4. This doesn't sound like a big
difference but if 350 psig were the design pressure (or MAWP) of the vessel, then a burst
pressure of 365 psig would be in violation of code (LAW). The opposite is also true. A disk at a
temperature hotter than specified when called into service will burst at a pressure lower than
stamped. Although this is considered to be the more conservative approach because code can't be
violated and there is no risk of catastrophic failure of the vessel, specifying too low of a
temperature can lead to the not so desirable action of premature bursting.
The bottom line is that the specified burst temperature must be carefully considered. Specify the
lowest temperature at the time the disk is expected to burst. Consider that this might be the
normal process operating temperature or even ambient rather than the calculated relieving
temperature.
Note that different materials and different types of rupture disks have different sensitivities to
temperature. This is an excellent topic of discussion for your rupture disk manufacturer!

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Backpressure
A rupture disk is actually a differential pressure device where the specified burst pressure is
equal to the difference between the desired upstream pressure (vessel) at the time of rupture disk
burst and the downstream pressure (backpressure):
Pburst = Pvessel - Pbackpressure

Or alternately the desired upstream pressure (vessel) at the time of rupture disk burst is equal to
the sum of the specified burst pressure and the downstream pressure (backpressure):
Pvessel = Pburst + Pbackpressure
Either way, it is apparent that the vessel pressure at the time the rupture disk bursts (commonly
called the relief pressure) is directly dependent on backpressure.
When discussing relief systems, three types of backpressure are considered, these being constant,
built-up and superimposed.
Figure 1A: Single Vessel, Single Rupture Disk Protection,

Expected Constant Back pressure = 0 psig
Figure 1A shows a system comprised of a single vessel protected by a single rupture disk with a
specified burst pressure of 100 psig. The relief pipe discharges a few inches below the liquid
surface in a knockout drum, which is held at a constant 0-psig pressure. Therefore, the rupture
disk sees a constant (fixed) backpressure of 0 psig. If the vessel were to go into relief, this disk
will burst at 100 psig and the vessel relief pressure will be 100 psig (100 + 0 = 100).
Figure 1B: Single Vessel, Single Rupture Disk Protection,

Actual Constant Back pressure > Expected
Figure 1B is the same system however for some reason the pressure in the knockout drum is to
be maintained at 5 psig instead of 0 psig. The constant (fixed) backpressure against the rupture
disk is now 5 psig. If the vessel were to go into relief, the rupture disk would still burst at 100
psig but the vessel relief pressure would now be 105 psig (100 + 5 = 105) rather than the 100
psig expected. This situation could result in a violation of code3.
Figure 1C: Single Vessel, Single Rupture Disk Protection,

Actual Constant Back pressure < Expected
Figure 1C is again the system however for some reason the pressure in the knockout drum is to
be maintained at -5 psig instead of 0 psig. The constant (fixed) backpressure against the rupture
disk is now -5 psig. If the vessel were to go into relief, the rupture disk would still burst at 100
psig but the vessel relief pressure would now be only 95 psig (100 + (- 5) = 95) rather than the
100 psig expected. There is no particular safety concern here because the vessel can't over
pressure. However, the Operating Ratio is affected, which can result in a very premature bursting
of the rupture disk.
For the vessel relief pressure to be specified correctly, the rupture disk vendor must be told the
constant back pressure so that the rupture disk can be designed accordingly. And, if you truly
want the vessel relief pressure to be at a specific value then the "constant" backpressure given to
the vendor must be maintained at all times.
The key point is that during design, be aware of the constant backpressure and ensure that the
vessel relief pressure will not violate code or affect normal operation.
Figure 2A: Two Vessel System - Common Discharge

Built-up and Superimposed Back Pressures
Now let's look at the system shown in Figure 2A. A second vessel with a single rupture disk also
specified to burst at 100 psig is added in close proximity to the first vessel. The relief piping
from the two vessels is tied into a common header before discharging into a knockout drum in
the same manner as before, the tie-in occurs near the vessels. At the exact moment Vessel No. 2
goes into relief and its rupture disk bursts, Vessel No. 2's relief pressure is 100 psig due to the
constant 0-psig backpressure as described above. After the disk bursts, flow is established
causing pressure to build up in the piping system (built-up backpressure). The amount of built-up
backpressure is dependent on the system pressure drop and possibly even the phenomenon of
choked flow. For the purpose of this discussion, assume total built-up backpressure is 10 psig
after rupture disk No. 2 bursts and the pressure in Vessel No. 2 is about 110 psig. Because of the
proximity of the two discharge pipes and vessels, the pressure near vessel No. 1 will also be at
about 110 psig. This pressure, which is exerted or imposed onto rupture disk No. 1, is called the
superimposed backpressure with respect to rupture disk No. 1. If vessel No. 1 were to go into
relief shortly afterwards, then for rupture disk No. 1 to burst, the pressure in vessel No. 1 would
have to build to about 210 psig (100 + 110)! This is clearly unacceptable!!
One solution to this potentially catastrophic condition is to separate the two relief lines so that
one cannot directly affect the other (see Figure 2B below). Of course the answer may very well
be that this is not an application for rupture disks but for relief valves! The key point is, avoid
combining multiple rupture disk piping into a common relief header.
Figure 2B: Two Vessel System - Common Discharge

Built-up and Superimposed Back Pressures
Note that built-up backpressure is variable and depends on the relieving rate, which is a function
of the relieving scenario. Also, built-up backpressure has no affect on the vessel's relief pressure
for systems such as those shown in Figure 1 above. Built-up backpressure is the result of fluid
flow only and there is no fluid flow before the rupture disk bursts.
Therefore, along with the Manufacturing Range (MR), Operating Ratio (OR) and Burst
Tolerance (BT) that were discussed in Part 3, the process design engineer must also strongly
consider the backpressure (especially superimposed backpressure) when specifying the rupture
disk.

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In Summary
Generally, burst pressure varies inversely with temperature so the specified burst
temperature must be carefully considered.
- Specify the lowest temperature at the time the disk is expected to burst.
- Different materials and different types of rupture disks have different sensitivities to
temperature effects.
The rupture disk is a differential pressure device.

- The specified burst pressure is a value equal to the vessel relief pressure minus the
backpressure.
Or
- The vessel relief pressure equals the specified burst pressure plus the backpressure.
There are three types of backpressure to consider, these being constant, built-up and
superimposed.
- Constant backpressure is the pressure in the system that does not vary. It is generally a
predictable component of the superimposed backpressure.
- Built-up backpressure is the pressure created in the system as a result of fluid flow. It is
a varying component of the superimposed backpressure.
- Superimposed backpressure is the total pressure exerted (imposed) on the rupture disk
by other sources. It is a variable that directly increases or decreases a vessel's relief
pressure. It can also interfere with the expected operating ratio of the disk.
Do not pipe multiple vessel relief systems into a common header; keep the piping
separate. However, the individual piping may go to a common disposal system.
Along with the Manufacturing Range (MR), Operating Ratio (OR) and Burst Tolerance
(BT), the process design engineer must also consider backpressure when specifying the
rupture disk.
References

(January 2000)
(1998)
4. Nazario, F. N., "Rupture Discs, A Primer", Chemical Engineering Magazine, June 20,
1988.

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discussed how to set the burst pressure. Part 4 discussed how temperature and backpressure
affects the rupture disk specification and the relief pressure in the system. In this part, I will
discuss the Relief Valve/Rupture Disk combination.
Subsequent parts will include how to specify the rupture disk and some discussion on the type of
rupture disks you can purchase. Before I begin, let me point out that most of what is included in
this series of articles can be found in API RP5201 and API RP5212, and ASME Section VIII,
Division 13. Much of what is found in these documents can also be found in vendor literature.
For the relief valve/rupture disk combination (Figure 1), rupture disk sizing is totally dependent
on relief valve sizing, regardless whether the rupture disk is installed upstream or downstream of
the relief valve. Consequently, the discussion at this point must turn to a brief overview of relief
valves.
Relief Valve Sizing Overview
Basically, the relief valve is treated as an ideal nozzle, i.e. isentropic (constant entropy) flow. A
correction factor, the coefficient of discharge, is incorporated into the sizing equations to take
into account the fact that this is not an ideal nozzle. The sizing equations themselves can be
found in one or more of the references presented at the end.
To size a relief valve, the process engineer first determines the required relieving flow and fluid
properties based on an analysis of "what can go wrong" scenarios. The flow and properties are
then inserted into the appropriate sizing equation to arrive at a calculated relief valve area. If this
were a stand-alone relief valve, the process engineer would use this calculated relief valve area to
choose an actual relief valve from
a vendor catalog. But since this is a
discussion of the relief valve/rupture disk
combination, adjustments should be made
to the calculated relief valve area before the
actual relief valve is chosen.
The Rupture Disk Affect
Figure 1: Relief Valve/Rupture Disk Combination
The presence of a rupture disk acts to derate the relief valve capacity. This de-rating
factor, called the Combination Capacity
Factor (CCF), may or may not be implicitly
included in the sizing formulas.
Nevertheless, it is the responsibility of the
process engineer to apply the factor
correctly.
The Combination Capacity Factor (CCF)

The Combination Capacity Factor (CCF) is a calculated value that is derived from data obtained
during certified capacity testing of the stand-alone relief valve and the relief valve/rupture disk
combination. The manufacturer first determines the capacity of the stand-alone relief valve. The
rupture disk is then added, close-coupled, to the inlet of the relief valve and the capacity of the
relief valve/rupture disk combination is determined. Finally, the CCF is calculated as the ratio of
the relief valve/rupture disk combination capacity to the stand-alone relief valve capacity:
CCF = Flow Combination Capacity / Flow Stand-Alone Relief Valve Capacity
Below is a list of certified Combination Capacity Factors for the Continental Disc Corporation
model ULTRX rupture disks with the Crosby JOS/JBS Relief Valve 4.
Table 1: CCF's from Continental Disk
Rupture Disk
Size
Burst Pressure, psig
1"
60 minimum
3"
30 - 59
Material
CCF
Nickel
Stainless Steel
Nickel
Stainless Steel
0.981
0.980
0.981
0.984
For comparison, the following is a list of certified Combination Capacity Factors for the Fike
model MRK rupture disk with the Crosby JOS/JBS Relief Valve5.
Table 2: CCF's from Fike
Rupture Disk
Size
Burst Pressure, psig
1"
60 minimum
3"
35 minimum
Material
CCF
Nickel
Stainless Steel
Nickel
Stainless Steel
0.977
0.967
0.995
0.982
Note that the CCF is a certified value and is only good for the design of the relief valve and the
rupture disk that are used in the test. Since it is in the best interest of the rupture disk
manufacturer to certify as many of their rupture disk designs with as many different types of
relief valve designs as possible, it is typical for the rupture disk manufacturer to perform this
testing and reporting of the CCF. The certified CCF will always be less than or equal to 1.0.
If the manufacturer and/or model of the rupture disk and relief valve are unknown at the time of
sizing, or there is no published value for a relief valve/rupture disk combination, ASME3
requires that the CCF is not to exceed 0.9.
Applying the CCF

API Recommended Practices 5201 shows the CCF as being applied to the denominator of the
relief valve sizing equation. For example, a typical sizing equation for gas relief might look
something like this:
Eq. (1)
Where:
W = required relieving rate, mass flow
T = relieving temperature, absolute
Z = compressibility factor
M = molecular weight
C = gas constant = a function of (Cp / Cv)
Cp = specific heat at constant pressure (consistent units)
Cv = specific heat at constant volume (consistent units)
Kd = coefficient of discharge, dimensionless
Kb = backpressure correction factor, dimensionless
P1 = relief pressure (absolute)
Note that this is the same as dividing the calculated, stand-alone relief valve area by the CCF to
arrive at a required relief valve area for the combination unit:
Eq. (2)
And:
A required = A calculated / CCF
Eq. (3)
The process engineer will use this required relief valve area as the basis for choosing a relief
valve from the vendor catalog.
One important thing to note is that the preceding methodology is not a requirement of code
(ASME). ASME only requires that the stand-alone relief valve's certified flow capacity be derated by the CCF:
Flow Combination Certified Capacity = Flow Stand-Alone Relief Valve Certified Capacity x CCF
Eq. (4)
There is no mention of using the CCF to arrive at a relief valve area. Indeed, prior to the most
recent edition of API RP5201, the sizing equations themselves did not explicitly include a
correction factor for the relief valve/rupture disk combination.
Note also that de-rating the certified flow capacity is only required if the rupture disk is installed
upstream of the relief valve, it is not required if installed downstream of the relief valve.
Certified (Rated) Capacity

As stated above, each stand-alone relief valve will have associated with it a certified flow
capacity, which is a function of both the relief valve area and the set pressure. This flow is
determined by certified capacity testing procedures and is to be considered the guaranteed flow
rate that can be achieved through the particular valve. With very few exceptions, this flow is used
in determining both the relief valve inlet and outlet (tail pipe) line sizes. The certified flow
capacity is officially stamped on the relief valve documentation. For relief valve/rupture disk
combinations, the de-rated certified flow will also be stamped on the documentation.
Although the relief valve is chosen based on area, the process engineer must still ensure that the
certified flow capacity is greater than or equal to the required relieving flow:
Certified Flow Capacity Required Relieving Flow
If it is not, the chosen relief valve is too small. For the relief valve/rupture disk combination, the
required relieving flow would be compared to the de-rated or combination certified flow
capacity:
Combination Certified Flow Capacity Required Relieving Flow

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Relief Valve Sizing
Inlet Line
The relief valve inlet line is defined as the piping between the inlet to the system (e.g. the inlet to
a vessel nozzle) and the relief valve inlet flange. Sizing this inlet line is a trial-and-error
procedure. First, the process engineer chooses a line size using guidelines set by code; code
requires that the flow area of the line and all associated piping components be at least equal to
the relief valve inlet flow area. Then, using
accepted fluid flow equations (e.g. Darcy for single phase liquid or gas/vapor and DIERS for two
phase) and the certified flow capacity of the stand-alone relief valve the non-recoverable
frictional losses in the line are determined. The sum of all non-recoverable losses should be less
than 3% of the relief valve set pressure, this criteria is commonly referred to as the 3% Rule. In
general, if the 3% Rule is exceeded then the chosen line size is too small.
Outlet Line (Tail Pipe) Sizing Overview
The sizing of the tail pipe is done in a similar manner to that outlined above for the inlet line. The
process engineer first chooses a pipe size. Then, using accepted fluid flow equations (e.g. Darcy
for liquids, Isothermal or Adiabatic for gas/vapor and DIERS for two-phase) and the same
certified flow capacity as used for the inlet line, a built-up (variable) backpressure is calculated.
The built-up backpressure is converted to a percentage of the relief valve set pressure and is then
compared to some maximum value that is set by the particular relief valve manufacturer. For
example, tail pipes on conventional style relief valves would be sized such that the built-up
(variable) backpressure does not exceed 10% of the relief valve set pressure. For balanced
bellows style relief valves, tail pipes would be sized such that the built-up (variable)
backpressure does not exceed 30% to 55% of the relief valve set pressure, depending on
manufacturer. If the calculated percentage is less than or equal to these maximums, the line size
is acceptable. If the calculated percentage is greater, the line size may or may not be acceptable.
This is because the only requirement of code is that the built-up backpressure does not affect the
relief valve's ability to relieve the required amount of flow necessary to protect the system. Builtup backpressures greater than the stated maximums require a de-rating of the relief valve based
on curves developed by the manufactures. As long as the de-rated valve can still relieve the
required relieving flow, the line size chosen is acceptable. If not, then the line is too small.
Now that we've sized the relief valve in the relief valve/rupture disk combination, what about
sizing the rupture disk? Actually, we already did!
The Rupure Disk
Sizing
You will recall from Part 2 of this series that sizing the rupture disk is a two-part procedure.
First, determine how much flow the rupture disk needs to pass. Then determine how big it needs
to be.
Both criteria have been met with the relief valve sizing. How much flow? The rupture disk must
be able to pass the certified flow capacity of the relief valve. How big? The rupture disk must be
big enough so that its contribution to the frictional losses does not pose a significant impact on
the ability of the relief valve to protect the system. For a rupture disk installed in the inlet line,
the rupture disk's net flow area must be at least equal to the relief valve inlet flow area; it may be
larger. Also, its contribution to the non-recoverable frictional losses should be minimal so as to
ensure that the piping system meets the 3% Rule. Indeed, you may even find that the rupture disk
must be one-size larger than the inlet to the relief valve in order to satisfy the 3% Rule. For
example (Figure 2), a 2" x 3" relief valve (2" being the inlet flange size and 3" being the outlet
flange size) may require a 3" rupture disk!
For a rupture disk installed in the tail pipe,
the rupture disk size should be large enough
so that it contributes minimally to the builtup backpressure. And again, the rupture disk
may very well have to be a size larger than
the relief valve outlet flange to accomplish
this (Figure 3).
For both the inlet line and tail pipe
calculations, the rupture disk's certified Kr is
used in the friction loss calculations.
Figure 2: 2" x 3" Relief Valve
What the Code Says About...

Bursting
The stamped (certified) burst pressure of the
rupture disk must be between 90% and
100% of the relief valve set pressure. Also,
the bursting of the rupture disk and the
opening of the relief valve must be
essentially coincident with each other.
Backpressure
When specifying a rupture disk that will be

used upstream of a relief valve, it is
Figure 3: Rupture Disk is Larger than Outlet Flange expected that the superimposed
backpressure will be constant and
essentially zero (after all, there should be nothing between the rupture disk and the relief valve
but some trapped air). However, over time the rupture disk may leak for a variety of reasons.
This leakage will cause a build-up of pressure between the rupture disk and the relief valve. As
we saw in Part 4, unexpected backpressure on the rupture disk will change the relieving pressure
of the vessel or system. To guard against this, code requires the use of a "tell-tale". The "tell-tale"
must consist of, as a minimum, a pressure gage and a vent line inserted between the rupture disk
and the relief valve. Typically, a valve is put into the vent line for a more controlled design
(Figure 4). In installations where the rupture disk holder is close-coupled with the relief valve,
this system is inserted into a chamber within the holder. Note that a better tell-tale design would
include a pressure transmitter with an alarm as well as the pressure gage.
Figure 4: Valve in Vent Line
For rupture disks installed after the relief valve, the disk's bursting pressure must not be affected
by any backpressure affects nor can there be allowed a pressure build-up between the relief valve
and rupture disk that may affect the operation of either device. A "tell-tale" should be used to
protect against pressure build-up between the devices due to leaks through the relief valve. The
only way to protect against backpressure affects is to make sure the superimposed backpressure
is well defined and constant (see Part 4 of this series).
Obstructions
A bursting rupture disk must not cause obstruction of the relief valve or the relief piping.
Therefore, the non-fragmenting rupture disk is used in this service. This disk will break cleanly,
with no material being broken off.
Final Thoughts
Above I discuss the fact that the rupture disk needs to be able to pass the certified flow
capacity of the relief valve! But which flow capacity, the stand-alone relief valve or the
relief valve/rupture disk combination? Unfortunately, the way ASME3 reads, there is
plenty room for interpretation. For example, paragraph UG-127 (a) (3) (b') (5) basically
says the rupture disk must be able to pass the certified capacity of the relief valve/rupture
combination. However, for the rupture disk installed in the tail pipe, paragraph UG-127
(a) (3) (c') (4) says the rupture disk must be able to pass, "...the rated capacity of
the attached pressure relief valve without exceeding the allowable overpressure." Now,
for individual cases where the rupture disk is installed only upstream of the relief valve or
only downstream of the relief valve, I can buy into this as not being contradictory, i.e. use
rated capacity of the relief valve/rupture combination for the inlet line or use the rated
capacity of the stand-alone relief valve for the tail pipe. But what about the case where
the rupture disk is installed both upstream and downstream of the relief valve?
The flow used to evaluate the inlet line is to be the same flow used to evaluate the tail
pipe. And, the 3% Rule clearly wants you to use the certified capacity of the stand-alone
relief valve with the rupture disk being treated as just another piping component.
So which do I suggest we Process Design Engineers use? The certified flow capacity of
the stand-alone relief valve in all instances; it will be a little more conservative.
The code requirements discussed above help to emphasize the importance of the material
presented in Parts 3 and 4 of this series, i.e. the maximum allowable specified burst
pressure, the Manufacturing Range, the Burst Tolerance, the Operating Ratio, and
superimposed, built-up and variable backpressures; especially as they relate to the relief
valve/rupture disk combination
Summary
Rupture disks may be installed upstream and/or downstream of a relief valve.
The rupture disk acts to de-rate the relief valve capacity. This de-rating factor is called the
Combination Capacity Factor. Standards call for the use of this factor in determining
relief valve area and in de-rating the stand-alone relief valve's certified capacity. Code
only requires the use of this factor in de-rating the stand-alone relief valve's certified
capacity.
The size of the rupture disk in this application is totally dependent on relief valve sizing.
The rupture disk must be able to pass the certified flow of the relief valve.
The size of a rupture disk installed at the inlet of the relief valve should have minimal
affect on the 3% Rule and must have a flow area of at least equal to the inlet flow area of
the relief valve.
The size of a rupture disk installed at the outlet of the relief valve should provide minimal
contribution to the built-up backpressure.
Code governs how a rupture disk is applied to a relief valve installation and the general
type of rupture disk to use (non-fragmenting).
Code addresses rupture disk bursting requirements.
Code addresses backpressure affects and what must be done to avoid it.
When specifying a rupture disk, especially in combination service with a relief valve, the
maximum allowable specified burst pressure, the Manufacturing Range, the Burst
Tolerance and the Operating Ratio all must be considered very carefully.
References

(January 2000)
(1998)
4. Continental Disc Corporation (www.contdisc.com), ASME Combination Capacity
Factors, Catalogue 1-1111

5. Fike (www.fike.com), Technical Bulletin TB8103, July 1999

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discussed how to set the burst pressure. Part 4 discussed how temperature and backpressure
affects the rupture disk specification and the relief pressure in the system. Part 5 discussed the
Relief Valve/Rupture Disk combination. In this part, I conclude the series with a discussion of the
rupture disk specification.
I will also touch upon the type of rupture disks you can purchase. Before I begin, let me point out
that most of what is included in this series of articles can be found in API RP5201 and API
RP5212, and ASME Section VIII, Division 13. Much of what is found in these documents can
also be found in vendor literature.
We've answered the two questions required to size a rupture disk, how much flow and how big.
Now it's time to specify the rupture disk so that it can be purchased for our process. Although
API RP5201 provides a specification sheet that can be adapted by any company as a standard,
there are fifty-three separate items asked for in this specification sheet. Much of what is on this
specification sheet is not required by the manufacturer to be able to provide you with the correct
disk. Let's look at the basic minimum information you, the Process Design Engineer must
provide.
Must Haves
Project Identifier/Company Information/Device identifier/Number of Devices
The vendor will want to know who you are. It is also necessary to "name" the relief device for
proper documentation. A unique instrument Tag number should suffice for each device ordered.
Code/Standard Requirements
Various codes and standards dictate how the rupture disk is to be marked and stamped.
Maximum Operating Conditions
Temperature
The maximum operating temperature is used to determine materials compatibility.
Pressure
The maximum operating pressure will be used with the stamped burst pressure to determine the
Operating Ratio. The Operating Ratio will help determine the type of disk to purchase.
Rupture Disk Burst Conditions
Temperature
This must be coincident with the bursting pressure and will also be stamped on the disk. You will
recall from Part 4 that this parameter is extremely important in making sure the disk will burst at
the pressure you need it to burst, not less or greater. Also remember that it is not necessarily the
same as the maximum operating temperature of the system.
Pressure
This is the pressure that meets system protection requirements, taking into account the
Manufacturing Range. The vendor will stamp this value on the disk. It is also used with the
Maximum Operating Pressure to determine the Operating Ratio.
Process Media (Liquid/Gas/2-Phase)
Some rupture disk models are designed according to the media in which they are used. Process
media is also used to determine materials compatibility.
Backpressure/Vacuum
The manufacturer uses the backpressure to help determine disk type and how it is to be supported
in the system. Vacuum service will either require the use of a special support for disk installation
or even dictate the type of disk to use. Note that exposure to vacuum conditions must be
considered both upstream and downstream of the disk.
Service Conditions (Status/Cyclic/Pulsating)
This typically refers to the upstream conditions. Cyclic service is considered to be large changes
in pressure over a relatively long period of time. Pulsating service is considered to be small
changes in pressure but occurring frequently or even rapidly. Both of these can have a major
affect on the Operating Ratio. The manufacturer uses the service conditions to help determine
disk type and how the disk is to be supported in the system.
Rupture Disk and Holder Material Requirements
Many installations require the rupture disk to be mounted inside a holder. The holder is then
bolted onto a vessel nozzle or between pipe flanges. Make very certain the materials of
construction of both the disk and its holder is totally compatible with the system media and
operating conditions.
Disk Size
This is the nominal size you determined when answering the question, how big?
Flange Connection Details
These tell the manufacturer how big the holder needs to be (connection size), the pressure rating
of the system it will be installed in (class) and the type of connection, e.g. raised or flat faced
flanges, sanitary connections, etc.
The pressure rating or class can be a most confusing concept. This refers to the flanges in the
piping system. More common flange ratings are 150 and 300 pounds (pressure pounds, not
weight) but they can go very much higher. A major difference in these classes is the thickness of
material, number of boltholes and the bolthole pattern you would get in the flange.
Required Accessories for Rupture Disk
Options can be added to the basic design. For instance to enhance corrosion protection, coatings
or linings can be applied. Some types of rupture disks can withstand upstream vacuum
conditions without doing anything special to them others may need special supports.
Required Accessories for Holder
Options can be added to the rupture disk holder as well. For instance to enhance corrosion
protection, coatings or linings can be applied. Tell-tales may be specified under this header or
can be specified under the heading of "Special Considerations".
Other Special Considerations

You can specify just about anything under this heading including the need for a tell-tale. You
may want to give more specific detail of a particular design item. You can ask for burst detection
and alarms, etc., etc. and etc. The best reference source would be your manufacturer and/or their
catalog.
Again, the above should be considered just the minimum amount of information the
manufacturer needs to provide the proper rupture disk. Of course your particular manufacturer,
or even your company standards, may require much more.
Should you stop here, perhaps not? Below is some information that I consider to be "should
haves".
Should Haves
MAWP (or Design Pressure) of the Vessel or System
A vendor does not necessarily require this information (they were already told what to stamp the
disk for). However a good vendor will actually be your second set of eyes and make sure that
this, along with the other information given, is consistent with Code requirements.
Manufacturing Range
One would think that this should fall under the "must haves" but not really. When the burst
pressure was specified in the "must haves", the manufacturing range had to be taken into
account. All the vendor needs to know is what to stamp the rupture disk at and will therefore
design the disk with the appropriate manufacturing range to accommodate. However, it never
hurts to spell it out so there are no misunderstandings.
In Combination with a PSV
With this information, the rupture disk vendor will be able to recommend the proper type of
rupture disk to use for this service. They will also be able to recommend proper installation
techniques. And again, the vendor is your second set of eyes and may be able to tell whether your
specification data is consistent.
Calculate and Report the Operating Ratio
I could never quite figure out why the vendor cannot just do the simple math but I've seen this as
requested information on a number of vendor's specification sheets.
What about all the rest of the information usually included in many specification sheets, e.g.
required relieving flow, molecular weight, specific heat ratio, specific gravity, compressibility
factor, viscosity, etc.? These are definitely important, but really only to the Process Design
Engineer. You need this information to answer the two questions, how much flow and how big?
The vendor doesn't need these but we all seem to include them on our specification sheets
nevertheless!
The best suggestion I can make is to talk to the vendor first, find out exactly what they need and
provide it. But of course, never violate your own company standards.
Types of Rupture Disks
The manufacturer can recommend the type of rupture disk that will best suit your application
based on the information supplied. However, it doesn't hurt to have some knowledge
of the type of rupture disks that can be purchased. There are a multitude of different types and
the following only represents the most common types you will most likely come across.
Forward Acting Solid Metal
This rupture disk is domed shape and installed such that the media is on the concave side of the
disk (Figure 1). It can be used in systems where the Operating Ratio is at about 70% or less. It
has a random bursting pattern which means it can be fragmenting (loose material) and thus
cannot be used in combination with relief valves. This type of rupture disk can be used in
vacuum or larger backpressure services but will require special supports to prevent reverse
flexing. Its number one advantage is that it is cheap.
Figure 1: Forward Acting Solid Metal Rupture Disk
Forward Acting Scored Metal

This rupture disk is similar to its solid metal cousin (Figure 1) except that the disk is scored
(Figure 2). Unlike the ill-defined bursting pattern of the solid metal design, this rupture disk has
scored lines that will force the disk to burst along a fixed pattern. This design is a little more
expensive but increases the useful Operating Ratio to about 85 to 90%. It also eliminates
fragmenting, which means it can be used in combination with a relief valve. Also, there are many
designs that allow this type of disk to be installed in vacuum environments without requiring
special supports; it will still need special supports in high backpressure service to prevent reverse
flexing.
Figure 2: Forward Acting Scored Rupture Disk
Forward Acting Composite

This rupture disk can be flat or domed and is comprised of a top section preceded by a bottom
seal (Figure 3). The burst pressure is a function of these two sections. It is not uncommon for the
bottom section to be of a totally different material of construction from that of the top section,
even non-metallic. The domed disk design will burst due to pressure applied to the concave side
whereas the flat disk design may bedesigned to burst in either direction!
Figure 3: Forward Acting Composite Rupture Disk
Slits and tabs in the top section control burst pressure and the bursting pattern. The flat
construction can be used for the protection of low-pressure systems. Operating ratios are
typically around 80% for the dome construction and 50% for the flat construction. This disk may
require special supports to be used in vacuum or high backpressure conditions. Some designs are
non-fragmenting, which means they can be used in relief valve combination.
Reverse Acting
This rupture disk is domed shape and installed such that the media is on the convex side of the
disk (Figure 4). It is designed such that pressure pushes against the disk causing it to flex back
into a forwarding acting disk and then burst. This rupture disk can be used in systems where the
Operating Ratio is at about 90% or less. It can be, and very often is, manufactured to be nonfragmenting and thus is a good choice for use in combination with relief valves. This type of
rupture disk can be used in vacuum or larger backpressure services without special supports.
Figure 4: Reverse Acting Scored Rupture Disk

Final Thoughts
Liquids
Liquids are treated the same way as gases/vapors in all aspects of determining those two
questions, how much and how big. However, do not forget to take the hydraulic pressure into
account. Pressure in the system will not be equal throughout. If the rupture disk is installed on a
nozzle or in a pipe at the top of a liquid filled vessel, the pressure at the rupture disk will be less
than all points below it. If the rupture disk is installed on a nozzle at the bottom of a liquid filled
vessel, the pressure at the rupture disk will be greater than all points above it.
What are the implications of this? If the rupture disk is located at the top of the vessel, the vessel
pressure will be greater than the bursting pressure so specify the burst pressure to be less than the
vessel's MAWP or design pressure. If the rupture disk is at the bottom of the vessel, the vessel
pressure will be less than the bursting pressure. However, the rupture disk cannot be specified at
a pressure higher than MAWP or design. Therefore, realize that the disk will burst even though
the pressure at the top of the vessel will be less than design or MAWP.
Also note that normal variations in level will cause normal variations in the pressure, i.e. the
rupture disk will experience pressure cycling or pulsing. Unlike gases/vapors where normal
system pressure cycling or pulsing is usually minimal, it may be significant in liquid filled
systems.
One More Option to Consider
Ask your manufacturer if they provide a "Fail Safe" design. This design will provide pressure
relief at or below the certified burst pressure even if the disk is damaged or installed improperly.
It will function in this capacity equally well in gas/vapor or liquid service. The major drawback
is that it is only available in forward acting non-composite rupture disks.
Other Non-Close Relief Devices
Figure 5A: Rupture Pin Relief Device

End of Pipe with Atmospheric Discharge
There are other options to consider for

non-closing relief devices other than
rupture disks. Although details are
beyond the scope of this article, there is
one particular device I wish to bring to
your attention and which is gaining in
popularity, the Rupture Pin6, 7. Although
ASME will not allow what is called a
Breaking Pin device to be used as a
primary relief device, as of May 1990, it
will allow the use of the Rupture Pin
device. The two are similar but for the
Breaking Pin device to work, the pin
must completely break but for the
Rupture Pin device to work, the pin only
needs to bend or buckle. Another name
for this device is the Buckling Pin.
Figures 5A and 5B show two types of
rupture pin devices. Device "A" might
be used directly on a vessel and will
relieve to atmosphere. Device "B" might
relieve into a piping header.
The rupture pin device usually consists

of a piston or plunger on a seat, kept in
Figure 5B: Rupture Pin Relief Device
position by a slender, usually cylindrical
Discharge to Header
pin. At set point, axial forces caused by
system pressure acting on the piston or plunger area causes the pin to buckle. The unrestrained
pin length, the pin diameter and the modulus of elasticity of the pin material determine the
buckling point of the pin.
There is virtually no device size limitation. They have been manufactured as small
as 1/8" and as large as 48". There are virtually no pressure or vacuum limits either.
They can be designed for a set pressure as low as 2" of water to as high as 35,000
psi and vacuums to as low as 1 psi. Unlike rupture disks, which are solely differential
devices, the rupture pin can be designed to sense system pressure only, or
differential pressure.
You are now ready to sit through one of those manufacturer's presentations and hopefully
understand what he is talking about!
Summary
API RP520 provides a specification sheet that can be adapted by any company as a
standard
Not all of the information asked for in the API specification sheet is actually required by
the manufacturer in order to design the correct rupture disk. This information can be
broken down into "must haves", "should haves" and "what is needed to size the disk".
The manufacturer will always be provided with the "must haves".
The manufacturer should also be given the "should haves" as this is a way to utilize them
as a second pair of eyes and for a consistency check of the sizing.
There are many different types of rupture disks on the market. Before selecting the
correct rupture disk for your particular application, always discuss this with the
manufacturer.
Liquid service has its own set of potential problems for rupture disk design. It is highly
recommended that you discuss liquid service with your manufacturer.
There are other "non-closing" relief devices that can be considered for use. Some can
only be used as secondary relief devices. However the one that can be used as a primary
relief device and is gaining in popularity is the Rupture Pin.
References
(January 2000)
(1998)
4. Continental Disc Corporation (www.contdisc.com), ASME Combination Capacity
Factors, Catalogue 1-1111
5. Fike (www.fike.com), Technical Bulletin TB8103, July 1999
6. www.burstpressuresystems.com
7. www.rupturepin.com

Rupture Disks For Process Engineers

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