SAFETY IN THE PLANT
fail-safe, meaning customers will be made aware there is a potential problem. Using discs in combination with modern burst detection systems can ensure that if a disc fails safe due to corrosion an instantaneous alert can be made, prompting for quick review and change out. In addition, double disc assemblies can be used to allow manufacturing to continue until a suitable maintenance schedule is due to take place.
INSTALLATION CONCERNS Correct installation of pressure relief devices is a real concern for customers operating in safety-critical environments. With many incidences reported by the HSE being related to ‘human factors’ it is imperative manufacturers off er designs that remove this issue. For buckling pins, it is almost impossible to install the pin improperly. Commonly, customers thought rupture disc designs could be installed incorrectly, however, modern solutions have eradicated this problem. With the introduction of a range of installation tools such as disc alignment tags, fl ange-mounted installation locks and RFID detection, such occurrences are almost eliminated.
NOTIFICATION OF FUNCTION Most manufacturers now encourage customers to take a burst detection system alongside the pressure relief device; this is the only safe and reliable way to get a notifi cation that the product has functioned. Although with the buckling pin it is visually apparent that the pin has activated, due to it having only two conditions – straight or buckled – it still relies on an employee noticing this state and doing something about it. For rupture discs, companies cannot rely on the
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fact that they will hear the disc burst and are therefore encouraged to install burst detection. Modern magnetic and reed switch burst detectors are non-invasive to the process and therefore not subject to spurious alarms, back pressures or damage during installation, unlike original designs. Such detectors give an instantaneous notifi cation of burst, and can even be wired to a control room to shut down a process as a further safety measure. This has several key advantages: fi rstly, it ensures a customer can get their process up and running as quickly as possible so they are not missing out on lost production; secondly, by stopping the process it ensures that no dangerous gasses are leaking into the environment; and thirdly, it enhances overall safety.
HIGH MAINTENANCE COSTS Most customers undertake regular and routine maintenance in line with their company’s quality manual. Reducing and improving maintenance schedules plays a critical part in improving site effi ciencies. Buckling pins are almost maintenance free and off er the major advantage that they can be inspected without breaking the line. Replacement pins can also be installed in a matter of minutes without disrupting the line. Although there is not a visible indication of rupture disc state without removing the disc from its holder, with the introduction of installation tools, quick and simple checks of the rupture disc state can be done without stopping the line, making the maintenance of both solutions equally as rapid and as environmentally friendly. Some rupture discs now come with a standard three-year warranty, increasing maintenance intervals accordingly.
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