Document 5LNZXq95kvjKNkjYyVn9aeORJ
ABD00250175
RUPTURE DISC/RELIEF VALVE PRACTICES MANUAL
VISTA CHEMICAL COMPANY ABERDEEN, MISSISSIPPI UPDATED MARCH 28, 1991
ABD00250176
RUPTURE DISC/RELIEF VALVE PRACTICES MANUAL
TABLE OF CONTENTS
I. INTRODUCTION A. Rupture Disc Quality Assurance Program Process Flow Diagram B. Introduction
II. RUPTURE DISC ORDERING AND PRE-INSTALLATION CHECKOUT A. Specification of Rupture Discs B. Lot Inspection and Pre-Testing C. Recordkeeping
III. RUPTURE DISC INSTALLATION A. Installation in Holders B. Pressure Testing in the Shop C. Installation in the Plant D. Pressure Checking after Installation on the Reactor
IV. RUPTURE DISC REMOVAL A. Rupture Disc Changeout B. Destructive Testing
V. RECORDKEEPING
VI. TRAINING
VII. RELIEF VALVES A. Reactor Relief Valves B. Other Relief Valves in Vinyl Chloride Service C. Recordkeeping
VIII. APPENDICES A. Reactor Rupture Disc Testing Log Sheet Example B. Rupture Disc Checkout Sheet Example C. Reactor Rupture Disc/Relief Valve Settings D. Rupture Discs in VCM Service
RUPTURE DISK QUALITY ASSURANCE PROGRAM PROCESS FLOW DIAGRAM
ABD00250177
ABD00250178
Rupture Disc/Relief Valves Practices Manual Page 1
1. INTRODUCTION B. Introduction Section 61.65 (b)(4) of the National Emission Standards for Hazardous Air Pollutants requires that a rupture disc be installed underneath any relief valve in vinyl chloride service minimize leakage through the relief valve to the atmosphere. In accordance with this requirement, Vista Polymers, Inc. has installed a large number of rupture discs in vinyl chloride service throughout the plant. In addition to preventing relief valve leakage, rupture discs also serve the vital function of protecting the relief valve from polymer buildup on the relief valve seat, which could hinder the proper functioning of the relief valve in an emergency. In either case, proper functioning of the rupture disc/relief valve combination is essential for plant safety.
This program has been developed because of the importance of maintaining
the integrity of rupture discs during their handling and installation.
Adherence to the procedures outlined in this manual will help to ensure
that the change of rupture disc/relief valve malfunctions will be
minimized, and that thorough documentation will be available whenever such
a malfunction does occur.
This documentation may become extremely
critical in the event of a VCM release caused by a premature rupture disc
failure or other process upset conditions.
ABD00250179
Rupture Disc/Relief Valve Practices Manual Page 2
II. RUPTURE DISC ORDERING AND PRE-INSTALLATION CHECKOUT A. Specification of Rupture Discs All rupture discs in VCM service are listed on Table 1. The following specifications should be noted on the purchase order when ordering these rupture discs. 1. Disc size (specify). 2. Type S-90. 3. Nickel material. 4. 0% manufacturing range. 5. Burst pressure (specify). 6. Burst temperature. 7. Certification of performance. 8. ASME code stamped and certified. 9. Test each disc to 90% of rated burst pressure. 10. Replaces lot no. . . (specify). 11. Serially number all discs in the lot. B. Lot Inspection and Pre-Testing All new rupture disc lots received at the plant receiving dock must be thoroughly inspected and tested before they are placed into stock. The following procedures are to be used when new rupture disc lots are received at the Plant: 1. When a lot rupture discs arrives at the receiving dock, care must be exercised when unloading the discs from the truck so as not to damage the discs.
ABD00250180
Rupture Disc/Relief Valve Practices Manual Page 3
II. RUPTURE DISC ORDERING AND PRE-INSTALLATION CHECKOUT - Continued B. Lot Inspection and Pre-Testing - Continued 2. The receiver must notify the Maintenance Department that there are new rupture discs at receiving, and a trained inspector will count the number of discs in the lot and inspect each individual disc for flaws.
3. A flaw in a disc is defined as follows:
a. Any scratch or indentation which can be felt on the opposite side of the disc.
b. Any irregularity in the shape of the domed portion of the disc that can be seen with the eye or felt.
c. A pinhole or scratch which could cause the disc to leak. d. A disc without a tag. e. A disc that will not fit the pins of a holder. f. A disc that is labeled differently than the other disc
in the same lot. 4. Flawed discs must be removed from the lot and returned to the
manufacturer. Discs which pass inspection are initialed on the box by the inspector. 5. Rupture discs which are to be installed on vessels in VCM service must be approved by lot before they can be placed in the storeroom. One disc from each of these lots will be sent to the maintenance shop and burst using the procedures specified in the destructive testing section of this manual.
ABD00250181
Rupture Disc/Relief Valve Practices Manual Page 4 II. RUPTURE DISC ORDERING AND PRE-INSTALLATION CHECKOUT - Continued
B. Lot Inspection and Pre-Testing - Continued 6. If any rupture disc does not burst within 5% of its rated burst pressure, the entire lot from which the disc was taken must be returned to the manufacturer. Maintenance must notify receiving that these discs have either passed or failed this test. 7. Rupture discs which pass inspection and testing are ok'd for placement in the storeroom. Rupture disc boxes which have not been initialed are not to be placed in the storeroom.
C. Recordkeeping Administrative Services must keep a record of rupture disc receiving and inspection data. An example logsheet is attached. This information must be stored in the plant for a period of at least two year.
III. RUPTURE DISC INSTALLATION A qualified maintenance installation observer must be present during all phases of rupture disc installation (vinyl reactors only). The Mechanical Superintendent will keep an updated list of qualified maintenance installation observers. A. Installation in Holders All rupture discs must be installed in the holders according to the manufacturer's specifications. These written specifications come with each rupture disc. The following steps outline the general procedure which is to be used when installing rupture discs in holders:
ABD00250182
Rupture Disc/Relief Valve Practices Manual Page 5 III. RUPTURE DISC INSTALLATION - Continued
1. Before a disc is placed in the holder, the disc, the holder and the holder bolts must be inspected for flaws.
2. Flaws are defined as follows: a. A disc that has any of the defects listed in Section II (b)(3). b. A holder face that is covered with dirt or debris, or is deeply gouged such that it will leak when installed. c. Set screws that are galled or cannot be screw-ed into the holder by hand. d. A holder with a damaged bite ring. A holder is considered damaged if there are indentations or flat spots on the bite ring. This is determined from a visual inspection of the holder. Also, the height of the bite ring must be checked. This is done by the inspector running his fingernail around the bite ring. The bite ring has sufficient height to be reused if it holds the fingernail all the way around the circumfer ence of the bite ring.
3. Flawed components must not be installed in the Plant. 4. Place the disc in the holder and hand install the holder
bolts. Using a torque wrench, tighten the holder bolts to the torque specified by the manufacturer. This tightening must be performed in at least four passes; i.e. 25%, 50%, 75%, and 100% of the final torque. A criss-cross tightening pattern must be used when torquing the bolts.
ABD00250183
Rupture Disc/Relief Valve Practices Manual Page 6 III. RUPTURE DISC INSTALLATION - Continued
A. Installation in Holders - Continued 5. When the installation of the disc in the holder is complete, visually inspect the disc again to see if it has been distort ed or otherwise damaged. 6. Rupture discs must not be removed from the holders after installation, otherwise the rupture disc must be discarded.
B. Pressure Testing in the Shoo All reactor rupture discs are to be pressure tested in the maintenance shop to 90% of their rated burst pressure before being installed in the plant. The following testing procedure must be used when pressure testing rupture discs in the maintenance shop. 1. Clean the flanges of the test bench and the faces of the rupture disc holder where the two surface meet. Use an asbestos gasket between the flange and the holder. 2. Install the holder on the test bench and tighten the bolts in a criss-cross pattern, making several passes on each bolt. 3. Warn nearby personnel that a rupture disc is being pressure tested. 4. Using pressurized air, slowly open the test valve and pressurize the space beneath the rupture disc. Increase the pressure to 90% of the rupture disc burst pressure 72F. 5. Slowly depressurize the space underneath the rupture disc and remove the assembly from the test bench. If the disc appears to have been distorted or otherwise damaged during the test, do not install the disc in the plant.
ABD00250184
Rupture Disc/Rellef Valve Practices Manual Page 7 III. RUPTURE DISC INSTALLATION - Continued
B. Pressure Testing in the Shop - Continued 6. If a rupture disc bursts prematurely (less than 90% of its rated burst pressure) or is damaged by the test, the disc must be given intact to Process Engineering. 7. The calibration of the test bench pressure gauge will be checked with a dead weight pressure gauge every six months.
C. Installation in the Plant Rupture disc assemblies must be installed in the plant accordingly: 1. Before installing the holder assembly between the companion flanges, thoroughly clean the flange faces with a putty knife to remove any solid buildup or debris. 2. Check to see that the flange faces are not gouged or otherwise damaged. Place the rupture disc between the flanges, with the bulged-out side of the disc facing the process. 3. On reactors, use asbestos-type gaskets only. Flexatalic gas kets may be used elsewhere in the plant if desired. 4. When tightening the companion flanges, torque the bolts to the manufacturer's specification using a criss-cross tightening pattern. Make at least four passes on each bolt.
D. Pressure Checking after Installation on the Reactor After a rupture disc has been installed on a reactor, the reactor will be pressure checked before it is charged. The reactors will be pressure checked to approximately 90% of the pressure of the lowest rated rupture disc on the reactor as shown on the following table:
ABD00250185
Rupture Disc/Relief Valve Practices Manual Page 8
III. RUPTURE DISC INSTALLATION - Continued
D. Pressure Checking after Installation on the Reactor - Continued
Lowest Rated Disc
Hydrotest Pressure
on a Reactor (PSIG)
(PSIO________________
185 165
195*
175
210 185
* Only for D-600 in low molecular weight resin service.
The pressure check must be witnessed by an approved pressure check observer. Approved pressure check observers consist of all the Vinyl Shift Supervisors, the Vinyl Operations Supervisor, the Vinyl Operations Engineer, and the Vinyl Operations Superintendent. Others may qualify as observers after training.
The pressure checking consists of filling the reactor with water and
then increasing the pressure in the reactor to the desired pressure
per established procedures.
The operators involved must be
extremely careful during pressure check procedures not to burst or
damage a rupture disc. Bursting a disc during the pressure check
will cause reactor downtime to change the disc. A disc can be
damaged by hydraulic shock if the reactor becomes liquid full during
the pressure check. A damaged rupture disc may burst at lower than
the rated pressure, causing leakage through the reactor relief
valve. In addition, a damaged disc may not burst at the rated
pressure, which could allow a reactor to overpressure. The pressure
check observer must witness the pressure check from the field and
must verify the final reactor pressure. The reason for the pressure
check, the signature of the approved observer, the final reactor
pressure, and other test findings will be noted in the reactor
pressure check log kept in the Vinyl Control Room.
ABD00250186
Rupture Disc/Relief Valve Practices Manual Page 9 IV. RUPTURE DISC REMOVAL
A. Rupture Disc Changeout Rupture discs are to be removed from service and changed accordingly: 1. Any rupture disc which fails in service must be changed as soon as possible after it is discovered that the disc has failed. 2. Any rupture disc which is believed to be covered with resin or otherwise damaged must be changed as soon as possible. 3. All rupture discs on reactors will be changed at least once every twelve months. 4. When a reactor is taken out of service for condenser drilling, the condenser rupture disc(s) will be removed or guard(s) will be installed over the rupture disc nozzle(s) before the drilling operation is started. 5. Any rupture disc which rails in reactor service must be given to Process Engineering.
B. Destructive Testing All rupture discs taken off of vinyl reactors must be burst in the maintenance shop when taken out of service permanently. The follow ing procedures also apply to new rupture discs which are to be burst when they arrive at the Plant. 1. When removing the holder assembly from the reactor and when transporting the holder assembly to the maintenance shop, use caution so as not to damage the disc or the holder.
ABD00250187
Rupture Disc/Relief Valve Practices Manual Page 10 IV. RUPTURE DISC REMOVAL - Continued
B. Destructive Testing - Continued 2. When destructively testing a vinyl reactor rupture disc, a qualified maintenance installation observer must be present to observe the testing. 3. Install the holder assembly on the test bench and pressurize the disc with air until the disc bursts. 4. If a rupture disc bursts prematurely (less than 95% of its rated burst pressure), the disc must be given to Process Engineering. Use care so as not to damage these discs.
V. RECORDKEEPING A record must be kept of all rupture disc installation and testing data. An example logsheet is attached. This information must be stored in the plant for a period of at least two years. This information is stored in the maintenance office.
VI. TRAINING All maintenance personnel involved in this program are to receive hands-on training in the installation and handling of rupture discs once each calendar year. Records of all personnel who attend these training sessions are to be kept for a period of at least two years.
VII. RELIEF VALVES All relief valves in vinyl chloride service will be periodically checked to assure that they will operate properly in an emergency situation.
ABD00250188
Rupture Disc/Relief Valve Practices Manual Page 11
VII. RELIEF VALVES - Continued
A. Reactor Relief Valves
Relief valves on PVC reactors will be removed and sent to a relief
valve repair shop for testing, inspection and reworking every five
years.
The rework includes disassembly, cleaning and
replacing/refurbishing internal parts as required so that the relief
valve meets the original manufacturers specifications.
All new reactor relief valves purchased will be pretested by the manufacturer. Upon installation, the relief valves will be removed and tested at a relief valve shop every five years. B. Other Relief Valves in Vinvl Chloride Service Relief valves in the vinyl chloride service, except those on the reactors, will be tested and refurbished at either a relief valve repair shop or by the plant maintenance personnel. The frequency of testing and refurbishing will be every five years for these relief valves. C. Recordkeeping The maintenance department shall keep a record of all tests and repairs made on the relief valves.
REACTOR - D-600
LOCATION DATE INSTALLED DISC SIZE STOREROOM STOCK NUMBER LOT NUMBER DESIGN PRESSURE @ 170F DESIGN PRESSURE @ 72F HOLDER NUMBER TEST PRESSURE (90% @ 72F) TESTER OBSERVER - TEST INSTALLED ON REACTOR BY OBSERVER - REACTOR RELIEF VALVE ASSET NUMBER DATE REMOVED
REASON FOR REMOVAL (CIRCLE)
* BURST PRESSURE * RERATED FROM LO-MOLE
ABD00250189
SHELL
SHELL
SHELL
CONDENSER
6/19/90
6/19/90
6/19/90
6/19/90
8" 8" 6"
6"
073-0006
073-0006 073-0018
073-0018
90002874-2 90002874-2 90002874-1
90002874-1
195 195 200 200
201.3 55
201.3 14
200 69
200 65
182 182 180 180
JWL
JWL
DEJ
JWL, TRS.RSK
DEJ
JWL, TRS.RSK
ECM
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JWL, TRS.RSK
JWL
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FWF FWF
FWF FWF
78-096
78-095
78-325
78-225
2/13/91
2/13/91
2/13/91
2/13/91
ANNUAL* BURST OTHER
ANNUAL* BURST OTHER
ANNUAL* BURST OTHER
ANNUAL* BURST OTHER
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ABD00250191
THIS IS THE CURRENT RUPTURE DISC AND RELIEF VALVE SETTINGS AND STOCK NUMBERS.
MARCH 28, 1991 *********
DATE IS
REACTOR
POSITION
RD SIZE
RUPTURE DISC RATING PSIG/F
RV SET PRESSURE PSIG
STOREROOM NUMBER
D-300 D-300 D-300 D-300
D-400 D-400 D-400 D-400
SHELL SHELL SHELL COND
SHELL SHELL SHELL COND
8 8 6 6
8 8 6 6
200/200 200/200 195/200 185/200
200/200 200/200 195/200 185/200
199 073-0016 199 073-0016 195 073-0019 185 073-0005
199 073-0016 199 073-0016 195 073-0019 185 073-0005
D-500 D-500 D-500 D-500
SHELL SHELL SHELL COND
8 8 6 6
200/200 200/200 195/200 185/200
199 073-0016 199 073/0016 195 073-0019 185 073-0005
D-600 NON--LOW MOLE RELIEF
D-600
SHELL
D-600
SHELL
D-600
SHELL
D-600
COND
8 8 6 6
200/200 200/200 195/200 185/200
199 073-0016 199 073-0016 195 073-0019 185 073-0005
D-600 LOW MOLE RELIEF
D-600
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D-600
SHELL
D-600
SHELL
D-600
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8 8 6 6
195/170 195/170 200/170 200/170
195 073-0006 195 073-0006 200 073-0018 200 073-0018
D-700 D- 700 D-700 D-700 D-700 D-700 D-700
SHELL SHELL SHELL SHELL SHELL COND COND
8 8 8 8 8 8 8
215/176 215-176 215-176 210/175 210/175 215/176 210/175
215 073-0023 215 073-0023 215 073-0023 210 073-0024 210 073-0024 215 073-0023 210 073-0024
D-741 D-741 D-741 D-741
D- 742 D-742 D-742 D-742
D-743 D-743 D-743 D-743
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SHELL SHELL SHELL COND
SHELL SHELL SHELL COND
8 8 6 6
8 8 6 6
8 8 6 6
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200/200 200/200 195/200 185/200
200/200 200/200 195/200 185/200
199 073-0016 199 073-0016 195 073-0019 185 073-0005
199 073-0016 199 073-0016 195 073-0019 185 073-0005
199 073-0016 199 073-0016 195 073-0019 185 073-0005
D-744 D-744 D-744 D-744
D-745 D- 745 D-745 D-745 D-745 D-745 D-745
SHELL SHELL SHELL COND
SHELL SHELL SHELL SHELL SHELL COND COND
8 8 6 6
8 8 8 8 8 8 8
ABD00250192
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199 073-0016 199 073-0016 195 073-0019 185 073-0005
215 073-0023 215 073-0023 215 073-0023 210 073-0024 210 073-0024 215 073-0023 210 073-0024
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