We have an ethylene system pre heater, shell side low pressure (LP) steam (4-5 kg/cm2), tube side ethylene (inlet pressure 40 bar, inlet temperature 30 deg C, outlet pressure 40 bar, outlet temperature 100 deg C). Ethylene outlet temperature is maintained by shell side LP steam. There is a temperature control valve at steam inlet. Shell side condensate goes to condensate header through a steam trap. Rupture disc is given at shell side (steam side) with set point of 11 kg/cm2 (considering tube leakage scenario). Rupture disc outlet goes to flare. In past one mont rupture disc has ruptured twice. We hace checked probable tube leakage but could not find any leak. LP steam header pressure remains in the range of 4-5 kg/cm2 always. What may be the other reasons of failure. Rupture disc is checked and there are no signs of aging.
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