The main causes of premature failure are:
- Cyclic fatigue from repetitive pulsations close to the burst limit.
- Corrosion or erosion that thins the diaphragm, reducing its rated pressure.
- Incorrect installation: improper flange torque or unauthorized gaskets.
- Temperature spikes that alter the mechanical properties of the material.
- Back pressure or vacuum not considered in the initial design.
To avoid failures, perform periodic visual inspections, select suitable materials and coatings, observe the specified tightening torque and metallographically analyze removed discs to detect wear patterns.
Complete guide: Common rupture disc failures and how to diagnose them