SIZING RUPTURE DISKS (RDs) FOR TWO-PHASE FLOW

Hans K. Fauske
Fauske & Associates, Inc., Burr Ridge, Illinois

SUMMARY
An easy and accurate method for estimating two-phase flow through RDs is outlined.
Given information about stagnation conditions the model can handle gas-liquid, vapor-liquid and
hybrid flows including subcooled flashing flows. Examples are provided illustrating sizing of
RDs for gas-liquid, vapor-liquid, hybrid and flashing flows. The examples illustrate the
importance of considering two-phase flows when sizing rupture disks.

Gxo = 2 ( Po Pb ) ! ,o

INTRODUCTION
RDs are extensively used for overpressure
protection in the chemical process industries and
sizing methods for all liquid and all gas flows are
well established and easy to use (see Fike Metal
Products catalog). In comparison, two-phase flow
methods proposed over the years have been far more
complex and difficult to use than the single-phase
flow methods. Here we introduce an equally easy to
use two-phase flow method with accuracy equal to or
better than that provided by the more complex
models (Fauske, 1998).
The RD size is obtained by assuring a balance
between the required venting rate, W (kg/s) and the
discharge rate
W = Kd A G

(1)

where Kd (0.62) is the rupture disk flow coefficient

given in the ASME Boiler and Pressure Vessel Code
(1983), A (m2) is the vent area, and G (kg/m2-s) is the
two-phase mass flux given by
1 x
x
G = 2 o + 2o
Gxo = 0 Gxo =1.0

(3)

where Po (Pa) is the stagnation pressure, Pb (Pa) is the

back pressure, and !,o (kg/m3) is the liquid density.
For critical flows Gxo =1.0 is given by
1/ 2

Gxo =1.0

M
= Po w
R To

2 ( k +1) /( k 1)
k

k + 1

1/ 2

(4)

and for subcritical flows by

1/ 2

Gxo =1.0

M
= Po w
R To

1/ 2

2 k P 2 / k P ( k +1) / k

b
b

1
k
P
P
o

o

(5)

where Mw is the molecular weight, R (8314 Pa-m3/Kkg-mole) is the gas constant, and k is the isentropic
coefficient (see Table 3, Fike Metal Products
Catalog, for values of k).
VAPOR-LIQUID FLOWS

1/ 2

(2)

where xo is the stagnation gas and/or vapor quality.

For one-component two-phase flows, such as

steam-water flows, Gxo = 0 can be estimated from
Gxo = 0 = v ,o o (To co )

1/ 2

(6)

GAS-LIQUID FLOWS
For two-compartment two-phase flows such as
air-water flows, Gxo = 0 is determined

where v,o (kg/m3) is the stagnation vapor density, o

(J/kg) is the latent heat of vaporization, To (K) is the
stagnation temperature and co (J/kg-K) is the liquid

specific heat. Similar to two-component two-phase

flows Gxo =1.0 is given either by Equation (4) or

Equation (5).

Gxo =1.0

1/ 2

HYBRID GAS-VAPOR-LIQUID FLOWS

1/ 2

0.99
0.01

G=
+
(3.46 i 104 )2 (1.63 i 103 )2

4
2
= 1.48 i 10 kg / m s

(7)

where Pg,o (Pa) is the stagnation gas partial pressure

and Gxo =1.0 is again given by either Equation 4 or

(8)

where Pv,o (Pa) is the vapor pressure corresponding to

the stagnation temperature To. The value of the
isentropic coefficient k can be estimated in a similar
manner.

Answer: 4 inch diameter rupture disk.

What size rupture disk is required to relieve only
the gas portion of the above air-water mixture, all
other conditions remaining the same.
A=

1/ 2

(9)

and for subcooled inlet conditions the expression is

the same as that for hybrid vapor-gas-liquid flows
with xo = 0
G = 2 Pg , o ! ,o + v2, o / To co

1/ 2

(10)

W xo
50 i 0.01
=
K d Gxo =1.0 0.62 i 1.63 i 103

= 4.95 i 10 4 m 2 or 0.77 in 2

For all liquid initial conditions, Equation 2

reduces to G = Gxo = 0 . In case of saturated inlet or
stagnation conditions, G is determined from

1/ 2

= 5.44 i 10 3 or 8.44 in 2

ALL LIQUID FLASHING FLOWS

G = v , o (To co )

1/ 2

A = 50 / (1.48 i 10 4 i 0.62 )

Equation 5 with the molecular weight Mw given by

M w = M w, g ( Pg , o / Po ) + M w, v ( Pv , o / Po )

(1.4 +1)

(1.4 1)
1.4 2

1.4 + 1

= 1.63 i 103 kg / m 2 s

For hybrid two-phase flows such as air-steamwater flows Gxo = 0 is determined from
Gxo = 0 = 2 Pg ,o !, o + o2 v2 / To co

29
= 7 i 105

8314 i 300

Answer: 1 inch diameter rupture disk, i.e., in case of

no liquid entrainment the required rupture disk size is
much smaller.
EXAMPLE 2 - SIZING FOR VAPOR-LIQUID
FLOWS
What size rupture disk is required to relieve a
vapor-liquid ethylene mixture under the following
conditions:
W = 300 kg/s, xo = 0.01, Po = 2 i 106 Pa,
Pb = 105 Pa, To = 245 K.
Other physical properties: v,o = 38.5 kg/m3,
o = 3.2 i 105 J/kg, co = 3050 J/kg-K, Mw = 28,
and k= 1.26.

EXAMPLE 1 - SIZING FOR GAS-LIQUID

FLOWS
What size rupture disk is required to relieve an
air-water mixture under the following conditions:

Gxo = 0 = 38.5 i 3.2 i 105 (245 i 3050) 1/ 2

W = 50 kg/s, xo = 0.01, Po = 7 i 105 Pa,

Pb = 105 Pa, To = 300 K, and !,o = 103 kg/m3.

= 1.43 i 104 kg / m 2 s

Gxo = 0 = 2 (7 i 105 )1000 = 3.46 i 10 4 kg / m 2 s

+

Critical flow condition is used: Pb/Po = 0.143 <

k /( k 1)
2
= 0.53, where Pc is the critical
Pc/Po =

K +1

pressure.

1/ 2

Gxo =1.0

28
= 2 i 106

8314 i 245

(1.26 +1)

(1.26 1)
1.26 2

1.26 + 1

1/ 2

Gxo =1.0 = 106 [(20.29 /(8314)(443)]

1/ 2

1/ 2

= 1.58 i 103 kg / m 2 s

= 4.89 i 103 kg / m 2 s

0.99
0.01

+
G=
(1.43 i 10 4 )2 ( 4.89 i 103 )2

4
2
= 1.38 i 10 kg / m s

(1.34 +1)

(1.34 1)
1.34 2

1.34 + 1

1/ 2

0.99
0.01

+
G=
( 2.02 i 10 4 )2 (1.58 i 103 )2

4
2
= 1.25 i 10 kg / m s

A = 300 /(1.38 i 10 4 i 0.62)

1/ 2

A = 100 /(1.25 i 104 i 0.62)

= 3.51 i 102 m 2 or 54.4 in 2

= 1.29 i 10 2 m 2 or 20.3 in 2

Answer: 10 inch diameter rupture disk.

Answer: 6 inch diameter rupture disk.

What size rupture disk is required to relieve only

the vapor portion of the above ethylene mixture, all
other conditions remaining the same

What size rupture disk is required to relieve the

above mixture in the absence of air, i.e., Po is reduced
to Pv,o = 7.92 i 105 Pa with all other conditions
remaining the same.

A = (300 i 0.01)(4.89 i 103 i 0.62)

Gxo = 0 = 4.12 i 2.05 i 106 (433 i 4366)1/ 2

= 9.90 i 104 m 2 or 1.53 in 2

= 6.07 i 103 kg / m 2 s
Answer: 1-1/2 inch diameter rupture disk, i.e., in
case of no liquid entrainment the required rupture
disk is much smaller.
EXAMPLE 3 - SIZING FOR GAS-VAPORLIQUID HYBRID FLOWS

W = 100 kg/s, xo = 0.01, Po = 106 Pa, T = 443 K,

Pb = 105 Pa.
Other physical properties: Pg,o = 2.08 i 105 Pa,
!,o = 8.97 i 102 kg/m3, v,o = 4.12 Kg/m3,

M w = 29 ( 2.08 i 105 /106 ) + 18 (7.92 i 105 /106 )

= 20.29
k = 1.4 ( 2.08 i 105 /106 ) + 1.324 ( 7.92 i 105 /106 )
= 1.34

0.99
0.01

+
G=
(6.07 i 103 )2 (1.18 i 103 )2

3
2
= 5.39 i 10 kg / m s

1/ 2

A = 100 / (5.39 i 103 i 0.62 )

o = 2.05 i 106 J/kg-K, and co = 4366 J/kg-K.

Gxo = 0

Gxo =1.0

1/ 2

(1.324 +1)

2
(1.324 1)
1.324

1.324 + 1

= 1.18 i 103 kg / m 2 s

What size rupture disk is required to relieve an

air-steam-water mixture under the following
conditions:

2
2

2.05 i 106 ) ( 4.12 )

(
2

= 2 i 2.08 i 8.97 i 10 +

( 443)( 4366 )

4
2
= 2.2 i 10 kg / m s

1/ 2

18
= 7.92 i 105

8314 i 443

= 2.99 i 10 2 m 2 or 46.35 in 2
1/ 2

Answer: 8 inch diameter rupture disk, i.e., in

absence of air the required rupture disk diameter is
significantly increased.
EXAMPLE 4 - SIZING FOR SUBCOOLED
FLASHING FLOWS
What size rupture disk is required to relieve
subcooled flashing water under the following
conditions:
W = 100 kg/s, Po = 106 Pa, To = 443 K,

Pb = 105 Pa.
Other physical properties: Pv,o = 7.92 i 105 Pa,
Pg,o = 2.08 i 105 Pa, !,o = 8.97 i 102 kg/m3,

REFERENCES
ASME Boiler and Pressure Vessel Code, 1983,
Section VIII, Div. 1, ASME, NY.

v,o = 4.12 kg/m3, o = 2.05 i 106 J/kg-K, and

co = 4366 J/kg-K.
2
2

2.05 i 106 ) ( 4.12 )

(
5
2

G = 2 i 2.08 i 10 i 8.97 i 10 +

( 433)( 4366 )

= 2.02 i 104 kg / m 2 s

1/ 2

Fauske, H. K., 1988, "An Easy to Use Two-Phase

Flow Model Including Subcooling, Non-Equilibrium
and Viscous Effects," Proc. 2nd Int. Symp. on
Runaway Reactions, Pressure Relief Design and
Effluent Handling, March 11-13, New Orleans.

A = 100 /(2.02 i 104 i 0.62)

= 7.98 i 103 m 2 or 12.37 in 2
Answer: 4 inch diameter rupture disk.
What size rupture disk is required if the water is
saturated, i.e., To = 453 K (!,o = 8.97 i 102 kg/m3,
v,o = 5.16 kg/m3, o = 2.02 i 106 J/kg, co = 4403
J/kg-K).
G = 5.16 i 2.02 i 106 (4403 i 453) 1/ 2
= 7.38 i 103 i 0.62)
A = 100 /(7.38 i 103 i 0.62)
= 2.19 i 10 2 m 2 or 33.87 in 2
Answer: 8 inch diameter rupture disk, i.e., in
absence of subcooling the required rupture disk
diameter is significantly increased.

For the assistance in DIERS Technology,

Emergency Relief System Design, Vent Sizing and
Two-Phase Flow, or information on the products and
services of Fauske & Associates, Inc. call (630) 3238750, e-mail kfauske@fauske.com, fax (630) 9865481, or visit us on the world wide web at http:
//www.fauske.com.