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您是否為您的應(yīng)用選擇了正確的連接器？
Are You Selecting the Right Coupler for Your Application?
By Dave Morrow, Director of Product Management, OPW Engineered Systems
隨著化學(xué)工業(yè)的發(fā)展，對先進轉(zhuǎn)移解決方案的需求也在增加。當今的現(xiàn)代化學(xué)工業(yè)需要連接以滿足高安全和監(jiān)管標準，同時為各種不同操作的應(yīng)用提供- 佳性能溫度和壓力。快速接頭是工廠和化學(xué)品運輸?shù)焦⿷?yīng)鏈下一環(huán)節(jié)之間的關(guān)鍵連接點。選擇正確的快速接頭的重要性不可夸大，定制也不可忽視。As the chemical industry has evolved, so have the needs for advanced transfer solutions. The landscape of today’s modern chemical industry requires connections to meet high safety and regulatory standards,while delivering the best performance for a wide range of applications with varying operational
temperatures and pressures.Couplers are the critical connection point between the plant and the transportation of the chemical to the next segment of the supply chain. The importance of selecting the right couplings cannot be overstated and customization cannot be overlooked.
The Evolution of Couplings
快速接頭的演化
當今的化學(xué)和石油工業(yè)所面臨的現(xiàn)實需要創(chuàng)新的、精心設(shè)計的耦合技術(shù)，以處理廣泛的應(yīng)用。從高壓或高溫下- 危險的流體輸送應(yīng)用到- 基本的流體輸送應(yīng)用。這些是工廠安全和制造專業(yè)人員- 感興趣的化學(xué)品類型，因為與人或環(huán)境接觸可能是災(zāi)難性的。像這樣的化學(xué)品包括易燃品、爆炸物、有毒產(chǎn)品和致癌物。耦合器和配件技術(shù)的發(fā)展很快，并且在投資過程安全計劃時引入了無數(shù)的選擇和變化。The realities faced by today’s chemical and petroleum industries demand innovative, carefully engineered coupling technologies that are built to handle a wide range of applications. These can range from the most extreme hazardous fluid-transfer application under high pressures or temperatures to the most basic.These are the type of chemicals that plant safety and manufacturing professionals are most interested in containing because contact with people or the environment can be disastrous. Chemicals like this include flammable products, explosive products, toxic products and carcinogens. The evolution of coupler and fittings technology has happened quickly and has introduced countless options and variations to consider when investing in your process safety program.
讓我們來看看快速接頭技術(shù)的發(fā)展，它將幫助您決定在選擇合適的配件或耦合器以保護您的產(chǎn)品、您的人員和我們的環(huán)境時需要走的道路。Let’s take a look at the evolution of coupling technology that will help you decide the path you need to take when selecting the right fitting or coupler to protect your product, your people and our environment.
螺紋Threads
美國國家管道錐形NPT螺紋是所有管道和閥門螺紋的美國標準。與典型螺栓（直螺紋）上的螺紋不同，錐形螺紋實際上會拉得更緊，從而增加螺紋的扭矩和磨損。這些設(shè)備很容易安裝在各種類型的管道或軟管上，使用這些設(shè)備只需很少的培訓(xùn)或?qū)Ｓ霉ぞ�。然而，隨著時間的推移，這些類型的連接往往會磨損，必須進行適當?shù)谋O(jiān)控。此外，如果不使用Teflon膠帶或密封劑密封，則連接件容易泄漏。National Pipe Tapered (NPT) thread is the American standard for all piping and valve threads. Unlike threads found on a typical bolt, which is a straight thread, tapered threads will actually pull tighter, increasing torque and wear on the threads. These are easy to assemble on various types of piping or hoses, and it takes little training or special tools to work with it. However, these types of connections tend to wear out over time and must be properly monitored. In addition, the connections are prone to leaks if not sealed with Teflon tape or sealant.
如果忽視維護和更換，發(fā)生嚴重事故的風(fēng)險就會增加。螺紋連接非常適用于低壓、低應(yīng)力管道，尤其是1-1/2“及更小尺寸的管道。在高壓應(yīng)用中，那些有振動或其他可能的機械負載，螺紋連接的問題更大。If maintenance and replacement are neglected, the risk for a serious accident increases. Threaded connections are very good for low-pressure, low-stress piping, especially in small sizes like 1-1/2" and smaller. In high-pressure applications,those with vibration or other possible mechanical loading,threaded connections are more problematic.
螺紋連接的另一個復(fù)雜問題是使用管鉗和作弊器時的暴力，這將成為一個安全隱患和符合人體工程學(xué)的問題。在連接和斷開螺紋連接時經(jīng)常需要。當連接處使用的力越大，連接就越牢固。然而，在另一方面，連接變得更難拆卸，這增加了損壞和泄漏的風(fēng)險。Another complication with threaded connections is the aspect of brute force when using pipe wrenches and cheaters, which becomes a safety hazard and ergonomic issue. It’s often needed when connecting and disconnecting threaded connections. When more force is used at connection, the stronger that connection is. However, on the flip side,the connection becomes harder to remove, which increases the risk that damage and leaks might occur.
OPW Quick & Dry Disconnect Fittings Catalog
Flanges法蘭
法蘭是另一種廣泛使用的連接，通常用于高壓、無重復(fù)連接。由于密封質(zhì)量的原因，一些跡象會使法蘭連接優(yōu)于NPT。Flanges are another widely used connection that are generally used for high-pressure, nonrepeated connections. Some indications would make flange connections superior to NPT due to seal quality.
每一種連接類型都是經(jīng)過試驗和驗證的，并且經(jīng)過多年和許多行業(yè)的驗證，它們都是有價值的。法蘭連接使用兩個法蘭和一定數(shù)量的雙頭螺栓和螺母，它們之間有一個墊圈來固定密封。這些連接也很常見，也很費時，但由于許多原因，包括墊圈處和錯誤安裝，它們很容易發(fā)生泄漏。此外，法蘭可能會受到熱變形和沖擊。Each of these connection types are tried and true,and have proven themselves worthy over many years and across numerous industries.Flanged connections are made using two flanges and a select number of stud bolts and nuts, with a gasket between them to secure a seal. These connections, too, are common and time consuming, but can be susceptible to leaks for many reasons, including at the gasket and due to faulty installation. Additionally, flanges can be subject to thermal distortion and shock.
法蘭管道系統(tǒng)需要更大的空間，安裝成本也更高。由于系統(tǒng)處理起來很重，法蘭連接很費時，而且在需要一個以上操作員的工廠中，需要管道安裝工。根據(jù)螺栓的數(shù)量（4、8、16等）和法蘭的尺寸，需要花費大量的時間來松開和重新啟動。More space is needed for flanged pipe systems and they are more expensive to install. Because the systems are heavy to handle, flanged connections are time consuming to connect and require pipe fitters in plants that can require more than one operator. Based on the number of bolts (4, 8, 16, etc.) and size of the flange, it can take enormous amounts of time to unbolt and rebolt.
法蘭有一個位置，但不適合重復(fù)或重復(fù)連接，因為它們需要很多時間來連接。對于許多高壓力、重復(fù)連接點來說，引入接頭是一個很大的改進。Flanges have a place but aren’t ideal for repeated or repetitive connections because they take a lot of time to connect. The introduction of unions was a big improvement for many higher-pressure, repeated connection points.
Unions活接頭
活接頭有“錘式管接頭”的綽號，因為你必須使用暴力來讓他們密封。由于平墊圈結(jié)構(gòu)，當施加力時，平墊圈容易被壓碎�？偸怯信欧诺娘L(fēng)險，因為密封總是有問題的。通常情況下，操作人員會準備好備用墊圈，因為它們?nèi)菀仔孤�。液壓錘接頭為高壓接頭，不匹配（或交叉匹配）導(dǎo)致潛在危險液體的不受控制釋放，可能導(dǎo)致傷害。由于這些危險，工會可能是危險的、昂貴的和不可靠的。Unions have the nickname “hammer unions” because you have to use brute force to get them to seal. Due to the flat-gasket construction, the flat gasket can easily be crushed when force is applied. There’s always the risk of emissions because the seal is always in question. Typically, operators will have spare gaskets readily available, as they are prone to leak. Hammer unions, being high pressure, have been mismatched (or cross-matched) causing uncontrolled releases of potentially hazardous fluids that can result in injury. Because of these hazards, unions can be risky,expensive and unreliable.
Kam和凹槽
Kam和凹槽技術(shù)提供更快、更低壓力的快速連接。專為重復(fù)連接的運營商設(shè)計，它實際上是快速連接的開始。由于螺紋和法蘭的痛點，人們需要一個堅固的快速連接接頭，其結(jié)果是一個自動鎖定雙臂設(shè)計，用于鎖定一根軟管或與另一根軟管配合到位。母接頭有兩個“凸輪”作為總成的一部分。公接頭的形狀允許凸輪“鎖定”到位。所有kam和溝槽配件的尺寸應(yīng)符合美國軍用規(guī)范A-A59326（1998年9月25日生效）。Kam-and-groove technology provides a faster, lowerpressure quick connection. Designed for operators that make repeated connections, it was really the beginning of quick connects. Due to the pain points of threads and flanges,there was the demand for a robust, quick-connect coupling.The result was an auto-locking twin-arm design that is used to lock one hose or fitting into place with another one. The female connector has two “cams” as part of the assembly.
The male connector has a shape that allows the cams to “l(fā)ock” into place. All kam-and-groove fittings should be dimensioned to U.S. Military specification A-A59326 (effective 9/25/1998).
多年來，kam和凹槽有了逐步改進。- 顯著的改進是開發(fā)了自動鎖定凸輪臂，- 大限度地降低了因臂未保持鎖定位置而導(dǎo)致產(chǎn)品意外釋放的風(fēng)險。Kam和溝槽廣泛應(yīng)用于所有行業(yè)。但是，必須記住，這些連接受壓力限制（通常小于250 psi），不應(yīng)用于任何壓縮氣體服務(wù)，包括蒸汽或空氣。There have been incremental improvements to kam and grooves over the years. The most significant improvement has been the development of auto-locking cam arms that minimize the risk of accidental releases of products that can be caused by arms not remaining in a locked position. Kam and grooves are widely used across all industries.However, it’s important to keep in mind that these connections are limited by pressure (generally, less than 250 psi) and should not be used in any compressed-gas service, including steam or air.
盡管它們被廣泛采用和使用，但kam和凹槽仍然存在一個問題——它們會泄漏。在許多應(yīng)用中，為了將這種風(fēng)險降到- 低，這些開放的連接帶來了風(fēng)險，市場需要更多。此外，如果在壓力下打開這些連接，可能會造成人身傷害和/或釋放有害物質(zhì)。Despite their widespread adoption and use, there was still an issue with kam and grooves - they leak. Whatever residual product is left in the line will spill when uncoupled.In many applications the lines are blown down to minimize this risk, but the reality is that these open connections posed a risk and the market wanted more. Additionally, if these connections are opened while under pressure, bodily harm can be caused and/or hazardous materials could be released.
The Birth of Dry Disconnects
干式快速接頭的誕生
人們開始將kam和凹槽技術(shù)與球閥結(jié)合起來，在適配器后面放置一個球閥，在聯(lián)軸器后面放置另一個球閥，以盡量減少滴水。這種方法基本上是第一次干斷開。結(jié)合一個閥門與一個卡姆和溝槽，干式快速接頭誕生。People started to combine kam-and-groove technology with a ball valve, placing a ball valve behind the adaptor and another ball valve right behind the coupling to minimize drippage. This method was essentially the first dry disconnect. Combining a valve with a kam-and-groove,dry disconnects were born.
干式快速接頭已經(jīng)存在了很多年，隨著時間的推移，已經(jīng)進行了改進，并制造了其他版本。雖然運營商采用了干式斷開裝置，但對更好的流量和更少的滴水量有著需求。為了實現(xiàn)這兩個目標，市場上推出了更大的版本。它們被設(shè)計成一種更堅固的耦合器，用于重工業(yè)，能夠提供更廣泛的化學(xué)相容性。The dry disconnect has been around for many years and over that time, improvements have been made and other versions have been manufactured. While operators adopted the dry disconnect, there was a demand for even better flow and less drippage. In an effort to achieve both, larger versions have been introduced to the market. These were designed to be a more robust coupler for heavy industries with the ability to offer broader chemical compatibility.
另一種主要類型的彈出式干式斷開裝置，北約式，扭轉(zhuǎn)連接耦合技術(shù)，是在歐洲創(chuàng)建的，因為歐洲公司要求對油罐車和ISO油罐容器的連接進行標準化。這些聯(lián)接器是根據(jù)NATO STANAG 3756制造的。The other main type of poppeted dry disconnects,NATO-style, twist-to-connect coupling technology, was created in Europe because there was a demand by European companies to standardize connections for tank trucks and ISO tank containers. These couplings are manufactured in accordance with NATO STANAG 3756.
這是一個簡單的連接與簡單的扭曲連接，廣泛的標準化接受已經(jīng)驅(qū)動了在歐洲各地的網(wǎng)站和機器的大量適配器。另外，twist-to-connect方法沒有操作手柄，因此非常緊湊，非常適合小空間使用。It’s an easy connection with the simple twist-to-connect,and the broad standardization acceptance has driven the abundance of adaptors at sites and machines across Europe. Additionally, the twist-to-connect method doesn’t have an operating handle, making it compact and ideal for small spaces.
但不管你在地球上的什么地方，運營商仍然希望更好的流量和更少的泄漏。But no matter where you were on the planet, operators still wanted even better flow and even less drippage.
非提升閥的干式快速接頭
Non-Poppeted Dry Disconnects
一個用戶可以接受的東西，另一個用戶可能完全不能接受。當轉(zhuǎn)移高風(fēng)險或高價值產(chǎn)品時，產(chǎn)品損失不是一個選擇，非提升閥式干斷開裝置的開發(fā)是從對- 佳流量和- 小可能滴漏的需求發(fā)展而來的。What’s acceptable to one user might be completely unacceptable to another. And when transferring high-hazard or high-value products, product loss is not an option.The development of non-poppeted dry disconnects evolved from the demand for optimum flow and the least possible drippage.
非提升閥干式斷開裝置是- 先進、- 昂貴的干式斷開裝置，但由于其在確保高價值和高危害產(chǎn)品時為企業(yè)和環(huán)境提供保護，因此通常是- 佳選擇。在傳統(tǒng)的干式斷開裝置中，提升閥是一個部件，它的消除會導(dǎo)致幾乎為零的壓降，在斷開裝置時具有卓越的流體損失預(yù)防功能。Non-poppeted dry disconnects are the most advanced and most expensive dry disconnects but are frequently the best choice because of the protection they give businesses and the environment when securing high-value and high-hazard products. The elimination of the poppet that is a component in traditional dry disconnect results in virtually zero pressure drop, with superior fluid-loss prevention upon disconnection.
這些快速接頭采用創(chuàng)新的雙球閥系統(tǒng)設(shè)計，可實現(xiàn)無限制流道和雙關(guān)閉可靠性的戰(zhàn)術(shù)平衡。由于這種獨特的雙球閥球閥系統(tǒng)，在斷開時沒有產(chǎn)品被困在腔中或丟失，在處理高低溫時，操作人員需要更加極端一些。These couplings were engineered with an innovative double ball-valve system, which delivers a tactical balance of unrestricted flow path and double shutoff reliability. Because of this unique double ball-valve ball system, no product is trapped in the cavity or lost at disconnection.When dealing with high and low temperatures, operators need to get a little more extreme.
Extreme Safety Connections Beyond Dry Disconnects
干斷開以外的極端安全連接
極端快速連接安全接頭專為- 苛刻的高溫、低溫和高壓應(yīng)用而設(shè)計。Extreme quick-connect safety connections are engineered for the toughest highand low-temperature and high-pressure applications.
這些連接服務(wù)于全球工業(yè)，為一些- 困難和- 苛刻的液體和氣體應(yīng)用提供安全傳輸解決方案。極端連接從與極端寒冷的兼容到極端炎熱，每一種都有其獨特的產(chǎn)品設(shè)計挑戰(zhàn)。從極端溫度到極端壓力，行業(yè)需求驅(qū)使耦合制造商開發(fā)解決方案以滿足這些需求。These connections serve global industries to provide safe transfer solutions for some of the most difficult and demanding liquid and gas applications. Extreme connections vary from compatibility with extreme cold to extreme heat,with each offering its own unique product design challenges.From extreme temperatures, to extreme pressures, industry demands have driven coupling manufacturers to develop solutions to meet these needs.
極端安全連接對于防止化學(xué)品或氣體在流動時泄漏、減少極端溫度（從低溫到400華氏度（204攝氏度））下?lián)]發(fā)性有機化合物的無組織排放以及將高達15000磅/平方英寸的壓力添加到等式中至關(guān)重要。一個例子是設(shè)計用于工作溫度為-260華氏度（-162攝氏度）的液化天然氣的聯(lián)接器。在井場進行的連接可以達到數(shù)千磅/平方英寸。這些應(yīng)用推動了設(shè)計和工程的極限，但工業(yè)界已經(jīng)通過提供安全、可靠的連接來應(yīng)對幾乎所有的應(yīng)用。Extreme safety connections are vital to preventing chemical or gas leakage while flowing, reducing fugitive emissions of VOCs in extreme temperatures, from cryogenic to 400oF (204oC), and pressures, up to 15,000 psi, are added to the equation. One example would be couplings designed for use with Liquefied Natural Gas with operating temperatures of -260oF (-162oC). Connections made at a wellsite could be in the thousands of psi. These applications push the limits of design and engineering, but the industry has stepped up to the challenge by providing safe, reliable connections to meet nearly any application.
如果您連接的卡車或軌道車意外離開，會發(fā)生什么情況？一個潛在的災(zāi)難性問題。已經(jīng)開發(fā)了安全分離聯(lián)軸器，以將這種風(fēng)險降到- 低。根據(jù)特定應(yīng)用程序的需要，可以使用許多類型和樣式。這里的重要注意事項是，這些是工程解決方案，應(yīng)按照制造商指南進行規(guī)定和安裝。系統(tǒng)不能安裝在真空中，除非考慮一系列標準，包括所處理的特定介質(zhì)、系統(tǒng)壓力和溫度、拉力角和支撐重量。What would happen if the truck or railcar that you’ve connected left unexpectedly? A potentially catastrophic issue. Safety Breakaway Couplings have been developed to minimize this risk. Many types and styles are available depending on the needs of the specific application. The important note here is that these are engineered solutions and should be specified and installed per manufacturer guidelines. Systems cannot be installed in a vacuum, without considering a host of criteria including the specific media being handled, the system pressures and temperatures, the angle of pull, and the amount of supported weight.
Prepare for the Unpredictable
為不可預(yù)知的事情做準備
選擇正確的快速接頭技術(shù)可能是一個非常困難的過程，如果你自己做的話。隨著法規(guī)的遵循和無數(shù)變量的考慮，包括流量、滴水量、價格、壓力和人體工程學(xué)，運營商可以依賴像OPW工程系統(tǒng)這樣的公司，這些公司在開發(fā)創(chuàng)新的耦合器技術(shù)方面一直處于領(lǐng)先地位。通過個性化流程，運營商將能夠幫助選擇保護產(chǎn)品、人員和環(huán)境的完美快速插拔接頭。Choosing the right coupling technology can be a very difficult process if you’re doing it on your own. With regulations to follow and countless variables to consider including flow, drippage, price, pressure and ergonomics,operators can rely on companies like OPW Engineered Systems that have been ahead of the curve in developing innovative coupler technologies. By going through a personalized process, operators will be able to assist in selecting the perfect coupler that protects product, people and the environment.
如需了解有關(guān)快速插拔接頭設(shè)備的更多信息，以幫助您消除液體泄漏，或了解有關(guān)創(chuàng)新型產(chǎn)品的更多信息，以防止泄漏并節(jié)省您的資金，請聯(lián)系您當?shù)氐氖跈?quán)OPW經(jīng)銷商或致電OPW客戶服務(wù)部010-84282935。For more information on UST equipment that will help you eliminate water intrusion or to learn more about innovative UST equipment to prevent water intrusion and save you money, please contact your local, authorized OPW Distributor or call OPW Customer Service at 010-84282935.
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