可靠的壓力安全解決方案：爆破片（中英文）
爆破片是工業(yè)裝置中除安全閥之外最常用的壓力保護裝置。它們保護容器和管道免于變形和其他損壞。其主要目標(biāo)是提供最佳保護，同時最大限度地減少系統(tǒng)停機時間。
爆破片是一種具有特定斷裂點的安全裝置，可對特定壓力做出響應(yīng)，并在各種應(yīng)用中用于泄壓。它們用于防止工藝過程中出現(xiàn)過壓或真空，從而保護人員、環(huán)境和機器。爆破片最初是一種非常簡單的解決方案，但隨著工業(yè)需求的不斷增長，例如交變壓力或更高的工藝溫度，以及近年來工藝技術(shù)水平的不斷提高，爆破片得到了巨大的發(fā)展。與電子、氣動或彈簧加載安全系統(tǒng)相比，爆破片的最大優(yōu)勢在于其故障安全性能——這使其成為工業(yè)企業(yè)中最經(jīng)濟、最重要的安全裝置。高可靠性對于避免系統(tǒng)不必要的停機至關(guān)重要。然而，爆破片的安全性很大程度上取決于其工藝和所用材料。
Rupture discs are, next to safety valves, the most commonly used pressure protection devices in industrial plants. They protect vessels and pipelines from deformation and other damage. The main objective is to optimally protect and, at the same time, minimise the downtime of the system.
Rupture discs are safety devices with a defined breaking point, which respond to a specific pressure and are used for pressure relief in the most diverse range of applications. They are used to protect against overpressure or vacuum within a process, for the protection of man, environment and machine. Originally a very simple solution, rupture discs have evolved enormously in response to growing industry requirements such as alternating pressures or higher process temperatures, and the increasing technologisation of processes in recent years. The biggest advantage over electronic, pneumatic, or spring loaded safety systems is the failsafe performance of rupture discs - this makes them the most economical and most important safety device in industrial enterprises. High reliability is important to prevent unnecessary downtime of the system. However, how failsafe a rupture disc is significantly depends on the workmanship and the material used.
爆破片的優(yōu)勢
The advantages of rupture discs
? 即時響應(yīng)——沒有什么比爆破片響應(yīng)更快。不必要的過壓和真空可在幾毫秒內(nèi)釋放。
? 完全釋放泄壓區(qū)域——最大開口橫截面積，可快速安全地泄壓。
? 防泄漏——防止工藝介質(zhì)在正常運行期間泄漏，從而降低此類損失帶來的成本和影響。
? 經(jīng)濟實惠的解決方案——與其他壓力保護措施相比，顯著節(jié)省成本。
可靠且經(jīng)濟的爆破片并非標(biāo)準(zhǔn)化產(chǎn)品，而是由專家根據(jù)具體工藝條件量身定制。生產(chǎn)過程中會考慮眾多參數(shù)，以確保最佳功能。
這些參數(shù)包括：
待保護的設(shè)備元件、工藝介質(zhì)、工作壓力、真空度、脈動、爆破壓力、爆破溫度、所需公稱寬度、待排放質(zhì)量流量
? Immediate response – nothing responds faster than a rupture disc. Unwanted overpressure and vacuum are relieved in milliseconds.
? Complete release of the relief area – maximum opening cross-section for quick and safe pressure relief.
? Leakproof – prevents process media from escaping during normal operation, reducing the costs and impact associated with such losses.
? Economical solution – significant cost savings compared to other pressure protections.
Reliable and economical rupture discs are not standardized products, but are always individually tailored to the respective process conditions by the specialists. Numerous parameters are taken into account for production in order to ensure optimum functionality.
These include, for example:
Plant element to be protected, process medium, operating pressure, vacuum, pulsation, bursting pressure, bursting temperature, required nominal width, mass flow to be discharged
爆破片的設(shè)計
Design of rupture discs
用于泄壓的爆破片呈圓形或方形，由一層或多層組成，形狀為扁平或半球形。許多爆破片都配有斷裂點，例如通過激光加工而成。這些斷裂點可以是簡單的切口，也可以是特殊的幾何形狀。爆破片的這一部分稱為爆破元件。不同的應(yīng)用需要不同類型的爆破片。它們由金屬或塑料制成，由一層或多層組成，形狀可以是半球形或扁平形。半球形爆破片的半球朝向工藝過程（反向作用爆破片），或遠(yuǎn)離工藝過程（正向作用爆破片）。在這些不同的類型中，存在著廣泛的組合可能性。
例如，對于三段式爆破片，塑料薄膜夾在金屬層之間，以達到最低的爆破壓力。所用材料范圍廣泛，從各種不銹鋼到更高質(zhì)量的材料，例如因科鎳合金、哈氏合金或鉭，甚至還有涂層或塑料內(nèi)襯，例如聚四氟乙烯 (PTFE) 或聚全氟乙丙烯 (FEP)。
爆破片可以直接安裝在法蘭之間，也可以插入相應(yīng)的爆破片支架，然后安裝在法蘭之間。在某些情況下，制造商已將爆破片焊接或熔接在支架上。然后，這些支架會安裝必要的連接件，例如螺紋（NPT、G 或客戶定制螺紋）、連接系統(tǒng)（例如 VCR）或各種法蘭（ISO-K、KF、ISO-F、CF）。
工業(yè)工廠中安裝了大量的爆破片和其他安全裝置。提供多種信號選項，以便立即接收有關(guān)爆破片觸發(fā)（打開）的信息。最簡單的方法是使用固定在爆破片上并連接到過程控制系統(tǒng)的觸發(fā)線。隨著爆破片的開啟，導(dǎo)線斷裂，電路被切斷，爆破片的觸發(fā)信號被傳送至過程控制系統(tǒng)。如果對密封性有特別高的要求，則可使用非侵入式信號傳輸方法（例如磁式接近傳感器NIMU）。
Rupture discs for pressure relief are round or square, consist of one or more layers, and are either flat or domed. Many rupture discs are equipped with breaking points which are created for example, by means of lasers. These can be simple cuts or even special geometries. This part of the rupture discs is known as the rupture element. Different applications require different types of rupture discs. They are made of metals or plastics, from one or more layers, and they can be domed or flat. Domed rupture discs either have the dome towards the process (reverse acting rupture disc), or away from the process (forward acting rupture discs). Within these different varieties, there is a broad range of possible combinations.
For example, plastic film is sandwiched between metal layers for triple section rupture discs, in order to reach even the lowest burst pressures. The materials used range from various stainless steels to higher quality materials such as Inconel, Hastelloy, or Tantalum, and all the way up to coatings or plastic liners such as PTFE or FEP.
Rupture discs are either installed directly between flanges, or inserted into a corresponding rupture disc holder, which is then mounted between flanges. In some cases the rupture disc is already soldered or welded into the holder by the manufacturer. These holders are then fitted with the necessary connections, e.g. thread (NPT, G or customer-specific thread, connection systems (e.g. VCR) or various flanges (ISO-K, KF, ISO-F, CF)).
A large number of rupture discs and other safety devices are installed in industrial plants. A broad range of signalling options are available, to immediately receive information about the triggering (opening) of a rupture disc. The easiest way to achieve this is with a tripping wire which is fixed on the rupture disc, and is connected to the process control system. With the opening of the rupture disc, the wire breaks, the circuit is interrupted and the triggering of the rupture disc is communicated to the process control system. If there are particularly high demands for leak-tightness, non-invasive signalling methods (e.g. magnetic proximity sensor NIMU) are used.
爆破片的關(guān)鍵技術(shù)參數(shù)
Key Technical figures of rupture discs
尺寸
爆破片的直徑與管道或法蘭的直徑相匹配，在歐洲，其直徑為公稱管道尺寸 DN（Diamètre nominal），在其他地區(qū)，其直徑為公稱管道尺寸 NPS（Nominal Pipe Size）。
爆破壓力（也稱為設(shè)定壓力）
這是爆破片開啟時的壓力。設(shè)定壓力應(yīng)確保爆破片在系統(tǒng)損壞之前開啟。爆破壓力高于正常運行時的壓力（也稱為工作壓力或工藝壓力），但低于相應(yīng)系統(tǒng)的耐壓值 (MAWP)。例如：當(dāng)系統(tǒng)的工作壓力 (Working Pressure) 為 1 bar，耐壓值 (MAWP) 為 2 bar 時，爆破壓力最高為 2 bar 或更低，具體取決于爆破片的類型。
爆破容差
定義爆破片開啟時的規(guī)定爆破壓力的容差。如果某種爆破片的爆破公差為 +/-10%，且規(guī)定的爆破壓力為 1 bar，則爆破片將在 900 mbar 至 1.1 bar 的壓力下打開。根據(jù)現(xiàn)行或適用的法規(guī)，爆破公差為 +/-10%（例如壓力設(shè)備指令 2014/68/EC），或 +/-5%（例如 ASME 第 VIII 部分第 1 部分），或在極高爆破壓力下為 +/-3%。根據(jù)具體工藝要求，也可采用其他爆破公差。
Dimensions
The diameter of the rupture discs is specified matching the diameter of pipes or flanges as the nominal pipe size DN (Diamètre nominal) in the European context, or as NPS (Nominal Pipe Size) in other regions.
Burst pressure (also referred to as set pressure)
This is the pressure at which the rupture disc opens. It is selected in such a manner, that the rupture disc opens before there is any system damage. The burst pressure is above the prevailing pressure during normal operation (also referred to as working pressure or process pressure) and below the pressure resistance (MAWP) of the respective system. Example: At an operating pressure (working pressure) of 1 bar and a 2 bar pressure resistance (MAWP) of the system, the burst pressure is at max. 2 bar or lower, depending on the type of rupture disc.
Burst tolerance
Defines the tolerance around the defined burst pressure, which opens the rupture disc. If a rupture disc type has a burst tolerance of +/-10%, and the defined burst pressure is 1 bar, the rupture disc will open between 900 mbar and 1.1 bar. Depending on the valid or applied rules and regulations the burst tolerance is at +/-10% (e.g. Pressure Equipment Directive 2014/68/EC), or +/-5% (e.g. ASME section VIII, Division 1), or +/-3% for very high burst pressures. Other burst tolerances are possible depending on the requirements of the respective process.
選擇爆破片時應(yīng)注意哪些事項？
What should I be aware of when selecting a rupture disc?
可靠且經(jīng)濟高效的爆破片并非標(biāo)準(zhǔn)化產(chǎn)品。專家始終會根據(jù)工藝流程的具體操作條件進行個性化調(diào)整?？紤]各種參數(shù)，以確保每個爆破片都能完美運行。
這些參數(shù)包括：
? 需要保護的設(shè)備組件
? 工藝介質(zhì)
? 工作壓力
? 真空/循環(huán)次數(shù)
? 爆破壓力
? 爆破溫度
? 所需公稱尺寸
? 待排放質(zhì)量流量
Reliable and cost-effective REMBE? rupture discs are not standardised products. Our specialists always adapt them individually to the specific operating conditions of your processes. We consider a wide range of parameters to ensure that every rupture disc functions perfectly
These parameters include:
? The plant components to be protected
? Process medium
? Operating pressure
? Vacuum/cycles
? Burst pressure
? Burst temperature
? Nominal size required
? Mass flow to be discharged
爆破片的類型分類
Type classification of rupture discs
反作用式爆破片
爆破片的圓頂朝向工藝過程，可實現(xiàn)極高的工作壓力（另見：爆破片的關(guān)鍵技術(shù)信息）和極高的工作壓力比。
正向作用式爆破片
爆破片的圓頂背向工藝過程。
緊湊型爆破片
這些通常是公稱管徑非常小的反作用式或正向作用爆破片，通常通過粘合或焊接連接到外殼/支架上。
Reverse acting rupture disc
The dome of the rupture disc faces the process and enables very high operating pressures (see also: key technical information on rupture discs) and a very high operating pressure ratio.
Forward acting rupture discs
The dome of the rupture discs is faced away from the process.
Compact rupture discs
These are usually very small nominal pipe size of reverse-acting or forward acting rupture discs which are often adhesively bonded or soldered to the housing / holder.
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