Peter Lemanczyk reports on a reliable spray shield for flange connections
Safety regulations require plant operators to comply with minimum general requirements for tools suitable for use with devices for retaining or draining off outflowing gases, vapours, liquids or dusts.
The risk of a sudden gasket rupture in a flange connection is a constant threat to people, equipment, and environment in a plant, causing a high risk of injury for the entire workforce as well as damage to the plant components.
In the Spray Control solution, a special metal filter inside the ring absorbs any spray-out and distributes it around the flange circumference. The product also provides for good steam protection. It is successfully used on practically every flange configuration, round, oval or other forms and with different gap or no gap between the flanges. The flexible net adapts itself to the gap. Where other spray shield rings cannot be applied when the flange connections deviate from the norm, the Spray Control practically always fits. These protection shields are available in different types for a variety of applications.
Made of DIN 1.4404 (ASTM 316) stainless steel, the system is highly resistant to oils and chemicals, does not suffer any embrittlement (in open-air plants, under exposure to UV) and is temperature-resistant up to 400°C.
Putting it to the test
In a simulation in 2017 on a defective flange connection with up to 300bar, tested in the renowned environmental simulation laboratory Treo, in Hamburg, Germany, the flange guard was thoroughly tested. On various sizes and shapes, with 100, 200 and 300bar over 10 minutes at each pressure, the result was the same every time: the flange guard had no signs of wear or deformation, nor any defect.
The integrated net prevents the product from slipping and adapts to fit into every little gap between the flanges. The solution can also be used on flanges without any sealing gaps.
In addition, Spray Control does away with expensive assembly work as it can be securely fitted and removed in seconds using the clasp. The four integrated hooks and tensioning springs allow for deviations in size and the net evens out any irregularities around the circumference. The great advantage for operating staff is that no assembly tools are required.
After cleaning and neutralising, the flange guard can be used again and again.
The flange shield is available in all sizes for all presently known types of flange connections. It can also be customised on request for other diameters and for square or oval flanges. Depending on the flange connections, the product can be supplied in the standard widths 50mm, 70mm and 90mm. Larger widths can be made to order. Special models with penetrations can also be made to order.
Spray Control is a reliable system that meets the requirements of plant operators and offers greater safety. It is certified by the German TÜV and DNV GL in accordance with: GL Rules I-1-2 Machinery Installations, Section 11G:2014; GL Rules VI-7-8, Section 1:2013; and SOLAS II-2 Reg.4-220.127.116.11.3.
Where other solutions are unsuitable, do not offer adequate protection, do not comply with environmental standards and consequently do not offer the required level of safety, Spray Control is the ideal choice.
Peter Lemanczyk is with Betek