可靠的压力安全解决方案：爆破片（中英文）

爆破片是工业装置中除安全阀之外最常用的压力保护装置。它们保护容器和管道免于变形和其他损坏。其主要目标是提供最佳保护，同时最大限度地减少系统停机时间。

爆破片是一种具有特定断裂点的安全装置，可对特定压力做出响应，并在各种应用中用于泄压。它们用于防止工艺过程中出现过压或真空，从而保护人员、环境和机器。爆破片最初是一种非常简单的解决方案，但随着工业需求的不断增长，例如交变压力或更高的工艺温度，以及近年来工艺技术水平的不断提高，爆破片得到了巨大的发展。与电子、气动或弹簧加载安全系统相比，爆破片的最大优势在于其故障安全性能——这使其成为工业企业中最经济、最重要的安全装置。高可靠性对于避免系统不必要的停机至关重要。然而，爆破片的安全性很大程度上取决于其工艺和所用材料。

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.

爆破片的优势

The advantages of rupture discs

• 即时响应——没有什么比爆破片响应更快。不必要的过压和真空可在几毫秒内释放。

• 完全释放泄压区域——最大开口横截面积，可快速安全地泄压。

• 防泄漏——防止工艺介质在正常运行期间泄漏，从而降低此类损失带来的成本和影响。

• 经济实惠的解决方案——与其他压力保护措施相比，显著节省成本。

可靠且经济的爆破片并非标准化产品，而是由专家根据具体工艺条件量身定制。生产过程中会考虑众多参数，以确保最佳功能。

这些参数包括：

待保护的设备元件、工艺介质、工作压力、真空度、脉动、爆破压力、爆破温度、所需公称宽度、待排放质量流量

• 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

爆破片的设计

Design of rupture discs

用于泄压的爆破片呈圆形或方形，由一层或多层组成，形状为扁平或半球形。许多爆破片都配有断裂点，例如通过激光加工而成。这些断裂点可以是简单的切口，也可以是特殊的几何形状。爆破片的这一部分称为爆破元件。不同的应用需要不同类型的爆破片。它们由金属或塑料制成，由一层或多层组成，形状可以是半球形或扁平形。半球形爆破片的半球朝向工艺过程（反向作用爆破片），或远离工艺过程（正向作用爆破片）。在这些不同的类型中，存在着广泛的组合可能性。

例如，对于三段式爆破片，塑料薄膜夹在金属层之间，以达到最低的爆破压力。所用材料范围广泛，从各种不锈钢到更高质量的材料，例如因科镍合金、哈氏合金或钽，甚至还有涂层或塑料内衬，例如聚四氟乙烯 (PTFE) 或聚全氟乙丙烯 (FEP)。

爆破片可以直接安装在法兰之间，也可以插入相应的爆破片支架，然后安装在法兰之间。在某些情况下，制造商已将爆破片焊接或熔接在支架上。然后，这些支架会安装必要的连接件，例如螺纹（NPT、G 或客户定制螺纹）、连接系统（例如 VCR）或各种法兰（ISO-K、KF、ISO-F、CF）。

工业工厂中安装了大量的爆破片和其他安全装置。提供多种信号选项，以便立即接收有关爆破片触发（打开）的信息。最简单的方法是使用固定在爆破片上并连接到过程控制系统的触发线。随着爆破片的开启，导线断裂，电路被切断，爆破片的触发信号被传送至过程控制系统。如果对密封性有特别高的要求，则可使用非侵入式信号传输方法（例如磁式接近传感器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.

爆破片的关键技术参数

Key Technical figures of rupture discs

尺寸

爆破片的直径与管道或法兰的直径相匹配，在欧洲，其直径为公称管道尺寸 DN（Diamètre nominal），在其他地区，其直径为公称管道尺寸 NPS（Nominal Pipe Size）。

爆破压力（也称为设定压力）

这是爆破片开启时的压力。设定压力应确保爆破片在系统损坏之前开启。爆破压力高于正常运行时的压力（也称为工作压力或工艺压力），但低于相应系统的耐压值 (MAWP)。例如：当系统的工作压力 (Working Pressure) 为 1 bar，耐压值 (MAWP) 为 2 bar 时，爆破压力最高为 2 bar 或更低，具体取决于爆破片的类型。

爆破容差

定义爆破片开启时的规定爆破压力的容差。如果某种爆破片的爆破公差为 +/-10%，且规定的爆破压力为 1 bar，则爆破片将在 900 mbar 至 1.1 bar 的压力下打开。根据现行或适用的法规，爆破公差为 +/-10%（例如压力设备指令 2014/68/EC），或 +/-5%（例如 ASME 第 VIII 部分第 1 部分），或在极高爆破压力下为 +/-3%。根据具体工艺要求，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.

选择爆破片时应注意哪些事项？

What should I be aware of when selecting a rupture disc?

可靠且经济高效的爆破片并非标准化产品。专家始终会根据工艺流程的具体操作条件进行个性化调整。考虑各种参数，以确保每个爆破片都能完美运行。

这些参数包括：

• 需要保护的设备组件

• 工艺介质

• 工作压力

• 真空/循环次数

• 爆破压力

• 爆破温度

• 所需公称尺寸

• 待排放质量流量

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

爆破片的类型分类

Type classification of rupture discs

反作用式爆破片

爆破片的圆顶朝向工艺过程，可实现极高的工作压力（另见：爆破片的关键技术信息）和极高的工作压力比。

正向作用式爆破片

爆破片的圆顶背向工艺过程。

紧凑型爆破片

这些通常是公称管径非常小的反作用式或正向作用爆破片，通常通过粘合或焊接连接到外壳/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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