Process Vessel Nozzle Arrangement Segmentation
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Solution Overview
Problem
Existing nozzle arrangements in process vessels, such as Ingold fittings, pose safety risks due to sudden ejection under pressure, cause deformation and damage during installation or removal, compromise aseptic conditions, and require complex maintenance, leading to operational interruptions and potential product contamination.
Innovation Solution
A nozzle assembly with a stationary and replaceable element design, featuring a positive locking mechanism and a holding device, allowing secure, tool-free replacement without damaging the vessel, and preventing contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fitting element is welded firmly into the vessel wall with a through-hole, then the connection is secure and reliable, but the fitting can be suddenly ejected like a projectile when removed under pressure, causing safety risks
Solution Approach 1:
The nozzle arrangement is divided into a stationary nozzle element (welded to vessel) and a replaceable nozzle element (inserted into stationary element). This segmentation allows the fitting to be removed by simply pulling the replaceable element out, which is contained within the stationary element, preventing projectile ejection while maintaining secure connection during operation
Solution Approach 2:
The stationary nozzle element acts as an intermediary between the welded connection and the replaceable fitting. It provides a receiving opening that contains the replaceable nozzle element, serving as a safety barrier that prevents the fitting from being ejected as a projectile while allowing easy replacement
2Ease of repair
If fittings or sensors are removed and reinstalled multiple times, then maintenance and replacement are possible, but the inner diameter, through-bore, or rim of welded-in fittings become damaged or deformed, compromising connection tightness
Solution Approach 1:
By segmenting the nozzle into stationary (welded) and replaceable (inserted) elements, the design allows the replaceable element to be removed and reinstalled without affecting the precision-critical stationary element. The stationary element's receiving opening maintains its geometric precision, while the replaceable element absorbs the wear from repeated installation/removal cycles
Solution Approach 2:
The replaceable nozzle element is extracted from the stationary element, allowing it to be removed, replaced, or maintained without disturbing the stationary element that contains the precision-critical receiving opening. This extraction protects the through-hole geometry from damage during maintenance operations
3Manufacturing precision
If nozzle elements are manufactured with undersized inner diameter and reamed after welding, then welding-induced deformation is compensated, but additional work and specifically trained personnel are required
Solution Approach 1:
The stationary nozzle element is manufactured with a receiving opening that already has the correct final dimensions and geometry (25H7 or 40H7) before welding. This preliminary precision machining eliminates the need for post-weld reaming operations, as the receiving opening is not subjected to welding heat that would cause deformation
Solution Approach 2:
By separating the precision-critical receiving opening (in stationary element) from the welding zone, the design allows the receiving opening to be machined to precise dimensions before welding. The stationary element's receiving opening is protected from welding-induced deformation, eliminating the need for complex post-weld reaming processes
4Ease of repair
If fittings are removed and replaced frequently, then maintenance is possible, but operation of the process vessel is interrupted for a relatively long period
Solution Approach 1:
The replaceable nozzle element is designed as a separate, easily removable component that can be pulled out from the stationary element without tools. This segmentation enables rapid replacement of sensors or fittings by simply inserting a new replaceable element into the stationary element's receiving opening, significantly reducing operational downtime compared to traditional welded fittings that require cutting and welding operations
Solution Approach 2:
The nozzle arrangement transitions from a static welded connection to a dynamic, easily replaceable connection. The replaceable nozzle element can be quickly inserted and removed from the stationary element, allowing maintenance personnel to rapidly replace sensors or fittings without interrupting the overall vessel operation for extended periods
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a connecting piece assembly for a process connection of a fitting (5) or a sensor in particular, having a first stationary connecting piece element (1) and a second replaceable connecting piece element (2) which is rigidly connected to the fitting (5) or the sensor. The second replaceable connecting piece element (2) is designed so as to be partly receivable in any case by a receiving opening (4) of the first stationary connecting piece element (1). Furthermore, at least one holding device (3) is provided which is designed to hold together the first stationary connecting piece element (1) and the second replaceable connecting piece element (2). The invention also relates to a process container (30) with a corresponding connecting piece assembly.