Remote Hydraulic Flange Joint Opening With Quick Emergency Closure
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Solution Overview
Problem
Conventional methods for opening and closing bolt flange joints in process equipment are hazardous to workers and can result in material loss and equipment damage due to the need for close proximity and manual tools, which pose risks of injury, death, and costly downtime.
Innovation Solution
A remote hydraulic system with actuator assemblies, a hydraulic pump, and sensors that allows for the safe and controlled spreading and closing of bolt flange joints using hydraulic fluid lines and an accumulator for quick closure, minimizing worker exposure and preventing material loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manual tools and close proximity methods are used to open and close bolt flange joints, then workers can directly control the operation, but workers are exposed to hazardous conditions including fire, explosion, pressurized blast, and contact with toxic substances
Solution Approach 1:
The patent introduces a remote hydraulic actuation system as an intermediary between the operator and the flange joint. The hydraulic pump and control mechanisms are positioned at a safe distance from the hazardous joint, transmitting force through hydraulic fluid via hoses. This allows workers to operate the spreading and closing mechanisms without being in close proximity to dangerous conditions such as pressurized blasts, toxic leaks, or fire hazards.
Solution Approach 2:
The patent replaces direct manual mechanical operation with a hydraulic actuation system. Instead of workers directly manipulating tools at the joint, hydraulic pressure transmitted through fluid lines actuates the spreading and closing mechanisms. This substitution eliminates the need for workers to be physically present at the hazardous location while maintaining full control over the joint operation.
2Adaptability or versatility
If conventional spreading tools are used to open bolt flange joints, then the joint can be spread apart, but there is no means for quickly closing the joint again should the need arise
Solution Approach 1:
The hydraulic actuation system is designed to perform multiple functions: it can both spread the flange joint apart and quickly close it again. The same hydraulic pump and control mechanisms that enable controlled opening can be reversed to provide rapid closing if needed, such as when leaks or hazards are detected. This dual functionality addresses the limitation of conventional tools that only enable opening.
Solution Approach 2:
The hydraulic system provides dynamic control over the flange joint operation. The flow of hydraulic fluid can be rapidly redirected or stopped, allowing the actuation mechanism to transition quickly between spreading and closing states. This dynamic responsiveness enables the system to adapt to changing conditions, providing quick closure capability when safety concerns arise during the opening process.
3Productivity
If workers perform bolt flange joint spreading procedures using conventional tools, then the operation can be completed, but there is significant risk of injury or death from fire, explosion, pressurized blast, or contact with toxic substances
Solution Approach 1:
The remote hydraulic actuation system serves as an intermediary that transmits operational force without requiring worker presence at the hazardous location. Hydraulic fluid acts as the medium, carrying energy from the pump to the actuation mechanism at the joint. This intermediary approach maintains operational capability while eliminating direct worker exposure to fire, explosion, pressurized blasts, and toxic substance contact.
Solution Approach 2:
The patent extracts the hazardous element from the operation by removing workers from close proximity to the flange joint. The critical spreading and closing functions are performed by the remote hydraulic system positioned at a safe distance, connected only by hydraulic hoses. This extraction of human presence from the immediate hazard zone maintains productivity while eliminating the risk of injury or death from hazardous conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system reduces the risk of injury and death to workers, minimizes material loss and equipment damage, and enables efficient maintenance with reduced downtime and costs by allowing remote operation and quick joint closure in hazardous conditions.
Implementation Method 1
A remote hydraulic system with actuator assemblies, a hydraulic pump, and sensors that allows for the safe and controlled spreading and closing of bolt flange joints using hydraulic fluid lines
Implementation Method 2
an accumulator for quick closure, minimizing worker exposure and preventing material loss
Data Source
AI summary
A system for remotely opening and closing a process equipment bolt flange joint may include a hydraulic cylinder actuator assembly for attaching to the flanges of a bolt flange joint to open and close the joint by operation of a remote hydraulic pump. More than one actuator assembly may be evenly spaced around the flange joint, to ensure even distribution of force around the joint. The system may have an accumulator for receiving hydraulic fluid expelled from the hydraulic cylinder during extension and to force hydraulic fluid back into the cylinder to close the flange joint upon pressure release at the pump. A drop trigger may be used to release hydraulic pressure at the pump for emergencies. The system may include a video camera for viewing the joint on a display. The components may be stored and transported on a mobile cart. A method of use is also disclosed.