Stepped Flange Assembly for Hoist-Free Gasket Replacement
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Solution Overview
Problem
The existing flanged connection systems in pipeline connections, particularly in large cooler units, require time-consuming and labor-intensive processes for gasket replacement due to the need for hoisting components, which is inconvenient for maintenance teams and customers without specific hoisting equipment.
Innovation Solution
A flanged connecting assembly featuring a first and second flange with a third flange forming a step, allowing for convenient assembly and disassembly by creating a gap for easy access and replacement of sealing elements without the need for hoisting, using a method where the first and second flanges are spaced by a distance facilitated by the step configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional flanged connection is used, then the connection firmness and reliability are improved, but the ease of maintenance deteriorates due to the need for hoisting equipment and complex disassembly procedures
Solution Approach 1:
The connection system is segmented into a fixed flange and a movable flange that can be independently separated. The movable flange is divided into a flange body and a connecting rod, allowing the sealing surface to be accessed without moving the entire pipeline or equipment, thus maintaining connection reliability while significantly improving maintenance ease.
Solution Approach 2:
The connection structure transitions from a static fixed connection to a dynamic adjustable connection. The movable flange can be shifted along the pipeline axis using the connecting rod mechanism, enabling dynamic access to the sealing surface for maintenance while maintaining a firm connection during operation.
2Ease of repair
If hoisting equipment is used to create assembly gap, then the ease of gasket replacement is improved, but the device complexity and cost increase
Solution Approach 1:
The movable flange is extracted as a separate, independently operable component from the fixed pipeline system. This extracted component can be manually shifted to create the necessary assembly gap, eliminating the need for complex hoisting equipment while maintaining ease of gasket replacement.
Solution Approach 2:
The connecting rod acts as an intermediary mechanism between the movable flange and the operator. It provides a mechanical advantage system that allows manual creation of assembly gaps without requiring external hoisting equipment, thus simplifying the overall system while maintaining repair ease.
3Reliability
If the flanges are closely connected, then the connection tightness is improved, but the ease of sealing element replacement deteriorates due to lack of access space
Solution Approach 1:
The connection allows dynamic adjustment of the gap between flanges. During normal operation, the flanges are closely connected for tightness. During maintenance, the movable flange can be shifted to create access space, and then restored to its original position after sealing element replacement, thus maintaining both tightness and accessibility.
Solution Approach 2:
The sealing system is segmented into a fixed sealing surface and a movable sealing surface. This segmentation allows the movable sealing surface to be independently accessed by shifting the movable flange, while the fixed flange remains in place, maintaining connection tightness while providing access for sealing element replacement.
Data Source
AI summary
A flanged connecting assembly, which comprises: a first flange (210); a second flange (220) with a diameter greater than the diameter of the first flange; and a third flange (230), provided with a first portion (231) and a second portion (232) forming a step; wherein the first portion (231) is fitted to the first flange (210) through a first sealing element (310), and the second portion (232) is fitted to the second flange (220) through a second sealing element (320); and the first flange (210) and the second flange (220) are spaced from each other by a first distance. In this way, a gap formed under the fit of the three flanges can allow a used sealing element to be taken out vie the gap and/or a new sealing element to be assembled in via the gap.