Quick-Change Cartridge Flat Rupture Disc
Product Model: ZD-FL11 (Quick-Change Cartridge)
Design: The rupture disc is pre-installed in a sealed, cylindrical cartridge that inserts into a permanent body fixed between pipe flanges.
Key Feature: Fast, safe replacement without disassembling pipeline flanges. The spent cartridge is slid out and a new one slid in.
Pressure Range: 1 barg to 16 barg.
Primary Use: Systems requiring frequent inspection or replacement, processes with high maintenance costs for downtime, and locations with limited wrench access.
Overview
In critical processes where minimizing downtime is paramount, or where space constraints make traditional two-flange replacement difficult, the quick-change cartridge system revolutionizes maintenance. The rupture disc is factory-installed and tested within a robust cartridge. This cartridge locks into a permanent, flanged housing welded into your pipeline. When the disc activates or requires preventive replacement, only the cartridge is exchanged—a one-bolt operation that takes minutes, not hours, dramatically reducing system outage time and labor costs while enhancing worker safety by minimizing exposure to line contents.
Features & Benefits
Minimized Downtime: Disc replacement is reduced from a full flange breakout procedure to a simple cartridge swap, slashing maintenance windows.
Improved Safety: Limits personnel exposure to process media during change-out, as the primary sealing is maintained by the cartridge O-rings within the housing.
Reduced Risk of Installation Error: Cartridges are pre-assembled and tested, eliminating field errors in gasket placement, bolt torque, or disc orientation.
Ideal for Tight Spaces: The compact, in-line housing and sliding cartridge design require far less lateral clearance than traditional flanged assemblies.
How It Works
The permanent housing is installed in the pipeline. The disc cartridge, containing the membrane and secondary seals, is inserted into the housing and locked in place with a securing mechanism (e.g., a single clamp bolt or breech lock). Process pressure acts on the disc within the sealed cartridge. Upon bursting, the pressure is relieved. To replace, the system is isolated, the lock is released, the spent cartridge is removed, and a new one is inserted and secured.
Specifications (Descriptive)
Available for common line sizes: DN50, DN80, DN100, DN150. Burst pressures align with standard industrial needs (e.g., 4-10 barg). The cartridge body is typically stainless steel. Seals are high-quality fluorocarbon or perfluoroelastomer O-rings. The permanent housing is made from carbon or stainless steel and includes guide rails for smooth cartridge insertion. Each cartridge is supplied with an individual test certificate.
Q&A
Q: How do I know if the O-rings on the cartridge are still good during replacement?
A: Each new cartridge comes with new, lubricated O-rings installed. It is a replaceable-unit concept; the O-rings are not reused. Visual inspection of the housing seal surfaces for damage is recommended during cartridge exchange.
Q: Can this design handle high temperatures that might degrade the cartridge O-rings?
A: O-ring material must be selected for the process temperature. Standard Viton is good to ~200°C; perfluoroelastomers can go higher. For very high temperatures, a metal-seal cartridge variant may be required.
Q: Is the initial installation of the permanent housing more complex?
A: It requires welding or bolting the housing into the line, which is a one-time task. The long-term benefit is the vastly simplified future replacements, which outweighs the initial installation effort.
About ZD Safety
We engineer for efficiency and safety. Our quick-change cartridge system transforms rupture disc maintenance from a time-consuming chore into a swift, streamlined procedure, aligning safety management with operational excellence and cost savings.
