OPW NTS-PU Series User manual

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OPW Emergency Safety Disconnector
Safety Breakaway Coupling
Type NTS-PU Series (Pull-Away)
Sizes!1”- 4’’ (DN25 – DN100)
M. Heublein, Seite 1, 11.08.2003M. Heublein, Seite 1, 11.08.2003

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Content
Please read carefully the following OPW user manual to avoid incidents and in correct use.
Page
Content ......................................................................................................................................... 2
1.0 Description of the NTS-PU Safety Breakaway Coupling ........................................................ 3
2.0 Operator’s manual NTS-PU .................................................................................................... 5
3.0 How to install the coupler........................................................................................................ 6
4.0 Testing of the coupler after a separation ................................................................................ 7
5.0 Reassembly of the NTS-PU after a separation....................................................................... 8
6.0 Testing and Maintenance Recommendations....................................................................... 13
7.0 Remarks................................................................................................................................ 14

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1.0 Description Safety Breakaway Coupling
1.1 Area of use
The Safety Breakaway Coupling (NTS-PU) can be used in loading arms, hose- and pipelines for the
transfer of fluids or gas. A typical application is the unintended tank truck/railcar/aircraft pull-off or
the drifting away of a barge or ship.
1.2 Design
Both halves of this emergency coupling are equipped with non returning, spring loaded valves; they
are held together by a fast coupling connection. Separation is triggered by a pulling force via the
hose or loading arm. The separation force is individually preset for max. protection of the hose
line.
1.3 Function
In the mounted status the NTS-PU is open and allows for free flow. If a tensile force exceeds the
preset value the two halves separate. The valves instantly close on both ends to prevent spillage.
The separation does not result in the destruction of parts (shear pins); no spare parts or special
tools are required to instantly reassemble it after depressurizing and draining the hose line.
1.4 Advantages
•Working in any direction (angle)
•Built-in possible in both directions
•Easy reassembly after separation
•Mounting: tighten mounting screws, push 2 halves together and remove the
mounting screws
•Cable-free activation
•Fully functional immediately after being built in; no further activation required
•Spare-part-free, non-destructive separation
•No shear pins involved and no destruction.
•Easily reassembled w/o tools or spare parts
•Ideal for LPG transfer lines

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1.5 Materials
The following combinations are suggestions depending on the media:
Housing/internals Seals
General chemical use: SS 316 (L / Ti) Elastomer o-rings
Acid- /
alkaline solutions: Alloys Elastomer o-rings
Fuels / oils : SS 304 Elastomer o-rings
Also available in
anodized aluminum!
Standard elastomer o-rings in FPM (FKM Viton®), EPDM, FFKM (Chemraz®/ Kalrez®)
Flat seals in PTFE (Teflon®)
Other materials and seal rings upon request
1.6 Specifications
Sizes: 1’’ - 4” (DN25 - DN100)
Pressure rating: 232psi (PN16) – Aluminium; 360psi (PN25) – SS
Connections: BSP- and NPT- threads, DIN/ISO-, ASA-, TW- and TTMA-flanges
Other treads and flanges on request
Separation force suggestions:
Size
1” (DN25)
2” (DN50)
3” (DN80)
4” (DN100)
WP - 90psi/6bar
660lbs
(300kg)
2650lbs
(1200kg)
3750lbs
(1700kg)
4630lbs
(2100kg)
1.7 Approvals
•CE-marked, Type-examination (Module B) according to Directive 97/23/EC
•ATEX, Manufactures Certificate of conformance according to Directive 94/9/EC (ATEX)
•Conform with clean air regulation (TA-Luft)
•Manufactured under DIN EN ISO 9001:2008

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2.0 Operator’s manual NTS-PU
2.1 Arrival condition of the NTS-PU
The NTS-PU is shipped with the reconnecting rods, nuts and bolts in place to prevent an
inadvertent separation during the transport
These parts have to be removed before the NTS-PU goes into service as explained in the
manual.
2.2 Removal of packing material
The NTS-PU is packed in special wrapping material and boxed for a safe transfer. All this
material needs to be removed completely and disposed off correctly. Care must be taken to
unpack and transport the coupler to its final destination without damaging it.

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3.0 How to install the coupler
1. To assure a safe function the NTS-PU needs to be installed as follows:
a. Tensile force either axial or at an angle
b. The coupling halves need to have enough space to fully separate.
This guarantees the complete closure of the valves.
For all sizes 1”- 4”(DN25 – DN100) the minimal required distance between the two halves is
4’’ (100mm) at the point of separation.
2. The NTS-PU can be installed in any direction.
3. Installation should not lead to stress on the production line.
4. Mounting screws must be removed before the use of the NTS-PU
5. During the separation small amounts of media could escape. We therefore recommend an
additional spray protection.
6. The user manual (installation instructions) and the mounting screws should be kept in
secure and accessible location.
Caution!
The Valves of the NTS-PU are spring loaded.
Inappropriate disassembly could lead to injuries!
7. Warning !
During the loading or offloading process no person should be standing in the danger zone of
the NTS. The separated hose end might pose an injury danger during the separation process.
Emergency contingencies are to be followed according to local regulations and jurisdictions.

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4.0 Testing of the NTS-PU after a separation
4.1 Test procedure
a. Process environment
Make sure the shut off valves on both sides to the NTS-PU are closed
... that the line is depressurized
... that the line is drained / purged
b. Optical inspection
Check for physical damage to the coupler
Check seal rings for damage
Check all release parts for damage
Check face o-rings (where the two NTS-PU halves mate) for damage
4.2 Evaluation of the damage and consequences
a. Minor damage
Repair on site possible by local crew
e.g. defective o-rings between the coupler halves or damaged seal ring
Use only original spare parts
b. More severe damage
e.g. damage to the housing or to any of the moving parts
Please contact the your OPW representative

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5.0 Reassembly of the NTS-PU after a separation
1. Terminology of the most important coupler parts
Inline Adapter
Release Lever
O-Ring
Threaded Hole for Mounting Screws
Hole for Threaded Rod
Threaded Hole for Threaded Rod

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Depending on the size and the placement it might be easier to remove the coupler from the
manifold in order to reassemble it.
2. Depressurize and empty line (page 7, point 4.1, line a)
3. Optical inspection (page 7, point 4.1, line b)
4. Place the 6 x Mounting Screws into the threaded hole at the Adapter
The Release Levers open to allow reconnection
Release Lever
Mounting Screws (Socket Set
Screws)
O-Ring
Coution!
Do not remove these
3 x Hexagon Head Screws

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5. Place the 2 x threaded rods by turning them clockwise
6. Place the Adapter on the top of the Inline and placing the 2 x washers and hex nuts of the
threaded rods
Threaded Rod
Inline
Adapter
Washer
Hex Nut

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7. Narrow the space between adapter and inline initially by applying manual pressure, then by
carefully tightening the hex head nuts crosswise as far as they go until the two halves are fully
flush.
8. Replace the 6 x Mounting Screws out of the threaded hole at the Adapter body
The Release Levers are closed and ready for use
Coution!
Do not remove these
3 x Hexagon Head Screws

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9. Remove the 2 x threaded rods including the washers and hex nuts
10. The Safety Breakaway Coupling is now complete and after the pressure test (page 13,
point 3.4) ready for use

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6.0 Test – and Maintenance recommendations –NTS-PU
6.1 Test periods of the Safety Breakaway Coupler
Independently from governmental regulations, we recommend to test Safety Breakaway
Couplers at least once a year according to the test recommendations for thermoplastic,
elastomer-type hoses.
A more vigorous use requires shorter test intervals. Elevated temperatures, higher
concentrations, impurities and abrasive particles can significantly influence the corrosion
resistance in Emergency Release Couplers.
6.2 Test procedure
Test procedures are regulated by the local plant safety committee. It could involve for
example pressure test of both coupler halves or the mounted coupler, a separation test and/or
visual inspection.
The results need to be documented.
6.3 Pressure testing the coupling halves
Test both halves individually (adaptor and inline) for leakage. Mount the threaded end (flange)
of the separated halve to the test unit and pressurize the system with fluid up to the required
working pressure. Increase the pressure stepwise and check for leakage.
6.4 Pressure testing of the mounted NTS-PU
Close the coupler on one side with a blind threaded end / blind flange and fill with fluid in an
upright position. Apply the test connection and pressurize the system to the requested
working pressure. Increase the pressure stepwise and check for leakage.
6.5 Separation testing
Build in the NTS-PU in an axial fashion and trigger the separation with e.g. a cable winch. The
use of a tensile force meter is recommended.
6.6 Maintenance
The Emergency Release Couplers (breakaways) have minimal need for maintenance. All
guiding elements, o-rings and seal rings should be periodically checked for porosity as well as
for wear and tear.
Upon request, we can train the operating staff.
Spare parts for the Emergency Release Couplers (breakaways) can be ordered with the
respective part number and product identification which can be found engraved onto the
coupler.
6.7 Repairs
Repairs to the Emergency Release Couplers (breakaways) can only be performed by trained
and authorized personnel followed by subsequent testing, labeling and documentation. The
spare parts available for many years.
6.8 Cleaning
The NTS-PU needs to be thoroughly cleaned before any repair.

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7.0 Remarks
Notes:
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