Safety Guide for Selecting and Using Quick Action Couplings and Related Accessories
Scope
This safety guide provides instructions for selecting and using quick action couplings and related accessories (including caps, plugs, blow guns, and two-way valves). It supplements specific AKJia publications for the quick action couplings and accessories being considered.
Fail-Safe Design
Quick action couplings or the hoses they are attached to can fail without warning for various reasons. Design all systems and equipment in a fail-safe mode to ensure that failure of the quick action coupling or hose will not endanger people or property.
Distribution
Provide a copy of this safety guide to everyone responsible for selecting or using quick action coupling products. Do not select or use quick action couplings without thoroughly reading and understanding this safety guide and the specific AKJia publications for the products considered.
User Responsibility
Due to the wide variety of operating conditions and uses for quick action couplings, neither AKJia nor its distributors can guarantee that any specific quick action coupling is suitable for a particular end-use system. This safety guide does not cover all technical parameters that must be considered in selecting a product. Users, through their analysis and testing, are solely responsible for:
- Making the final selection of quick action couplings.
- Ensuring that their requirements are met and that the use presents no health or safety hazards.
- Providing all appropriate health and safety warnings on the equipment where the quick action couplings are used.
Additional Questions
For additional information or questions, contact the appropriate AKJia customer service department. Refer to the AKJia publication for the product being considered or used for the telephone numbers of the appropriate customer service department.
Quick Action Coupling Selection Instructions
1. Pressure:
Select quick action couplings with a rated pressure equal to or greater than the maximum system pressure. Surge pressures higher than the rated pressure will shorten the coupling’s life. Do not confuse burst pressure or other pressure values with rated pressure.
2. Fluid Compatibility:
Ensure the coupling’s body and seal materials are compatible with the fluid media used. Refer to the fluid compatibility chart in the AKJia publication for the product being considered.
3. Temperature:
Ensure fluid and ambient temperatures, whether steady or transient, do not exceed the coupling’s limits. Use caution and hand protection when handling couplings heated or cooled by the media or environment.
4. Size:
Ensure the size of the couplings and system components minimizes pressure losses and avoids damage from heat generation or excessive fluid velocity.
5. Pressurized Connect or Disconnect:
If connecting or disconnecting under pressure is necessary, use couplings designed for that purpose. The rated operating pressure may not be the safe pressure for connecting or disconnecting.
6. Environment:
Ensure couplings are compatible with or protected from the environment (e.g., UV radiation, ozone, moisture, chemicals) to prevent degradation and premature failure.
7. Locking Mechanism:
Ball locking couplings can accidentally disconnect if dragged over obstructions or if the sleeve is bumped. Use sleeve lock or threaded sleeve designs where accidental uncoupling is a concern.
8. Mechanical Loads:
Consider mechanical loads such as excessive tensile or side loads and vibration, as these can reduce coupling life or cause failure. Special testing may be required for unusual applications.
9. Specifications and Standards:
Review and follow applicable government, industry, and AKJia specifications when selecting quick action couplings.
10. Vacuum:
Not all quick action couplings are suitable for vacuum service. Ensure the couplings can withstand the vacuum and pressure of the system.
11. Fire Resistant Fluids:
Some fire-resistant fluids require seals other than the standard nitrile used in many couplings.
12. Radiant Heat:
Quick action couplings can be heated to destruction by nearby hot items, even without direct contact. This can lead to a fire despite cool air being present around the couplings.
13. Welding and Brazing:
Heating plated parts, including quick action couplings and port adapters, above 450°F (232°C) can emit deadly gases and damage seals. Avoid welding, brazing, or soldering at these temperatures.
Quick Action Coupling Installation Instructions
1. Pre-Installation Inspection:
Before installing a quick action coupling, visually inspect it and check for correct style, body material, seal material, and catalog number. Before final installation, connect and disconnect the coupling halves with a sample of the mating half to be used.
2. Quick Action Coupling Halves from Other Manufacturers:
If a quick action coupling assembly includes one AKJia half and one half from another manufacturer, do not exceed the lower pressure rating of the two halves.
3. Fitting Installation:
Use a compatible thread sealant or lubricant when assembling pipe thread joints. Avoid system contamination by using liquid or paste sealant instead of tape. Use the flats provided to hold the coupling when installing fittings. Do not use pipe wrenches or a vice on other parts of the coupling as it can cause damage or loosen threaded joints. Avoid excessive torque on taper pipe threads to prevent cracking or splitting.
4. Caps and Plugs:
Use dust caps and plugs when couplings are not connected to exclude dirt and contamination and protect critical surfaces.
5. Coupling Location:
Place couplings where they can be easily connected or disconnected without exposing the operator to slipping, falling, getting sprayed, or coming into contact with hot or moving parts.
6. Hose Whips:
Use a hose whip (a short length of hose between the tool and the coupling half) instead of rigidly mounting a coupling half on hand tools or other devices. This reduces the potential for coupling damage if the tool is dropped and provides isolation from mechanical vibration.
Quick Action Coupling Maintenance Instructions
1. Maintenance Program:
Implement a maintenance program to ensure the longevity of quick action couplings. The frequency of maintenance should depend on the severity of the application and risk potential. The program should include the following as a minimum:
2. Visual Inspection of Quick Action Couplings:
Replace the coupling immediately if any of the following conditions are observed:
- Cracked, damaged, or corroded parts.
- Leaks at the fitting, valve, or mating seal.
- Broken mounting hardware, especially breakaway clamps.
3. Visual Inspection of All Other Components:
Tighten, repair, or replace as needed:
- Leaking seals or port connections.
- Remove excess dirt buildup on the locking mechanism or interface area.
- Clamps, guards, and shields.
- System fluid level, fluid type, and air entrapment.
4. Functional Test:
Operate the system at maximum operating pressure to check for malfunctions and leaks. Avoid potential hazardous areas during testing.
5. Replacement Intervals:
Consider specific replacement intervals based on previous service life, government or industry recommendations, or when failures could result in unacceptable downtime, damage, or injury risk.
By following this guide, you can ensure the safe selection, installation, and maintenance of quick action couplings and related accessories. Always refer to specific product manuals and consult with experts when necessary.