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60 000 352 Axial Expansion Joints - LowRes 02 PDF
60 000 352 Axial Expansion Joints - LowRes 02 PDF
Table of
contents
General
Axial expansion joints 1
Internal sleeves 2
Design
Determination of the pipe 3
expansion
Anchor point forces 4
Program summary 6
Safety instructions 11
Installation instructions,
pipe guides and support 12
Anchors 13
Vibration compensation,
movement capacity,
operating pressure 14
Pre-stressing,
Expansion joint delivered
in a pre-stressed state 15
Pre-stressing diagram,
example to the diagram 16
Installation of flanged
expansion joints,
installation of pipes
with pressfittings,
installation of expansion joints
with threaded sockets 17
Installation of BOA
disassembly joints 18
Control,
insulation,
Unacceptables modes of operation,
start-up of the system,
maintenance 19
FP
anchor
anchor
pump
A precondition for the diverse applications
of axial expansion joints is the presence of
suitable anchors and guides/supports.
1
General
main anchor pipe support / pipe support / main anchor pipe support /
guide guide guide
main anchor pipe support / pipe support / pipe support / pipe support / main anchor
guide guide guide guide
main anchor pipe support / pipe support / intermediate pipe support / pipe support / main anchor
guide guide anchor guide guide
main anchor
main anchor pipe support / pipe support / pipe support / main anchor
guide guide guide
2
Design
Based on the routing and length of the Thermal expansion coefficient Calculation of
pipeline as well as the operating tempera- thermal expansion
Temp. resistant
Austenitic mat.
Austenitic mat.
ture, one has to calculate the thermal
pipe materials
1.4541/1.4878
expansion that the individual expansion For
joints must compensate for. temperatures
According to the type of joint, this can be fromto
1.4571
axial or lateral movements. For a precise [oC]
calculation of the expansion, particulary for
heat resistant and stainless pipe materials,
we recommend the use of the following for- 190 to 0 0.88 1.42 1.46
mula: 0 to 100 1.11 1.64 1.68
0 to 200 1.21 1.71 1.75
0 to 300 1.29 1.76 1.80
0 to 400 1.35 1.80 1.84
Ro = Lo t [mm] 0 to 500 1.39 1.83 1.88
100 0 to 600 1.43 1.86 1.91
3
Design
FDR = 10 p AB [N]
Ref. 2.
The bellows spring force describes the
opposing force of a bellows to its compres-
sion or extension. The specific bellows
spring rates per + or - 1 mm are listed in the
expansion joint data sheets under spring
rate cax and c lat [N/mm].
FE = cax ax [N]
FH p FH
4 Fig. 1
Design
FH p FZW p FH
Fig. 2
5
Program
DN 800 to DN 1000
Axial expansion joint
with bellows of stainless steel 1.4541. On
both sides with weld ends of carbon steel,
with external shroud of carbon steel.
Suitable for ax without prestressing.
Type 7112 00X (previous: 307/214)
DN . . . . , PN . . . , ax . . . . , Bl . . . .
DN 200 to DN 700
Axial expansion joint
with bellows of stainless steel 1.4541. On
both sides with weld ends of carbon steel,
with external shroud of carbon steel
50% prestressed
Type 7114 00X (previous: 307/214)
DN . . . . , PN . . . , ax . . . . , Bl . . . .
6
Program
DN 200 to DN 700
Axial expansion joint
with bellows of stainless steel 1.4541. On
both sides with flanges of carbon steel, with
external shroud of carbon steel
50% prestressed
Type 7124 00X (previous: 307/215)
DN . . . . , PN . . . , ax . . . . , Bl . . . .
7
Program
DN 200 to DN 700
Axial expansion joint
with bellows of stainless steel 1.4541. On
both sides with weld ends of carbon steel
with inner sleeve and external shroud of
carbon steel
50% prestressed
Type 7117 00X (previous: 307/224)
DN . . . . , PN . . . , ax . . . . , Bl . . . .
DN 200 to DN 700
Axial expansion joint
with bellows of stainless steel 1.4541. On
both sides with flanges of carbon steel with
inner sleeve and external shroud of carbon
steel
50% prestressed
Type 7127 00X (previous: 307/225)
DN . . . . , PN . . . , ax . . . . , Bl . . . .
8
Program
9
Program
Anchors and pipe guides must be firmly Internal sleeves are also recommended for Safety
installed prior to filling and pressure testing expansion joints with DN 150 if the flow instruction
the system. velocity of the air, gas, or steam exceeds
The expansion joint must not be strained 8 m/s, or 3 m/s in case of liquid media.
by torsion. This is particularly important for
the installation of expansion joints with
threaded sockets. Excluded from this rule
are the expansion joints types 7918 ... and
7928 ... which are equipped with a torsion
protection.
The steel bellows must be protected
against damage and dirt (e.g. welding
chips, plaster or mortar splatter).
Steam pipelines should be installed in such
a way that water hammers are avoided.
This is achieved by means of a sufficiently
designed drainage, by correct insulation,
by avoiding water pockets and by installing
the pipeline with an inclination.
Expansion joints with internal sleeves must
be installed with consideration given to the
flow direction.
Avoid the installation of expansion joints Fig. 3
in the immediate proximity of pressure
reducers, superheated steam coolers and Installation of expansion joints with
shut-down valves, if high frequency vibra- threaded sockets in gas conduits
tions are to be expected due to turbulence. - Due to the threaded fittings, the maxi-
Otherwise, special precautions must be mum permitted excess pressure of these
taken (e.g. heavy-walled sleeves, per- expansion joints is only 4 bar when used
forated disks, etc.). in gas conduits.
If high frequency vibrations or turbulence - Rubber seals must not be lubricated or
or higher flow velocity are to be expected greased.
in the medium, we recommend the in- - Oxygen pipelines must not get into
stallation of expansion joints with internal contact with oil or grease. Otherwise,
sleeves. there is danger of explosion!
11
Installation
Installation Allow inclination for condensate drainage. measures to avoid buckling and lifting of the
instructions Align pipeline and install the pipe guides pipeline.
acc. to Figs. 4, 5, and 6. CAUTION
Pipe guides NOTE Swing supports or suspensions are not
and support Gliding or roller supports are the safest acceptable adjacent to expansion joints!
L1 = max. 2 . DN + (mm)
2
L2 = 0,7 . L3 (mm)
L3 is the distance between the pipe supports according to the above formula. If buckling
must be anticipated, the distance L3 must be reduced according to the diagram in Fig. 6.
Fig. 4
DN L1 L2 L3 DN L1 L2 L3
mm mm mm mm mm mm
15 30 + /2 1050 1550 200 400 + /2 3950 5650
20 40 + /2 1200 1750 250 500 + /2 4400 6300
25 50 + /2 1400 2000 300 600 + /2 4850 6900
32 64 + /2 1550 2250 350 700 + /2 5200 7450
40 80 + /2 1750 2500 400 800 + /2 5600 8000
50 100 + /2 1950 2800 450 900 + /2 5900 8450
65 130 + /2 2250 3200 500 1000 + /2 6250 8900
80 160 + /2 2500 3550 600 1200 + /2 6850 9800
100 200 + /2 2800 4000 700 1400 + /2 7450 10600
125 250 + /2 3100 4450 800 1600 + /2 7900 11300
150 300 + /2 3450 4900
Fig. 5 (valid only for steel pipelines)
12
Installation
Fig. 6
Install main anchors at locations where the frictional forces of the pipe supports / Anchors
pipeline changes its direction. guides.
Each pipe section that is to be compen- - Intermediate anchors must be installed
sated for must be reduced in length by if the movement capacity of one axial
anchors. expansion joint is not sufficient to com-
- Only one expansion joint is allowed bet- pensate for the entire expansion of a long
ween two anchors. pipeline and if several axial expansion
- Main anchors must installed at locations joints are required.
where the pipeline changes its direction. - In the case of vacuum operation, the
They must absorb the pressure thrusts anchors must be capable of withstanding
of the expansion joints as well as the compression and tensile forces.
Fig. 7 13
Installation
Fig. 8
CAUTION
If unrestrained expansion joints are used, the
thrust must be taken into account.
Fig. 9
All common expansion joints must be in- If an expansion joint is not installed at the Pre-Stressing
stalled pre-stressed by 50 % of their move- lowest operating temperature of a heating
ment capacity (for heating systems overall system or the highest operating temperature
length of expansion joint plus 50 %, and for of a cooling system (e.g. replacement at pipe
cooling systems overall length of expansion that is still warm) it must be pre-stressed
joint minus 50 % of the movement). individually (see pre-stressing diagram Fig. 13).
Fig. 11
15
Installation
Pre-stressing
diagram
Fig. 13
Align flange bolt holes. Make sure that the expansion joint is not Installation
- Ensure flanges are parallel. exposed to torque. of flanged
- Ensure gaskets are on center. Ensure that bellows are free of objects that expansion joints
- Tighten bolts crosswise. hinder free movement.
Fig. 14
IWK axial expansion joints types 7179 00X per assembly is possible at site. Installation of
und 7170 00S are suitable for the compen- When expansion joints are installed in pipes with
sation of axial movements in straight pipe- HAVC systems, the installation guide- pressfittings
lines and are especially developed for the lines of the Mannesmann-Pressfitting-
Mapress system. With the connection System company must be observed.
elements welded on both sides, fast and pro-
Align flange bolt holes. Make sure that the expansion joint is not Installation of
- Ensure flanges are parallel. exposed to torque. expansion joints
- Tighten bolts crosswise. Ensure that bellows are free of objects that with threaded
hinder free movement. sockets
1 3 2 4 3 5 3 2 1 4 3
7160 00S -TI, -RI, -EI, -TA, -RA, -LF 7162 00S -TI, -RI, -EI, -TA, -RA, -LF
Fig. 15
Fig. 16
Installation of NOTE
BOA Depending on the nominal diameter, the
disassembly installation length EL of the disassembly joint
joints must be max. 20 to 30 mm longer than the
unrestrained total length TLneutral.
Installation
Flange the disassembly joint with one side
Fig. 17
to the pipe end (Fig. 18). On the other side,
pull the disassembly joint towards the
components (valve, shut-off valve, pumps TL neutral
etc.) either with long bolts (unrestrained)
or with the delivered threaded rods (re-
strained) (Fig. 19). When installed correctly,
the disassembly joint is restraint.
Disassembly
Untie the long bolts or threaded rods. The
disassembly joint swings back, creating a Fig. 18
gap, which is necessary for comfortable
assembly and disassembly of the compo-
nents.
18 Fig. 19
Installation
Before starting-up, make sure that: - the flow direction has been observed for Control
- the pipeline is installed with an inclination expansion joints with internal sleeves,
to avoid water pockets; - the steel bellows is free from dirt, welding
- there is sufficient drainage; chips, plaster or mortar splatter or any other
- pipe anchors and pipe supports/guides are soiling clean, if necessary;
completely installed prior to filling and - all screwed connections are tightened
pressure testing the system; properly;
- the expansion joint is not exposed to torque - in general, special care is taken to avoid
(with the exception of types 7918 ... and corrosion damages, e.g. in water treatment
7928 ... which are equipped with a torque or measures to avoid galvanic corrosion
protection). This is especially important for in copper and galvanized pipes.
the expansion joints with threaded sockets.
- The restrictions listed in the Axial Expan- - If the pipeline will be cleaned with steam, Unacceptable
sion Joints brochure, section Technical make sure that no steam hammers occur modes of
Data, must not be exceeded. as they may damage the expansion joint. operation
Maintenance Maintenance
The axial expansion joints are maintenance-
free.
Prior to disassembly and maintenance the
system must be
- depressurized,
- cooled down, and
- drained.
Failure to do so can result in serious
accidents !
19
Expansion
joint data sheet
Quality tests:
Hydraulic press. test yes no
Leak test
with air yes no
with helium yes no
permissible leak rate mbar l/s
QA/QC requirements
Design code
Special specifications
Certification
Authorized inspection party
20
BOA Balg- und Kompensatoren-
Technologie GmbH
Lorenzstrasse 2-6
D-76297 Stutensee
Postfach 11 62
D-76288 Stutensee
BK.0612.3.1.en.Sto.2238