Metal Expansion Joints. Technical Guide FROM KE-BURGMANN

Transcription

1 Metal Expansion Joints Technical Guide FROM KE-BURGMANN

2 1 2 3 CONNEX Metal Expansion Joints Introduction Manufacturing technique and product range Nomenclature Technical Information & Bellows Theory Design parameters End connections & sleeves Movements & Materials General Overview of CONNEX types General & product type designations Metal expansion joint types CONNEX selection guide 4 Standard Designs 5 Special Designs Rectangular metal expansion joints Metal expansion joints with deep convolutions 6 Practical Advice Enquiry form 7 Quality Assurance Programme 8 Other Types of Expansion Joints Fabric expansion joints Rubber expansion joints 9 Shipping, Storage & Installation 10 Terms of Sale and Delivery

3 F12 (GB) CONNEX Metal Expansion Joints 1. Connex metal expansion joints 1. 1 Introduction to CONNEX metal expansion joints KE-BURGMANN A/S Engineering software Definition of metal expansion joints Metal expansion joints - highly engineered products A metal expansion joint is able to compensate for complex movements Metal expansion joints - the best choice for piping, duct systems and vessels 1.2 Manufacturing technique and product range Manufacturing technique Manufacturing capability Manufacturing disciplines CONNEX metal expansion joints - product range CONNEX metal expansion joints - available configurations Quality Standards 1.3 Nomenclature

4 F12 (GB) Introduction to CONNEX metal expansion joints 1.1 Introduction to CONNEX metal expansion joints KE-BURGMANN A/S Founded in 1963 as a company dedicated to the manufacture of expansion joints, KE-BURGMANN can claim more than 35 years of experience with expansion joints as our core product. We develop, engineer, and manufacture fabric, rubber and metal expansion joints in an almost unlimited variety of designs for the solution of a similarly vast range of industrial alignment problems in industrial facilities throughout the world. Our aim is to combine the experience we have acquired in the past with our knowledge of the present and to blend this with the technology of the future to the benefit of our customers and partners all over the world. Product quality and reliability; delivery; technical service; and commercial integrity have always been, and will remain the keystones of our relationships with our customers and suppliers Engineering software A metal expansion joint is a highly engineered product and its design requires a series of technical calculations to ensure that the resulting expansion joint is the one most suited to the purpose. To guarantee the accuracy of these calculations we at KE-BURGMANN have developed our own calculation software which we have integrated into an overall management system that not only optimises design calculations, it simultaneously provides quotations, manufacturing specifications and QA procedures. Our design calculations are based on the latest edition of EJMA recommendations. QA procedures are based on ISO 9001, and EN 729.

5 F12 (GB) Introduction to CONNEX metal expansion joints Definition of metal expansion joints The term metal expansion joint is used to describe any device containing one or more metal bellows that are used to absorb dimensional changes such as those caused by thermal expansion or contraction in pipe-lines, ducts or vessels and their components Metal expansion joints - highly engineered products Metal expansion joints are employed in piping systems to absorb differential thermal expansion while containing the system pressure. Typical, but not limiting, service conditions cover pressures ranging from full vacuum to 1000 psig and temperatures from -215 C (-420 F) to C (+2190 F). Such expansion joints can truly be described as highly engineered products. The system operating characteristics; the expansion joint design, material and manufacturing quality; and the installation, test and operating procedures; must all be considered carefully before any expansion joint is installed. Unlike most commonly used piping components, a bellows is constructed of relatively thin gauge material in order to provide the flexibility needed to absorb the mechanical and thermal movements expected in service. This requires design, manufacturing quality, handling, installation and inspection procedures which reflect the unique nature of the product. In general, the most reliable and safe metal expansion joint installations can be assured only after close co-operation, communication and understanding between the user and manufacturer A metal expansion joint is able to compensate for the following movements axial ± movements lateral ± movements angular movement (1 and 2 planes) and combinations of the above movements, which may be caused by the thermal expansion pressure, pressure pulsation and pressure thrust vibration misalignments foundation settlement assembly movement relative movements between other elements that are typical of piping and duct systems which feature prominently in the processing and chemical industries, such as petro-chemical plants, chemical plants, cement works, steel works, the pulp and paper industry etc., and in the energy sector, such as power generation, gas turbine systems, diesel engine systems, power boats, district heating systems etc Metal expansion joints - the best choice for piping, duct systems and vessels, when a solution is required that is: vacuum proof pressure proof temperature proof corrosion proof reliable and safe durable, with long service life maintenance free and an optimum balance between flexibility and pressure. Axial compression (-) Angular offset (+) (-) Lateral offset (+) (-) Axial elongation (+)

6 F12 (GB) Manufacturing technique and product range 1.2 Manufacturing technique and product range Manufacturing technique KE-BURGMANN manufactures a full range of CONNEX metal expansion joints customised to the specific needs of the process/chemical industries and the energy/power sectors - providing an optimum balance between flexibility and pressure. KE-BURGMANN manufactures bellows from longitudinally welded cylinders. As standard, multi-layered bellows are made by combining and joining several longitudinal cylinders inside each other. Multi-layered bellows can also be made from an inside welded cylinder with additional layers wrapped around it (spiral wrapped). Because our forming methods are highly flexible, we can offer a wide range of bellows shapes configured with almost any number of convolutions and various convolution heights, pitches etc. We are therefore always able to optimise the bellows design with respect to parameters such as spring rates etc. In addition to the standard types found in our tables, our product range covers a full range of individually calculated and manufactured expansion joints Manufacturing capability Diameter: DN40 and upwards Convolution heights: 8-60 mm (diameter dependant) Thickness: mm single layer and up to 15 layers 1.0 mm (diameter dependant) Manufacturing disciplines Our manufacturing disciplines entail: 1. Code calculation (according to the standards defined by EJMA, ASME, AD Merkblatt 13, Stoomwezen, SA etc..) 2. Bellows forming 3. Welding engineering Using these disciplines the following manufacturing procedures, specific to KE-BURGMANN, are the fundamental basis of our manufacturing procedures: 1. Dimensional drawing of the expansion joint 2. Manufacturing specifications of bellows 3. Welding specifications (WPS) 4. QA specifications

7 F12 (GB) Manufacturing technique and product range CONNEX metal expansion joints - Product range A full range of standard and special metal bellows from DN40 to DN2000; width 10 to 50 mm; length 30 to 1500 mm; thickness 1 to 15 layers in thicknesses from 0.3 mm to 3 mm CONNEX metal expansion joints - available configurations See below IMPORTANT NOTE: Dimensions between the standard DN dimensions can be manufactured at no extra cost! Available configurations Axial Lateral Angular UNO/DUO/TRIO UNO/DUO Hinged UNO Hinged DUO Gimbal UNO Gimbal DUO DN PN Universal Pressure balanced Corner Relieved DUO/TRIO 3) 4) ) depending on diameter 2) depending on material 3) special three bellows construction 4) two or three bellows construction Burst Pressure (1 BarG Temperature (2 C Quality Standards KE-BURGMANN is approved to the ISO 9001 quality standard. Our quality assurance system covers written procedures and defines minimum quality standards for our manufacture of expansion joints, from the selection of material through manufacturing and testing to preparation for delivery. OUR QUALITY OBJECTIVE IS DEFINED AS: Expansion joints manufactured and installed in KE- BURGMANN' name shall meet the requirements and expectations of our customers. A copy of our quality assurance procedures is available on request. At the enquiry stage customers are requested to use our Metal Expansion Joints Specification and Data Sheet to ensure that all requirements relating to the configuration and design are known by KE-BURGMANN and can be considered in the design. As stated in our quality assurance procedures, we carry out extensive testing and control with all metal expansion joints manufactured by KE-BURGMANN. Our testing procedures include the application of non-destructive tests to our entire range of metal expansion joints. Sleeve/ shroud Int/ext. Int/ext. Int/ext. Int/ext. Int/ext. Int/ext. Int/ext. Int/ext. Int/ext. Material Re. Table Re. Table Re. Table Re. Table Re. Table Re. Table Re. Table Re. Table Re. Table Movement AX LAT Ang 1 One All Ang 2

8 F12 (GB) Nomenclature 1.3 Nomenclature: Absolute diameter Diameter of the expansion joint. Not to be confused with nominal diameter, e.g. the nominal diameter of DN 700 is mm. AN Type designation for a hinged expansion joint. Can be of UNO, DUO or TRIO type. AX Type designation for an untied expansion joint. Can be of UNO, DUO or TRIO type. Bellows tangent diameter Inside diameter of the straight section of a bellows. Bellows Convoluted pipe consisting of one or more layers of bellows material. If the bellows only is supplied it is delivered in the compressed condition. Built-in length The delivered length of the expansion joint. Bördel flanges See: Van Stone. Cardan See: Gimbal. Control rods Bars or rods primarily used to distribute the movement between the two bellows of a DUO expansion joint. Control rods are not designed to restrain bellows pressure thrust. Convolution height The height of the convolutions measured from the outside - preferably with a slide gauge. Convolution pitch Distance between the convolutions measured from e.g. top-to-top. Convolutions The number of convolutions in a complete bellows. The number is always calculated on the outside Compression Contractive movement of the bellows (-). Cover External protection. Also referred to as a shroud Cycles Expected number of allowed full movement cycles calculated according to EJMA. Note: Unless otherwise stated, it is assumed that the movements are not in combination. Design pressure Pressure at which expansion joint parameters are calculated. DUO Expansion joint with 2 bellows connected by an intermediate pipe. Double hinge Allows the DUO expansion joint to absorb lateral and angular movements in one plane only without transferring reaction forces to the pipe system. Dye penetration test NDT method for detecting surface cracks. A coloured liquid is applied to the weld or surface. Reveals surface cracks. Expansion joint A bellows complete with end connections. Fixed flanges Flanges welded directly onto the bellows. Suitable for high pressure and facilitates replacement. Floating flanges Loose flanges. Full bore bellows A bellows in which the inside diameter is equal to the bellows tangent diameter. These bellows are usually manufactured using a hydraulic process. Gimbal unit Same as a hinge construction except for the fact that the angular movements can be absorbed in two planes. GM Type designation for a gimbal expansion joint. Can be used for UNO and DUO types. Hinge Allows the expansion joint to absorb angular movements in only one plane without transferring reaction forces to the pipe system. Inner sleeve/liner/baffle Straight pipe inside the expansion joint. Protects the bellows

9 F12 (GB) Nomenclature from particles in the medium. Can provide a smoother flow at high velocities. Can be installed as single or telescopic construction and may be of loose or fixed type. Inside diameter The diameter of free passage measured inside the bellows. Intermediate pipe Section between the two bellows in a double bellows construction. Consists of either a separate pipe or, for lower pressure operation, a simple bellows material (TRIO type). Loose flanges See: Van Stone. Lap flanges joints See: Van Stone. LAT Type designation for a tied expansion joint. Can be of UNO, DUO or TRIO type. Leak test Test to establish expansion joint tightness. Limit rods Typically, these are bars welded to the end connections and used to prevent the expansion joint from axial overstress. Designed to retain full pressure thrust. Membrane The thin layer(s) within the bellows. Neutral length The length assumed by an expansion joint when it is released from all restraints. Nominal diameter Nominal size of the expansion joint. Nominal pressure Pressure rating at 20 C. Note that the design pressure for the bellows may vary from the NP (Nominal pressure). Outside diameter Diameter of the bellows measured from the outside. Pantograph linkage A scissors like device. Primary function is to distribute the movement evenly between the two bellows in a DUO construction. Pre-setting Extending the expansion joint above its neutral length allowing it to absorb larger movements or e.g. operate closer to its neutral length. In this way smaller forces on the pipeline and longer operating spans are imposed. Compression (-), extension (+). Pressure test Test of expansion joints pressure integrity. Normally carried out at 1.5 x design pressure. Pressure thrust Force generated from the internal pressure on the active surface of the bellows. Shroud Pipe on the outside of the bellows to protect the bellows membrane from its surroundings. Available as single or double construction and detachable. Spring rate The resistance of a bellows to move - measured in N/mm or Nm/. Stub ends See: Welding ends. Tie rods Bars fitted with spherical washers to prevent reaction forces being imposed on the pipe system. Designed to retain full pressure thrust. Torsion Angular movement around the bellows central axis. Such movement is not recommended. A torsional moment can be absorbed in the bellows. Please contact KE-Burgmann in such cases. TRIO Expansion joint with two bellows connected by the same bellows material and manufactured from one cylinder. Turnable flanges Loose flanges. Van Stone ends Popular end connections for pressures up to 16 barg. Easy installation. Easy recycling of flanges. More economical than fixed flanges. Media does not come into contact with the flange material. Weep holes Small holes drilled in the coned section of the inner sleeve. The purpose is to prevent a build up of material between the convolutions. Often a neglected option. Welding ends Cheapest and most common type of connection method. Suitable for both high and low pressures. Used as filler material. Welding band 1 mm thick band, resistance welded to the bellows prior to mounting the end connections. X-ray Radioactive examination of welding seams.

10 F12 (GB) Technical Information and Bellows Theory 2. Technical information and bellows theory 2.1 How a metal expansion joint bellows works 2.2 Metal expansion joint bellows design parameters Operating conditions and critical parameters Temperature Pressure Medium, Flow and Sleeve Bellows design criteria Pressure stress Deflection stress Bellows stability The effect of fatigue on bellows life - movement cycles Spring rates Bellows design variables and their effect on bellows performance 2.3. End connections and Sleeves End Connections Loose flanges Welding ends Fixed flanges Sleeves 2.4. Movements and their definitions Axial movement Lateral movement Angular movement Torsional movement Movements in combination Pre-setting an expansion joint 2.5 Materials Technology Materials in stock Calculating the coeffient of thermal expansion Calculating the maximum allowed pressure at a given temperature Calculating the maximum allowed pressure for a given material quality Material properties temperature table

11 F12 (GB) How a metal expansion joint bellows works 2.1 How a metal expansion joint bellows works In its basic form the bellows acts like a flexible seal. It must therefore be designed to withstand the forces characteristic of the operating system, such as pressure and temperature, and at the same time it must be sufficiently flexible to absorb the applied movements. The number of convolutions included in a bellows design depends on the amount and type of movement for which the bellows must compensate and/or on the reaction force incurred. In addition to the forces generated in the bellows due to movement it is also important to understand the principles of the basic forces acting on the bellows. The bellows has to be strong enough circumferentially to withstand the operating pressure and at the same time it must have sufficient flexibility to respond to movement. Two very important parameters in this respect are the pressure thrust and the spring rate of the bellows. One way to illustrate the effect of pressure thrust is to model a single bellows as a hydraulic cylinder with a spring inside. The hydraulic piston represents the effective area of the bellows and the spring represents the spring rate of the bellows. The force (F) generated over the bellows acting on adjacent piping anchors can then be calculated as: F = Operating pressure x effective area spring rate x axial movement. Example of pressure thrust F It should be noted that the effect of the pressure thrust is normally much higher than the effect of the spring rate, but that for some applications the effect of the pressure thrust can be eliminated by adding tie rods, hinges etc. Example Operating pressure: 5 BarG = 5 x 10 5 Pa Effective area: mm 2 Spring rate Ax: 100 N/mm Ax Movement: -15mm (compression) F = 5 x x (100 x 15) = N F

12 F12 (GB) Metal expansion joint bellows design parameters 2.2 Metal expansion joint bellows design parameters Operating conditions and critical parameters Temperature The maximum and minimum design, operating and installation temperatures should be accurately stated. In situations where the ambient temperature is expected to vary significantly during pipe line construction, special care in expansion joint positioning may be necessary. Pressure The system design pressure, operating pressure and test pressure should be specified realistically without the addition of arbitrary safety factors, because this practice necessitates greater bellows material thickness to withstand the overstated pressures. This in turn may have an adverse effect on the fatigue life of the bellows. Standard expansion joints are designed for nominal pressure (PN) and are listed in PN pressure steps in the product type designation programme. For standard metal expansion joints the PN (nominal pressure) factor can be defined as the allowed positive operating pressure at room temperature. If the temperature is increased, the allowed PN factor is proportionately decreased to compensate for the reduction in the material resistance values typical of the material being used. The design pressure for the bellows may in general vary from the PN. Medium, Flow and Sleeve The bellows material specified must be compatible not only with the flowing medium, but also with any water treatment or pipeline cleaning chemicals that may be used, and with the external environment at the operating temperature. Due consideration should also be given to all possible corrosion effects, particularly stress corrosion. If the flowing medium is a powder that can compact, or a liquid or a slurry that may solidify or deposit solid particles in the line, then provision should be made to prevent entrapment or solidification in the convolutions which could result in serious damage to the expansion joint or pipeline. Internal sleeves are usually installed in the direction of flow. It is obviously undesirable that any of the fluid material should be trapped behind the sleeve. To avoid this we recommend that drain holes, drilled into either the sleeve or the purge connections should be specified. Where back-flow will be encountered, an extra heavy sleeve should be specified to prevent buckling of the sleeve and to obviate possible damage to the bellows. In applications where the gas or fluid in an expansion joint is traveling at high speed, the use of a sleeve is highly recommended Bellows design criteria The design of a bellows is complex in that it involves an evaluation of pressure related stress, stress due to deflection, fatigue life, spring forces and instability (squirm). The determination of an acceptable design is further complicated by the numerous variables involved such as diameter, material thickness, pitch, height, number of plies, method of reinforcement, manufacturing technique, material type and heat treatment. In many cases, the most successful design for a particular

13 F12 (GB) Metal expansion joint bellows design parameters application will involve a compromise between conflicting requirements. A bellows design should always be based on the expected temperature of the bellows metal during operation. In this section a short description of the different bellows design criteria is presented to allow the reader to study a specific EJMA calculation. The table at the end of this section presents the different design variables and their effect on the properties of the bellows. Pressure stress A major source of stress in a bellows is due to the effects of pressure. Pressure produces circumferential (hoop) membrane stress in the bellows tangent and convolutions. Reference to this kind of stress is made in the EJMA codes S1 and S2 respectively. Meridianal membrane and bending stress is also produced in the convolutions by pressure. This kind of stress runs in the longitudinal direction of the bellows. Reference: EJMA codes S3 and S4. S4 S1 Deflection stress Both membrane and bending stress can be caused in a bellows by deflection in the longitudinal direction. Reference: EJMA codes S5 and S6. S6 S3 P S5 S2 Pressure Convolution shape after deflecting Bellows stability Excessive internal pressure may cause a bellows to become unstable and this could culminate in the condition called 'squirm'. Squirm is detrimental to bellows performance in that it can greatly reduce both resistance to fatigue and pressure capacity. The two most common forms are column squirm and in-plane squirm. Column squirm Column squirm is defined as a gross lateral shift of the centre section of the bellows. It results in curvature of the bellows centerline as shown. This condition is mostly associated with bellows which have a relatively high length-to-diameter ratio and is analogous to the buckling of a column under compressive load. In-plane squirm is defined as a shift or rotation of the plane of one or more convolutions such that the plane of these convolutions is no longer perpendicular to the axis of the bellows. It is characterised by tilting or warping of one or more convolutions. This condition is predominantly associated with high meridianal bending stress and the formation of plastic In-plane squirm

14 F12 (GB) Metal expansion joint bellows design parameters hinges at the root and crest of the convolutions. It is most common in bellows which have relatively small length-todiameter ratios. A U-shaped bellows wall design combines the best performance criteria of all the different potential cross-sections because it permits great deflection and superior pressure containment capacity. One method of providing an increased internal pressure capacity, if this should be required, is to add external reinforcement to the U-shaped bellows. External reinforcement offers circumferential restraint and supports the root radius against collapse from internal pressure loading. The pressure capacity of a bellows can also be improved by the use of multi-ply construction or by increasing the thickness of the bellows; however, increasing bellows thickness can significantly reduce the bellows life due to increased fatigue. The effect of fatigue on bellows life - movement cycles The life of a bellows is influenced by the fatigue created as a result of the combined stresses imposed by pressure temperature, and deflection. The life of the bellows for a given configuration and material thickness will be a function of the imposed pressure and deflection. Most expansion joints are designed so that they will take a permanent set at the rated movement. This means that there will be a finite numbers of cycles before the bellows will eventually fail due to fatigue. Thicker plies Thinner plies More plies Fewer plies Higher convolutions Lower convolutions More convolutions Less convolutions Larger diameter Smaller diameter Pressure Hoop stress Pressure meridional stress Deflection meridional stress Inplane squirm stability Legend: = increase, = decrease, = same Column squirm stability It is important to state a realistically small number of cycles to failure at the design stage. To design around a high number of cycles could well justify the use of a soft bellows that may make the joint susceptible to squirm instability. In such cases further design considerations must be observed to account for this. Spring rates The spring rate expresses the flexibility of the bellows or its resistance to movement and calculations of its value for the different movements are based on the chosen bellows design. The force required to move the bellows can be calculated as movement x spring rate and a bellows will have different spring rates for the axial, lateral and angular movements. When specific spring rates are required it is important first of all to compare them with the generated pressure thrust, bearing in mind that the pressure thrust is often much higher than the force generated from the spring rate. A very soft bellows may solve one problem but this feature may well be in conflict with its ability to absorb pressure stress Bellows design variables and their effect on bellows performance The chart below provides an overview of the different basic design variables and their effect on bellows performance. When comparing the different variables and their effects, other parameters such as the total wall thickness must always be considered. Vacuum stability Cycles Rated axial mov. Rated lateral mov. Axial spring rate Lateral spring rate Torsional moment resistance

15 F12 (GB) End connecdtions and Sleeves 2.3 End connections and sleeves End Connections Loose flanges: LOOSE FLANGES / V AN STONE + _ - easy installation - flanges not in contact with medium - possible connection of non-weldable materials - lower costs compared to fixed flanges - no circumferential welding seams - recycling of flanges - permits galvanisation/coating of flanges - gaskets can often be left out - only suitable for low pressures - only loose sleeve possible + _ - easy installation - flanges not in contact with medium - possible connection of non-weldable materials - recycling of flanges - permits galvanisation/coating of flanges - fixed sleeve possible - gaskets can often be left out LOOSE FLANGES / L AP JOINTS - More costly than Van stone flanges + _ - easy installation - flanges not in contact with medium - possible connection of non-weldable materials - recycling of flanges - permits galvanisation/coating of flanges - gaskets can often be left out - fixed sleeve possible LOOSE FLANGES / W ELDED RING - More costly than Van stone flanges

16 F12 (GB) End connecdtions and Sleeves Welding ends: - low cost - simple Fixed flanges: - easy to install - easy to replace WELDING ENDS + _ - requires skilled installation - requires on-site welding and inspection FIXED FLANGES + _ - flanges in contact with medium - usually requires gaskets - relatively high cost

17 F12 (GB) End connecdtions and Sleeves Sleeves The use of inner sleeves is recommended for use in situations where it is necessary to Protect the bellows from wear caused by abrasive media. A heavy gauge sleeve must be used for this type of duty; Protect the bellows from flow-induced bellows resonance or vibration; Reduce the frictional resistance of the medium; Prevent turbulence due to high flow velocity; Enable the expansion joint to function properly in high temperature applications in which it is required that the bellows material operates at a reduced temperature. v m/s v Gas v Fluids When there is a risk of media building up on the bellows side of the sleeve, such devices should be used only as a last resort - even so, great caution should be exercised in their application. In fact, as a general rule, the use of a sleeve in such cases should be avoided. General EJMA recommendations for the use of an inner sleeve in terms of media, flow velocity and diameter are: See below 0 DN 40 DN 80 DN 150 DN 250 DN 600 DN 1000 t v= velocity m/s t= min. recommended sleeve thickness In applications where velocities in excess of 30 m/s or turbulent, non-uniform, flow are possible contact KE-BURGMANN t mm 2,5 1,5 1,2 0,9 0,6 Dia. mm

18 F12 (GB) End connecdtions and Sleeves - protection of bellows - weep holes possible - optimum protection of bellows SINGLE SLEEVE + _ - reduction of flow diameter DOUBLE SLEEVE + _ - protection of bellows - enable inspection of bellows interior - reduction of flow diameter - more costly than single sleeve LOOSE SLEEVE + _ A Sufficient distance must be provided to allow full lateral movements - more costly than fixed sleeve - can require gasket IMPORTANT B If the joint is compressed beyond the indicated distance (B), the sleeve will touch the adjacent connection A B

19 F12 (GB) Movements and their definitions Expansion joints may be subjected to: axial movement (i.e. the various dimensional changes which an expansion joint is required to absorb, such as those resulting from thermal changes in a piping system) 2.4 Movements and their definitions angular rotation lateral deflection; or any combination of these. The movements are defined as follows: Axial movement Axial movement (+) (-) Axial movement may be referred to as Compression (-): the decrease in length of an expansion joint along its longitudinal axis, and Elongation/Extension (+): the increase in length of an expansion joint along its longitudinal axis. The maximum rated axial movement for CONNEX metal expansion joints is expressed as + value 1 / - value 2. The total axial displacement is the span from value 1 to value 2 and any pre-setting can be made within these limits Lateral movement Lateral offset (-) (+) Lateral movement may be referred to as Lateral Offset or Deflection (±) - the relative displacement of the two ends of an expansion joint perpendicular to its longitudinal axis. In reality, lateral deflection is a special case of angular rotation. The two bellows in a universal type expansion joint, or each end of the bellows of a single type expansion joint, rotate in opposite directions to produce the total lateral deflection. Lateral deflection in UNO types results in unequal distribution of movement over the bellows, the amount of displacement increasing with the distance from the centre of the expansion joint. The maximum rated movement for a Connex metal expansion joint is expressed as the absolute value resulting from lateral deflection in the y and z directions Angular movement Angular offset (+) (-) Max. lateral movement, any direction Angular movement may be referred to as Angular Rotation or Rotational Movement - the displacement of the longitudinal axis of the expansion joint from its initial straight line position into a circular arc. The expansion joint bellows absorbs pure angular rotation by extending uniformly on one side and compressing uniformly on the other. Angular movement initiates a column squirm. Compensation is made for this in the design calculation taken from the EJMA handbook, 7th edition. The maximum rated angular rotation for Connex metal expansion joints is expressed as the absolute value whether plus or minus. Max. angular movement, any direction

20 F12 (GB) Movements and their definitions Torsional movement Torsional movement may also be referred to as Torsional Rotation - the twisting of one end of the expansion joint with respect to the other end about its longitudinal axis. Such twisting generally produces extremely high shear stresses in the bellows. Torsional movement should be avoided!! Please contact KE-BURGMANN if any torsional movement or moments could be created in the system that the expansion joint will be required to absorb Movements in combination Combining movements to be absorbed in an expansion joint may be expressed as axial compression (x), lateral deflection (y) and angular rotation ( ) occurring in the same plane. The specified axial and lateral values are all maximum values, calculated for a minimum of 3000 full cycles. It is possible to exploit the ability of an expansion joint to take up movements in more than one direction by using various expansion joint combinations. This is best illustrated in an axis diagram, where the maximum axial and lateral movements are indicated. When combining the movements within the diagram, the required main movement (axial or lateral) will set a limit to the maximum allowable secondary movement. By keeping within the allowed combinations, the functionality and service life of an Movements in combination Lateral mm cycles 5000 cycles x Axial mm expansion joint may be exploited to its full potential. The individual life time value (max. cycles) for an expansion joint may be read from the diagram directly Pre-setting an expansion joint Ex. of pre-setting Neutral, length Build in length The movement diagram also defines in which area the expansion joint can operate. If the operating point lies outside the defined movement area, and if the expansion joint is installed in its normal length at delivery (neutral length), it may be preset during installation. This will move the operating point inside the allowed movement area. Full movement potential of the expansion joint and the consequent extension of its lifetime can be achieved by pre-setting the expansion joint even further in the axial direction. By pre-setting expansion joints laterally at the same time, the optimum operating conditions for the expansion joint are achieved and thereby the longest life. Movements with presetting Lateral mm y y y cycles 5000 cycles Lateral mm 1 Equal to presetting of +10 Ax, 5 LA x x 1 Neutral Preset Axial mm Axial mm

21 F12 (GB) Materials TEchnology 2.5 Materials technology Materials in stock KE-BURGMANN carries a full stock of standard steel qualities such as AISI 309, 316Ti, 321 (as plates) and St 35.8 & AISI 316 Ti (as pipes). In addition we hold a stock of Hastelloy C276, Inconel 600, 253MA etc. These qualities are adequate to cover the majority of standard applications. Special material types are available on request. The following parameters are vitally important in selecting the material quality best suited for the construction of bellows for any special purpose: Forming ability; Welding ability; Temperature resistance; Material stability; Corrosion resistance Our standard materials are carefully chosen to comply with the above requirements. Application dependent parameters that are important factors in material selection include: the expansion ratio of the actual pipeline the interrelation of pressure and temperature; and the interrelation of pressure and material values Calculating the coefficient of thermal expansion The thermal elongation of a pipeline exposed to a thermal load may be calculated by using the coefficient of expansion (α) for the metal in question. Coefficient of expansion (α) Reference temperature = 20 C The elongation/expansion can then be calculated as follows: L t α = L x t x α x 0.01 where: = expansion = total length of the pipeline = temperature difference ( C) = coefficient of expansion Calculating the maximum allowed pressure at a given temperature DIN Temperature C Factor Kt 20 C C C C C C C C C C C C C All the standard CONNEX metal expansion joints in the charts at the end of this catalogue are designed for a temperature of 120 C and exhaust for 550 C. Please note that for standard materials, such as stainless steel / AISI 321, mechanical stability will be reduced if the temperature exceeds 120 C. It is possible to calculate the maximum allowed pressure for these steel qualities by using a Kt factor, which is defined as the ratio of allowed tension at the required temperature to that at 120 C. Temperature C Ferritic Carbon steel Austinitic Stainless steel

22 F12 (GB) Materials TEchnology Allowed pressure = P(120 ) x Kt Calculation example: Would a standard CONNEX metal expansion joint, type AX-10(10) UNO, calculated at 120 C be the right choice for an application where the pressure is 6 barg and the temperature 300 C? Answer: Allowable Pressure = 10 x 0,823 = 8,23 barg therefore this design would still be suitable for use at this pressure and temperature Calculating the maximum allowed pressure for a given material quality Just as the choice of materials is influenced by the operating temperature of the system so too is it influenced by the pressure in that system. If material qualities other than those of or AISI 321 are used, it is possible to calculate the maximum allowed pressure by using a factor Kw, which is defined as the ratio of the allowed stress at 120 C for the chosen stainless steel and allowed stress at 120 C for /AISI 321. Material Factor Kw / AISI / AISI 304 L / AISI / AISI / AISI 316 L / AISI 316 Ti DIN Allowed pressure = P(120 ) x Kw Calculation example: Calculate the max. allowed pressure for a CONNEX metal expansion joint, type AX-10(10) UNO in /AISI 316 L (standard steel quality would have been /AISI 321)? Answer: P = 10 x 0,938 = 9,38 barg Please refer to our Materials Table for temperature values for the individual metal qualities Material properties temperature table Depending on the required properties for temperature resistance, pressure resistance, corrosion resistance etc., CONNEX metal expansion joints can be manufactured from any of the materials mentioned in the table below. Main type Material Name AISI Recom. No. Operating limit in C None/low/Alloy St St St St St H II 480 Ferritic Mo CrMo CrMo Austenitic X5CrNi X2CrNi L X10CrNiTi No. Austenitic + MO X5CrNiMo X5CrNiMoTi Ti X2CrNiMo L Avesta 254 SMO 400 Heat resistant X15CrNiSi Austenitic Avest 253 MA Incoloy Incoloy 800H 900 Nickel based Alloy Incoloy Inconel Hastelloy C Hastelloy C

23 F12 (GB) General Overview of CONNEX types 3. General overview of CONNEX types 3.1 CONNEX metal expansion joint types, type designation and selection guide General type designation Product type designation system Metal expansion joint types Single expansion joint Universal expansion joint Hinged expansion joint Gimbal expansion joint Pressure balanced expansion joint In-line pressure balanced expansion joint Selection Guide - CONNEX metal expansion joints

24 F12 (GB) CONNEX metal expansion joint types, type designation and selection guide 3.1 CONNEX metal expansion joint types, type designation and selection guide General type designation Product Type Designation System GENERAL T YPE D ESIGNATION General type Type designation Ties Type Single AX None UNO LA Tie rods UNO AN Hinges UNO GM Gimbal UNO Double/Universal AX None DUO/TRIO LA Tie rods DUO/TRIO AN Double hinges DUO/TRIO GM Double gimbal DUO/TRIO Inline pressure PB Tie rods TRIO balanced Pressure balanced LB Tie rods DUO/TRIO elbow/ Corner relieved CONNEX metal expansion joints are manufactured as a wide range of standard types as well as in special designs, which are all described by a product type designation system. The product code ensures a quick and simplified method of selection. The product type designation consists of the following items: Type; Nominal pressure; Design pressure, Connection type; Nominal diameter; Neutral length; Accessories; and Model. (see overleaf)

25 F12 (GB) CONNEX metal expansion joint types, type designation and selection guide Pos. 1 Type Ex. AX Pos. 2 Nominal pressure Ex. AX 10 Pos. 3 Design pressure Ex. AX 10 ( 8 ) Pos. 4 Connection type Ex. AX 10 ( 8 ) S Pos.5 Nominal diameter Ex. AX 10 ( 8 ) S 250 Pos.6 Neutral length Ex. AX 10 ( 8 ) S Pos.7 Accessories Ex. AX 10 ( 8 ) S SL Pos.8 Model Ex. AX 10 ( 8 ) S SL UNO AX = axial LB = pressure LA = lateral balanced elbow/ AN = angular corner relieved GM = gimbal PB = inline pressure balanced PN = pressure step Design pressure in barg S = weld ends F = fixed flanges B = loose flanges DN = nominal diameter Ln = the neutral length of the expanson joint SL = single sleeve DL = double sleeve SC = single cover DC = double cover UNO = single bellows DUO = double bellows TRIO = "three" bellows Spec = special type acc. to drawing

26 F12 (GB) CONNEX metal expansion joint types, type designation and selection guide Metal expansion joint types Single expansion joint: Single expansion joint This is the simplest form of expansion joint. It is a single bellows construction for the purpose of absorbing any combination of the three basic movements - axial movement, lateral deflection; and angular rotation - but most frequently, axial or angular motion. Where small thermal movements are involved and where proper anchoring and guiding are feasible, a single expansion joint will provide the most economical solution. However, such a joint will require the maximum of guiding, anchoring and installation supervision. A common use of the single expansion joint is the absorption of the axial movement of a straight pipe between main anchors. The joint should be placed near one anchor and guides are recommended to ensure its proper alignment and to control its movement. In some cases, a single expansion joint can be used to absorb small amounts of lateral movement. A directional main anchor must then be used to absorb the pressure thrust. Universal expansion joint: Universal expansion joint A universal expansion joint consists of two bellows joined by a common connector, a configuration that will absorb any combination of the three basic movements: axial, lateral; and angular. Universal expansion joints are normally provided with tie or control rods (a tied universal expansion joint) to distribute the movement between the two bellows of the expansion joint and eventually to stabilize the common connector. A tied universal expansion joint can absorb large amounts of lateral deflection while absorbing the pressure thrust forces. An important advantage of this type of expansion joint is that the piping system does not have to be in one plane, the two horizontal legs may lie at any angle in the horizontal plane. An untied universal expansion joint (without tie or control rods) would be recommended for the absorption of significant amounts of lateral movement because this type of expansion joint will minimize the magnitude of the forces exerted on the anchors. Hinged expansion joint: Hinged expansion joint Typically, a hinged expansion joint consists of either one or two bellows in a double hinge design, and, by the use of a pair of pins through the hinge plates attached to the expansion joint ends, it will permit angular rotation in only one plane. The hinges and hinge pins must be designed to restrain the thrust of the expansion joint in response to internal pressure and extraneous forces, where they are present. Hinged expansion joints are often used in sets of two or three in order to function properly. Where the flexibility of the piping in a single plane system is not sufficient to absorb the thermal expansion of the spool, a system of three, hinged expansion joints may be used. In this system, the combination of expansion joints absorbs all the thermal expansion of the piping, thus preventing its deflection. This system produces the lowest forces possible on the intermediate anchors and guides. The amount of lateral movement that can be absorbed by a system containing a set of hinged expansion joints depends on the distance between the hinge pins. This distance should therefore be as large as possible, in order to exploit the hinge system to its best advantage. If the thermal movements of a piping system occur in only one plane, the use of hinged expansion joints will provide the most efficient method of absorbing them.

27 F12 (GB) CONNEX metal expansion joint types, type designation and selection guide Gimbal expansion joint: Gimbal expansion joint Gimbal expansion joints are designed to permit angular rotation in any plane by the use of two pairs of hinges attached to a common floating gimbal ring. The gimbal ring, hinges and pins must be designed to restrain the thrust of the expansion joint due to internal pressure and extraneous forces, when they are present. This type of construction ensures close control of the movement imposed on the bellows. In case of external loadings such as wind, shear and dead weight loads shall be transmitted through the gimbal it must be clearly stated at the time of an inquiry. Other advantages include low forces and the elimination of pressure thrust on adjacent equipment. Gimbal expansion joints are used either in pairs or in combination with a hinged expansion joint to absorb complex multiplanar movement in a piping system. Furthermore, gimbal expansion joints offer the best possible system for eliminating the effects of thermal expansion; they minimize reaction forces while simultaneously curtailing installation costs because expensive main anchors are unnecessary and only minimal guiding is required. Pressure balanced expansion joint Pressure balanced expansion joint Pressure balanced expansion joints are designed to absorb axial movement and/or lateral deflection simultaneously restraining the pressure thrust imposed on the system. This is achieved by using tie devices to inter-connect the flow bellows with an opposed bellows that is also subjected to line pressure. As the flow bellows is compressed, the tie devices make the balancing bellows extend an equal amount. Since there is no change in the volume of the system, the pressure forces remain in balance. The most common application of the pressure balanced elbow expansion joint is next to a piece of equipment such as a pump or turbine. When substantial amounts of lateral movement are expected, or when the lateral force must be held to a minimum, it is recommended that a pressure balanced universal expansion joint be used with two bellows at the flow end of the expansion joints and a single bellows in the balancing end. In-line pressure balanced expansion joint: In-line pressure balanced expansion joint In-line pressure balanced expansion joints absorb axial movement and/or lateral deflection while restraining the pressure thrust on the system. This is achieved by means of tie devices interconnecting the line bellows with outboard compensating bellows that are also subjected to line pressure. Each bellows set is designed to absorb the axial movement and the line bellows will usually absorb the lateral deflection. Pressure forces that are normally present in a piping system containing bellows expansion joints are not generated when this form of construction is used because the volume changes in the piping system are of equal values. These expansion joints are used where the location of the expansion joint prohibits or makes it very costly to install main anchors. Please refer to the CONNEX expansion joints selection chart for an overview relating to the above guide lines (see overleaf).

28 F12 (GB) CONNEX metal expansion joint types, type designation and selection guide Selection Guide - CONNEX metal expansion joints E XPANSION J OINT S TYLE AX UNO LA UNO AN UNO GM UNO AX DUO LA DUO AN DUO PB TRIO LB DUO M OVEMENT C APABILITIES Axial Lateral Angular - one direction Angular - multi-direction S PRING F ORCES Axial Lateral Angular Restrains pressure thrust forces Legend: yes no high medium Low Use Primarily axial movements Limited lateral offset Only lateral movements Limited lateral offset Angular movement in one plane Angular movements in multiple planes Axial, lateral and angular movements Primarily lateral movements Lateral or angular movement in one plane Axial and lateral movements Installed in straight runs of piping system Axial and lateral movements Installed where change of direction occurs in a run of pipe FEATURES Advantages Low price Small building length Easy to preset Easy to install Easy to install Easy to preset Eliminates pressure thrust forces on piping system Easy to install Eliminates pressure thrust forces on piping system Low forces on piping system Easy to install Eliminates pressure thrust forces on piping system Low forces on piping system Any movement in axial, lateral and angular direction Easy to install Low forces on piping system Eliminates pressure thrust forces on piping system Low forces on piping system Eliminates pressure thrust forces on piping system Low forces on piping system Eliminates pressure thrust forces on piping system Eliminates pressure thrust forces on piping system Remarks Simplest and most commonly used expansion joint Commonly used when pressure thrust must be absorbed Often used in sets of 2 or 3 Often used in sets of 2 or 3 Very common in low pressure application for all purposes Can absorb large lateral deflection Limited ability for dead weight support Flexible at high pressure applications Compact solution

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45 F12 (GB) Special designs 5. Special designs 5.1 Rectangular metal expansion joints 5.2 Metal expansion joints with deep convolution

46 F12 (GB) Rectangular metal expansion joints 5.1 Rectangular metal expansion joints KE-BURGMANN offers a wide range of rectangular metal expansion joints: Single / multi-layer Made from austenitic / ferritic materials Various convolution geometries Round, camera, or miter corners UNO and DUO types Axial, lateral, angular/gimbal types Full EJMA calculations including: pressure capability, spring rates etc. For specific information please contact KE-BURGMANN.

47 F12 (GB) Metal expansion joints with deep convolutions 5.2 Metal expansion joints with deep convolutions KE-BURGMANN offers a range of deep convoluted metal expansion joints: Single / multi-layer Made from austenitic / ferritic materials Various convolution geometries UNO and DUO types Axial, lateral, angular/gimbal types Calculations according eg. EJMA, ASME, AD etc. For specific information please contact KE-BURGMANN.

48 F12 (GB) Pracitacal advice 6. Practical advice 6.1 Enquiry form

49 F12 (GB) Pracitacal advice 6.1 Enquiry form

50 F12 (GB) Quality assurance programme 7. Quality assurance programme 7.1 Quality assurance programme 7.2 ISO Certificate

51 F12 (GB) Quality assurance programme 7.1 Quality assurance programme KE-BURGMANN is approved to the ISO 9001 quality standard. We also operate a quality assurance system that covers written procedures and defines minimum quality standards for the manufacture of expansion joints, from the selection of material through manufacturing and testing to preparation for delivery. Our quality assurance system ensures a very high degree of safety for the customer in the quality of the product. NDT name: Description: Main use: As standard, all our products are manufactured to exceed a defined minimum quality by submitting them to rigorous testing and checking procedures. All materials used for bellows are supplied with a certificate of quality, the minimum being a 3.1B certificate. If our customers require it, our products can be manufactured and exposed to an extended degree of testing. The table below indicates the range of non-destructive test procedures (NDT) that are offered by KE-BURGMANN. Dimensional control Manual check of all dimensions. All important bellows dimensions. Visual inspection Visual inspection of welding seams and surfaces. All welds and surfaces. Dye penetration Colour penetration test for the detection of surface Bellows longitudinal welds and circumferential cracks and leakage welds for end attachments. Welds for welding ends, hinges etc. Very suitable and economical test for bellows longitudinal seam Ultra sound Ultra sound test for the detection of cracks. Longitudinal welds of thicker welding ends, intermediate pipes etc. X-ray X-ray test to detect cracks and hollow spaces. Bellows longitudinal welds. Can often be replaced by dye penetration to provide a better result. Magnetoflux Magnetic detection of surface cracks. Tests on magnetic surfaces. Pressure test Hydraulic test for leakage and tightness. Bellows tightness and resistance stability. 1.5 times operating pressure Leakage test Leakage test using air or water depending on Bellows tightness. pressure. Airpressure test of 0.8 BarG for 5 min as standard Nekal test Leakage test using Nekal fluid. Bellows tightness to Nekal standard.

52 F12 (GB) Quality assurance programme 7.2 ISO Certificate

53 E17 (GB) Shipping, storage and installation 9. Shipping, storage and installation 9.1 Shipping and storage 9.2 Installation instructions