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1 7
Bellows Design and Metal Leak Detection
Expansion Joint basics and PTFE Coating
• Quality • Leak Monitoring Bellows
• Reliability • PTFE - a Coating for Aggressive
• Flexibility Medias
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Axial, Lateral and Petrochemical and
Angular Types Styrene Processing
• For Movements in Pipelines • Extreme Pressure
with Pressure • High Operating
Temperatures
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FCCU, Continuous Catalytic
Ducting Expansion Joints Reforming and Turbo
Expander Units
• High Temperature
• Low Pressure • Large Thermal Offsets
• Abrasive Media
• High Temperatures
• High Pressures
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• Refractory Lined
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Rectangular District Heating
Ductings
• Large Movements
• Absorb Vibrations • High Pressure
in Rectangular Ductings
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Installation, Service
Pressure and Preventive
Balancing Maintenance
• Quality
• Reliability
• Flexibility
Metal expansion joints can be used Lateral Types pendicular to the end connections.
in closed piping systems with move- Lateral expansion joints are designed Lateral expansion joints are therefore
ments in the axial, lateral and angular to absorb movement as the two ends ideal for installation in pipe systems
direction or a combination of the three of the expansion joints are sheared with bends.
types. away from each other but are kept
parallel. Lateral expansion joints are
available with tie rods secured to the
Axial flanges by means of nuts and a special-
ly designed spherical washer, allowing
angular movement between bolt and
flange.
Lateral
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The external hardware absorbs the of a two hinge arrangements joined
pressure thrust force arising from the together by a floating central “gimbal”
operating pressure but makes axial ring, allows for angular rotation in all
expansion impossible. Angular expan- planes.
sion joints can only absorb bending
movements and are ideal when sturdy, Typical applications are:
fixed locations are not present in the • Power Plants
piping system. • Chemical Plants
• Pulp and Paper Plants
Hinged Types • Mining
Hinged expansion joints are designed to • Desulphurisation plants
Angular Types absorb angular movement in only one
Angular expansion joints are designed plane while restraining pressure thrust
with only one bellows; however mul- and any external loads that may be
tiple angular expansion joints can be applied
installed in a pipeline without a fixed
point in between. Gimbal Types
Gimbal expansion joints are designed to
Angular Expansion Joints are divided absorb angular movement in any plane
into two types: while restraining pressure thrust and
• one plane angular; a hinged type any external loads that may be applied.
• multiplane; a cardan or gimbal type. The gimbal assembly, which consists
3D drawing of a multiplane, angular expan- Multiplane, angular expansion joint with 3D drawing of a single plane, hinged
sion joint with gimbal and weld ends. gimbal. expansion joint.
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3
Ducting
Expansion
Joints
• High Temperatures
• Low Pressure
• Engines
• Boilers
• Turbines
• Ventilation
• Other low pressure systems
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4
Penetration
Seals
Pipe penetration seals are used to al- Metal expansion joints provide good
low tubes or pipes to expand thermally insulation between the boiler wall and
by penetrating the shell or pressure the attachment ring.
casing. It eliminates the leakage of heat
and other emissions, reduces noise Penetration Seal Expansion Joint Ad-
and protects maintenance personnel. vantages:
• Personnel are protected
• No leaks
• Reduces pipe stress
• Increased boiler efficiency Our new PS Seal® offers an increasingly
• Noise reduction effective boiler seal with easy installation and
• No maintenance lower maintenance costs.
• With insulation on request
Pipe penetration seals can accommo- As particulates build up in the seal and
date most applications from original further restricts passage of gas, any gas
manufacturer to retrofits of existing leakage in the seal increasingly reduc-
installations. High operating tempera- es over time. The stainless steel wire
tures typically keeps the temperature mesh seal can be replaced easily dur-
in the bellows warm enough to prevent ing shutdowns eliminating the need to
media from condensing. Corrosion can replace the entire unit.
occur if the media condenses and col-
lects in the lower end of the seal during PS Seals™ from KE-Burgmann EJS makes it easy
operation. to replace metal and fabric type bellow seals
without the need for specially trained welders
or installations technicians.
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5
Rectangular
Expansion Joints
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6 Pressure
Balanced
Turbine Crossover
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7 Leak Detection
and PTFE
Coating
Two Ply Testable Bellows PTFE into the most advanced versatile
A two ply testable bellows has two metal expansion joints on the market.
plies and each is independently desig-
ned for the full system design condi- The PTFE liner offers a relevant alter-
tions. native to use high alloy nickel materi-
als, eliminating the risk of stress cor-
rosion.
• Chemical Plants
When the expansion joint is instal- • Medical/Pharmaceutical Plants
led into the system the test ports are • Food Industry
used to detect any leakage. Gauges, • Pulp and Paper Industry
leak monitors, pop up detectors or • Many Other Industries
direct monitoring to the control room
can be attached to the test ports. The PTFE In-liner is excellent resistan-
ce to chemical attacks from:
• Chloride Water
• Diesel Oil
• Fuel Oil Acids
PTFE • Hydrochloride Acids
PTFE material can be added in ex- • Lubricating Oils
pansion joints where the media is • Saltwater
aggressive. PTFE is manufactured by • Ozone
KE-Burgmann. The foil is sintered and
A two ply testable design can be used laminated together. The PTFE tube is
to monitor the bellows for deteriora- welded inside the steel tube, and the
tion. This prevents unexpected shut- bellows corrugations are subsequent-
downs and allows you to plan mainte- ly formed into the tubes.
nance of the pipeline.
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8 Petrochemical
and Styrene
Processing
• Extreme Pressure
• High Operating Temperatures
Petrochemical and styrene process li- These expansion joints are commonly ded to the expansion joint by welding
nes require expansion joints to handle equipped with testing ports to detect in special stainless anchors. A form is
extreme pressures and operating tem- leakage in between two plies bellows made and liquidized concrete is added
peratures up to 926 deg C/1700 deg F. and/or have a refractory lining to elimi- between the form and the steel parts.
nate erosion from catalyst.
The refractory lining is often used at:
• Steel Plants
• Refineries
• Copper and Aluminum Smelters
• Cement Plants
• Galvanizing Furnaces
• Chemical Plants
Vertical piping system with hinged joints are Metal expansion joint with refractory lining
a commonly used configuration for styrene
processing.
Refractory Lining
Refractory lining can be added in ex-
pansion joints for high temperature ap-
plications.
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9 •
•
•
FCCU, CCR
and Turbo
Expander
Units
Metallic expansion joints are an inte- assembly. Its relatively thin wall con- With a great need to achieve higher
gral component of these complex re- struction is designed for maximum fle- performance and profitability, these
finery processes and their reliability xibility, but must be protected against expansion joints are critical to the
can be significant to the refinery’s pro- erosive catalyst and other corrosive overall success of the refinery.
ductivity and performance. An unex- media.
pected joint failure can represent mil- The high temperature Turbo Expander
lions of dollars in losses to a refinery. Expansion Joints for FCC Service fall is another important system within a
into three major categories: refinery that can have a significant ef-
Expansion joints used in FCCU service • Cold Wall fect on production profits. The losses
are some of the most critical and com- • Hot Wall Lined are extremely high to a refinery that
plex expansion joints manufactured. • Hot Wall Unlined must shutdown for major repairs to
Fluid Catalytic Cracking Units (FCCU) any equipment related to the expander
operate at very high pressures and Various types of expansion joints and such as the universal (double) hinged
temperatures, consequently resulting hardware (accessories) used in FCC or gimbaled expansion joints installed
in large thermal movements that must applications including: within the turbo expander piping sy-
be absorbed by the expansion joint. • Gimbled stem.
Furthermore, the introduction of abra- • Hinged
sive media (catalyst) requires additio- • Pressure Balanced As with the FCC and CCR processes,
nal protection to avoid gradual dete- • Pantographic Linkages this piping system requires experien-
rioration and premature failure of the • Restrained Universals ced professionals to provide expansion
expansion joint. joint designs to ensure long term safe-
Continuous Catalytic Reforming (CCR) ty, reliability and maintainability.
The bellows membrane is the most requires an unlined thin-wall, high al-
critical element of the expansion joint loy expansion joints to accommodate
high temperatures and movements.
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10 • High Temperature
Engines
and
Vehicles
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11 District
Heating
• Large Movements
• High Pressure
Danmuff® expansion joints have been DanOne® is a one cycle expansion joint
designed especially for installation in di- especially designed for district heating.
strict heating pipe systems. The expansion joint is mounted in-line
into the pipe system.
Danmuff®
The axial compressive forces in the DanOne®
pipe system can be transferred directly Once temperature has increased, the
through the media pipe without the bel- expansion joint will be compressed due
lows being overloaded. to the growth of the pipe system. The
expansion joint is secured by welding
If the temperature in the pipe system the outside casing to the pipe system.
drops significantly, the stresses in the
media pipe will be transferred to the The bellows is designed for only one cy-
stop ring through the outer casing pipe. cle. Afterward, the bellows is no longer
The expansion joint is pre-stressed 100% active. Future expansion in the pipe sy-
at the factory using break-away bolts. stem caused by fluctuations in tempe-
rature will be absorbed as tensile and
When the installation is put into opera- compressive stresses.
tion, the break-away bolts are initiated
distributing movement throughout the
expansion joint.
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12 Installation,
Service and
Preventive
Maintenance
• Improve Reliability
• Increase Service Life
• Worldwide Service Teams
02/01/01.rev0/09.10/GB
KE-BURGMANN BREDAN A/S KE-BURGMANN EJS
Metal Expansion Joint Division A Division of KE-Burgmann USA, Inc.
Odinsvej 1 10035 Prospect Ave. Ste 202
DK-6950 Ringkoebing Santee, CA 92071 USA