BOA Group

Axial Expansion Joints

Disassembly Joints

Assembly and Start-up Instructions

Table of
Contents
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8

General Information ................................................................................ 1

General Safety Notes ................................................................................ 1
Definition of Application ............................................................................ 1
Transportation, Packaging, and Storage ................................................... 1
Warranty .................................................................................................... 1
Manufacturer and Country of Origin .......................................................... 1
Description and Range of Application of Axial Expansion Joints .............. 2
Description of Disassembly Joints ............................................................ 2
Type Overview ........................................................................................... 3

2
2.1
2.2
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
2.2.8
2.3
2.4
2.5
2.6

Installation ............................................................................................... 4
Safety Instructions .................................................................................... 4
Installation Instructions ............................................................................. 5
Pipe Guides and Supports ........................................................................ 5
Anchors ..................................................................................................... 6
Vibration Compensation ............................................................................ 7
Movement Capacity .................................................................................. 7
Operating Pressure ................................................................................... 7
Pre-Stressing ............................................................................................ 8
Pre-Stressing Diagram .............................................................................. 9
Example to the Diagram ............................................................................ 9
Installation of Flanged Expansion Joints ................................................ 10
Installation of Pipes with Pressfittings .................................................... 10
Installation of Expansion Joints with Threaded Sockets ......................... 10
Installation of BOA Disassembly Joints .................................................. 11

3
3.1
3.2
3.3
3.4
3.5

Start-Up .................................................................................................. 12
Control ..................................................................................................... 12
Insulation ................................................................................................ 12
Unacceptable Modes of Operation .......................................................... 12
Start-Up of the System ........................................................................... 12
Maintenance ............................................................................................ 12

1 General
Information
Prior to assembly and commissioning, these
Assembly and Start-up Instructions must be
read carefully and observed.
Necessary assembly, start-up, and maintenance work may only be performed by
qualified and authorized personnel.

Warning !

Axial expansion joints are suited to compensate for axial expansion movements in
straight pipeline sections.
As a precondition for the various applications
of axial expansion joints, suitable anchors
and axial guides/supports must be present.
The application must be limited to the rated
conditions as stated in our technical data
sheets and the rating plates that are mounted

to each expansion joint.

These Assembly and Start-up Instructions
are valid for the types listed on page 3, Fig. 2.

Immediately upon receipt, the shipment

must be checked for completeness.
Any shipping damage must be reported to
the carrier and to the manufacturer.
In case of intermediate storage we recommend utilization of the original packaging
material.

Permissible ambient conditions during storage and transportation

- Ambient temperature: -4 C to +70 C
- Relative humidity: up to 95 %
The axial expansion joints and disassembly
joints must be protected against dampness,
humidity, dirt, shocks, and damage.

1.3 Transportation,
Packaging,
and Storage

A warranty claim requires proper assembly

and commissioning in accordance with these
Assembly and Start-up Instructions.

Necessary assembly, commissioning, and

maintenance work may only be performed
by qualified and authorized personnel.

1.4 Warranty

BOA BKT GmbH

P.O. Box 11 62
D-76288 Stutensee
Germany

BOA AG
P.O. Box 11 62
CH-6023 Rothenburg
Switzerland

1.5 Manufacturer and

Country of Origin

Prior to assembly and maintenance the

system must be
- depressurized,
- cooled down, and
- drained.

1.1 General Safety

Notes

1.2 Definition of
Application

Special care should be taken to avoid corrosion damages, e.g. in water treatment or
measures to avoid galvanic corrosion in
copper and galvanized pipes.

BOA Rating Plate

BOA Rating Plate

1 General
Information
1.6 Description and
Range of
Application of
Axial Expansion
Joints

1.7 Description of
Disassembly
Joints

BOA axial expansion joints are suited to

compensate for axial expansion movements
in straight pipeline sections. In addition, they
are used:
- to dampen mechanical vibrations and
reduce sound conducted through solids on
pumps and compressors.
- as flexible seals at the end of jacketed
pipes in district heating systems.
- to compensate for thermal expansion
movements and vibrations in flue gas conduits of boilers and engines.
- as disassembly aids for pumps, fittings and
plate heat exchangers.
- as gas-tight wall penetrations of pipelines
in nuclear power stations and ship building.
- in boilers and pressure vessels to compensate for differential expansion.

The assembly of pipeline systems as well

as the disassembly and re-assembly of
components (valves, shut-off valves, pumps,
etc.) for maintenance purposes requires an
axial gap for a comfortable assembly and
disassembly of the components. Installation

Welded end
Bellows

Internal
sleeve

Protective
cover

Fig. 1

inaccuracies often occur due to offset flange

positions. In addition, the pipes are submitted
to thermal expansion during the operation
of such systems. Therefore, so-called
disassembly joints are installed between
pipes and components.

1 General
Information
Type Overview BOA Axial Expansion Joints/Disassembly Joints
Connection
Suitable for ax.
Connection Pre-stressed Connection
unrestrained
type
without pre-stressing *)
type
by 50 %
type
BKT - 7110 000
1
7112 00X
1
7114 00X
1
BKT - 7120 000
2
7122 00X
2
7124 00X
2
BKT - 7112 000
1
7119 00X
1
7117 00X
1
BKT - 7122 000
2
7129 00X
2
7127 00X
2
BKT - 7111 000
1
7918 00S
1
BKT - 7121 000
2
7928 00X
2
BKT - 7119 000
1
7160 00S- TI, RI, EI
10
BKT - 7129 000
2
7162 00S- TI, RI, EI
10
BKT - 7150 000
5
7160 00S- TA, RA
10
BKT - 7951 00S
5
7162 00S- TA, RA
10
7160 00S- LF
10
7162 00S- LF
10
7179 00S- MS
8
7179 00S- ME
8
BOA - FS
2
BOA - ZA
1
BOA - FB
5
BOA - GA
11
BOA - W
1
BOA - I
6
BKT - Alpha-C
5
BOA - EXF
5
BOA - EXW
1
AKFB-U1
AKFB-U2
AKFS-U1
AKFS-U2

1.8 Type Overview

5
5
2
2

AKFB-Z1
5
AKFB-Z2
5
AKFS-Z1
2
AKFS-Z2
2
*) The expansion joints are suited to compensate for the movement capacity indicated
on the rating plate by 100 % in compression direction.
Fig. 2

Connection:
1
Welded end
2
Flange, welded
5
Flange, van-stone
6
Threaded socket, female thread (I)
6
Threaded socket, male thread (A)
8
Press fitting
10
Brazing fitting LF
11
Threaded nipple, welded

Permissible operation temperature with

type
- 7160 00S-T., -E.
(malleable iron, stainless steel)
max. 300 0C
- 7160 00S-R (gunmetal) max. 225 0C
- 7160 00S-LF (gunmetal) max. 225 0C
- 7162 00S-T., -R., -E. (with protective cover)
(malleable iron, gunmetal, stainless steel)
max. 180 0C
- 7162 00S-LF (with protective cover)
(gunmetal) max. 180 0C

2 Installation

2.1 Safety
Instructions

Anchors and pipe guides must be firmly

installed prior to filling and pressure testing
the system.
The expansion joint must not be strained
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
in the immediate proximity of pressure
reducers, superheated steam coolers and
shut-down valves, if high frequency vibrations are to be expected due to turbulence.
Otherwise, special precautions must be
taken (e.g. heavy-walled sleeves, perforated disks, etc.).
If high frequency vibrations or turbulence
or higher flow velocity are to be expected
in the medium, we recommend the installation of expansion joints with internal
sleeves.

Internal sleeves are also recommended for

expansion joints with DN 150 if the flow
velocity of the air, gas, or steam exceeds
8 m/s, or 3 m/s in case of liquid media.

Fig. 3

Installation of expansion joints with

threaded sockets in gas conduits
- Due to the threaded fittings, the maximum permitted excess pressure of these
expansion joints is only 4 bar when used
in gas conduits.
- Rubber seals must not be lubricated or
greased.
- Oxygen pipelines must not get into
contact with oil or grease. Otherwise,
there is danger of explosion!

2 Installation

Allow inclination for condensate drainage.

Align pipeline and install the pipe guides
acc. to Figs. 4, 5, and 6.
NOTE
Gliding or roller supports are the safest

measures to avoid buckling and lifting of the

pipeline.
CAUTION
Swing supports or suspensions are not
acceptable adjacent to expansion joints!

2.2 Installation
Instructions
2.2.1 Pipe Guides
and Supports

L1 = max. 2 . DN + (mm)
2
L2 = 0,7 . L3 (mm)
L3 = 400  DN (mm) valid only for steel pipelines
= movement capacity of the expansion joint (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

15

L1
mm
30 + /2

L2
mm
1050

L3
mm
1550

20

40 + /2

1200

25

50 + /2

32

64 + /2

DN

200

L1
mm
400 + /2

L2
mm
3950

L3
mm
5650

1750

250

500 + /2

4400

6300

1400

2000

300

600 + /2

4850

6900

1550

2250

350

700 + /2

5200

7450

DN

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)

2 Installation

Fig. 6

2.2.2 Anchors

Install main anchors at locations where the

pipeline changes its direction.
Each pipe section that is to be compensated for must be reduced in length by
anchors.
- Only one expansion joint is allowed between two anchors.
- Main anchors must installed at locations
where the pipeline changes its direction.
They must absorb the pressure thrusts
of the expansion joints as well as the

Fig. 7

frictional forces of the pipe supports /

guides.
- Intermediate anchors must be installed
if the movement capacity of one axial
expansion joint is not sufficient to compensate for the entire expansion of a long
pipeline and if several axial expansion
joints are required.
- In the case of vacuum operation, the
anchors must be capable of withstanding
compression and tensile forces.

2 Installation

Fig. 8

The expansion joint should be installed as

closely as possible to the vibrating aggregate.
A pipe anchor should be mounted directly
behind the expansion joint which is to be
installed without pre-stressing.

2.2.3 Vibration
Compensation

CAUTION
If unrestrained expansion joints are used, the
thrust must be taken into account.

Fig. 9

NOTE
The maximum permissible extension, which
can be compensated for, is specified on the
expansion joint. It refers to 1000 fatigue
cycles. With higher fatigue cycles, the
movement capacity must be reduced by the
fatigue cycle factor KL according to the table
in Fig. 10.

Fatigue cycles
Nperm.
1000
2000
3000
5000
10000
30000
50000
100000
200000
1000000
25000000

Fatigue cycle factor

KL

2.2.4 Movement
Capacity

1.00
0.82
0.73
0.63
0.51
0.37
0.32
0.26
0.22
0.14
0.05

KL = (1000 / Nperm.)

0.29

Fig. 10

NOTE
The permissible operating pressure is determined by the nominal pressure, taking the
reduction factors listed in the Axial Expansion Joints brochure, section Technical Data,
into account.

At higher temperatures the nominal pressure must be reduced in accordance with

the reduction factors.

2.2.5 Operating
Pressure

2 Installation

2.2.6 Pre-Stressing

All common expansion joints must be installed pre-stressed by 50 % of their movement capacity (for heating systems overall
length of expansion joint plus 50 %, and for
cooling systems overall length of expansion
joint minus 50 % of the movement).

If an expansion joint is not installed at the

lowest operating temperature of a heating
system or the highest operating temperature
of a cooling system (e.g. replacement at pipe
that is still warm) it must be pre-stressed
individually (see pre-stressing diagram Fig. 13).

Fig. 11

Expansion Joints
delivered in a
pre-stressed
state

NOTE
The following axial expansion joints are delivered already pre-stressed (expanded), see
also Fig. 2.
50 % pre-stressed

suitable for ax without pre-stressing

7112 00X
7122 00X
7119 00X
7129 00X
7179 00X - ME
7179 00X - MS
7170 00S - ME
7918 00X
7928 00X
7160 00S
7162 00S

7114 00X
7124 00X
7117 00X
7127 00X

CAUTION
The anchors of the pipeline must be firmly
secured prior to the removal of the prestressing tab.
Remove the pre-stressing tab (pre-stressing lock) after installation and prior to
starting-up of the axial expansion joint.
Make sure that
- the expansion joint is not damaged;
- the bellows does not get into contact with
shavings.
8

Pre-stressing tab

Fig. 12

2 Installation

2.2.7 Pre-Stressing
Diagram

Fig. 13
An axial expansion joint is utilized to compensate for a pipeline measuring 22 m in
length. The lowest temperature is -15 C. The
highest temperature is +165 C. The maximum anticipated thermal movement equals
50 mm at the temperature difference of 180 C.
If the expansion joint is installed at the lowest
temperature it shall be pre-stressed (expanded) by 50 % of this movement (25 mm).
During operation, the expansion joint will then
be compressed by the thermal movement of
50 mm. When the expansion joint is installed,
special care should be taken to assure correct pre-stressing. If the temperature at the
time of installation is not -15C but +20C,
the corresponding thermal movement of the
pipeline is 9 mm (see Fig. 13). This amount
must be subtracted from the original prestressing value of the expansion joint:
25 - 9 = 16 mm
The pre-stressing diagram Fig.13 allows to
determine the correct pre-stressing value as

follows:
1. Temperature difference between installation temperature and lowest temperature
-15C +20C = 35C
2. Length of pipeline to be compensated for:
22 m
3. Draw a straight line from the point Length
of pipeline 22 m to the 0 C point.
4. Draw a vertical line from the 35C point
towards the beam coming from 22 m.
5. Draw a horizontal line from this intersection to the line Thermal expansion of pipeline in mm; the result is, as stated above,
9 mm.
6. Draw a straight line from the 9 mm point
to Total anticipated movement, this
equals 50 mm and go further to Prestressing of expansion joint in mm.
The intersection shows a pre-stressing of 16
mm. This is the value by which the axial
expansion joint is to be expanded during
installation.

2.2.8 Example to the

Diagram

2 Installation

2.3 Installation
of Flanged
Expansion Joints

Align flange bolt holes.

- Ensure flanges are parallel.
- Ensure gaskets are on center.
- Tighten bolts crosswise.

Make sure that the expansion joint is not

exposed to torque.
Ensure that bellows are free of objects that
hinder free movement.

Fig. 14

2.4 Installation of
Pipes with
Pressfittings

BOA axial expansion joints types 7179 00X

und 7170 00S are suitable for the compensation of axial movements in straight pipelines and are especially developed for the
Mapress system. With the connection
elements welded on both sides, fast and pro-

2.5 Installation of
Expansion Joints
with Threaded
Sockets

Align flange bolt holes.

- Ensure flanges are parallel.
- Tighten bolts crosswise.

per assembly is possible at site.

When expansion joints are installed in
HAVC systems, the installation guidelines of the Mannesmann-PressfittingSystem company must be observed.

Make sure that the expansion joint is not

exposed to torque.
Ensure that bellows are free of objects that
hinder free movement.

7160 00S -TI, -RI, -EI, -TA, -RA, -LF

1 4

7162 00S -TI, -RI, -EI, -TA, -RA, -LF

Fig. 15
1 bellows:

10

stainless steel
material No. 1.4571
2 support ring: stainless steel
material-No. 1.4301
3 threaded socket:
type T: gunmetal
type R: stainless steel
type E: brazing fitting
type LF: brazing fitting

4 gasket:
5 shroud:

Klinger C-4400
type T: carbon steel, galvanized
soft soldered
type R: brass
soft soldered
type E: stainless steel
type L: brass
soft soldered

2 Installation

Type 7160 00S

Pipe support / guide

Pipe support / guide

Anchor

Installation length
and 2 gaskets

Anchor

Type 7162 00S

Pipe support / guide

Pipe support / guide

Anchor

Installation length
and 2 gaskets

Anchor

Fig. 16

NOTE
Depending on the nominal diameter, the
installation length EL of the disassembly joint
must be max. 20 to 30 mm longer than the
unrestrained total length TLneutral.

2.6 Installation of
BOA
Disassembly
Joints

Install fixed points on each side:

With unrestrained expansion joints the
thrust must be absorbed by the anchors.

Installation
Flange the disassembly joint with one side
to the pipe end (Fig. 18). On the other side,
pull the disassembly joint towards the
components (valve, shut-off valve, pumps
etc.) either with long bolts (unrestrained)
or with the delivered threaded rods (restrained) (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
gap, which is necessary for comfortable
assembly and disassembly of the components.

Fig. 17
TL neutral

Fig. 18

Fig. 19

11

3 Start-Up

3.1 Control

Before starting-up, make sure that:

- the pipeline is installed with an inclination
to avoid water pockets;
- there is sufficient drainage;
- pipe anchors and pipe supports/guides are
completely installed prior to filling and
pressure testing the system;
- the expansion joint is not exposed to torque
(with the exception of types 7918 ... and
7928 ... which are equipped with a torque
protection). This is especially important for
the expansion joints with threaded sockets.

- the flow direction has been observed for

expansion joints with internal sleeves,
- the steel bellows is free from dirt, welding
chips, plaster or mortar splatter or any other
soiling clean, if necessary;
- all screwed connections are tightened
properly;
- in general, special care is taken to avoid
corrosion damages, e.g. in water treatment
or measures to avoid galvanic corrosion
in copper and galvanized pipes.

3.2 Insulation

Insulation
Axial expansion joints shall be insulated like
the complete pipeline unless stated otherwise.
Protect the bellows by means of a suitable
cover to avoid insulation material dropping
into the convolutions.

3.3 Unacceptable
Modes of
Operation

- The restrictions listed in the Axial Expansion Joints brochure, section Technical
Data, must not be exceeded.

- If the pipeline will be cleaned with steam,

make sure that no steam hammers occur
as they may damage the expansion joint.

3.4 Start-up of the

System

CAUTION
During pressure testing and operation, the
permissible test pressure or operating
pressure for the expansion joint must not
be exceeded.

3.5 Maintenance

Maintenance
The axial expansion joints are maintenancefree.
Prior to disassembly and maintenance the
system must be
- depressurized,
- cooled down, and
- drained.
Failure to do so can result in serious
accidents !

12

If the axial expansion joint will be installed

under plaster, the bellows again requires
protection to avoid that plaster and other
building material negatively affects the free
movement of the bellows. The utilization
of BOA expansion joints with a standard
bellows cover is to be considered.

Excessive pressure peaks as a consequence of closing valves too quickly and

water hammers, etc. are not permitted.
Avoid contact with aggressive media.
Steam pipelines must be started in such a
way that condensate can drain off in time.

BOA AG
Postfach 2 72
Stationsstrae 95
CH-6023 Rothenburg
Telefon +41 289 41 11
Telefax +41 289 42 02

Postfach 11 62, D-76288 Stutensee

Lorenzstrae, D-76297 Stutensee
Telefon +49 72 44 99-0
Telefax +49 72 44 99-372
Internet:www.boa-bkt.de
E-Mail: kompensatoren@boa-bkt.com

6 000 014 083

BK. 0308. 3. 20. en. Sto. 2210
Gedruckt in der Bundesrepublik Deutschland

BOA BKT GmbH

Balg- und
Kompensatoren-Technologie