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Original instructions
Created by: BK
Approved by: AO
4 Installation ......................................................................................................................... 20
4.1 Storage on site ............................................................................................................................................... 20
4.1.1 Bellows, insulation, glass felt auxiliaries etc. ...................................................................................... 20
4.1.2 Steel parts .................................................................................................................................... 20
4.1.3 Lining materials ............................................................................................................................. 20
4.2 Unpacking of materials .................................................................................................................................... 20
4.2.1 The bellow supply .......................................................................................................................... 20
4.2.2 The steel parts .............................................................................................................................. 20
4.3 Planning and installation procedures ................................................................................................................. 21
4.3.1 Documentation .............................................................................................................................. 21
4.3.2 Expansion joint legend.................................................................................................................... 21
4.3.3 Planning and schedule .................................................................................................................... 21
4.3.4 Scaffolding .................................................................................................................................... 22
4.3.5 Auxiliary tools ............................................................................................................................... 22
4.4 The installation task on a step-by-step basis ...................................................................................................... 22
4.4.1 Installation: Figure 7 to Figure 9 and Figure 12 to Figure 15, steel parts ............................................... 22
4.4.2 Installation for Figure 10, Figure 11, Figure 16, Figure 18 ................................................................... 26
4.4.3 Installation for Figure 19 (Scissor) ................................................................................................... 27
4.4.4 Installation for the fabric bellow. ...................................................................................................... 27
4.5 Installation tools ............................................................................................................................................. 29
4.5.1 The taptite .................................................................................................................................... 29
4.5.2 Various installation aids .................................................................................................................. 30
4.6 Detailed direction to the assembly of bellow ....................................................................................................... 31
4.6.1 Assembly of bellow materials........................................................................................................... 31
4.6.2 Mounting of large bellows (supplied open)......................................................................................... 34
4.7 Repair of bellow .............................................................................................................................................. 35
4.7.1 Repair during operation .................................................................................................................. 35
4.7.2 Emergency repair........................................................................................................................... 36
4.8 Installation documentation ............................................................................................................................... 37
4.8.1 Quality documentation .................................................................................................................... 37
5 Operation ........................................................................................................................... 37
5.1 Pre-operational check ...................................................................................................................................... 37
5.2 Operational supervision ................................................................................................................................... 37
6 Maintenance ....................................................................................................................... 37
6.1 Preventive maintenance................................................................................................................................... 37
6.1.1 Cleaning ....................................................................................................................................... 38
6.1.2 Inspection and adjustment .............................................................................................................. 38
6.1.3 Status check ................................................................................................................................. 38
6.1.4 Replacement of spares ................................................................................................................... 38
6.1.5 Functional test ............................................................................................................................... 39
List of figures
Figure 1. HT 350 ............................................................................................................................................. 6
Figure 2. HT 100 ............................................................................................................................................. 6
Figure 3. MN 300............................................................................................................................................. 6
2/39 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
27421-07-3.1
NOTE !
The present instruction manual is concerned with the situations which, according to the experience of
FLSmidth, are the most likely to occur. An exhaustive enumeration of all conceivable situations, which may
occur during manufacture, installation, operation and maintenance of the equipment, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in the instruction manual,
and which the operator is/or feels unable to handle, it is recommended that FLSmidth is contacted without
undue delay for advice on appropriate action.
1 General information
1.1 Scope and purpose
This manual includes principles and directions to the installation and maintenance of
expansion joints on ducts, chutes and pipes.
An expansion joint consists of steel parts and fabric parts for expansion. Thermal
insulation, lining with densulate, densit or casted brickwork may exist on certain
components.
Expansion joints serve to compensate for the axial and lateral movements, which occur
in connection with thermal expansion of the steel structures. An expansion joint may
serve the purpose to isolate vibrations of ducts or machines from other structures. The
expansion joint ensures that considerable forces or vibrations do not apply to
neighbour components.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 3/39
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
27421-07-3.1
1.3 Legend
Mandatory!
This symbol appears in the instruction manual to indicate dangers which, in case of non-
observance, may cause fatal or serious injuries!
Attention!
This sign is shown in the instruction manual where specific attention and caution is needed to
avoid damage to or destruction of the equipment and/or parts of the installation.
Delivered by
steel
Expansion joint type manufacturer Delivered by the fabric manufacturer Delivered by other
Duct 1. Rectan/circular Large bellow with open ends, small as an assembled ring.
Pos numbers 4, Beam for bracing the
Duct 2. Rectan/circular MN300, MN400 or LN200, (51).
20, 21, 22, 23 expansion joint steel
Figure 7, butt weld. Taptite, (3), with fixation tool.
parts before installing
Lock washer, (5).
the bellow. The same
Duct 3. Rectan/circular Glass felt, (7).
Pos numbers 4, beam may be used for
Duct 4. Rectan/circular Insulation, 60 kg/m3 loose wool (8). lifting for installation.
20, 21, 22, 23, 24
Figure 7, flange. Or See Figure 23.
Insulation bag with 80 kg/m3 loose wool (8, 9).
Assembled ring bellow, HT100 or HT350. (52) Beam for bracing the
Taptite, (3), with fixation tool. expansion joint steel
Reinforced 1 Lock washer, (5). parts before installing
Pos numbers 4,
Rectangular/circular Glass felt, (7). the bellow. The same
20, 21, 22, 23, 24
Figure 8. Insulation bag with 80 kg/m3 loose wool (8, 9). beam may be used for
Connection wire for electrical connection to adjacent lifting for installation.
equipment. See Figure 23.
Large bellow with open ends, small as an assembled ring. Beam for bracing the
MN300, MN400, MN500 or LN200, (56). expansion joint steel
Taptite, (3), with fixation tool. parts before installing
the bellow. The same
Pos numbers 4, Lock washer, (5).
Lined 1, Figure 12. beam may be used for
20, 21, 22, 23, 24 Glass felt, (7).
lifting for installation.
Insulation, 60 kg/m3 loose wool (8). See Figure 23.
Or Heat resistant
Insulation bag with 80 kg/m3 loose wool (8, 9). materials (9)
Beam for bracing the
Large bellow with open ends, small as an assembled ring. expansion joint steel
MN300, MN400, MN500 or LN200, (56). parts before installing
the bellow. The same
Taptite, (3), with fixation tool.
beam may be used for
Pos numbers 4, Lock washer, (5). lifting for installation.
Lined 2, Figure 12.
20, 21, 22, 23, 24 Glass felt, (7). See Figure 23.
Insulation, 60 kg/m3 loose wool (8). Heat resistant
Or materials. (9)
Insulation bag with 80 kg/m3, loose wool (8, 9). Anchors (9)
Ceramic felt (10)
4/39 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
27421-07-3.1
Delivered by
steel
Expansion joint type manufacturer Delivered by the fabric manufacturer Delivered by other
Large bellow with open ends, small as an assembled ring. Beam for bracing the
MN300, MN400, MN500 or LN200, (56). expansion joint steel
Taptite, (3), with fixation tool. parts before installing
Pos numbers 4, Lock washer, (5). the bellow. The same
Lined 3, Figure 13.
20, 21, 22, 23 Glass felt, (7). beam may be used for
Insulation, 60 kg/m3 loose wool (8). lifting for installation.
Or See Figure 23.
Insulation bag with 80 kg/m3 loose wool (8, 9). Densit (11)
Large bellow with open ends, small as an assembled ring. Beam for bracing the
MN300, MN400, MN500 or LN200, (56). expansion joint steel
Taptite, (3), with fixation tool. parts before installing
Pos numbers 4, Lock washer, (5). the bellow. The same
Lined 4, Figure 13.
20, 21, 22, 23 Glass felt, (7). beam may be used for
Insulation, 60 kg/m3 loose wool (8). lifting for installation.
Or See Figure 23.
Insulation bag with 80 kg/m3 loose wool (8, 9). Densulate (10)
The information transmitted by this document is the proprietary and confidential property of FLSmidth 5/39
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
27421-07-3.1
Bellow type HT350: 7 layers bellow. Temperature direct on inside of bellow max. 350 C. Explosion
pressure shock resistant.
Pos 1 Needled glass felt. Thickness 6 mm
Pos 2 PTFE coated glass fabric. Thickness 0,4 mm, 600 g/m2 .
Pos 3.1 Glass fabric polyurethane impregnate. Thickness 1,3 mm, 980 g/m2 .
Pos 3.2 Glass fabric polyurethane impregnate. Thickness 1,3 mm, 980 g/m2 .
Pos 3.3 Glass fabric polyurethane impregnate. Thickness 1,3 mm, 980 g/m2 .
Pos 3.4 Glass fabric polyurethane impregnate. Thickness 1,3 mm, 980 g/m2 .
Pos 4 RST 1502 PTFE / film / fabric. Thickness 1,1 mm, 1830 g/m2 .
Pos 5 Glass fibre string. 8 mm.
Figure 1. HT 350
Bellow type HT100: 4 layers bellow. Temperature direct on inside of bellow max. 100 C. Explosion
pressure shock resistant.
Pos 1 EPDM rubber, 2 layers reinforced. 4 mm, 4800 g/m2 .
Pos 2.1 Hypalon coated polyester fabric. 0.5 mm, 530 g/m2 .
Pos 2.2 Hypalon coated polyester fabric. 0.5 mm, 530 g/m2 .
Pos 2.3 Hypalon coated polyester fabric. 0.5 mm, 530 g/m2 .
Pos 3 Glass fibre string. 8 mm.
Figure 2. HT 100
Bellow type MN300: 3 layers bellow. Temperature direct on inside of bellow max. 300 C.
Pos 1 Glass fabric polyurethane impregnate. 1.1 Pos 3 Silicone coated glass fabric. 1.1 mm,
mm, 600 g/m2 . 1300 g/m2 . (Silicone 400 g/m2 outside
Pos 2 2
PTFE foil. 0.2 mm, 440 g/m . and 100 g/m2 inside).
Figure 3. MN 300
6/39 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
27421-07-3.1
Bellow type MN400: 4 layers bellow. Temperature direct on inside of bellow max. 400 C.
Pos 1 Silicone coated glass fabric. 1.1 mm, 1300 g/m2 . (Silicone 400 g/m2 outside and 100 g/m2
inside).
Pos 2 PTFE foil. 0.2 mm, 440 g/m2 .
Pos 3 Needle glass felt. 13 mm, 2000 g/m2 .
Pos 4 Glass fabric polyurethane impregnate 1.3 mm, 980 g/m2 .
Figure 4. MN 400
Bellow type MN500: 4 layers bellow. Temperature direct on inside of bellow max. 500 C.
Pos 1 Silicone coated glass fabric. 1.1 mm, 1300 g/m2 . (Silicone 400 g/m2 outside and 100 g/m2
inside).
Pos 2 PTFE foil. 0.2 mm, 440 g/m2 .
Pos 3 Glass felt. 13 mm, 2000 g/m2 .
Pos 4 Wire mesh, stainless steel.
Pos 5 Glass fabric polyurethane impregnate 1.3 mm, 980 g/m2 .
Figure 5. MN 500
Bellow type LN200: 1 layer bellow. Temperature direct on inside of bellow max. 200 C.
Pos 1 Silicone coated glass fabric. 1.1 mm, 1300 g/m2 . (Silicone 400 g/m2 outside and 100 g/m2
inside).
Figure 6. LN 200
The information transmitted by this document is the proprietary and confidential property of FLSmidth 7/39
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
27421-07-3.1
Rectangular.
Circular.
Pos 51 Bellows to fit the steel parts for Duct 1 Pos 9 Insulation bag (pillow). Only for chosen
to 4 models. See Figure 3, Figure 4, purpose, see Expansion Joint Legend.
Figure 6. Pos 20 Retaining iron.
Pos 3 Taptite ISO 7053, M8x45-C. Pos 21 Steel part. See mechanical drawing.
Pos 4 One round bar per 100 mm. Pos 22 Floating skirt to protect the inside of the
Pos 5 Lock washers, 30. One washer for each expansion joint from wear.
round bar. The washer must press the Pos 23 Steel part. See mechanical drawing. The
glass felt (7) firmly to avoid dust steel part to be orientated with the flow in
penetrating into the insulation. the duct/machine, see flow arrow on the
Pos 6 Installation measure is defined as drawing.
H installation in this instruction see Expansion
Joint Legend.
Pos 7 2 off 10-13 mm layers of glass felt.
Pos 8 Loose mineral wool, 60 kg/m3 .
Figure 7. Expansion joint for circular or rectangular/square section.
8/39 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
27421-07-3.1
Rectangular.
Circular.
Pos 52 Bellows Figure 1 and Figure 2 fit the steel parts Pos 9 Insulation bag (pillow) encloses the
for model, Reinforced 1. loose mineral wool.
Pos 3 Taptite ISO 7053, M8x45-C. Pos 20 Retaining iron.
Pos 4 One round bar per 100 mm. Pos 21 Steel part. See mechanical drawing.
Pos 5 Lock washers, 30. One washer for each round Pos 22 Floating skirt to protect the inside of
bar. The washer must press the glass felt (7) the expansion joint from wear.
firmly to avoid dust penetrating into the Pos 23 Steel part. See mechanical drawing.
insulation. The steel part to be orientated with
Pos 6 Installation measure is defined as Hinstallation in the flow in the duct/machine, see flow
this instruction see Expansion Joint Legend. arrow on the drawing.
Pos 7 2 off 10-13 mm layers of glass felt. Pos 24 Flange connection to duct.
Pos 8 Loose mineral wool, 60 kg/m3 .
Figure 8. Expansion joint for circular or rectangular/square section in coal grinding department.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 9/39
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
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Chute expansion joint for temperatures less Chute expansion joint for temperatures less
than 100 oC. than 100 oC.
Rectangular: Circular:
Figure 9. Reinforced expansion joint for chute in coal departments. Circular and rectangular.
10/39 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
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Maximum temperatures 350 C. The joint is pressure Pos 54 Bellow as Figure 2 supplied as an
shock resistant. assembled ring. See Expansion Joint
Circular: Legend. The bellow is explosion proof,
shock resistant.
Pos 1 Flow direction.
Pos 3 Strapping band, extra heavy, 25x15.
Pos 4 2 off 4 mm round bar welded to the
pipe.
Pos 23 De-dusting piping or chute.
This expansion joint does not include any steel part
delivery. Steel parts are delivered with the dedusting
pipes or chutes.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 11/39
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
27421-07-3.1
Heat resistant lining. Thickness 214 or 264 mm. Max. gas temp. < 1100 oC.
Circular shown - Rectangular available. Lined 2:
Bellow to be selected among models shown on Figure Pos 72 off 10-13 mm layers of glass felt.
3 to Figure 6. See Expansion Joint Legend and the Pos 8Loose mineral wool, 60 kg/m3 .
marking designation on the delivery.
Pos 9Heat resistant material and anchors.
Pos 56 For heat resistant lining 114 and Pos 10
Ceramic felt. See sub-section 6.1.4.
214/264. Pos 11
Free space for expansion.
Pos 3 Taptite ISO 7053, M8x45-C. Pos 20
Retaining iron.
Pos 4 One round bar per 100 mm. Pos 21
Steel part, see mechanical drawing.
Pos 5 Lock washers, 30. One washer for each Pos 22
Floating skirt to protect the inside of the
round bar. The washer must press the expansion joint from wear and dust.
glass felt (7) firmly to avoid dust Pos 23 Steel part, see mechanical drawing. The
penetrating into the insulation. steel part to be orientated with the flow in
Pos 6 Installation measure is defined as the duct/machine, see flow arrow on the
H installation in this instruction, see drawing.
Expansion Joint Legend. Pos 24 Flange connection to duct.
Insulation, 60 kg/m3 loose wool (8) or insulation bag with 80
kg/m3 wool (8, 9).
Figure 12. Heat resistant lined with 114 or 214 or 264 mm thickness. Circular duct.
12/39 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
27421-07-3.1
Bellow to be selected among models shown on Pos 8 Loose mineral wool, 60 kg/m3 .
Figure 3 to Figure 6. See Expansion Joint Legend Pos 9 Insulation bag (pillow). Only for chosen
and the marking designation on the delivery. purpose, see Expansion Joint Legend.
Pos 10 50 mm Densulate.
Pos 56 For densulate and densit lining. Pos 10.1 Free space for welding of root pass.
Pos 3 Taptite ISO 7053, M8x45-C. Pos 11 20 mm Densit Wearflex 2000 HT.
Pos 4 One round bar per 100 mm. Pos 11.1 Free space for welding of root pass.
Pos 5 Lock washers, 30. One washer for Pos 20 Retaining iron.
each round bar. The washer must press Pos 21 Steel part, see mechanical drawing.
the glass felt (7) firmly to avoid dust Pos 22 Floating skirt to protect the inside of the
penetrating into the insulation. expansion joint from wear and dust.
Pos 6 Installation measure is defined as Pos 23 Steel part, see mechanical drawing. The
H installation in this instruction, see steel part to be orientated with the flow
Expansion Joint Legend). in the duct/machine, see flow arrow on
Pos 7 2 off 10-13 mm layers of glass felt. the drawing.
Insulation, 60 kg/m3 loose wool (8) or insulation bag with
80 kg/m3 wool (8, 9).
The information transmitted by this document is the proprietary and confidential property of FLSmidth 13/39
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
27421-07-3.1
2.7 Assembly of expansion joint for chute, temp less than 500 oC
Expansion Joint Legend representation below: Expansion Joint Legend representation below:
Chute 1. Chute 2.
Figure 14. Chute 1 and chute 2: Rectangular and circular, axial through.
14/39 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
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Chute 4:
The information transmitted by this document is the proprietary and confidential property of FLSmidth 15/39
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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Pos 1 Lateral movement +/- 185 mm. Pos 60 Gas-proof flexible material.
Pos 2 Axial movement +/- 55 mm. Pos 61 Gas-proof flexible material.
Pos 3 Strapping band. Temperature < 100 oC.
Pressure > minus 4 kPa.
Figure 17. Chute S circular.
Pos 59 Air-proof bellow, flexible material as Pos 59 Air-proof bellow, flexible material as
Figure 3, Figure 4 or Figure 6. Figure 3, Figure 4 or Figure 6.
Pos 20 Retaining iron. Pos 3 Strapping band.
Pos 3 Taptites ISO 7053, 8x45-C.
Expansion joint legend representation below: Expansion joint legend representation below:
Dedusting 1: Dedusting 2:
Figure 18. Expansion joint for cold duct. Dedusting pipe joint.
16/39 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
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2.10 Scissor
Duct or chute expansion joint. Maximum temperatures < 500 oC.
Scissor 1 Scissor 2
Duct expansion joint Chute expansion joint
Pos 1 Bellow.
Pos 2 Steel parts for expansion joint.
Pos 3 M24 nut to be firmly hand-tightened and spot-welded to the bolt.
Pos 4 Washer.
Pos 5 Hexagon head bolt with nut.
Pos 6 Retaining iron.
Pos 7 Flow direction.
Figure 19. Long circular expansion joint (Scissor) for duct and chute.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 17/39
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
27421-07-3.1
Duct / Dimension GA Tempe- Axial Lat. Installation Installation Drawing model Remarks
chute / A x B / A Plan rature move- move- offset length
Item dedusting no. ment ment
no. pipe [mm] [C] [mm] [mm] X [mm] H [mm]
3.2 Duct lined 2000 5 150 40 40 - 700 Lined 2 264 mm, std. flange
3.3 Duct lined 2000 5 150 40 40 - 700 Lined 2 214 mm, std. flange
18/39 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
27421-07-3.1
3 Safety instructions
3.1 General notes
3.1.1 Introduction
FLSmidth will not assume responsibility for any damage resulting from abuse or
improper operation or inadequate maintenance of the expansion joint or resulting
from its operation or maintenance by unqualified personnel, including personnel
who have not acquired the skills required to operate or maintain the equipment on
the basis of the directions provided in the technical documentation.
Attention!
Any installation activity must be carried out by skilled persons and is subject to the
supervision of authorized personnel. See sub-section 1.2.
A final installation check must result in a release note to commence test or operation
of the equipment. See sub-section 4.8.1. Non-conditional installed expansion joints
may result in escape of hot air or exhaust gas with personal injury as the
consequence.
Bellow should be mounted after all welding works have been completed. Otherwise a
bellow must be protected against welding sparks, sharp objects etc.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 19/39
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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Mandatory!
In particular all kinds of combustible material constitute a risk of fire or dust explosion. Keep
the equipment cleaned from combustible material. Explosion resistant bellows of type HT 100
and HT 350 must not be repaired. Stop the operation of the plant and change the entire bellow
if any need of repair should arise.
Media flow to or through the expansion joint constitutes a risk to personnel working inside the
expansion joint. Ensure that no media rush, exhaust gas/air flow to or through the expansion
joint may occur. Gravity force may cause media rush.
Attention!
Emergency repaired bellow must be replaced at first opportunity. See sub-section 4.7.2.
4 Installation
4.1 Storage on site
4.1.1 Bellows, insulation, glass felt auxiliaries etc.
When bellows with auxiliary materials arrive at site, they should be stored indoors
in a dry place and remain in their transport packaging until the installation
commences. Safety data sheets are enclosed and may be found among the specific
order documentation. The identification of goods on receipt must be carefully
executed. Deficiency must be registered and reported to site management. Scope
of delivery must be consistent with the Expansion Joint Legend, see Figure 21 and
Figure 22.
4.1.2 Steel parts
Steel parts for expansion joints can be stored as other large steel structure. The
steel parts must be kept free from corrosion. Keep marking labels visible during
storage and installation and operation.
20/39 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
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Check all parts of delivery for damage and report any non-conformity to site
management.
General Arrangemt Legend (front page text below) Expansion joint legend (front page text below)
Plant: PT SEMEN GRESIK (PERSERO) Plant: PT SEMEN GRESIK (PERSERO)
Tbk. Tbk.
Tuban 4, EAST JAVA, INDONESIA Tuban 4, EAST JAVA, INDONESIA
Department: 321 Raw mill Department: 321 Raw mill
Contract: 0945242 Contract: 0945242
Appr. date: 20-04-2010 Appr. date: 05-Mar-10
Created by: KGG Created by: SUVR
Approved by: AC Approved by: CBOK
This example shows GA drawing with two identical expansion joints (93-2 and 93-3) placed between
the duct and the inlets to the mill. The General Arrangement Legend refers under Ref. no. 93 to the
Expansion Joint Legend number, where 93-2 and 93-3 are specified according to example shown in
sub-section 2.12, Figure 21.
The reverse reference from the Expansion Joint Legend to the relevant GA drawing is given in the
overview table of the Expansion Joint Legend.
Figure 22. Documentation.
Ensure work space for the bellow and thermal insulation material.
Containers for collection of waste materials in particular insulation and sheet waste
must be prepared.
4.3.4 Scaffolding
Installation scaffolding may be needed for other activities such as thermal
insulation and lining of the duct and retightening of the flat bar clamp screws. See
sub-section 5.2. Do not remove scaffolding before relevant parties have agreed.
Ensure that scaffolds are available at the support/fixation on the duct/machine
sufficient close to the duct ends to be offset. See step I below.
4.3.5 Auxiliary tools
A large number of screw clamps must be available. Other special tools for assembly
of the bellow are included with the bellow, see Figure 27.
Pos 1 Lifting line for crane transport of Pos 5 the pos 2 beam shall be welded to
expansion joint. the duct/steel part with appropriate
Pos 2 Lifting and reinforcing fixation weld dimension. Foot plate to
beam on the steel parts Se sub prevent inside fillet weld which is
section 2.1 concerning supply. difficult to remove.
The number of beams on the
circumference must match the Attention: Do not deform expansion joint
diameter or rectangle size. flange (3) or the pre-drilled holes.
Typical the beam shall be able to
lift the entire structure from
ground. Attention: The fixation and lifting beam must
be removed immediately before installing the
Pos 3 Expansion joint flange with
bellow in order to ensure that the duct and
predrilled holes for the bellow.
steel structures are stress free and remain in
22/39 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
27421-07-3.1
Attention, lining
Lining before installation of steel parts with butt weld ends must have 30 mm un-lined
pipe/duct ends for the sake of weld of the root pass, see Figure 13, (10.1) and (11.1).
(pos 10 Figure 24) into the gap "a" until the full circumference is covered. Hint:
Glue the felt to the lining (hatched pos 9.1 Figure 24).
Assemble the steel parts (pos 23.1 and pos 23.2) concentric and brace to obtain a
rigid body to overall length of "Hinstallation" mm.
Insert glass felt in the inside "c" opening from inside. The felt itself allows for 50 %
compression in operational state.
Hoist and lower the braced and assembled steel part into the final position.
Connect, weld or bolt (pos 23.1 Figure 24) first.
The steel part and duct/machine should now be ready for fine-tuning to fit the (pos
23.2 Figure 24).
Adjust axial pre-compressing and transversal offset if necessary (Figure 25).
Connect, weld or bolt (pos 23.2 Figure 24).
Remove the bracing between (pos 23.1 Figure 24) and (pos 23.2 Figure 24).
Maintain the measuring aids in place and observe that the expansion joint is in
place after release of bracing.
If not - Adjust to foreseen position.
This type of joint is normally connected with flanges. Here shown without flanges.
The glass felt can as maximum be compressed to 50 % thickness due to pre-compression or
operational state. Likewise it should be expected, that pre-compressed glass felt can expand to
operational state. See further instructions in Expansion Joint Legend.
Pos 10: In the vertical gap always use ceramic felt thickness "a".
The glass felt in the horizontal gap must be of dimension "c" and implemented from inside of the
joint structure. See dimensions in the Expansion Joint Legend.
Figure 24. Stuffing of ceramic felt.
24/39 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
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H. Installation of the steel parts (for axial insertion of the steel parts)
The information transmitted by this document is the proprietary and confidential property of FLSmidth 25/39
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
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The picture above show an offset joint both lateral and axial.
Pos a and pos b are from the point of departure approximate of same size. When offsetting
lateral the a increases and the b decreases correspondingly.
Pos c Lateral offset as given in the Expansion Joint Legend.
Pos d Represents the distance which will change (positive or negative) during start
up of the plant.
Pos H H installation as given in the Expansion Joint Legend.
Pos 4 Fastener for glass felt.
Figure 25. The offset of expansion joint.
Attention
Transversal offset of the joint shall be conducted by setting the duct ends/machine with the
expansion joint steel parts mounted according to information given in Expansion Joint
Legend in the Offset column and any explanatory sketch in the Legend. See Figure 20.
Lateral displaced sketch.
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Attention:
The identification label on the bellow must be visible after installation of the bellow.
Open end bellow must be assembled around the expansion joint steel part as
follows:
Wrap the open ends bellow around the duct:
On horizontal ducts with the open ends in an upward position (to facilitate
the assembly of the ends).
On vertical duct with the open ends where access for assembly of the
ends is the best possible.
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Ensure that identification label is facing outwards and that correct layer of the
bellow is present (see sub-section 4.2.1).
Fasten the bellow temporarily to the flanges with screw clamps (see Figure 26) as
tight as possible and keep the bellow fixed firm to the flange while taptites are set.
Every taptite is applied by mean of two screw clamps, one at opposite sides of the
taptite.
Insert the taptites through the retaining iron and the bellow in a sequence from the
centre of the open-end bellow, working alternately to the left and the right of this
position until the open ends have been reached.
For each taptite to be set the temporarily fixed bellow must be tightened firm to the
flange most likely resulting in pushing a fold towards the open ends. Ease the fold
forward to the open ends.
For the vertical duct all taptites should be set in the upper flange first.
For horizontal duct set the taptites in both flanges simultaneously.
Ensure that no askew folds across the bellow occur.
Do not apply taptites 500-800 mm over the open ends to be jointed.
Assemble the open ends following the direction given in sub-section 4.6 below and
insert the remaining taptites.
No taptites should be tightened before the bellow joint has been made and all
taptites have been inserted. Once all taptites are inserted, tightening from the side
opposite the joint may commence.
D. Installation of the small and pressure resistant closed bellow with workshop joint
Smaller bellows and pressure resistant bellows will be supplied as an assembled
ring (closed ends) which must be hung on the duct/chute/pipe or the expansion
joint steel part before installation of the steel parts.
When welding: Protect the bellow against weld splashes.
Apply screw clamps on the flanges' circumference and spread any surplus bellow
length around the entire circumference. Avoid askew folds in the bellow.
Insert the taptites as described under C above in a sequence from the workshop
joint diametrical opposite side, working alternately to the left and the right of this
position.
No taptite should be tightened before all taptites have been inserted. Once all are
inserted, start tightening from starting point, alternating left and right. Ensure that
no folds in the bellow develop.
E. Installation of the bellow with strapping band
Strapping bands used on circular joints for chute and dedusting pipes only.
Strapping bands may appear as a collection of a number of bands depending on the
length of the bellow circumference.
Strapping bands may include snap lock for dismounting the bellow.
Explosion resistant bellows are fixed by a strapping band and are equipped with a
glass fibre string, 8 mm, (Figure 1 and Figure 2) and the matching steel pipe shall
be equipped with a 4 mm round bar, (Figure 9 to Figure 11).
The strapping band must be positioned between the glass fibre string and the 4
mm round bar.
Position any snap lock in a direction for easy approach.
Tighten the bands firm observing above mentioned directions.
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Pos 1 Bellow.
Pos 3 The taptite cuts thread directly in predrilled hole in the flange, taptites and
fixation tool (magnetic) are supplied with the bellow. Standard drilling
machine to be used.
Pos 5 Use one washer for each round bar (Figure 12, pos 4) only.
Pos 7 The washer must press the glass felt firmly to avoid dust penetrating into the
insulation.
Pos 20 Retaining iron.
Pos 23 Flange for bellow.
Pos 30 Attach two screw clamps. One on each side of the taptite.
Attention!
The bellow is insulated from the inside. Do not cover the bellow outside with thermal
insulation or cladding.
Figure 26. Thermal insulation and insertion of taptites.
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Expansion Joints
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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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Prepare a 100-200 mm material overlap Sew together the material ends across the
overlap with parallel stitches.
Cut away the top layer of one material end and Overlap the two material ends to form a smooth
the bottom layer of the other material end. join.
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Clean a 250 mm area of the material ends with Prepare a strip of self adhesive PTFE foil longer
acetone or simular. Fold down a 100 mm overlap on than the width of the material. Roll on one overlap
both material ends. to half the width of the PTFE tape.
Roll on the other overlap until the fold. Bend over both material ends, at the same time,
to half the width.
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Clean both material ends with acetone or simular Within 1 minute, roll on the other overlap
and apply silicone glue over a width of 75 mm.
Apply a string of silicone glue onto the join. Using a lap of PTFE foil, or similar material, form a
smooth layer of glue across the material.
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Expansion Joints
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Multi layer bellow. Final joining procedure. Adding flange reinforcement in the splicing
area.
Figure 32. Multi layer bellow. Final joining procedure. Adding flange reinforcement in the splicing
area.
Steel plate as underlay for the assembly work to be positioned directly on the flanges. Use a stabilizing
clean steel plate of appropriate thickness as the basis for assembling of the bellow ends. Maintain the
plate in position until complete finishing the assembly work.
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Expansion Joints
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A. Material:
Bellow material can be ordered as spare parts or an old/new bellow (same
type) can be used as spare parts, actual material to be used must be in good
condition.
B. Dismount of bellow
Dismount the expansion joint retaining iron (4) over a distance large enough to
turn the bellow (1) with the inside out enabling the repair from inside and out.
Repair work must be carried out according to the bellow type. See Figure 1 to
Figure 6.
Protect the insulation material against water and thinning during open surface.
C. Procedure (see Figure 34):
For each damaged layer in the bellow, cut out a piece of new fabric (2),
approximate 400 mm longer than the damaged length and of same width as
the damaged bellow.
Attach these pieces to the damaged bellow according to direction in sub-
section 4.6, layer by layer, inside first.
D. Mount the bellow
Position the repaired piece of bellow and mount the retaining iron (4).
E. Consequence of a repair
This type of repair can bring the bellow back in condition where its not
necessary to change the bellow at next major stop. Inspect the bellow after
repair meticulously.
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A. Material:
Use one layer of silicone coated glass fabric with silicone layer on outside for
the repair work.
Glass fabric from an old bellow can be used if in good condition.
B. Procedure (see Figure 35):
Cut out a piece of silicone coated glass fabric approximate 1 m longer than the
damaged length and width enough to overlap both flanges.
Leave the damaged bellow (1) in place and fix the glass fabric (2) to the
flanges with screw clamps and sewing (3).
Apply silicone glue around the damaged place between (1) and (2) and sew
the new glass fabric (2) together with the old glass fabric (1) round the glue
and where possible.
Leave the screw clamps in place until change of bellow can take place.
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5 Operation
5.1 Pre-operational check
Check the installation notification of completion of works. Check cancellation of permit
to work status.
6 Maintenance
6.1 Preventive maintenance
6.1.4 Replacement of
6.1.2 Inspection and
Equipment
6.1.1 Cleaning
spares
3 Bellow of all A A
Operation pressure and temperature
types.
4 Bellow of all A A
Clean the outside of the bellow for dust.
types.
5 Ceramic felt Change the ceramic felt in joint type Lined 2 A A
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6.1.1 Cleaning
4 Combustible dust
To reduce risk of fire and dust explosion, dust and to a greater extent
combustible dust must be removed from equipment and structures.
7 Lining
It is of importance to clean clearance for expansion movement. See Figure
12. Free space between linings in expansion joint, transversal and axial
must be cleaned under each maintenance stop.
6.1.2 Inspection and adjustment
1 Tightness of bellow
The first sign of disintegration is that the cover layer starts peeling off or
crackles, depending on whether it was subject to thermal or chemical
disintegration.
It takes at least a couple of months from the time the cover layer starts
coming off and until the expansion joint becomes unfit for continued
service. Repair of damaged bellow can be done according to direction in
sub-section 4.7.
Leakage may occur from excessive load on the bellow, weld spatter,
mechanical damage and check also for such.
7 Lining
Damaged lining must be repaired. Otherwise it can result in damage on
steel part and bellow.
6.1.3 Status check
2 Installation position
The dimension H is given on the steel part mechanical drawing and
Hinstallation in the Expansion Joint Legend.
Check these dimensions during standstill and compare with installation
values given on the Expansion Joint Legend. See sub-section 4.8.1.
Any departure from installation value should be evaluated and related to
operational functionality, see 6.1.5. Re-align the steel parts if necessary.
Measuring the distance, Hinstallation is not possible after insulation of the
duct. Measure the analogue dimension over the visible flanges and
calculate H on the mechanical drawing on expansion joint. The measured
dimension can be related to H and Hinstallation .
3 Operational parameter
At operation temperature and nominal load of the plant the position of the
bellow should be checked and evaluated in concern of any possibility for
damage caused by excessive load.
The pressure in the bellow and the temperature on the structures, which
the bellow shall protect are variables, which must be considered and
compared with design values.
6.1.4 Replacement of spares
5 Ceramic felt
Ceramic felt placed in the free space (expansion space) between linings
Figure 12, (10) must be changed under each maintenance stop. Observe
safety precaution, sub-section 3.4.
See direction for first establishing of the ceramic felt in installation
direction in sub-section 4.4.1.
The change of ceramic felt may follow one of two procedures of which is
considered the best:
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Provide access to the gaps for felt from the inside of the expansion
joint.
Cut pieces of ceramic felt suitable for stuffing into the gab a through
gab c, see Figure 24.
Use different kinds of bended 2 or 3 mm wire with angled ends
short enough to go through gap c and long enough to stuff the felt in
gab "a" and "c".
B: The ceramic felt must be set when the steel parts are drawn apart:
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