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3 CONTENTS 4 EXPANSION JOINTS DEFINITION 5 EXPANSION JOINTS STRUCTURE CALCULATION OF THE MOVEMENT AND SELECTION OF THE EXPANSION JOINTS PERIODIC LIFE FLOATING FLANGED EXPANSION JOINTS FIXED FLANGED EXPANSION JOINTS WELD-END EXPANSION JOINTS WELD-END EXTERNAL PRESSURE EXPANSION JOINTS FLANGED EXTERNAL PRESSURE EXPANSION JOINTS WELD-END UNIVERSAL TYPE EXPANSION JOINTS WITH TIE-ROD FLANGED UNIVERSAL TYPE EXPANSION JOINTS WITH TIE-ROD WELD-END GIMBAL TYPE SEISMIC-DILATATION EXPANSION JOINTS FLANGED GIMBAL TYPE SEISMIC-DILATATION EXPANSION JOINTS INSTRUCTION OF METAL EXPANSION JOINTS INSTALLATION RUBBER EXPANSION JOINTS INSTRUCTION OF RUBBER EXPANSION JOINTS INSTALLATION OMEGA TYPE FLEX DILATATION EXPANSION JOINTS FAN - COIL CONNECTORS FLEXIBLE METAL CONNECTORS WITH BRAIDING SPRINKLER CONNECTION METAL HOSES INSTRUCTION OF FLEXIBLE METAL HOSE INSTALLATION VALVE JACKETS FABRIC EXPANSION JOINTS OUR CERTIFICATES TECHNICAL TABLES NOTES

4 KOMPANSATÖRÜN TANIMI EXPANSION JOINTS DEFINITION The problem of dealing with thermal expansion joints in pipelines has been existing since the first use pipe itself. Firstly, the engineer s simple solution were only pipe bends, omegas and packet slip type joints to absorb the thermal expansion problems. ( Shape 1 ) Today, the expansion joints which consists of a flexible part made of metal, rubber or composite fabric materials are designed. ( Shape 2 ) The purpose of using expansion joints is to solve thermal expansion, mechanical movements and vibration problems of pipelines. Expansion joints absorb the thermal expansion stresses, mechanical movements and vibrations through their flexible bellows element thus easing the pipe stresses. When compared with the pipe element the rigidity of bellows element is very small and practically negligible. Therefore, the expansion joints are considered as zeroload elements. The stresses due to the thermal expansion, mechanical movements or vibrations are compansated by by the bellow which are the flexible parts of the expansion joints. 4

5 KOMPANSATÖRÜN YAPISI EXPANSION JOINTS STRUCTURE Expansion joints consists of bellows part with one or more ondulations in the general terms and the bellows protection equipments ( liner, external sleeves, tie-rods etc. ) and the fitting elements ( flange, welding-neck etc. ) providing their connection to the relevant piping installation. Ondülasyon ( Körük ) : Ondulations ( Bellows ) : It is the flexible part of expansion joints consisting of one or more ondulations. The number of the ondulations constituting the bellows changes depending on the amount of the total movement. Flanges : The equipment is used for connection of an expansion joints to the pipe system via bolts and nuts. Such connections provide advantage in mounting and demounting. Kaynak Boyun : Weld-Ends : They are used for the purpose of making a welded connection of an expansion joints to the pipe in the installation. Inner Sleeve ( Liners ) : It is one of the expansion joints equipment produced by thin walled stainless steel material mostly in the same quality with the metal bellows material and for purpose of minimizing the contact of the internal surface of the bellows and the liquid. Guide Sleeve : The increased length of the expansion joints brings along the risk of bending. External Sleeve : Limit Rods : The primary function of the limit rods it to limit the axial, lateral and angular movements of the bellows under usual operation conditions. Tie - Rods : They are used for the purpose of limiting the forces over the expansion joints exposed to lateral movements not to damage the bellows. External Sleeve Tie - Rod Inner Sleeve Guide Sleeve External Sleeve 5 Tie - Rod

6 CALCULATION OF THE MOVEMENT AND SELECTION OF THE EXPANSION JOINTS An example for the selection of the expansion joint from the catalogue is given below. Min. Temperature Tmin : -10 C temperature difference. T Since the temperature difference in our example is 170 The total axial movement is, That value could be rounded off as the closest upper value in the table. L ÇA NOMINAL DIAMETER DN KOMAT BOYU EXPANSION JOINTS FREE LENGTH L KT MOVEMENT mm could be as found as the free lenght of the expansion joints. The installation lenght of the expansion joints could be calculated by the formula; The connection type of the expansion joints should be choosen among the following three main groups after total axial movement and free lenght were determined. Flanged Connection Floating Flanged ( DF ) Fixed Flanged ( SF ) Weld-Ends ( KB ) Type Connections

7 PERIODIC LIFE Design life for the standart expansion joints is taken as 1000 full periods. The real expansion period is realized less due to maximum temperatures are given with higher values to be on the safe side in real life and minimum temperatures are almost never rached due to the insulation applications and higher environmental temperatures than estimated. The ratio of the real expansion to the designed expansion is defined as Periodic Life Factor Fc Real Expansion Designed Expansion Example : is less than the real operation value and the real movement value has been determined as 44 mm. Accordingly ; The periodic life is found from the Graphic of Periodic Life as 3400 periods periods safely. GRAPHIC OF PERIODIC LIFE The periodic life, the pressure rate, spring coefficient, stresses and similar design variables for metallic bellows type expansion joints are determined by use of special pc programming constructed according to EJMA standards

8 FLOATING FLANGED EXPANSION JOINTS DESCRIPTIONS DIMENSIONAL TABLE FOR EXPANSION JOINTS Part Bellow Flange Material L A NOMINAL DIAMETER KT MOVEMENT (mm) 45 D Ø EFFECTIVE AREA (cm ) OPERATION PRESSURE PN NOT : NOTE :

9 FIXED FLANGED EXPANSION JOINTS DESCRIPTIONS DIMENSIONAL TABLE FOR EXPANSION JOINTS Part Bellow Flange Material L A NOMINAL DIAMETER KT MOVEMENT (mm) 45 D Ø EFFECTIVE AREA (cm ) OPERATION PRESSURE PN NOT : NOTE :

10 WELD - END EXPANSION JOINTS DESCRIPTIONS DIMENSIONAL TABLE FOR EXPANSION JOINTS Part Bellow Weld - End Material L A NOMINAL DIAMETER KT MOVEMENT (mm) 45 h EFFECTIVE AREA (cm ) OPERATION PRESSURE PN NOT : NOTE :

11 WELD - END EXTERNAL PRESSURE EXPANSION JOINTS L DESCRIPTIONS DIMENSIONAL TABLE FOR EXPANSION JOINTS Part Bellow Weld - End Material L A NOMINAL KT DIAMETER MOVEMENT (mm D EFFECTIVE AREA (cm ) OPERATION PRESSURE PN NOT : NOTE :

12 FLANGED EXTERNAL PRESSURE EXPANSION JOINTS L DIMENSIONAL TABLE FOR EXPANSION JOINTS DESCRIPTIONS Part Material Bellow Flange Weld - End A NOMINAL KT DIAMETER MOVEMENT (mm D EFFECTIVE AREA (cm ) OPERATION PRESSURE PN NOT : NOTE :

13 WELD - END UNIVERSAL TYPE EXPANSION JOINTS WITH TIE - ROD DESCRIPTIONS DIMENSIONAL TABLE FOR EXPANSION JOINTS Part Bellow Weld - End Tie-Rod Material L A NOMINAL DIAMETER L KT MOVEMENT (mm) PRESSURE NOT : NOTE :

14 FLANGED UNIVERSAL TYPE EXPANSION JOINTS WITH TIE - ROD DIMENSIONAL TABLE FOR EXPANSION JOINTS Part Bellow Flange Weld - End Tie-Rod DESCRIPTIONS Material L A NOMINAL DIAMETER L KT MOVEMENT (mm) PRESSURE NOT : NOTE :

15 WELD - END GIMBAL TYPE SEISMIC - DILATATION EXPANSION JOINTS DIMENSIONAL TABLE FOR EXPANSION JOINTS DESCRIPTIONS Part Material Bellow L Weld - End Gimbal A NOMINAL DIAMETER L KT MOVEMENT (mm) OPERATION PRESSURE PN NOT : NOTE :

16 FLANGED GIMBAL TYPE SEISMIC - DILATATION EXPANSION JOINTS DIMENSIONAL TABLE FOR EXPANSION JOINTS DESCRIPTIONS Part Material Bellow L Flange Weld - End Gimbal A NOMINAL DIAMETER L KT MOVEMENT (mm) OPERATION PRESSURE PN NOT : NOTE :

17 INSTRUCTION OF METAL EXPANSION JOINTS INSTALLATION Only one expansion joints should be installed between two fixed points. Fixed points (main anchors) and guides should be located and designed as it is shown below. Expansion joints and pipe line should be on the same axis. False False True Opposite flanges should be perpendicular to pipe axis. False True Expansion joints are zero loaded tools. During installation of fixed flanged expansion joints torsional rotation on the expansion joints should be avoided. False Expansion joints should be installed with Pre - Setting (PS). It is calculated as follows. PS T T Care shall be exercised to prevent any damage to the thin bellows section, as dents, scores etc. False True

18 INSTRUCTION OF METAL EXPANSION JOINTS INSTALLATION Care shall be exercised to prevent any damage to thin bellows, such as arc strikes, weld splatter. The bellows should be prevented with a protective cover. False True The flow direction shoul be considered for expansion joints installations with inner sleeves. Flow Flow False True Work - shop pre - setting is avaible for external pressure expansion joints. Pre- setting bars should be removed after installation. Pre-Setting Bar Torsional rotation during installation should be avoided for central heating expansion joints. Pre - setting should be applied to this type of axpansion joints until the pin reaches location (1 ). Nominal pressure and movements of pipelines should be less (or equal) than selected expansion joints nominal pressure and movement capacity. Before the pressure tests, be sure about the pipeline forces are under control by use of fixed points and guides.

19 RUBBER EXPANSION JOINTS TEMPERATURE : FLANGE : DUCTIL IRON BODY : ( REINFORGED NYLON - CORD ) TEMPERATURE : FLANGE : POLYAMIDE BODY : ( REINFORGED NYLON - CORD ) TEMPERATURE : UNION : CAST IRON BODY : ( REINFORGED NYLON - CORD ) RUBBER STRUCTURE AND APPLICATIONS C temperature. Rubber bellows is consisted of special rubber, steel wire and reinforced nylon-cord. Good solution for vibration, noise and dilatation problems. Absorption of axial, lateral, angular and transverse movements. Easily installation with its floating flanged. Joints and seals are not needed. A NOMINAL DIAMETER L AXIAL (mm) YL LATERAL (mm) ANGULAR L L

20 INSTRUCTION OF RUBBER EXPANSION JOINTS INSTALLATION 1 - rubber expansion joints can be installed without any extra gasket. 2 - Flange to flange dimensions of the expansion joints must match in order to prevent rubber cutting. If opposite flange s inner diameter is over than required or cornered, the risk of rubber cutting is very high. True False 3 - Please follow these steps correctly to avoid over tightening the bolts. * First, nuts should be squeezed by hand. 4 - Please avoid using sharp tools during installation and avoid welding splashes and welding heat. use tall bolts above required standard since they will cause friction and rubber damages. False True joints. 7- Measurement should be taken for pressure absorption during expansion joints application for axial and lateral movements. Otherwise expansion joints will unfold and destroy as it s shown in the figure. 8 - Measurement should be taken against opening force at the pump outlets. True False

21 OMEGA TYPE FLEX DILATATION EXPANSION JOINTS U-V FLEX : Weld - Ends, Threaded Ends, Grooved Ends, Flanged WELD - ENDS THREADED ENDS GROOVED ENDS FLANGED A B ÇA DIAMETER A B T M KT MOVEMENTS ( ALL DIRECTIONS ) 445 Braid Material : AISI 304 Elbow Material : AISI St37.2 Flange Material : AISI St37.2 C ADVANTAGES V - FLEX Their assembly is easy and can be handled in a shorter time period. They are flexible and capable of moving in every directions. Absorbs also the thermal movements. Only one support is required.

22 DIMENSION TABLE T TYPE DIMENSIONS D WITHOUT BRAIDING WITH BRAIDING T TOLERANCE YUVA Y BEND RADIUS ONCE-ONLY BENDING r min FREQUENT BENDING r n MA WORKING PRESSURE A WEIGHT

23 FAN - COIL CONNECTORS Fan - coil connectors are used for flexible connections of fan - coil units to With Insulation Without Insulation Hose : Unions : Carbon Steel ( Cr-Ni Coated ) Insulation : Closed cell structure PE foam Length (cm) * For special diameter, length and connection type, please consult us. FLEXIBLE METAL CONNECTORS WITH BRAIDING Braided flexible connectors are used as flexible connections for steam, water, gas and oil line applications to provide high pressure and flexibility. Hose : Braid : Unions - Flange : Carbon Steel ( Galvanized ) Produced only with flanged connection for diameters 2 and greater than 2 Diameter : * For special diameter, length and connection type, please consult us.

24 SPRINKLER CONNECTION METAL HOSES Sprinkler system, when the fire starts to spray water to the blaze automatically and control the fire in fixed place or extinguish. These systems are installed on the ceiling and takes water from the main fire pipeline. Sprinkler system prefered when the area is difficult to reach or in the dangerous place. Sprinkler connection hoses, braided flexible metal hoses that provide the connection between the sprinkler and the fire line which are not affected by seismic or mechanical movements. Hose Material Braid Material Fittings Material Connection Dia Hose Diameter Operating Pressure APPLICATION AREAS Shopping Malls Hospitals Hotels Business Centers Schools Fabrics Public Areas Bending Radius CONNECTION TYPE

25 Put the hose regular coils. INSTRUCTION OF FLEXIBLE METAL HOSE INSTALLATION Dimension the hose adequately. Take care of that the flexible length is not too short. Don t allow the hose to move in only direction. Centre it to permit absorption of half of the movement in both direction. Don t permit axial movement. Install the hose vertically to the direction of movement. Avoid excessive bending of hose. Ose pipe bends if necessary. Avoid extreme lateral movement. Install the hose with a bend of 90 Install the hose in one plane only to avoid torsional twist and moments. Keep the installation plane parallel with the hose plane to avoid inclination.

26 VALVE JACKETS * Valve jackets are used to minimize heat loss through pipe line armatures and to prevent steam and density made through cooling system and to increase the system productivity. * The maximum temperature allowed for the insulation fabric in standard jackets is approximately 280 C. The WHY USE VALVE JACKETS? Easy to mount and dismount. They are re-usable. They can be re-attatched and used repeatedly when repairing or maintaining equipment. Cost of mounting is very low. They are long lasting. They are provide thermal insulation and are energy saving. They allow for longer lasting equipment. * As temperature of the non-insulated valve surface is observed by thermal cameras C, the temperature of the valve surface insulated by valve jackets is INSTALLATION Jacket is installed on the equipment such that it encompasses the section to be insulated. The alignment of the vectro fasteners on the lower and upper connections is provided. Vectro fasteners are attached to each other. Fitting of the edges on the equipment is provided by drawing the lateral threads.

27 FABRIC EXPANSION JOINTS Fabric expansion joints are designed to minimize the mechanical movements by seismic, the stress and the mounting defects occurred through the pipe lines by having loaded high thermal dilatation and vibration on itself. max. temperature There are four necessary components in projecting a fabric expansion joints ; Temperature, Pressure, Environment, and Chemical corrosion. SPECIFICATIONS T M HIGH VIBRATION AND NOISE ELIMINATION L COMPENSATION OF THERMAL EXPANSION K HIGH FLEXIBILITY MA WORKING TEMPERATURE UP TO 1300 C M MINIMUM REACTION FORCE LAYERS OF FABRIC EXPANSION JOINTS REINFORCING LAYER FOR FLANGE FLEXIBLE OUTER LAYER SEALING LAYER HIGH TEMPERATURE HEAT INSULATION LAYER HEAT INSULATION LAYER STRENGTH AND RESISTANCE LAYER

28 OUR CERTIFICATES

29 TECHNICAL TABLES D

30 TECHNICAL TABLES T T Torr Unit Symbol Torr Mo T Material

31 TECHNICAL TABLES KAUÇUK K MYL DAY RUBBER CHEMICAL RESISTANCE COMPARISON APPLICATIONS T L A TFresh Water B A A A Sewerage A B A Potable Water B A A A Hot Water B A A A Chilled Water B A A A TBrine Water A A A A Ya Vegetables Oil B A A Ya Peanut Oil B A Ya Soybean Oil B B A Ya Animal & Vegetables Oil B A A Ya Lube Oil B A Baking Soda A A A A Beer A A A Corm Syrup B A B B Dextrose B A B B Milk A A B A Glycol A A A A Vinegar B A B Wines A A A A Black Liquor A A B A Y Green Liquor A A A A White Liquor A A A A Caustic Soda B B A Sufuric Acid 10% A A B A Sufuric B B B Sufuric Acid Dilute A A B A Sufuric Acid Concentrated Phosphoric Acid Concentrated B B Phosphoric Acid 10% B A A A Phosphoric Acid 20% B A B Phosphoric B B

32 TECHNICAL TABLES COMPRASION TABLE FOR MATERIAL STANDARDS YA GERMANY ABD USA L UK A FRANCE Materials No A A A A A T T T T T T T T T T T

33 NOTES

34 NOTES

35 35

36 Ajans Designed by Kompansatör ve Esnek Bağlantı Elemanları San. ve Tic. Ltd. Sti. Dudullu Org. San. Bölgesi 1. Cadde No:30 K:2/A Y.Dudullu - Ümraniye - İstanbul - TURKEY Tel : +90 (216) pbx Fax : +90 (216) info@protemateknik.com