EXPANSION JOINT

HANKOOK RASEONKWAN CO., LTD

#447-2, MOGOK-DONG, PYONGTAEK-CITY,
KYUNGGI-DO, KOREA (ZIP CODE : 459-040) EXPANSION
JOINT
E-MAIL: [email protected] / [email protected] Metallic Expansion Joint
TEL: +82-31-665-2111 / FAX : +82-31-665-7949
Non-metallic Expansion Joint
http:// www.hkr.co.kr
Rubber Expansion Joint

HANKOOK RASEONKWAN CO., LTD

Copyrightⓒ2006 Hankook Raseonkwan Co., Ltd. All rights reserved

 RUBBER EXPANSION JOINT

9. ADDITIONAL TIPS

1) Do not insulate over a non-metallic expansion joint. If required, allow enough space for the tightening
of loosened bolts without
any access difficulties for regular inspection.
2) Do not weld near a non-metallic expansion joint.
3) Checks whether the cover material of the outdoor installed joint is resistant to ozone or sunlight.
Neoprene and Chlorobutyl are recommended. Use weather resistant paint on other materials to avoid
the effects by ozone and sunlight.
4) Check for leakage 2~3 weeks after installation. If necessary, tighten it again.
Note: Expansion joint may be used in pipelines or equipment that transfers temperature and pressure
generating gas or harmful materials. Therefore, do not install a rubber joint where checking is impossible
due to difficult access. Leakage unable to be recovered must be checked for proper exhaust.

10. INSTALLATION OF CONTROL UNIT

1) Install the products provided with retaining ring in the piping section, allowing the same distance face
to face, of the expansion joint.
2) Place the control rod plate behind of the pipe flange.
Use bolts of sufficient length to apply the plate. The plates should be assembled at an equally spaced
around the flange. Use two or more control rods in accordance with pressure and size.
3) Insert a control rod through the plate hole. Positioned a steel washer outside the plate. For additional
rubber washers, assemble them between the plate and steel washers.
4) Fasten a nut, considering the proper distance between washers and nuts for the extension range of the
product. Apply tack welding or bind it with wire to avoid unfastening of a nut. Tightening nuts are also
available.
5) Install pipe sleeve by using normal pipe as long as product’s compression.
6) The control rod for reducer type product should also be parallel to pipes.

11. INSTALLATION LOCATION

The expansion joint should always be installed in an accessible location to allow for future inspection or
replacement.
 DIRECT BURIED TYPE EXPANSION JOINT

It is built to absorb the land pressures and seismic against the duct breakage because of the ground settlements
and the earthquake shocks.

Single type (HDBJ-S) Double Type (HDBJ-D)

I) Single Type(Vaccum~20kg/cm2) II) Double Type (Vaccum~20kg/cm2)

Corr. Length Angular Corr. Lateral Movement Capability (mm)

N.D (A) N.D (A)
No. (mm) Mov’t (deg) No. 1500L 2000L 2500L 3000L 3500L
150 3 400 10 150 3+3 230 355
200 3 400 10 200 3+3 190 290 380
250 3 450 10 250 3+3 155 240 320
300 3 450 9 300 3+3 180 275 375
350 3 450 9 350 3+3 165 250 340
400 3 600 8 400 5+5 165 275 395
450 3 600 8 450 5+5 150 225 345
500 5 800 12 500 5+5 135 240 315
600 5 800 12 600 5+5 120 190 270 350
700 5 800 10 700 5+5 105 155 225 290
800 5 1000 10 800 5+5 90 150 345 450
900 5 1000 10 900 5+5 80 135 300 395
1000 5 1000 10 1000 5+5 75 120 270 355
1100 5 1200 6 1100 5+5 255 335
1200 5 1200 6 1200 5+5 225 295 370
1350 5 1200 5 1350 5+5 215 280 345
1500 5 1200 5 1500 5+5 185 240 300
1600 5 1200 5 1600 5+5 200 255
1800 5 1400 5 1800 5+5 185 230
2000 5 1400 5 2000 5+5 165 210
2200 5 1400 4 2200 5+5 150 180
2400 5 1400 4 2400 5+5 135 165
2800 5 1400 4 2800 5+5 110 145

18
NON-METALLIC EXPANSION JOINT
목 차

1. INFORMATION ABOUT NON-METALLIC EXPANSION JOINT 42

2. STRUCTURE OF NON-METALLIC EXPANSION JOINT 43

3. APPLICATION FOR NON-METALLIC EXPANSION JOINT 44

4. COMPARISON OF NON-METALLIC AND METALLIC PRODUCTS 56

5. EXPANSION JOINT DESIGN 57

6. EXPANSION JOINT MATERIAL 62

7. COMPOSITION AND APPLICATOPN OF STANDARD PRODUCTS 64

NON-METALLIC EXPANSION JOINT

CONTENTS
RUBBER EXPANSION JOINT

8. INFORMATION ABOUT RUBBER EXPANSION JOIN 66

9. TYPE OF RUBBER EXPANSION JOINTS 69

10. OPERATIONAL FEATURE OF RUBBER EXPANSION JOINT 71

11. STANDARD PRODUCT 72

12. INSTALLATION 78

13. PRECAUTIONS INSTALLATION 80

NON-METALLIC EXPANSION JOINT

INFORMATION ABOUT NON-METALLIC EXPANSION JOINT

Definition of Product

The non-metallic expansion joints are flexible connectors designed

to eliminate the thermal stress created by absorption of
displacement from thermal changes in ducting systems. It also
absorbs vibrations and compensates for minor installation errors in
its ducting or equipment. They are fabricated from a wide variety of
non-metallic materials, including synthetic elastomers, fabrics,
insulation materials and fluoroplastics, depending on the designs.

Major Applications
The range of use for non-metallic expansion joints has widened since its
introduction in the early sixties. The stricter environmental regulations have
resulted in the development of more sophisticated duct systems, requiring
non-metallic expansion joints to solve those problems caused by the thermal
and mechanical stresses generated in these complex systems.

Although the major user of the non-metallic joint continues to the power
generation industry, the use of this product has expanded into virtually every
industry, which conveys gases. A partial list of those industries is as follows:

1) Power generation 3) Refineries 7) Refuse Incineration

- Fossil Fired Plants - Petroleum industry 8) Marine
- Gas Turbine Plants - Chemical equipment 9) Food Processing
- Cogeneration Plants 4) Steel Mills 10) HVAC-Heating,
- Nuclear Power Plants 5) Smelters Ventilating and Air Conditioning
2) Pulp and Paper Plants 6) Cement Plant

42
 NON-METALLIC EXPANSION JOINT

STRUCTURE OF NON-METALLIC EXPANSION JOINT

A. Gas Seal Membrane The gas seal membrane is intended to withstand system pressure and be resistant to chemical
attack from the interior and the exterior. The gas seal must also have the flexibility to absorb thermal movements.
Depending on system temperature, it may or may not require additional thermal protection.

B. Insulting Layer The insulating layers provide a thermal barrier to ensure that the inside surface temperature of
the gas seal membrane does not exceed its maximum service temperature. The insulating layer can also reduce
condensation caused by the gas stream coming in contact with the“cool”surface of an un-insulated gas seal membrane.

C. Insulating Retainer Layer This layer is provided solely to keep the insulating layers in place in order to maintain thermal
integrity. The retaining layer must be capable of withstanding gas stream temperatures and must be chemically compatible
with system media.

D, Back-Up Bars A back up bar, positioned at the flange attachment, uses clamping pressure to create the
fabric-to duct seal and restrains the fabric when it is subjected to the system pressure. The thickness and width of the
back up bar should be sufficient to perform this function with the bolt spacing being used. The edges of the back up bar
should have a radius to preclude cutting of the fabric.

E. Metal Liner A liner designed to protect the gas seal membrane and insulating layers of the flexible element
from abrasive particles, which may be present in the gas stream. A liner is also used to reduce flutter of the fabric element
caused by turbulence, to help control the accumulation of duct or ash in the expansion joint cavity, and to reduce the
temperature of the flexible element.

F. Accumulation Bag An accumulation bag is intended to deter fly ash from building up in the expansion joint cavity.
It is typically used, in conjunction with a liner, in duct runs from boilers to air clean-up equipment such as precipitators,
scrubbers and bag houses, or whenever high amounts of dust or ash are present in the gas. A fly ash barrier must be
capable or retaining its strength and flexibility while being exposed to maximum system temperatures and media.

G. Metal Frame Fabric attachment flanges are required to connect the flexible element to duct work. Properly
designed, they can be attached directly to the duct work and thus eliminate the necessity for an adjoining duct flange.
Flanges can be designed with a “landing bar”duct attachment, which allows some installation misalignment without
affecting the flexible element. The flanges establish the stand off height of the fabric, which is necessary to achieve thermal
integrity during all movement conditions. The edges of the flanges in contact with the Gas Seal Membrane should also have
a radius to prevent damage.

H. Gasket or Cuff Fabric belts with insulating layers require a special thermal insulating gasket to protect fabric components
from hot attachment flanges and back up bars. Low temperature, single ply belt designs require flexible, chemically inert gasket.

43
 APPLICATION FOR NON-METALLIC EXPANSION JOINT

APPLIED INDUSTRIES

APPLICATIONS SYSTEM DESIGN CONSIDERATIONS

Economizer to Air Heater Temperature:

Gas Recirculation to Boiler 700°
F~900°F for continuous operation, excursions to 1200°
F
Air Heater to Precipitator
Recovery Boiler to Precipitator Media:
Turbo-Expander to CO Boiler Low pH Flue gas from the combustion of coal, oil, or caustic black liquor;
CO Boiler to Precipitator Flue gas from regeneration process.

Particulate:
Transferred with heavy fly ash from coal combustion, salt cake from black
liquid fuel or catalyst carryover from the FCCU unit at a Refinery.

Insulation / Lagging:
Do not lag over the expansion joint. Also, remove lagging back away from
the flanges to allow radiant cooling.

Pressure:
Slightly negative for balanced draft boilers, otherwise positive pressure as
much as 40-50 inches water gage. Low pressure off the Turbo-Expander.

Operating Conditions:
Systems usually on line for 12 to 18 months. Refineries have longer durations
between major outages. Only Power‘peaking’plants will cycle more
frequently.

Movements:
Ductwork/boilers generally have large expansions and require joint system
with large lateral and compression capabilities.

44
 COMPONENTS AND FEATURES

A Belt
High performance gas seal membrane
DESIGN APPLICATIONS Heat Seal Splice
Flexibility for large movements
High tensile for particulate build up.
Repairable
Assembled by heating.

B Insulation
Formed by needle insulation blanket.
Reinforced with wire mesh
Must not allow temperature to exceed belt
maximum.

C Accumulation Pillow
Reduce Fly ash build up in Cavity

D Radiused Back-Up Bar and Frame Edges

Protects belt from damage
Note: Above design is available for all
applications. Different types of main body E Telescoping Lingers
Shortens installation period.
structures are available according to user’s
Eliminates direct impingement (abrasion)
duct installation conditions.
Reduces temperature at the belt element

F Cuff-Flange insulation
Produced with woven glass fiber tape.
Protects a belt from high hot flange and back-up bar.

Outboard Flanges
G Allows radiant cooling
Lower cost belt installation

GAS SEAL MATERIAL CONSIDERATION

Wet/dry media Optional chemical resistant barrier is not required since the system maintains temperatures
greater than dew point so that fluids do not produce moisture while operating. Regular
operation may cause corrosive condensate. Chemical resistant barrier prevents corrosion.

Flutter Eliminate the possibility of the mechanical damage due to flutter by using a composite design
of bellows and accumulation pillow.

Pressure Continuous pressures below 50 inches water gauge do not require special belt construction.

Abrasion Above design avoids the direct effects of fly ash, salt cake or catalyst that will be present.

Gas / Air Combustible gasses are produced by the combustion of fossil fuel or black liquid fuel,
creating highly corrosive condensation.

45
 APPLICATION FOR NON-METALLIC EXPANSION JOINT

APPLIED INDUSTRIES

APPLICATIONS SYSTEM DESIGN CONSIDERATIONS

Temperature:
Air Heater to Fossil Fired Boiler
600°F~750°F for continuous operation
Air Heater to Coal Mills.
Media:
Clean ambient air pushed from the FD Fan and from the Primary Air Fan
thru the Air-heater to the Boiler both directly and thru the mills

Particulate:
Clean Air

Insulation / Lagging:
Do not lag over the expansion joint. Also, remove lagging back away from
the flanges to allow radiant cooling.

Pressure:
Positive 5”water to as high as 80”of water for positive pressure boilers.

Operation:
After start up movement is nominal. Severe high pressure operating
conditions may be experienced in the Primary Air Ducts of Positive
Pressure Boilers.

Movements:
Moderate high temperatures will generate moderate compressive and
movements when the unit is on line. Each change in direction in the
ductwork will generate a resultant lateral offset.

46
 COMPONENTS
구성요소 및 특성 AND FEATURES

A Belt
High performance gas seal membrane
DESIGN APPLICATIONS Heat Seal Splice
Flexibility for moderate movements
Repairable

B Insulation
Formed by needle insulation blanket.
Reinforced with wire mesh
Must not allow temperature to exceed belt
maximum.

C Flow Liner
Increase Service Life
Outage personnel safety

D Radiused Back-Up Bar and Frame Edges

Protects belt from damage

Note: Above design is available for all E Outboard Flanges

applications. Different types of main body Allows radiant cooling

structures are available according to user’s Lower cost belt installation

duct installation conditions. Easier belt access

F Cuff-Flange Insulation
Produced with woven glass fiber tape.
Protects a belt from high hot flange and back-up bar.

GAS SEAL MATERIAL CONSIDERATION

Wet/dry media Since temperatures are well above flue gas dew point temperature during continuous
system operation the media will be dry and membranes without chemical film barriers may
be used.

Flutter Composite type of belt structure is inherently rigid enough to eliminate the possibility of
mechanical damage due to flutter.

Pressure No special belt design is required for continuous operation pressure below 50inches water
gage. However, if it is a positive pressure boiler, pressure may reach 75”to 80”of water
resulting in the need for higher strength materials.

Abrasion None

Gas / Air The media is clean air drawn from the Fan thru the Air-heater to Boiler and the Mills.

47
 APPLICATION FOR NON-METALLIC EXPANSION JOINT

APPLIED INDUSTRIES

APPLICATIONS SYSTEM DESIGN CONSIDERATIONS

Temperature:
Primary Air Fan to Air Heater
Ambient air, -20°F~120°F
FD Fan Air to Air Heater
Primary Air to Recovery Boiler Media:
Ambient Air to Turbine Ambient air
FD Fan Air to Recovery Boiler
Particulate:
None

Heat Insulation and Insulation:

Heat insulation and insulation can be used on the outside of the product
in the case of low operating temperatures.

Pressure:
Positive pressure, 40~50 inches water gauge or higher.
Turbine air inlets are slight negative pressure. Outlet at fans may produce
pressure pulsations and/or extreme turbulence.

Operation:
Operational conditions have little effect on the airside ducts. Cyclical
conditions and dew point have little effect as well.

Movements:
Joints at boilers subject to large movements. Fan outlet joints see little
movement, primarily vibration.

48
 구성요소 및 특성 AND FEATURES
COMPONENTS

A Belt
Gas Seal membrane
DESIGN APPLICATIONS Moderate Flexibility
Medium Tensile Strength
Heat Seal
Repairable

B Flow Liner
Increases product’s service life.
Outage for personnel safety.

C Radiused Back-Up Bar and Frame Edges

Prevents the damage to the belt.

D Outboard Flanges
Easy access reduces installation and replacement
labor cost

E Gasket
Prevents gas leakage.
Note: Above design is available for all
Easy to installation
applications. Different types of main body
Optional for some gas seal membranes
structures are available according to user’s
duct installation conditions.

GAS SEAL MATERIAL CONSIDERATION

Wet/dry media Dry ambient clean air

Flutter Direct air impingement is likely at the Primary Air Fan Outlet and at the FD Fan Outlet.

Pressure Continuous positive pressure rating from 30 inches to 90 inches water gauge. Some gas
seal membranes may require special belt construction. Turbine air inlet slightly negative
and constant.

Abrasion None

Gas / Air Ambient air usually contains no contaminants that may be harmful to the gas seal
membrane.

49
 APPLICATION FOR NON-METALLIC EXPANSION JOINT

APPLIED INDUSTRIES

APPLICATIONS SYSTEM DESIGN CONSIDERATIONS

Re-Heater to Chimney Temperature:

Continuous operation temperature, 350°F~500°F
Precipitator to Induced Draft Fan
Induced Draft Fan to Chimney
Media:
Induced Draft Fan to Scrubber Flue gas from precipitator drawn by Induced Draft Fan; Scrubbed Flue
Steam Generator to Stack gas from Re-Heater going to Chimney. Turbine Exhaust Gas from Heat
Precipitator to Chimney Recovery Steam Generator to Chimney.

Particulate:
Minimal before scrubber systems, negligible after scrubber systems.

Insulation / Lagging:
Temperatures allow lagging over the expansion joints without adverse
effects.

Pressure:
-15”wg after precipitators and +15”wg after I.D fan
The ducts of scrubbers and steam generator ends are affected by the
pressure -5~+5”wg.

Operation:
Although movements are not severe temperatures will approach dew point
present potential corrosion problems.

Movements:
Moderate compressive and lateral movements expected depending on
ductwork configuration and length. Fan Joint usually see minimal
movements.

50
 구성요소 및 특성 AND FEATURES
COMPONENTS

A Belt
High performance gas seal membrane.
DESIGN APPLICATIONS Heat Seal Splice (No vulcanization)
Flexibility for moderate movement.
Repairable

B Flow Liner
Increases product’s service life.
Outage personnel safety

C Radiused Back-Up Bar and Frame Edges

Prevents the damage to the belt.

D Outboard Flanges
Easy access reduces installation and
replacement labor cost.

E Gasket
Prevents gas leakage.

Note: Above design is available for all Easy to installation.

applications. Different types of main body Selectively used according to the gas seal
structures are available according to user’s material in a belt.
duct installation conditions.

GAS SEAL MATERIAL CONSIDERATION

Wet/dry media Since temperatures are above the flue gas dew point, media will dry during continuous operation.
Membranes without chemical barrier may be used. If changes in system operation or frequent
outages cause wet, corrosive conditions, an optional chemical barrier should be considered.

Flutter Direct flue gas impingement is likely at the induced Draft Fan Outlet.

Pressure The pressure range of continuous operation is under 50”WG, and a special stiffening
structure is not necessary. However, if it is a positive pressure boilers, pressure may
reach 75~80”of water resulting in the need for higher strength material.

Abrasion None

Gas / Air The combustion gas produced by fossil fuel or black liquid fuel creates corrosive
condensate. Turbine exhaust is clean and non-corrosive.

51
 APPLICATION FOR NON-METALLIC EXPANSION JOINT

APPLIED INDUSTRIES

APPLICATIONS SYSTEM DESIGN CONSIDERATIONS

Scrubber to Re-Heater Temperature:

Scrubber Bypass to Scrubber Continuous operation temperature, 150°F~350°F
Scrubber Bypass to Re-Heater
Scrubber Outlet to Re-Heater Media:
Dry flue gas to scrubber or bypass pushed by Induced Draft Fan; Wet
flue gas at scrubber inlet; Wet, scrubbed flue gas from Scrubber (flue gas
desulfurization) going to Reheater.

Particulate:
Minimal before scrubber systems, negligible after scrubber systems.

Insulation / Lagging:
Temperatures allow lagging over the expansion joints without adverse
effects.

Pressure:
Positive after the Induced Draft Fan, as mush as 15”wg. Slightly negative,
-5”wg. to slightly positive, +5”wg after Scrubber depending on unit load
and weather conditions.

Operation:
Although movements are not severe temperatures will approach dew point
and present potential corrosion problems. Wet Scrubber Service is
potentially highly corrosive.

Movements:
Small movements expected.

52
 구성요소 및 특성 AND FEATURES
COMPONENTS

A Belt
Chemical resistant barrier.
DESIGN APPLICATIONS High performance gas seal membrane.
Heat Seal Splice (No vulcanization)
Flexibility for moderate movements
Repairable

B Flow Liner
Increases product’s service life.
Outage for personnel safety

C Radiused Back-Up Bar and Frame Edges

Prevents damage to the belt.

D Outboard Flanges
Easy access reduces installation and replacement labor cost.

E Gasketing
Chemical resistance required

Note: Above design is available for all Prevents gas leakage.

applications. Different types of main body Easy to installation
structures are available according to user’s
duct installation conditions.

GAS SEAL MATERIAL CONSIDERATION

Wet/dry media Temperatures are in or near the flue gas dew point; media will be wet during continuous
operation. Membranes with chemical barrier should be used.

Flutter Partially open Bypass damper or changes in direction of ductwork may create excessive
gas stream turbulence resulting in direct flue gas impingement.

Pressure Varies from positive to negative depending on system operation. Membrane may see more
flexing then other applications. Good flexibility needed.

Abrasion None

Gas / Air Gas streams from fossil fuel or black liquor combustion processes may create corrosive
condensation.

53
 APPLICATION FOR NON-METALLIC EXPANSION JOINT

APPLIED INDUSTRIES

APPLICATIONS SYSTEM DESIGN CONSIDERATIONS

Diverter Bypass to Stack Temperature:

Diverter Exhaust to HRSG Continuous operation temperature, 1000°F~1200°F, excursions to 1350℉.

Media:
Turbine Exhaust to Diverter Inlet
Turbine Exhaust Gas from combustion of natural gas or fuel oil. Dry and
Turbine Outlet Stack
non-corrosive.

Particulate:
None

Insulation / Lagging:
Do not lag over the expansion joint. Also remove lagging back away from
the flanges to allow radiant cooling.

Pressure:
Constant positive pressure generally no higher then 15 to 20 inches water
gauge.

Operation:
Systems with heat recovery are usually on line for 12 to 18 months. Power
‘peaking’plants may cycle frequently as much as once per day.

Movements:
Ductwork/ equipment expansions are large due to the temperature.
Generally, lateral movements are small due to short, direct ductwork runs.

54
 구성요소 및 특성 AND FEATURES
COMPONENTS

A Belt
High performance gas seal membrane.
DESIGN APPLICATIONS Heat Seal Splice
Flexibility for large movements
Repairable

B Insulation
Formed by needle insulation blanket.
Reinforced with wire mesh.
Must not allow temperature to exceed belt
maximum

C Insulation Pillow
Critical for reducing cavity temperatures
High performance insulation blanket
Wire mesh/silica cloth cover for long life
integrity

D Radiused Back-Up Bar and Frame Edges

Prevents damage to the belt.

Note: Above design is available for all E Outboard Flanges

applications. Different types of main body Allows radiant cooling
structures are available according to user’s Lower cost belt installation
duct installation conditions.
F Cuff
Made of woven glass fiber tape.
Protects a belt from Hot Flange and Back-Up Bar.

G Telescoping Lingers
Required to install an insulation pillow properly.
Dampens turbulence reduces temperature at
the belt element

GAS SEAL MATERIAL CONSIDERATION

Wet/dry media Generally dry and non-corrosive.

Extreme turbulence is generated near the turbine outlet.

Flutter The composite belt design, insulation pillow and telescoping liners sufficiently dampen
turbulence pulsations.

Pressure Continuous pressure below 50 inches water gauge does not require special belt construction.

Abrasion None

Gas / Air Gas streams from Turbine combustion usually have no chemical effects on gas seal
membranes. However, with the increased importance of emissions control, chemical
additives to the turbine combustion process may require chemically resistance gas seal
membranes.

55
NON-METALLIC EXPANSION JOINT

COMPARISON OF NON-METALLIC AND METALLIC PRODUCTS

Advantages of Non-Metallic Expansion Joint

1) Large movements: The non-metallic expansion joint offers multi-plane movement

in a shorter face-to-face dimension.
2) Low load: Very small reaction force created by expansion amount.
3) Corrosion Resistance: Able to be used with a wide variety of elastomers, fabrics
and fluoroplastics.
4) Sound and Vibration elimination: Superior reduction of vibration and noise.
5) High Temperature Resistance: Available for operating temperatures up to 2000°F.
6) Cost Effective: Cost effective design, reduction in number of devices and simple
system structure
7) Economical Material Cost: Easy to apply non-corrosive materials.
8) Cost Effective Transportation and Installation: Lightweight and minimal field
assembling cost.
9) No Need for Gasket: Product itself is a gasket.
10) Economical Replacement Cost: The time required for replacement is short.

Advantages of Metallic Expansion Joint

1) High Pressure Capability: Can be used in high-pressure conditions.

2) Low Temperature Application: Can withstand large temperat ure extremes,
including cryogenic.
3) Fluid Transfer: Can be designed for liquid or gaseous media
4) Perfect Sealing: Perfect sealing of gas or fluid
5) Non-combustible
6) No Need for Maintenance & Repair: Additional maintenance & repair is not
necessary.

56
 NON-METALLIC EXPANSION JOINT

EXPANSION JOINT DESIGN

Movement Conditions
1) Type of Movements
Axial Compression: The dimensional shortening of the expansion joint face-to-face gap
parallel to its longitudinal axis.
Axial Extension: The dimensional lengthening of the expansion joint face-to-face gap
Axial Compression parallel to its longitudinal axis.
Lateral Movement: The dimensional displacement of the inlet and the outlet flanges of the
expansion joint perpendicular to its longitudinal axis.
Torsion Rotation: The twisting of one end of the expansion joint with respect to the other
end about its longitudinal axis.
Angular Rotation: That movement which occurs when one flange of the expansion joint is
moved to a put-of-parallel position with the opposite flange.
Axial Extension Vibration: The rapid, small movements, back and forth that can occur in any single plane
or multi-planes.

2) Independent or Concurrent Movement

Independent movement: Defined as acting along and in only one direction at one time.
Concurrent movement: Defined as any two or more movements acting simultaneously.
3) Normal Operating and Excursion Movement
Lateral Movement
Consider design expansion by normal and excursion movement data.
4) Typical Movement Capabilities

Axial Active Axial Lateral

Type
Compression Length Expansion Movement
Torsion Rotation
150mm 40mm 13mm 25mm

230mm 75mm 13mm 38mm

Single Layer
BREACH OPENING ACTIVE LENGTH
ACTIVE LENGTH 305mm 100mm 25mm 50mm

405mm 125mm 25mm 63mm

Angular Rotation 150mm 25mm 13mm
BREACH OPENING 13mm

230mm 50mm 13mm 25mm

Composite type
INTEGRAL FLANGE TYPE 305mm 75mm 25mm 38mm

405mm 100mm 25mm 50mm

The active length of the flexible element is a major design consideration. In general, by increasing the active
length of the expansion joint, greater movements can be accommodated.
Above movement range is applicable only to Independent movement, and Concurrent movement follows HKR standards.

57
NON-METALLIC EXPANSION JOINT

Set-Back (Stand-Off Height)

Consider set-back (stand-off height) when you determine the outside size of a duct.
Set-back refers to the height from the inside of a duct to the bellows.

Integral Flange type Belt type

HKR Standards for Set-back (by Type/Pressure Direction)

Active Length 150mm 230mm 305mm 405mm

Belt Type/
75mm 75mm 100mm 150mm
Positive Pressure
Belt Type/
Set-Back

100mm 150mm 150mm 175mm

Negative Pressure
Integral Flange Type/
25mm 38mm 50mm 63mm
Positive Pressure
Integral Flange Type/
50mm 75mm 100mm 125mm
Negative Pressure

Face to face or brench opening

The Face-to-Face distance or Breach Opening is the distance between the mating
duct flanges in which the expansion joint is to be installed.
The active length of the flexible element is a major design consideration. When
designing active length, both movements and system pressure must be considered.

Back-Up Bar
Composed of steel bar. Tightens the connection with belts and duct flanges or
expansion joint structures
Standard size Back-up Bars is 9mm thick and 50mm wide.
All edges connected to flexible element should be grinded smooth or radiused
so as not to damage the flexible element.
Bolt hole spacing is standardized at 4 inch or 6 inch center-to center distance.

Bolt Size Flange Bolt Hole Spacing

1/2”bolt 4”

5/8”bolt 4”or 6”

58
 NON-METALLIC EXPANSION JOINT

Connection Method of the Product to Duct Structure Features

FF Type
Accommodates a flanged
duct.
Same advantage as an
“FW”type.
If bolting is necessary,
holes matching the duct
flange and welded nuts
can be provided.

FW Type
Best choice when liners
are required.
Landing bar type fit permits
duct misalignment.
Accommodates any flat
belt selection.
Shipped fully assembled
for easy installation.
Rectangular joints have
full radius corners.
Low replacement cost of
flexible element.
Best choice for attachment
of fly ash barrier.
Flanges can act as duct
stiffeners.
WLW Type
Accommodates any flat
belt selection.
Rectangular joints have
full radius corners.
Shipped fully assembled,
for easy installation.
Welded to ducts.
Liner welded at site.

MC Type
Accommodates a flanged
duct.
Bolting accessible from
exterior of duct.
Liner is used selectively.
Economic installation cost.

59
NON-METALLIC EXPANSION JOINT

System Temperature
Insulation and Condensation within the Ducting
High temperature ducting systems are often insulated to conserve energy and to prevent internal condensate.
Expansion joint should be designed properly for this condition to avoid problems. The description below is
an example of proper expansion joint and heat insulation design.

Insulating Layers
The thermal barrier of a multiplayer fabric element must resist heat, moisture and acid attack. Additional
retaining layers must be made of materials which remain strong and flexible when exposed to high
temperatures and acids or condensates resulting from operation at or below the dew point.

When the maximum continuous system, operating temperture is near the gas dew point and less
than the allowable service temperature of the gas seal membrane material
Good Design Pool Selection Of Material Single Ply Seal Membrane

Dew Point Composite“Belt Style”

Expansion joint flexible element is fully insulated to conserve Ducting and expansion joint are not properly insulated.
energy, yet easily accessible for inspection and replacement. Severe condensation is possible. Costly heat energy is lost.

Single ply“Belt style”

Condensate infiltrates heat insulation material. Heat loss.

Accelerated deterioration of fabric materials.

Operation temperature exceeds the minimum temperature of gas seal material

Good Design Example Pool Selection Of Material & Construction Ply

Minimizes heat loss and permits optimum cooling of gas seal membrane. Gas seal membrane is exposed to full system temperature.
Flanges standoff reduces the temperature of the belt and Accelerates deterioration of gas seal membrane, as the
the critical attachment area, thereby maximizing service life. flange is not cooled due to insulation.

Inserting additional insulation to the space of the product Gas seal membrane and frame are unable to be cooled
properly lowers the temperature affecting bellows properly. due to insulation. This causes deterioration of efficiency.

60
 NON-METALLIC EXPANSION JOINT

Insulation
When insulating the ductwork care should be taken to properly insulate
around the expansion joint assembly. Low temperature expansion joints,
(below 500℉), may be insulated over with the concurrence of the
expansion joint manufacturer. High temperature expansion joints, (over
500℉) should not be insulated over. The connection point between the
expansion joint element and the mounting frame should allow for
adequate cooling.

Prevention of Fly Ash

Accumulation

Insulation Pillow
The insulation pillow fills the cavity
The Connection of Expansion Joint and Duct Flange between flexible element and the metal
liner and helps prevent the accumulate
matter, and in some applications
unburned fuel, from becoming trapped in
the expansion joint cavity. If there is no
cavity pillow, fly ash or other solid
particulates can accumulate in the
expansion joint cavity in such quantities
that they can cause damage to the
flexible element if they solidify to a
cementations state. Also, certain non-
cementatious particles (fly ash) can create
a severe corrosive (acidic) environment
when subjected to cooling (below H 2 SO4
dew point) during a maintenance outage.

61
RUBBER EXPANSION JOINT

INFORMATION ABOUT RUBBER EXPANSION JOIN

Product Definition Advantages
Rubber expansion joint is flexible connector HKR has set a standard that meets clients and
coefficient that is produced by reinforcing natural builder’s expectations, considering various
rubber or synthetic rubber with fiber or metal to operational conditions, and manufactures and
release the piping stress caused by thermal and supplies products that meet this standard. Its
mechanical vibration and displacement in piping products offer unique features by using synthetic
systems. Products have flexibility, absorb composite rubbers and synthetic fabrics.
displacement, reduce noise and vibration and are
consumption resistant to chemical abrasion. 1) Minimal Face-to-Face Dimensions:
Maximum cost reduction, compared to expensive
expansion bends or loops. Loop might cost less
Functions than pipe itself, but the total expense, including
space, labor costs and supports, are much higher.
An engineer is able to solve vibration, noise,
impact, corrosion, abrasion, stress and space 2) Lightweight:
problems by using a rubber expansion joint. No need to use special handling equipment. Lowers
installation labor costs.
1) Reduce Vibration:
Rubber expansion joints reduce or isolate vibration 3) Low Movement Forces Required:
caused by equipment. Some equipment demand The inherent flexibility of rubber joints permits
more vibration control than others. For example, almost unlimited flexing to recover from imposed
reciprocating pumps and compressors generate movements, requiring relatively less force to move,
extensive and irregular force. Rubber expansion thus preventing damage to motive equipment.
joints can decrease very loud noise and vibration
produced by the vibration of a centrifugal pump or 4) Reduced Fatigue Factor:
fan. This has been proved by practical experiments. The inherent characteristics of natural and synthetic
Also, rubber expansion joints restrain and prevent elastomers are not subject to fatigue breakdown or
vibration transfer. embrittlement and prevent any electrical effects as
they come in contact with flanges.
2) Reduce Noise:
The abrasion caused by irregular operation of
equipment and general aging such as corrosion and
wear by steam can transmit noise around equipment.
The rubber expansion joint reduces noise as it puts
metal flanges in contact with rubber.

3) Compensate Lateral, Torsional and Angular Movements:

Pumps, compressors, fans, piping and related
equipment move out of alignment due to wear, load
stresses, relaxation and settling of supporting
foundations. Rubber expansion joints compensate for
lateral, torsional and angular movements-preventing
damage and undue downtime of plant operations.

4) Compensation for Axial Movement:

Rubber expansion joints compensate for the
extension and compression generated by thermal
changes or hydraulic surge effects. This
displacement is absorbed by the rubber expansion
joint in a similar fashion to a helix spring application.

66
 RUBBER EXPANSION JOINT

5) Reduced Heat Loss: 7) No Gasket:

Loop type produces high operation costs due to As tubes and flanges are produced in one body,
the large amount of thermal loss though additional an additional gasket for connection is not
piping used for while transferring fluid. On the required. Though the pipe flange is not flat, the
other hand, rubber expansion joints reduce flange of the rubber expansion joint can equalize
thermal loss and are operated for long periods the sealing of fluid.
without maintenance or repair.
8) Noise Reduction:
6) Corrosion, Erosion Resistance: The rubber expansion joint reduces the noise and
The rubber expansion joint can be composed of vibration of piping.
various kinds of natural rubber or synthetic
rubber and fabrics, and be manufactured to meet 9) Greater Shock Resistance:
each pressure and temperature condition and to The rubber expansion joint can
withstand the effects of corrosion and abrasion. withstand against the shock
TFE/FEP lining structures are available as needed. stress caused by excessive
hydraulic surge, water
hammers or pump cavitation.

Construction Details

1) Tube:
Lined with synthetic or natural rubbers to prevent leakage. Manufactured seamless
from the inside to the end of a flange. Prevents holes in the body or weakening
of fabric. These tubes can be designed to cover service conditions for
chemical petroleum, sewage, gaseous and abrasive materials.

2) Cover:
Outer surface composed of synthetic or natural rubbers protects the frame from damage or severe
conditions.
Special polymer is resistant to oil, sunlight, acid fumes and ozone, and it is additionally coated to protect
the exterior surface.

3) Carcass:
SPLIT
The carcass or body of the rubber joint consists of fabric METAL
RETAINING
and, when necessary, metal reinforcement. RING

- Fabric reinforcement: Maintains tube and cover, being 3B.CARCASS 2.COVER

METAL
flexible. Made of fine quality synthetic fabric, but REINFORCING

occasionally natural fabric used within acceptable CONTROL ROD

temperature and pressure conditions. All fabric plies are

impregnated with rubber or synthetic compounds to 3A.CARCASS
FABRIC 1.TUBE
REINFORCING
permit flexibility between the fabric plies. EXPANSION
JOINT
- Metal reinforcement: Wire or solid steel rings maintain FLANGE
MATING
the rigidity of the joint, being inserted into the body. It FLANGE

extends the operational pressure range and ensures the Figure : Corss Sectional View Of Standard Spool
“Arch” Type Expansion Joint
product’s rigidity in vacuum service.

67
 RUBBER EXPANSION JOINT

TYPE OF RUBBER EXPANSION JOINTS

SPOOL TYPE
A full face integral flange design is available in both Single Arch and Multiple Arch Types. These basic
types can be manufactured to meet the requirements of the related Code and Standards. These types are
available in several construction design series, based on the application pressure requirement.

1) Single Arch Type:

Consists of fiber and rubber reinforced with metal rings or wire. Joint body and flange are in one body.
Has same type of bolt holes as the metal flange of the pipe to be connected. The rubber flange is
designed to be thick enough to avoid leakage without a gasket for connecting the other flange. Allows
minimum face-to-face dimensions.

2) Multiple Arch Type:

Applied where a larger movement is required compared to single arch. Each arch of multiple arch type is
able to absorb the same movements as one arch of single arch type does. Minimum length is in
proportion to arithmetic, and maintains lateral stability and the joint installed horizontally generally
requires a maximum of four scenes to prevent loosening.

SINGLE ARCH TYPE MULTIPLE ARCH TYPE

3) Reducer Type:
Applied when each side has a different diameter. Have two types:“Concentric Type”(both pipes have the
same central axis line) and“Eccentric Type”(having the axis of each end offset from each other). Taper
angle does not exceed 15°.

Concentric Reducer Type Eccentric Reducer Type

4) Filled Arch Type:

It fills a gap by inserting soft rubber into the inside gap, preventing separation of the rubber while
operation. Movements of expansion joints with filled arches are limited to 50% of the normal movements of
comparable size of expansion joint with unfilled (open) arches.

69
RUBBER EXPANSION JOINT

Filled Arch Type Offset Type Expansion Joint

5) Offset Type:
Manufactured by request of client in the case of non-identical piping axis line. Occasionally used where it
is difficult to compensate for the lineup errors.

DOG-BONE TYPE BELT

A molded construction of plies of rubber-
impregnated fabric, rubber covered and
spliced endless, to a specified peripheral
dimension. Used as a flexible connection
in central power stations on condensers.
Designed for compression and lateral
movements for full vacuum service and
maximum pressure of 15 psig. Must be
used with special clamping devices.

RETAINING RING AND CONTROL UNITS

1) Retaining Ring: Retaining rings must be used to distribute the bolting load and assure a pressure
tight seal. They are coated for corrosion resistance and drilled as specified. The rings are installed
directly against the back of the flanges of the joint and bolted through to the mating flange of the pipe.
Ring has a thickness of 10mm, but can be used according to conditions. Ring in interior that is connected
to rubber flange is round to avoid damage to the rubber.

2) Control Unit Assembly: Install a suitable control unit in accordance with designed pressure conditions.
It protects the product against excessive expansion of pipes, and as it is not designed to reinforce the
anchor of pipes, this should be clearly indicated.
Because of the direct installation of the pump flange, the back should be allowed sufficient space,
considering installation length of bolt, nut and washer as well as the space for the plate.

70
 RUBBER EXPANSION JOINT

OPERATIONAL FEATURE OF RUBBER EXPANSION JOINT

EXPANSION JOINT MOVEMENT
1) Axial Compression: Shortening displacement of distance, face-to-face
2) Axial Elongation: Lengthening displacement of distance, face-to-face
3) Lateral Movement: the movement or relating displacement of the two ends of
the joint perpendicular to its longitudinal axis.
4) Vibration: Flexible connecter absorbs the mechanical oscillations of the system.
Usually high frequency.
5) Angular Movement: The angular displacement of the longitudinal axis of the
expansion joint from its initial straight line position, measured in degrees.
This is a combination of axial elongation and axial compression.
6) Torsional Movement: The twisting of one end of an expansion joint with
respect to the other end about its longitudinal axis. Such movement is measured
in degrees.
7) Concurrent Movement: the combination of two or more of the above expansion joint movements.
This value is expressed as the resultant movement.

OPERATING TEMPERATURE RANGE

The types of rubbers and reinforced fiber materials are generally classified by temperature.

Type of Elastomer CLASS Type of Fabric CLASS

Gum Rubber Std.I Cotton Std.I

Natural Rubber Std.I Rayon Std.I
SBR/GRS/Buna-S Std.I Nylon Std.II
Neoprene Std.II Polyester Std.III
Buna-N/Nitrile Std.II Fiberglass Std.III
Hypalon Std.II Kevlar Std.III
Butyl Std.II Nomex Std.III
Chlorobutyl Std.III STD I : Recommended up to 180°F
EPDM Std.III STD II : Recommended up to 230°F
Viton /Fluorel Std.III STD III : Recommended for over 230°
F
Silicone Std.III (Note: Each material has different
Teflon /TFE/FEP Std.III temperature limits.)

71
RUBBER EXPANSION JOINT

INSTALLATION
It can be stated generally that the proper location of rubber expansion joints is close to a main anchoring
point. Following the joint in the line, a pipe guide or guides should be installed to keep the pipe in line and
prevent undue displacement of this line.

ANCHOR AND GUIDE OF PIPING SYSTEM

Anchor Anchor

Flow Expansion Joints

Pump
Anchor Pipe Guides

Elbow Support
(Anchor to Base)
Solid Base Foundation

Typical Piping Layout

2) Thrust Calculation:
1) Anchors Are Required: Thrust is generated by maximum
Observe the simple piping system example above. The piping pressure (design/test) of pipes and
should be careful to finish the section where pipe direction is arch of a product.
changes or joint is installed with solid foundations. This joint is
able to maintain the original layout of pipes through the use of
an additional guide. The pump base, blocking the pipe thrust
transferred through pump flanges, supports the elbow near
pump safely. The solid foundations installed at 90°and 45°are
designed firmly to withstand pipe thrust and force.

3) Branch Connection Anchors:

The picture at left shows how to install an
anchor with branch connection. In designing
an anchor, consider all the forces that affect
Proper Usse of Anchors in Branch Connection the connecting part of the tee section and
the elbow part. Indicate that a guide or
anchor is required in the installation section
of the joint.

78
 RUBBER EXPANSION JOINT

CONTROL UNIT

1) Definition and Purpose:

Designed to prevent damage to the product by
connecting more than two control rods (tie rods)
from the flange on one side to the flange on the
other side. Extreme movement of piping may
cause damage to pipe line or other devices. The
control rod fixes the product within the allowed
extension and compression range, and absorbs
the thrust created by the pressure in a joint.
Adding such safety materials minimizes the
possibility of damage to a product and devices.
Control units will adequately protect the joints, but
the user should be sure that pipe flange strength
is sufficient to withstand total force that will be
encountered.

2) Use in Restraining the Piping System:

Control units may be required to limit both extension and compression movements.
a. Extension: Necessary when an appropriate anchors cannot be installed. In this case, the thrust created
by pressure is extended to the control rod that is set to avoid excessive extension. Use control rods when
you are unable to install a suitable anchors.
Joint can never be too strong, considering the fact that an anchor
absorbs the essential thrust of pipes. Ignoring these principles can
cause the early damage of a joint.
b. Compression: You can install a pipe sleeve over the control rod.
Its purpose the prevent on of excessive compression of the joint.
Select the pipe sleeve length, so as not to allow it to reduce greater
than the compression range of joint.
c. Specifics: Number and size is chosen by installation pressure or
test pressure. Indicate the flange thickness if a control unit is
required.

d. Use Example of Control Rod:

ANCHOR

Picture shows a case where an anchor cannot be used.

The anchor point at the upper 90° elbow in the
discharge line has been eliminated. In this situation, it
PIPEGUIDES
(TYPICAL) is necessary to employ properly designed control
units with the joints located in this non-anchored line.
EXPANSION JOINTS
WITH CONTROL UNITS

If a control unit is not used, the pipe at the elbow

Flow
45° from the pump moves excessively through the
ANCHOR elongation of expansion joint.
Pump
The expansion will keep proceed until the expansion
PIPE SLEEVE

joint is destructed. The control unit enables the pipe

ANCHOR
PIPEGUIDE
between the anchor and pump to the 45°elbow to
SOLID FOUNDATION

be lengthened. Though each pipe is compressed, it

is impossible for a joint to be expanded by the
control unit, exceeding the set expansion range.

79
RUBBER EXPANSION JOINT

PRECAUTIONS INSTALLATION
1. SERVICE CONDITIONS 6. TIGHTENING BOLTS

Check the temperature, pressure, vacuum and Tighten bolts in stages by alternating around the
movement conditions of a joint. If the required flange. To tighten a rubber-surface flange, the side
condition of the system does not meet the joint’s of the flange should bulge slightly between the
use range, adjust it by consulting the manufacturer. retaining ring and the flange. Torque bolts
Be aware of the chemical problems resulting from sufficiently to assure leak-free operation at
elastomer applied to fluid or gas. hydrostatic test pressure.

2. ALIGNMENT 7. STORAGE

The expansion joint is not usually taken into A dry and cool warehouse is recommended. Lay
account in the compensation value for piping the flange side onto a palette or wooden board,
misalignment errors. Therefore, pipe should be and avoid placing other objects on the joint.
arranged within the error value, 1/8”. Failure to Expected product life under ideal storage
properly arrange pipes decreases the expansion conditions is about 10 years. For outdoor storage,
absorption capacity and causes extreme stress, place the flange side onto a wooden board, not
consequently lowering the product’s service life. directly on the ground, covering it with a
The pipe guide assists in the alignment of pipes waterproof canvas such as tarpaulin.
and prevents severe displacement.
8. LARGE JOINT HANDLING
3. ANCHORING
Do not insert rope or rods into the bolt holes to lift
Solid anchoring is required at both sides of a joint where it up. Use a pad or wooden support to disperse
the piping direction is changed. If not, these may be the weight when using an interior hole. Be careful
extreme movement of a joint, resulting in damage. not to allow a forklift truck leg to touch rubber side
directly. Do not put pressure on the flange side
4.PIPE SUPPORT edge during transportation or handling.

Piping must be supported so expansion joints do

not carry any pipe weight.

5. MATING FLANGE

Install a joint at the mating flange, and ensure the

head of the bolt and washer meet the retaining
ring. Face to face distance is the same as the
pipe’s installation space. Check that the contact
point of the mating flange is clean and flat. Do not
allow the raised face to protrude more than 1/16”.
Avoid using a split retaining rings next to wafer-
type check valve or butterfly valve.

80