Vibration Mounts Installation Instructions Manual

Transcription

1 Vibration Mounts Installation Instructions Manual Telefax.: Copyrights: Quickborn/Hamburg - Germany mail@broneske.de Phone:

2 1 CONTENTS 1 Safety instructions Contents 1.1 Safety instructions Instruction manual 1.2 Safety instructions How to use 1.3 Safety instructions Protective clothing Safety instructions Protective clothing 2 2 Why SB Broneske products? Contents 2.1 Why SB Broneske products? Inventor of the modern elastic support 2.2 Why SB Broneske products? Global Player 2.3 Why SB Broneske products? What is resilient mounting/elastic support for the exhaust pipe? 2.4 Why SB Broneske products? Why rubber based and not steel based mounts? 2.5 Why SB Broneske products? High quality products 2.6 Why SB Broneske products? How does the SB Broneske business work? 2.7 Why SB Broneske products? How to read the Technical Offer? 2.8 Why SB Broneske products? Calculations Technical Offer 1: Vibration Calculation 2.9 Why SB Broneske products? Calculations Technical Offer 2: Vibration Calculaton Example 3 Design Contents 3.1 Design: Fix point Contents Design: Fix point Vibration mounts: Fix Points Design: Fix point Vibration mounts: Fix Points (Compression Mount) Design: Fix point Experimental test series: Temperature curve vibration mounts Design: Fix point Fix points arrangement Design: Fix point Brackets for Compression Mounts Design: Fix point Installation of Compression Mount or Tension Compression Mount Design: Fix point Tension Compression Fix Point Mount 3.2 Design: Anchorage point Contents Design: Anchorage point Anchorage Point: Tension/Compression Mount Design: Anchorage point Arrangement with two or three anchorages Design: Anchorage point Angle between deck, vibration mount and pipe Design: Anchorage point Maximum rotational deflection Design: Anchorage point Threaded rod: Length in vertical pipe section Design: Anchorage point Lashes/Pad eye brackets Design: Anchorage point Alignment of pad eye brackets Design: Anchorage point Alignment of angle steel Design: Anchorage point False direction of anchorage point in vertical pipe Design: Anchorage point Doupling 3.3 Design: Sliding Point Contents Design: Sliding point Basics Design: Sliding point Bushes Design: Sliding point Oblonghole in Bracket 3.4 Design: Rain Caps Table: Comparison of rain caps Ernst-Abbe-Str. 9 D Quickborn Germany Telefax:

3 1 CONTENTS 4 Handling Contents 4.1 Handling Protecting the products from moisture 4.2 Handling Storage 4.3 Handling Transport 5 Assembly Contents 5.1 Assembly Lifetime of a Vibration Mount 5.2 Assembly Before assembling: Elastic Support 5.3 Assembly Before assembling, examine the following of the vibration mount: 5.4 Assembly ASSEMBLY Assembly ASSEMBLY Assembly Protection of the elastic support during assembling 5.7 Assembly Insulation of vibration mount 6 Commissioning and sea trail Contents 6.1 Commissioning and sea trail Prior to the commissioning and sea trail 6.2 Commissioning and sea trail During commissioning and sea trail 7 Maintenence General Notes 8 Causes of defects Contents 8.1 Causes of defects Damage caused by transportation, handling or installation 8.2 Causes of defects Damage caused by transportation, handling or installation 8.3 Causes of defects Damage caused by transportation, handling or installation 8.4 Causes of defects Damage caused by transportation, handling or installation 9 Warrenty Exclusion from the warranty Ernst-Abbe-Str. 9 D Quickborn Germany Telefax:

4 Contents 1.1 Instruction manual 1.2 How to use 1.3 Protective clothing Protective clothing 2 Page 4

5 Instruction manual Before beginning installation, trained professionals must read this guide carefully. The manual must have been read and understood. If you have any questions, please contact: Ernst-Abbe-Str. 9 D Quickborn/Hamburg Germany Telefax: Technical Hotline 8:00 to 16:00 o'clock Central European Time CET Telephone: Page 5

6 How to use The products are specially designed and produced to reduce vibrations, structure borne noise and compensate thermal heat expansion in piping systems: The maximum loads and the geometry of each product is calculated by SB Broneske engineers in accordance with internationally valid regulations (such as engineering standards) and standardized calculations. Products damaged during transport or storage must not be installed. The manufacturer is not liable for damage suffered as a result of transport or incorporation of damaged or deformed parts! Page 6

7 Protective clothing 1 During the installation or storage of products, safety and protective clothing must be worn. These are for example a protective suit and gloves. Please take into account the country-specific security provisions for the installation or storage of such products. Page 7

8 Protective clothing 2 During the installation or storage of products, safety and protective clothing must be worn. These are, for example, safety footwear. If welding work is carried out, a welding shield must be used. Please take into account the country-specific security provisions for the installation or storage of such products. Page 8

9 Contents 2.1 Inventor of the modern elastic support 2.2 Global Player 2.3 What is resilient mounting/elastic support for the exhaust pipe? 2.4 Why rubber based and not steel based mounts? 2.5 High quality products 2.6 How does the SB Broneske business work? 2.7 How to read the Technical Offer? 2.8 Calculations Technical Offer 1: Vibration Calculation 2.9 Calculations Technical Offer 2: Vibration Calculation Page 9

10 Inventor of the modern elastic support The beginnings of SB Broneske go back to the late 60s. In the past century, Erwin Broneske developed the modern, elastic fixed-point mounts and the modern sway bracing (anchorage). Erwin Broneske developed the elastic mounts especially for the ship-building industry and the special requirements combined with modern ship-building. Furthermore, in the early 70s, Erwin Broneske developed the rubber-based elastic mount for exhaust pipes in the ship-building industry. Since then, the rubber-based elastic mount has become an industrial standard and has more or less superseded the steel spring mount. Since the 70s, SB Broneske has successfully manufactured more than 2 Million vibration mounts and has sold them worldwide. SB Broneske was the first company to carry the following developments: -The world s first rubber-based fix point mount (in the 70s) The world s first rubber-based bracing (in the 70s) The world s first FEM analysis of a vibration mount for exhaust pipes and engine mounts (in the 90s) The world s first flexible fire- AND water-proof bulkhead pipe fitting (in the 21st century) -The world s first labelling system for exhaust pipe systems (in the 21st century). Page 10

11 Global Player Since the 1970s, SB Broneske has been running several offices around the world or been working together with representatives. Employees in the SB Broneske offices and SB Broneske representatives are educated at the highest engineering level. SB Broneske also runs storehouses in several countries to provide short delivery times for spare parts or fast deliveries for additional units. Please ask the headquarters of SB Broneske for addresses of SB Broneske offices or representative offices or storehouses around the world. Page 11

12 What is resilient mounting/elastic support for the exhaust pipe? Resilient mounting or elastic support includes vibration mounts, elastic pipe penetrations, elastic rain caps and expansion bellows. These product groups reduce or eliminate structureborne noise and vibrations very effectively. These products compensate the thermal heat expansion of the exhaust pipe sections. SB Broneske products are specially designed to fulfil these requirements on board of vessels. Page 12

13 Why rubber based and not steel based mounts? Elastomers are the genus for rubber-based or siliconebased materials that are assembled in the SB Broneske vibration mounts, bulkhead pipe fittings and rain caps. Only elastomers can reduce vibrations and structureborne noise, thanks to their physical properties. If elastomers are pressed together, then the property of reducing vibrations and structure-borne noise is increased (sound velocity in rubber is m/s). Steel mesh springs, for example, do not have this property, because the steel spring passes on the vibration and structure-borne noise very effectively (sound velocity in steel is 5000m/s), the more they are pressed together. Particularly in the ship-building industry, it is very important to effectively reduce structure-borne noise and vibrations. The drive motors and auxiliary motors on board a ship generate vibration and structure-borne noise, which can spread throughout the ship. Page 13

14 High quality products SB Broneske is a traditional family-owned and -run company. SB Broneske produces all vibration mounts, pipe penetrations, rain caps and expansion bellows in the SB Broneske owned factories in Germany. SB Broneske employees are educated to the highest level in engineering or production. SB Broneske only uses certified materials of highest quality to guarantee high product quality. The quality of the elastomers used is of utmost importance. The elastomers used by SB Broneske have been especially developed for use on exhaust pipes in ships andtheyusuallyhavealifespanofapprox.15to20 years. Page 14

15 How does the SB Broneske business work? Before the customer purchases the elastic support, SB Broneske offers an engineering service (free of charge). SB Broneske suggests the following work flow: [1] Drawings: Customer sends the drawing of the exhaust pipe system to SB Broneske with or without positions of vibration mounts, expansion bellows, pipe penetrations or rain caps. [2] Technical Offer: SB Broneske creates the technical offer (layout proposal how to arrange the products in the exhaust pipe system, vibration analysis). [3] Commercial Offer: SB Broneske draws up a commercial offer and sends this offer to the customer. [4] Revisions: Customer sends request for revisions. SB Broneske sends revised offers (up to 15 revisions possible). [5] Order of Products: Customer approves the technical offer and orders the products. [6] Production of products: SB Broneske receives order and immediately plans production/saves production time. [7] Order Confirmation: SB Broneske sends the order confirmation within three to six works days. [8.1] Production of project package: SB Broneske produces the products project based. Time of dispatch confirmed in order confirmation. [8.2] Spare parts: Spare parts or smaller quantities are available from stock on three continents America, Asia, and Europe). Page 15

16 How to read the Technical Offer? SB Broneske engineers create the layout proposal in the drawings of the exhaust pipe system. The experience of SB Broneske, SB Broneske performs this business since 1972, helps to create this layout proposal very effectively. SB Broneske has developed a very complex data base to standardise the required calculations. SB Broneske generates the technical offer with the database. The technical offer of SB Broneske consists of the following chapters: (A) Cover, Index, Remarks, Revisions (B) Vibration Analysis, Calculations, Vibration Diagrams (C) Layout Proposal (Drawings) (D) Design Office Check List, Product Data Sheets The database system supports the engineers to perform the vibration analysis and the calculation for the structure borne noise reduction. Page 16

17 Calculations Technical Offer 1: Vibration Calculation Laying out the exhaust pipe system: In order to correctly lay out the exhaust pipe, various levels of vibration have to be calculated and attuned to each other. Only with the help of theses calculations is it possible to attune the vibrations to each other. With the help of the technical offer, SB Broneske can prove that these calculations were made (please, see picture chapter 2.9): [1] Product type, quantity, flexible holder: SB Broneske suggests (chooses) the product size based on weight per pipe section. [2] Weight of pipe section, direction of pipe section: SB Broneske calculates the pipe section weight. [3] Load per mount, deflection: SB Broneske calculates deflection of vibration mount. [4] Natural frequency mount: SB Broneske calculates the natural frequency of the vibration mount as a result of the deflection. [5] Exhaust frequency: This is a result of the engine data [6] Pipe and propeller frequency: SB Broneske compares also propeller frequency and pipe frequency if required. [7] Vibration isolation and structure-borne noise reduction: This reduction bases on the correlation of natural frequency of the mount and exhaust frequency. Page 17

18 Calculations Technical Offer 2: Vibration Calculaton Example Page 18

19 Contents 3.1 Fix points 3.2 Anchorage points 3.3 Sliding points Page 19

20 Contents Vibration mounts: Fix Points Vibration mounts: Fix Points (Compression Mount) Experimental test series: Temperature curve vibration mounts Fix points arrangement Brackets for Compression Mounts Installation of Compression Mount or Tension Compression Mount Tension Compression Fix Point Mount Page 20

21 Vibration mounts: Fix Points The SB Broneske fix points were developed and patented in These products have been produced and installed more than one Million times. The fix point fixes a pipe section and holds this pipe section in place. SB Broneske produces the vibration mounts fix points with a highly effective silicone (elastomer). The SB Broneske vibration mounts are very effective reducing vibrations and structure-borne noise. The SB Broneske fix points are tear-proof, fireproof and they have an internal anti-break-away device. Page 21

22 Vibration mounts: Fix Points (Compression Mount) Diagonal load: If there is diagonal load on the fix point, it can absorb about twice the vertical compressive force. Dynamic load: The dynamic load amounts to about three or four times static load. If the load is greater, the antibreak-away device in the vibration mount triggers causing a steel-steel connection. The SB Broneske fix points are pre-mounted on a welding plate to make installation easier. SB Broneske produces the fix point in four standard sizes: SBB82001 load max. 200 kg SBB82002 load max. 400 kg SBB82003 load max. 750 kg SBB82004 load max. 1500kg The fix point consists of the following: The fix point consists of the following main components: [1] Cap [2] Foot [3] Welding Plate with screws [4] Integrated anti-break-away device Page 22

23 Experimental test series: Temperature curve vibration mounts Broneske vibration mounts fix points are specially designed for the exhaust pipe system of ships (maritime environment). The SB Broneske elastomer of the fix point is heat resistant up to 300 Celsius (572 Fahrenheit). In a series of tests in the late 1980s, SB Broneskle investigated the temperature at the vibration mount. SB Broneske displays the result of the experimental series in the attached temperature curve. If the exhaust pipe temperature is 500 Celsius, the temperature at the insulation (100mm) is not higher than 140 Celsius. The temperature at the bracket (vibration mount) is lower than 100 Celsius. Page 23

24 Fix points arrangement The SB Broneske fix points should be installed at a 180 angle at the pipes or in a radial arrangement. Please, avoid a 90 arrangement situation. If the fix points are installed at a 90 situation, torque and forces of the exhaust pipe must be recalculated and approved by engineers. Page 24

25 Brackets for Compression Mounts Please, choose the thickness of the brackets with the weight of the pipe section! Brackets must be recalculated by the shipyard s design office. ka a i e _ ` h téáöüí=âö NMM NNQ OVM NP NOM NMM OOM U NOR NQM OVM NP NOM NMM OOM UIR NRM NSU OVM NP NRM NMM ORM V OMM ONV OVM NP NRM NRM ORM NM ORM OTP OVM NP OMM NRM PMM NN PMM POQ OVM NP OMM NRM PMM NO PRM PRR OVM NT OMM NRM PMM NQ QMM QMS OVM NT OMM OMM PMM NR QRM QRT PMM NT OMM OMM PMM NS RMM RMU PMM NT OMM OMM PMM NT SMM SNM PMM ON OMM OMM PMM NU TMM TNN PMM ON OMM OMM PMM NV UMM UNP PMM ON OMM OMM PMM OM VMM VNQ PMM ON OMM OMM PMM ON NMMM NMNS PMM ON OMM PMM PMM OO NNMM NNOM PMM ON OMM PMM PMM OP NOMM NOOM PMM ON OMM PMM PMM OR Page 25

26 Installation of Compression Mount or Tension Compression Mount In some cases, a fix point should be installed in a tension situation (narrow casing, pipe closer to the ceiling than to the floor). SB Broneske produces fix points for tension installations - the SB8308x series. Please, ask the SB Broneske engineering team to consider this design requirement during creation of the technical offer! Page 26

27 Tension Compression Fix Point Mount The SB Broneske tension compression fix points are specially designed for marine applications. They are shear-proof. The tension compression fix point fixes a pipe section and holds this pipe section in place. SB Broneske produces these fix points with a high effective silicone (elastomer). These mounts are very effective in reducing vibrations and structure borne noise. SB Broneske produces the fix point in four standard sizes: SBB83081 load max. 200 kg SBB83082 load max. 400 kg SBB83083 load max. 800 kg SBB83084 load max. 1600kg The fix point consists of the following main components: [1] Body and foot [2] Disc [3] Welding plate with screws Page 27

28 Contents Anchorage Point: Tension/Compression Mount Arrangement with two or three anchorages Angle between deck, vibration mount and pipe Maximum rotational deflection Threaded rod: Length in vertical pipe section Lashes/Pad eye brackets Alignment of pad eye brackets Alignment of angle steel False direction of anchorage point in vertical pipe Doupling Page 28

29 Anchorage Point: Tension/Compression Mount The SB Broneske anchorage points are tension compression mounts and are specially designed for marine applications. These fix points were developed in the 1970s. These products have been produced and installed more than 1, times. The tension compression vibration mount for anchorages/sway braces are designed to keep the resilient supported exhaust pipe system from tilting and to keep the lateral movement of the expansion bellows within restricted limits. The anchorage points stabilize the pipe sections. Also, the anchorage points compensate heat expansion. Turnbuckle with right and left hand threaded bolts make precise adjustments possible. SB Broneske produces the anchorage point in five standard sizes: SBB61000 load max. 200 kg SBB61001 load max. 400 kg SBB61002 load max. 750 kg SBB61003 load max kg SBB61005 load max kg The anchorage point consists of the following components: [1] Vibration mount body (elastomer protected) [2] Threaded rod [3] Turnbuckle [4] Fork crown Page 29

30 Arrangement with two or three anchorages Two Anchorages The anchorages must be optimally assembled at an angle of 90. When assembling at 90, the forces on the two anchorages is the most optimal. It is also possible to assemble the anchorages at an angle of between 70 and 110. Please avoid assembling the anchorages at an angle of less than 70 or more than 110 because the exhaust pipe is then no longer held in an optimal lateral position Three Anchorages The anchorages must be optimally assembled at an angle of 120. When assembling at 120, the forces on the two anchorages is the most optimal. It is also possible to assemble the anchorages at an angle of between 100 and 140. Please avoid assembling the anchorages at an angle of less than 100 or more than 140 because the exhaust pipe is then no longer held in an optimal lateral position Page 30

31 Angle between deck, vibration mount and pipe In general, the angle between SB Broneske anchorage point, the deck and the pipe should be 90 : In general, in the horizontal pipe section, the anchorage point should be installed in vertical direction. In general, in the vertical pipe section, the anchorage point should be installed in horizontal direction. ATTENTION: SB Broneske indicates the exact direction of the anchroage points in the layout proposal. If design office or production department has any questions about the direction of the anchorage points, please contact SB Broneske office to clearify details. Page 31

32 Maximum rotational deflection SB Broneske anchorages (tension compression mounts/sway braces) must not be deflected more than 12. The deflection is a result of the heat expansion of the pipe section and the distance from the fix point to the anchorage point and the length of the threaded rod. Please install the anchorages under consideration of the maximum deflection. Do not shorten the threaded rod if heat expansion will exceed the maximum rotational deflection. Page 32

33 Threaded rod: Length in vertical pipe section SB Broneske anchorages (tension compression mounts/sway braces) must not be deflected more than 12. The deflection is a result of the heat expansion of the pipe section and the distance from the fix point to the anchorage point and the length of the threaded rod. Picture 1: The minimum length from fork crown to vibration mount is: L1=700mm L2=500mm L3=300mm Please install the anchorages under consideration of the maximum deflection. Picture 2: We strongly suggest using anchorage points with two fork crowns, if the distance from the fix point is more than 10 meters. Page 33

34 Lashes/Pad eye brackets Strength of lashes to be recalculated with the specific design situation. Page 34

35 Alignment of pad eye brackets Pad eye brackets When installing or assembling the pad eye brackets of the anchorages, please make sure that the pad eye brackets are installed or aligned long the heat expansion. Please choose the direction so that a free expansion of the exhaust pipe towards the heat expansion is possible. The pad eye brackets may by no means be assembled perpendicular to the direction of expansion. Page 35

36 Alignment of angle steel Angle steel When installing or assembling the angle steel of the anchorages make sure that the angle steel is welded to the frame correctly. Weld the two sides of the angle: [1] Weld the complete lower edge to the angle steel to the frame. [2] Weld each end of the frame to the frame or bulkhead/deck. Page 36

37 False direction of anchorage point in vertical pipe section Never anrrange the anchorage points like this on board of a ship. This configuration might cause critical damange to the pipe or the ship. Page 37

38 Doupling Strength of doupling to be recalculated with the specific design situation. Page 38

39 Contents Basics Bushes Oblonghole in Bracket Page 39

40 Basics Some exhaust pipe constructions need sliding points to be installed. There are always fix points in a pipe section. A sliding point is always installed close to a fix point on the same level. This is usually the case if the exhaust pipe is lead into a 90 bend (horizontal pipe section to a vertical pipe section) and has to take on the weight of the exhaust pipe. A slip joint is a fix point in that allows the bracket to move or sliding on a fix point in one direction. For this purpose, a oblone hole is made in the bracket and a bush is installed that allows for the moving or sliding. When assembling or installing the slip joint, it must be ensured that the direction of the oblong hole has been correctly calculated. If the direction is wrong, then the middle bolt in the vibration mount will break. Page 40

41 Bushes The bushes for the sliding point are 0.3mm higher than the bracket is high. A washer should be assembled on the bracket. The outer diameter of the bushes is the same as that of the oblong hole. Washer to be used. SB Broneske can supply the bushes and washers on request (length of bush depends on how thick the bracket is). Example shows bushing for vibration mount SB82003 (center bolt SB82003 diameter 16mm) and bracket thickness 12mm. Page 41

42 Oblonghole in Bracket The oblong hole should be in exactly the same direction as the direction of heat expansion. The exhaust pipe expands from the fix point of each exhaust pipe section in all linear directions. For this reason, it is easy to determine the direction of the oblong hole: It is parallel to the direction of expansion. It is possible to install the oblong hole at the same level as the fix point because the slip joint solution only allows for expansion parallel to the bracket. The picture on the left demonstrates an example for the construction of an oblong hole. Page 42

43 Table: Comparison of rain caps Why are SB Broneske rain caps so effective.? SB Broneske has developed all rain caps under the aspect of reducing structure-borne noise. The SB Broneske rain cap transfers none or very little structure-borne noise! Such little structure-borne noise if transferred because the silicone cushions reduce the transfer of structure-borne noise to a minimum. SB Broneske supplies all rain caps pre-mounted. Page 43

44 Contents 4.1 Protecting the products from damp 4.2 Storage 4.3 Transport Page 44

45 Protecting the products from moisture The products must be protected from rain, water and moisture. Furthermore, the products must be protected from oil, soot, chemicals, earth and sand. The products should be stored on a level, firm, waterproof and dry surface. The products should be stored under a rain-proof roof or similar rain-proof cover. The products should be protected from high humidity or damp in combination with high temperatures exceeding 25 C. The products should not be stored for more than six months. The products should be assembled within six months. The must also be protected from damp at the construction site. The products should be protected from damp or water by using a suitable varnish at the place of installation. Products that are installed outside should comprise special, rust-proof material (such as stainless steel or galvanised steel) or be painted with an anti-corrosive paint on a regular basis. Page 45

46 Storage Attention thread: Please take utmost caution when storing the vibration mounts and their components. These products are product groups that comprise thread among others. These threads can be malformed by slight mechanical load. Improper load on the thread can damage or destroy the thread: [1] The products may not be stacked in an improper way. [2] The products may not be walked on or loaded. [3] The products may not be stood on. [4] The products should not be stored for longer than six months. [5] The products should be assembled at the construction site within six months. Page 46

47 Transport Attention thread rod: Take utmost caution when transporting the vibration mount. These products are product groups that comprise thread among others. These threads can be malformed by slight mechanical load. Improper load on the thread can damage or destroy the thread: [1] The products may not be stacked in an improper way. [2] The products may not be walked on or loaded. [3] The products may not be stood on. [4] The products should not be stored for longer than six months. [5] The products should be assembled at the construction site within six months. Page 47

48 Contents 5.1 Lifetime span of a vibration mount 5.2 Prior to assembly: Elastic mount 5.3 Prior to assembly: Inspection of piping 5.4 Assembly Assembly Protecting the vibration mount during assembly 5.7 Insulating the vibration mount Page 48

49 Lifetime of a Vibration Mount A vibration mount has a lifetime span of approx. 15 to 20 years. The lifetime span of the vibration mount is usually limited by the lifetime span of the elastomer in the vibration mount. The vibration mount should be replaced after this period. The pre-condition for the vibration mount to reach this lifetime span is that it is not overloaded. If the guidelines in this handbook are not adhered to, then the lifetime span of the vibration mount can be reduced considerably. A reduction in the lifetime span of the vibration mount can have direct effects on the exhaust pipe system and lead to damage or impairment to the functionality of the exhaust pipe system. Page 49

50 Before assembling: Elastic Support The exhaust pipe system is a system which, due to the high temperature of the exhaust gas, heats and expands due to heat (thermal expansion). Additionally, the exhaust pipe of the engine causes vibrations and structure borne noise. The exhaust pipe system transports the engine and exhaust gas noise into the ship's structure. To compensate the, vibration mounts and expansion bellows from SB Broneske must be installed. To reduce the, vibration mounts from company SB Broneske must be installed. Before the assembly of the vibration mount, it has to be examined whether the following calculations have been carried out: [1] The piping system must be supported by a resilient support system (fix points, anchorage points (sway braces), elastic pipe penetrations and expansion bellows). The arrangement of the elastic support must be created by specially trained engineers. SB Broneske provides free calculations (layout proposal). SB Broneske recommends that customers use this free service. [2] The elastic support must be designed and calculated by taking into consideration the wheights of the pipe, acceleration forces of the exhaust gases, reaction forces of vibration mounts and expansion bellows. Page 50

51 Before assembling, examine the following of the vibration mount: 1] Check whether the products were damaged during transport or storage. In the case of any damage, the products must not be installed. Please report any dents, signs of rust on the steel, bent or damaged components to the manufacturer. [2] The pipe with the elastic support must have been installed before the expansion bellows are assembled. [3] The construction inspection must approve the elastic support, the frames of the elastic support, the doubling and brackets and the piping system before the vibration mounts are assembled. [4] The brackets and lashes and doublings of the vibration mounts have to be assembled and welded to the construction before the vibration mounts are assembled. This work must be performed by professional welders and supervised by welding engineers. Page 51

52 ASSEMBLY 1 The assembly of the vibration mounts can be, for example, performed in the following steps: [1] Doublings, lashes and brackets are already installed (welded) to the structure, frames and pipe system. [2] The frames/base for the vibration mounts are already installed (welded) to the deck/bulkhead. [3] Should sliding points be used, the installation is to be prepared and carried out according to the chapter Sliding point. [4] The pipes should be installed in sections. Each section of pipe should be held by one pair of fix points and one or several pairs of anchorage points in accordance with the construction drawing. [5] Each pipe section: First of all install the pair of fix points and then the anchorage points. [6] Each section of pipe should be prepared in an assembly hall, for example. The brackets, doublings and pad eye brackets have to be welded to the respective pipe section in accordance with the construction drawing. This work must be supervised by trained welders and welding engineers. [7] The respective base plates of the fix points should be assembled in the ship in the machine room and exhaust stack. Page 52

53 ASSEMBLY 2 [8] Fix points: There are various methods of assembling fix points. SB Broneske recommends first screwing the fix point to the bracket, then the foot of the fix point to the base plate in the machine room/exhaust stack. After that, the welding plate of the fix point should be welded to the base plate. [9] Anchorages: There are various methods of assembling anchorages. SB Broneske recommends first welding the doublings and butt straps to the pipe and the bulkhead and the screwing on the anchorages. [10] The vibration mounts must not be exposed to rotation or torque forces during assembly. [11] The pipe section can be stabilized during assembly by using straps and cranes. [12] Expansion bellows to be installed after the installation of the pipe sections and the vibration mounts on board of the vessel. If the expansion bellows are installed together with the pipe sections, the expansion bellows might be damaged. Page 53

54 Protection of the elastic support during assembling The vibration mounts are very sensitive and have to be particularly protected for example: [1] The vibration mounts are to be protected from welding spatter. [2] The vibration mounts may not be stepped on. [3] During and after assembly, the threaded rod of the anchorage points may not be touched by assembly tools or hosting equipment. [4] The thread rod of the vibration mounts may not be stepped in any case. [5] When bolting, screwing or welding of the vibration mounts, please ensure that the vibration mounts are not damaged. [6] Do not use oil or chemicals near the vibration mounts. Page 54

55 Insulation of vibration mount The exhaust gas pipe must be insulated, because the pipe may get very hot (500 Celsius or more). The temperature at the outside of the insulation is less than 150 Celsius. Vibration mounts or pipe penetrations must NOT be inside the insulation. Page 55

56 Contents 6.1 Prior to the commissioning and sea trail 6.2 During commissioning and sea trail Page 56

57 Prior to the commissioning and sea trail The inspection must check the exhaust pipe system and vibration mounts before commissioning and sea trail. Please check before commissioning and sea trail: [1] Have the vibration mounts been damaged during installation or transportation? [2] Has the whole elastic support been installed according to the requirements and design templates? [3] Have the specific vibration mounts been installed in the "correct" position in the pipe system? [4] Are the vibration mounts and their moving parts free from other bodies? [5] Have all vibration mounts assembled in the correct way? [6] Have all pad eye brackes and lashes installed in the correct direction? [7] Had the threaed rod of the anchorage points shorten too much (Maximum rotational deflection = 12 )? [6] Are all pipes in the correct position? Page 57

58 During commissioning and sea trail During commissioning and sea trail the vibration mounts must be inspected by means of a visual examination: [1] Leakage or pressure on the respective pipe sections, vibration mounts or expansion bellows. [2] Prohibited movements and improper rotation or torsion of the vibration mounts and its components. [3] Prohibited movements of the exhaust pipe system. [4] Dents or instability of the pipe sections, vibration mounts or expansion bellows. Page 58

59 General Notes One of SB Broneske designed and properly build vibration mount requires no special maintenance. However, the vibration mount, together with the piping system, is to be monitored on a regular basis. A regular inspection / maintenance once a week increases the life time of the vibration mount in the existing pipe system. It must be verified whether the vibration mount reveals signs or bolts become loose. Page 59

60 Contents 8.1 Damage caused by transportation, handling or installation 8.2 Damage caused by transportation, handling or installation 8.3 Damage caused by transportation, handling or installation Page 60

61 Damage caused by transportation, handling or installation SB Broneske draws the customer s attention to the most frequent causes of failure of vibration mounts. Causes of failure: [A] Installation: Pad eye brackets/lashes are installed in the incorrect direction: The lashes do not move freely in the direction of heat expension and could break. [B] Installation: The threads have been cut off too short. The maximum angle of the thread rod allowed of 12 on the anchorage was exceeded and the vibration mount damaged. Page 61

62 Damage caused by transportation, handling or installation SB Broneske draws the customer s attention to the most frequent causes of failure of vibration mounts. [C] Installation: The angle steel of the vibration mount was installed incorrect. The angle steel should have turnd 90 to create more stability! [D] Installation: Compression mount was installed up side down. The picture show a compression fix point that is installed in a tension situation. Please, see next page for details. Page 62

63 Damage caused by transportation, handling or installation SB Broneske draws the customer s attention to the most frequent causes of failure of vibration mounts. [E] Installation: The directon of the force on a comression mounts creates a tension situation. This wrong installation does not create a situation that the breaks. But it creates a situation where no rubber. Installation like shown in picture (1) and (2) is not correct, installaiton like in (3) is correct. Page 63

64 Damage caused by transportation, handling or installation [F] Installation: The silicone cushions of the rain cap were assembled directly to the exhaust pipe. Silicone cushions NOT to be mounted to the exhaust pipe. [G] Installation: The vibration mounts or bulkhead pipe fitting were installed inside the insulation. Elastomer components (Silikone, rubber) of vibration mounts or penetrations may melt. Page 64

65 Exclusion from the warranty We would like to point out that the warranty is void if the preceding instructions for assembly, verification of assembly and commissioning are not adhered to. Page 65