POLYFLURON PTFE expansion joints

Transcription

1 POLYFLURON PTFE expansion joints Characterized by exceptional safety and long service life Expansion joints with white and antistatic black POLYFLURON liners POLYFLURON expansion joints have a unique combination of outstanding properties, and are suitable for very diverse applications. The universal chemical resistance of POLYFLURON PTFE allows the operation with nearly all kinds of aggressive media. Therefore, these expansion joints are used particularly as components in chemical plants. POLYFLURON expansion joints are installed in steel and PTFE-lined steel pipelines, and especially, thanks to their large adjustment range, both in plastic and FRP pipelines. Because of their flexibility and low spring rates, they are also used for sensitive plant components with glass or enameled finishes, graphite process equipment, and graphite heat exchangers. The thermal expansion is usually an unintended phenomenon when operating pipes. It requires compensation measures that have to be taken into account during planning and are state of the art. POLYFLURON expansion joints compensate thermal expansion of the pipeline and thus prevent stresses, so offering a compact alternative to material-intensive horseshoe bends. They are also used to absorb oscillations and vibrations, for example those generated by pumps. Here, the very special properties of POLYFLURON PTFE are utilized, e. g. the low tendency to material fatigue and complete absence of brittle fracture due to aging effects compared to other polymers, elastomers or certain metals. Depending on the operation conditions and pipeline isometrics various POLYFLURON expansion joints types are available which differ in their design, the number of convolutions and are even available with antistatic properties suitable for use with solvents and other liquids where electrostatic charge is an issue.

2 2 High performance bellow material Through more than 60 years of experience, Dr. Schnabel has continuously optimized the processing techniques to manufacture paste extruded PTFE based on highest quality fine powder grades. POLYFLURON PTFE has a minimum possible level of voids that allows lowest permeation and a unique flexural fatigue resistance/flex life due to the absence of critical micro voids that may expand to micro cracks up to rupture by alternating load. Void content, density, elongation and tensile strength are constantly measured and controlled to guarantee the outstanding performance. Manufacturing process and design The convolutions are made without machining using a proprietary forming process. This results in a uniform wall thickness across the entire bellow cross section. Accumulation of stress peaks in heavily loaded areas can be avoided which has a significant influence on the lifetime performance. To limit excessive movements, POLYFLURON expansion joints have loose bolts with sleeves located between the flanges. In case of malfunction they may act as protection against overstress e. g. at full compression or expansion. This can potentially avoid damage of the bellow, however the limit bolts are not specifically designed for this purpose. The POLYFLURON expansion joints come as standard with 3 limit bolts to offer a certain safety against or overstress. Even our designs for solely - or movements are equipped with limit or guide elements. Wide product range POLYFLURON expansion joints are available with nearly unlimited diameters and up to 10 convolutions. Customized designs with non-standard flanges and clearance holes as well as stainless steel flange material, J-bolt flanges according to various standards are possible. Types with restricted movements like (one-plane or all-plain), or reducing flange arrangements can also be supplied. Bellow with assured uniform wall thickness POLYFLURON expansion joints (type FLUROFLEX FX-0) are vacuum resistant for full vacuum operation at high temperatures or can be equipped with internal vacuum rings for larger sizes. Types with electrically isolating limit bolts are also available. For high pressure applications, we offer POLYFLURON PTFE lined metal expansion joints (FLUROFLEX FX-10, FX-16 or FX-25). The multiple metal layer design minimizes spring rates and can be supplied in stress crack corrosion resistant alloys too. Characteristics of POLYFLURON bellows POLYFLURON bellows produced by SGL Group are characterized by exceptional safety and long service life. Their operational reliability, in particular, is the result of our special manufacturing process, careful material selection, and targeted optimization through extensive practical trials and FEM simulations. Based on this, we are able to supply POLYFLURON bellows that perform impressively, even under extreme operating conditions. Long service life and reliable operation of plants with POLYFLURON bellows thanks to optimized geometry Minimized notch effect for safe, reliable plants with a long service life Simultaneous movements in all directions Reliabele performance under pressure/temperature loading High vacuum resistance, even under continuous vacuum No material fatigue and excellent long-term stability

3 3 Pressure rating The pressure rating (= maximum operating pressure at different temperatures) of PTFE expansion joints is the most important property beside of allowable movements and flexibility. However, there are no standards available to define and determine these values. Burst pressure testing With instantaneous burst pressure tests, internal pressure is increased until failure within a very short time. By using a safety factor, the allowable working pressure is rated. Due to practical reasons the tests are done at ambient temperature with small sized expansion joints and extrapolated to other sizes. We have developed a method using numerical simulation of the pressure-caused deformation up to bursting at various temperatures. It is based on a FEM model and the non-linear plastic behavior of PTFE, the real stress-strain curves measured up to 200 C. The simulation results were verified with experimental tests and show a remarkable consistency. With this method the deformation of POLYFLURON expansion joints can be simulated at different temperatures and sizes (diameters and number of convolutions) instead of widely used extrapolations. Creep rupture testing Creep rupture tests according the test method described in ISO 9080 at elevated temperatures are used to predict longterm service life of plastic pipes. This method can be used even for POLYFLURON expansion joints because of the special convolution forming process with its uniform wall thickness and absence of structural inconsistencies. Tests done by the German TÜV have proven successfully the long term creep strength of POLYFLURON expansion joints at 150 C. Those results confirm the pressure ratings considering in fluences of PTFE manufacturing, bellow forming, aging and resulting operation performance at elevated temperatures. Smoothbore sleeves POLYFLURON smoothbore sleeves prevent damage to convolutions in abrasive service and prevent build-up of solids in the convolution in vertical installation. The smoothbore sleeves are recommended when fluid vevelocity is high. Safety shields It is recommended to use safety devices around flanges and expansion joints to prevent spray of hazardous or corrosive media in the unlikely case of leakage or damage. Please ask for our various safety products as assessories. Delivery and installation POLYFLURON expansion joints are adjusted to neutral length during manufacture and flange faces covered by wooden plates. These plates should be removed only directly before installation to avoid damage and deformation of the PTFE liner. The maximum allowable length also considering combined movements must be adjusted at the limit bolts after installation. Please refer to the manual. FEM simulation of a bellows convolution under stress. Top: axial loading with maximum stress on the inside of the convolution crest (red area). Bottom: tangential loading with maximum stress on the outside of the convolution trough in the area of the supporting ring (orange-red area).

4 4 POLYFLURON PTFE bellows Features and options These bellows feature Dr. Schnabel s compression stops that prevent damage to the POLYFLURON PTFE convolutions from over-compression of the bellows in case pipe supports are not sufficient. Dr. Schnabel bellows are vacuum resistant, for details see page 21. Non-standard flanges and clearance holes are available. Stainless steel flange material, J-Bolt flanges according to various standards are possible according to customer specifications. Reducing flange arrangements can also be supplied. Axial/Lateral/Angular movement Our POLYFLURON bellows can be supplied with tie rods engineered to restrict movements according to customer requirements. Dr. Schnabel can also provide plain or plain (hinged) bellows. Lateral movement Angular movement POLYFLURON N1 to 6 (1-6 Convolutions) up to ND 2500 (100") POLYFLURON 16 (for PN16) also available fpr PN25 or N10 ND 40 (1.5") to ND 600 (24") Combines the corrosion resistance of POLYFLURON PTFE and the high pressure rating of a stainless steel bellows. Multiple metal construction (HASTELLOY, Titanium, etc. are also available) to minimize spring rate. POLYFLURON 0 (for full vacuum) ND 200 (8") to ND 1400 (56") Full vacuum rating to 200 C Eliminates internal vacuum support rings made from expensive alloy. FXS smoothbore sleeve Prevents damage to POLYFLURON PTFE convolutions in abrasive service and prevents buildup of solids in the convolution. POLYFLURON PTFE is standard, but alloys are also available according to customer-specified requirements.

5 5 POLYFLURON N1 to POLYFLURON N2 All POLYFLURON bellows are supplied with carbon steel flanges as standard: 1) Flange drilling according to 2501 PN 10 (the diameters ND 1300 and ND 1500 are not considered in the standards) 2) Flange drilling according to B lb, from ND 28" to ND 60" according to MSS SP lb Flanges are threaded, except for the POLYFLURON N2 from ND 80 up to ND 400. Special flange designs are available on request (i. e. flanges for glass connections). The movements (axial,, ) indicated in the table, are values for non combined movements. For values at combined movements please contact us. ¹) POLYFLURON N1 POLYFLURON N2 ND Operating pressure Length Movement⁴) Operating pressure Length Movement⁴) Weight 100 C 100 C ½ ½ For higher temperature/pressure ratings please contact us. Operating temperature range: 10 C up to C ³) neutral length can be adjusted within and length ⁴) at mentioned neutral length neutral³)

6 6 POLYFLURON N3 to POLYFLURON N4 All POLYFLURON bellows are supplied with carbon steel flanges as standard: 1) Flange drilling according to 2501 PN 10 (the diameters ND 1300 and ND 1500 are not considered in the standards) 2) Flange drilling according to B lb, from ND 28" to ND 60" according to MSS SP lb Flanges on POLYFLURON N3 and POLYFLURON N4 up to ND 65 (2 1/2") threaded, from ND 80 (3") onwards are with clearence holes. Special flange designs are available on request (i. e. flanges for glass connections). The movements (axial,, ) indicated in the table, are values for non combined movements. For values at combined movements please contact us. ¹) ²) POLYFLURON N3 POLYFLURON N4 ND Operating pressure Length Movement⁴) Operating pressure Length Movement⁴) 100 C 100 C ½ ½ For higher temperature/pressure ratings please contact us. Operating temperature range: 10 C up to C ³) neutral length can be adjusted within and length ⁴) at mentioned neutral length neutral³)

7 7 POLYFLURON N5 to POLYFLURON N6 All POLYFLURON bellows are supplied with carbon steel flanges as standard: 1) Flange drilling according to 2501 PN 10 (the diameters ND 1300 and ND 1500 are not considered in the standards) 2) Flange drilling according to B lb, from ND 28" to ND 60" according to MSS SP lb Flanges up to ND 65 (2 1/2") threaded, from ND 80 (3") with clearence holes. Special flange designs are available on request (i. e. flanges for glass connections). The movements (axial,, ) indicated in the table, are values for non combined movements. For values at combined movements please contact us. ¹) ²) POLYFLURON N5 POLYFLURON N6 ND Operating pressure Length Movement⁴) Operating pressure Length Movement⁴) 100 C 100 C ½ ½ ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) ⁵) For higher temperature/pressure ratings please contact us. Operating temperature range: 10 C up to C ³) neutral length can be adjusted within and length ⁴) at mentioned neutral length ⁵) please contact us neutral³)

8 8 POLYFLURON special bellows Hinged typed () POLYFLURON bellows Hinged bellows allow only movement of the bellows about the centre of the bellows. This type of bellow can serve as a directional anchor for the piping system. The hinges are designed to carry the full weight of flooded pipe mounted to the bellows. When combined with a bellow having slotted hinges these bellows can be used to handle large misalignments using only two bellows as shown on the right. Hinged and slotted POLYFLURON bellows allow axial movement of the bellow in addition to movement. Lateral POLYFLURON bellows The flanges of a POLYFLURON bellow can be tied using spherical washers and nuts that eliminate or reduce the axial travel of the bellow yet allow for full offset of the bellow. This type of bellows replaces a direction anchor when properly located in the pipeline. The spherical nuts and washers are supplied in carbon steel as standard. POLYFLURON N1 to N6 bellows with internal support rings for higher vacuum resistance POLYFLURON N1 to N6 bellows can be supplied with internal vacuum support rings made of virgin paste-extruded POLYFLURON PTFE lined stainless steel rings. These rings increase the vacuum resistance of the bellows up to full vacuum depending on bellow size. The internal support rings are avail able also made of virgin paste-extruded POLYFLURON PTFE lined HASTELLOY, Tantalum etc. A special design and manufacturing method of the ends of these rings provide long life-time for this component, as long as the bellows are used within our recommended limits.

9 9 POLYFLURON 0 bellows for full vacuum The POLYFLURON 0 bellow for full vacuum is available from ND 200 (8") to ND 1400 (56"). 1) Flange drilling according to 2501 PN 10 2) Flange drilling according to B lb, from ND 28" to ND 40" according to MSS SP lb. All flanges are with threaded holes. Special flange designs are available on request (in example flanges for glass-connections). The movements (axial,, ) indicated in the table, are values for non combined movements. For values at combined movements please contact us. Features and options These bellows feature Dr. Schnabel s compression stops that prevent damage to the POLYFLURON PTFE convolutions from over-compression of the bellows. Stainless steel flange material, J-Bolt flanges according to various standards are possible to customer specification. Reducing flange arrangements can also be supplied. Axial/Lateral/Angular movement Dr. Schnabel POLYFLURON 0 bellows are mainly designed for axial movements. Lateral movement Angular movement ¹) POLYFLURON 0 ND Operating pressure Length Movement¹) Weight ²) Vacuum 200 C neu tral Operating temperature range: 10 C up to C ¹) at mentioned neutral length

10 10 POLYFLURON 16 PTFE lined metal bellows for high pressure The POLYFLURON 16 is available from ND 40 (1 ½") to ND 600 (24"). Combines corrosion resistance of POLYFLURON PTFE and the high pressure rating of a metal bellow. Multiple metal layer design minimizes spring rates. POLYFLURON 10/16/25 bellows are supplied standard with carbon steel flanges and stainless steel body. 1) Flange drilling according to 2501 PN 10. 2) Flange drilling according to B lb Special flange designs are available on request. ¹) POLYFLURON 16 ND Operating pressure Length Movement³) ca. Weight ²) neu tral 40 1 ½ ½ ½ ½ Operating temperature range: 10 C up to C ³) higher and movements are possible, but then the operating pressure must be reduced, please contact us

11 11 POLYFLURON 10 and 25 PTFE lined metal bellows for high pressure The POLYFLURON 16 is available from ND 40 (1 ½") to ND 600 (24"). Combines corrosion resistance of POLYFLURON PTFE and the high pressure rating of a metal bellow. Multiple metal layer design minimizes spring rates. POLYFLURON 10/16/25 bellows are supplied standard with carbon steel flanges and stainless steel body. 1) Flange drilling according to 2501 PN 10. 2) Flange drilling according to B lb Special flange designs are available on request. ¹) POLYFLURON 10 POLYFLURON 25 ND Operating pressure Length Movement³) Operating pressure Length Movement³) Weight ²) neu tral³) neu tral³) 40 1 ½ ½ ½ ½ ³) higher and movements are possible, but then the operating pressure must be reduced, please contact us

12 12 Accessories for the POLYFLURON bellows Smoothbore sleeves Dr. Schnabel FXS smoothbore sleeves prevent damage to PTFE convolutions in abrasive service and prevent build-up of solids in the convolution. The smoothbore sleeves are recommended when fluid velocity is high. POLYFLURON PTFE sleeves are standard, but alloys are also available per customer specification. ¹) Smoothbore sleeves for POLYFLURON N1 to N6 ND d4 d s POLYFLURON N1 POLYFLURON N2 POLYFLURON N3 POLYFLURON N4 POLYFLURON N5 POLYFLURON N6 ²) (ø mm) (ø mm) (ø mm) (mm) Length (mm) Weight (kg) Length (mm) Weight (kg) ¼ ½ ½ ¹) ¹) ¹) according to costumer specification Length (mm) Weight (kg) Length (mm) Weight (kg) Length (mm) Weight (kg) Length (mm) Weight (kg)

13 13 Accessories for the POLYFLURON bellows Smoothbore sleeves Dr. Schnabel FXS smoothbore sleeves prevent damage to PTFE convolutions in abrasive service and prevent build-up of solids in the convolution. The smoothbore sleeves are recommended when fluid velocity is high. POLYFLURON PTFE sleeves are standard, but alloys are also available per customer specification. Smoothbore sleeves for POLYFLURON 0 ND d4 d s POLYFLURON 0 (ø mm) (ø mm) (ø mm) (mm) Length (mm) Weight (kg) Safety shields It is highly recommended to use safety shields around flange connections and bellows if corrosive or other dangerous media is handled! Especially when the plant is used under the European Pressure Equipment Directive. Please ask for our detailed RAMCO Safety shield catalogue.

14 14 Flange dimensions, effective are and spring rates POLYFLURON 0 Flange dimensions Spring rates +/ 30 % (at room temperature) ND Raised force (ø mm) Bolt circle (ø mm) Hole dimensions Series 1 Series 2 Series 1 Series 2 Flange thickness Effective area (cm²) ax. compr. ax. expans. (no. x ø mm) (no. x ø mm) (mm) (N/mm) (N/mm) x 22 8 x M20 8 x 22 8 x ¾"UNC x x M20 12 x x ⅞"UNC x x M20 12 x x ⅞"UNC x x M20 12 x x 1"UNC x x M24 16 x x 1"UNC x x M24 16 x x 1 ⅛"8UN x x M24 20 x x 1 ⅛"8UN x x M27 20 x x 1 ¼"8UN x x M27 28 x x 1 ¼"8UN ¹) ¹) x x M30 28 x x 1 ½"8UN ¹) ¹) x x M30 32 x x 1 ½"8UN ¹) ¹) x x M33 36 x x 1 ½"8UN ¹) ¹) x x M36 44 x x 1 ½"8UN ¹) ¹) ¹) Please contact us Temperature correction factors (TCF) for spring rate conversion Temperature ( C) TCF Example: spring 120 C = spring rate x 0.5

15 15 Flange dimensions, effective are and spring rates ND Raised force (ø mm) Bolt circle (ø mm) Hole dimensions Series 1 Series 2 Series 1 Series 2 POLYFLURON N1 to N6 POLYFLURON N3 Flange dimensions Spring rates +/ 30 % Flange thickness Effective area ax. compr. ax. expans. (no. x ø mm) (no. x ø mm) (mm) (cm²) (N/mm) (N/mm) (N/mm) degree (Nm/) x 14 4 x M12 4 x 16 4 x ½"UNC ¼ x 18 4 x M16 4 x 16 4 x ½"UNC ½ x 18 4 x M16 4 x 16 4 x ½"UNC x 18 4 x M16 4 x 19 4 x ⅝"UNC ½ x 18 4 x M16 4 x 19 4 x ⅝"UNC x 18 8 x M16 4 x 19 4 x ⅝"UNC x 18 8 x M16 8 x 19 8 x ⅝"UNC x 18 8 x M16 8 x 22 8 x ¾"UNC x 22 8 x M20 8 x 22 8 x ¾"UNC x 22 8 x M20 8 x 22 8 x ¾"UNC x x M20 12 x x ⅞"UNC x x M20 12 x x ⅞"UNC x x M20 12 x x 1"UNC x x M24 16 x x 1"UNC x x M24 16 x x 1 ⅛"8UN x x M24 20 x x 1 ⅛"8UN x x M27 20 x x 1 ¼"8UN x x M27 28 x x 1 ¼"8UN x x M30 28 x x 1 ½"8UN ¹) ¹) ¹) ¹) x x M30 32 x x 1 ½"8UN ¹) ¹) ¹) ¹) x x M33 36 x x 1 ½"8UN ¹) ¹) ¹) ¹) x x M36 44 x x 1 ½"8UN ¹) ¹) ¹) ¹) ²) 1461 ²) 1537 ²) ²) 44 x x 1 ¾"8UN ¹) ¹) ¹) ¹) x x M39 48 x x 1 ¾"8UN ¹) ¹) ¹) ¹) ²) 1676 ²) 1759 ²) ²) 52 x x 1 ¾"8UN ¹) ¹) ¹) ¹) ¹) Please contact us ²) according to costumer specification Convolution correction factors (CCF) for spring rate conversion Number of convolutions CCF Example: spring rate POLYFLURON 5 = spring rate POLYFLURON 3 x 0.6 Temperature correction factors (TCF) for spring rate conversion Temperature ( C) TCF Example: spring 120 C = spring rate x 0.5

16 16 Temperature vacuum rating The vacuum resistance can be increased up to full vacuum with internal support rings shown on page 13. Vacuum resistance of POLYFLURON N1 to N6 POLYFLURON N1 POLYFLURON N2 POLYFLURON N3 POLYFLURON N4 POLYFLURON N5 POLYFLURON N6 ND Operating temp. Operating temp. Operating temp. Operating temp. Operating temp. Operating temp. 20 C 100 C 150 C 20 C 100 C 150 C 20 C 100 C ¼ ½ ½ C 20 C 100 C 150 C 20 C 100 C 150 C 20 C 100 C 150 C The POLYFLURON 0 is fully vacuum resistand up to 200 C ND Vacuum resistance of POLYFLURON 0 Operating temperature 20 C 100 C 150 C 200 C

17 Materials of construction/how to order 17 Materials of construction flanges: S235 JRG2 up to ND400/16" S355 J2G3 from ND450/18" upwards surface protection: flanges ND200/8" and bigger are painted with 2-components epoxy paint RAL 5003 smaller diameters are zinc galvanized & yellow chromated bellow material: virginal paste-extruded PTFE, white external support rings: , similar to AISI 316 Ti tie rods: 8.8 A2P, carbon steel zinc galvanized support flange: S235 JRG2, painted with (POLYFLURON 0) 2-components epoxy paint RAL 5003 Options flanges: stainless steel, etc. bellow material: virginal paste-extruded PTFE, anti-static, black external support rings: HASTELLOY, POLYFLURON PTFE-lined metal internal support rings: stainless steel, HASTELLOY, etc. always POLYFLURON PTFE lined tie rods: stainless steel, etc. support flange: stainless steel (POLYFLURON 0) How to order Example: FX N2 300 D C C W 110 SP ANG FXS I I I I I I I I I I A B C D E F G H I J A: number of convolutions 0 = means vacuum bellow 16 = means metal bellow POLYFLURON PTFE lined B: ND (mm or inch) according to flange standard under C C: flange standard A = 150 lbs D = PN10 J = JIS D: C = clearance holes T = drilled and tapped S= standard E: flange material C = carbon steel S = stainless steel F: PTFE w = white a = anti-static G: shipped length within / range in mm or inch H: internal support rings = no rings SP = vacuum support rings stainless steel/polyfluron PTFE-lined H: TA = vacuum support rings tantalum/polyfluron PTFE lined HA = vacuum support rings HASTELLOY/POLYFLURON PTFE lined I: bellow type STD = standard bellow ANG = hinged bellow for plain movement LAT = plain bellow AXI = bellow for plain axial movement J: FXS = with smooth bore sleeve

18 We would be pleased to provide you with the following data sheets: POLYFLURON PTFE lined piping systems POLYFLURON PTFE lined dip and inlet pipes Please contact us. TIS POLYFLURON /0 E Printed in Germany registered trademarks of SGL Carbon SE Graphite Materials & Systems SGL CARBON GmbH Sales Europe/Middle East/Africa pt-europe@sglcarbon.com Sales Americas pt-americas@sglcarbon.com Sales Asia/Pacific pt-asia@sglcarbon.com The data contained herein represent the current state of our product knowledge and are intended to provide general information on our products and their application spectra. In view of the variety and large number of application possibilities, these data should be regarded merely as general information that gives no guarantee of any specific properties and/or suit ability of those products for any particular application. Consequently, when ordering a product, please contact us for specific information on the properties required for the application concerned. On request, our technical service will supply a profile of characteristics for your specific application requirements without delay.