Metal Expansion Joints Installation

Inspection

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FLEXPERT Metal Expansion Joints Installation are thoroughly inspected at factory and are packed suitably to take care of the delicate components during transportation.

Storage

Metallic Expansion Joints Installation should be stored in clean and dry place and keep them away from moisture, sand and chemicals. Metal expansion joints with heavy end fittings should not be stacked on each other or should not touch each other. Please inspect the metallic expansion joints immediately up on receipt at the stores to verify the transportation damages like dents. broken shipping brackets, damaged tie rods, hardware etc. In order to achieve the required flexibility the bellows element of the metal expansion joint is constructed from a relatively thin material which requires special care during handling and installation of the joint.

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Before Installation of Metal Expansion Joints

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Proper Handing Arrangement for Lifting

Do not wrap lifting chain or sling on the Bellows

  • Check the gap in the opening of the pipeline in which the metallic expansion joint is to be installed. The gap should be within tolerance as specified by the manufacturer or the purchaser. The metal expansion joint should not be deflected, extended or compressed excessively to match for the excessive piping misalignment.
  • The area around the installation should be clear from all sharp objects and projections which may possibly damage the bellows.
  • The two duct ends between which the metallic expansion joint is to be installed should be clean, smooth and parallel and perfectly aligned to each other.
  • The Metal Expansion Joints fitted with lifting lugs should be lifted only by means of the lifting lugs.
  • Shipping brackets painted in yellow colour should not be used to lift the metallic expansion joints.
  • Chains or slings should not be wrapped directly up on the bellows or the bellows cover.
  • Smaller Expansion Joints weighing less than 200 kgs or larger expansion joints where lifting lugs cannot be provided due to limitations should be carefully lifted by proper means without affecting the bellows portion.
  • Please ensure that the anchors and guides of sufficient strength have been installed properly and are functioning well.

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During Installation of Metal Expansion Joints

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    • Remove the flange face transportation protection if any and check inside of the expansion joints Installation for foreign particles and desiccant bags and remove them.
    • Never drop the metal expansion joint to avoid mechanical damage.
    • Bring the expansion joints within the gap in which the joint is to be installed with due care to flow direction indicated on the metallic expansion joint if there is internal sleeve in the expansion joint.
    • For flanged end expansion joints never torsion the metal expansion joint to match its holes with the matching flanges. Instead rotate the matching flanges to match with the holes of the body flanges. While installation the holes in the body flanges of the expansion joints should be freely aligned with those in the matching flanges. It is always good practice to keep one side matching flange freely rotating till the other side of the expansion joints is fitted completely. This matching flange can be welded to pipe after aligning it properly with the holes in the body flange of the expansion joint.
    • For weld ends joints prior to welding the ends cover the bellows portion securely with fire retardant cloth to avoid contact of weld spark, arc and spatter with the bellows element. Welding cables , earthing or electrodes should never touch the bellows portion.
    • Do not apply torsion to the bellows element by rotating the two end in opposite direction.
    • Movement limiting devices such as tie rods, hinges and gimbals should never be removed nor be adjusted they are properly set at the factory and need no setting change unless otherwise specified.
    • Avoid cleaning agents which contain chlorides and avoid using steel wool or wire brushes on the bellows.
  • Remove the shipping brackets painted with yellow color only after complete installation.

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During Installation of Metal Expansion Joints

  • Inspect the entire system to ensure that the anchors, guides and pipe supports have been installed as per the piping system drawings and are working properly. The anchors must be designed to withstand the thrust load at test pressure. The thrust load at test pressure can be obtained from us.
  • Check for damage to the expansion joint during handling and installation.
  • Check if the expansion joint is free to move within the desired movements without any obstruction.
  • Check if every temporary device like transportation bars or shipping brackets have been removed and every permanent devices like cover, tie rods, limit rods, control rods, gimbals and hinges are in proper position ,shape and settings and can move properly within the set constraints without any obstruction.
  • Ensure that the pipeline is capable of supporting the dead weight of the expansion joint and the weight of water contained in it.
  • REMOVE THE SHIPPING BARS /BRACKETS BEFORE PRESSURISING THE UNIT FOR HYDROTESTING.

After Installation But before Hydro Test of Metal Expansion Joints

  • Inspect the entire system to ensure that the anchors, guides and pipe supports have been installed as per the piping system drawings and are working properly. The anchors must be designed to withstand the thrust load at test pressure. The thrust load at test pressure can be obtained from us.
  • Check for damage to the expansion joint during handling and installation.
  • Check if the expansion joint is free to move within the desired movements without any obstruction.
  • Check if every temporary device like transportation bars or shipping brackets have been removed and every permanent devices like cover, tie rods, limit rods, control rods, gimbals and hinges are in proper position ,shape and settings and can move properly within the set constraints without any obstruction.
  • Ensure that the pipeline is capable of supporting the dead weight of the expansion joint and the weight of water contained in it.
  • REMOVE THE SHIPPING BARS /BRACKETS BEFORE PRESSURISING THE UNIT FOR HYDROTESTING.

During and After Hydro Testing of Metal Expansion Joints

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  • Check for leaks or pressure drops.
  • Check for imbalance, in-plane/column squirm or torsion.
  • Check if Anchors, guides and supports have moved in an abnormal way and direction.
  • The water used for hydro-testing should be free from chlorides.
  • Water should not be left standing in the corrugated portion of the bellows, and should be removed immediately after testing.

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Maintenance

Metal Expansion Joints do not require any special maintenance if installed properly and functioning properly.

Periodical Inspection

  • Visually check the movements absorbed by the metallic expansion joints during working conditions.
  • Check for leaks, mechanical damage. Corrosion, abnormal vibrations etc.
  • Check and remove any deposits of dust debris that has accumulated between the convolutions of the expansion joints which may affect the movement and decrease the life span of the metal expansion joint.