09-05-26 Handbuch Flugzeug Expansion Bellows - · PDF file3.2 Design requirements Bellows body...

Expansion Bellows Installation Instructions

www.broneske.de [email protected] Telephone: +49-4554-70210-0 Telefax.: +49-4554-70210-18

© Copyrights: Schwingungstechnik-Broneske GmbH – Gutenbergweg 3 – 23812 Wahlstedt/Hamburg - Germany www.broneske.de [email protected]

Phone: +49-4554-70210-0 – Fax.: +49-4554-70210-18

Schwingungstechnik-Broneske GmbH Gutenbergweg 3 • D-23812 Wahlstedt • Germany Internet: www.broneske.de

Telephone: +49-4554-70210-0 Telefax: +49-4554-70210-18

Email: [email protected]

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 1 1.4 Safety instructions Protective clothing 2 2 Handling Contents 2.1 Handling Protect the product against moisture 2.2 Handling Storage 2.3 Handling Transportation 3 Design requirements Contents 3.1 Design requirements Notes for design/construction 3.2 Design requirements Bellows body and flanges 3.3 Design requirements What is Build Length (BL) and Installaton Length (EL)? 4 Assembly Contents 4.1 Assembly Lifetime of expansion bellow 4.2 Assembly Before assembling: Resilient suppport (elastic support) 4.3 Assembly Before assembling: Inspection of the pipe and the compensator 4.4 Assembly Assembly - steps [1] to [5] 4.5 Assembly Assembly - steps [6] to [8] 4.6 Assembly Protection of the bellow during the assembly 4.7 Assembly Insulating at the expansion bellow 5 Commissioning and sea trail Contents 5.1 Commissioning and sea trail Prior to the commissioning and sea trial 5.2 Commissioning and sea trail During commissioning and sea trial 6 Maintenence General Notes 7 Causes of defects Contens 7.1 Causes of defects Damage caused by transportation, handling or installation 7.2 Causes of defects Damage caused by transportation, handling or installation 7.3 Causes of defects Operational failure 8 Warrenty Exclusion from the warranty

1.1 Instruction manual

1.2 How to use

1.3 Protective clothing 1

1.4 Protective clothing 2

Contents

Schwingungstechnik-Broneske GmbHGutenbergweg 3 • D-23812 Wahlstedt • GermanyInternet: www.broneske.de

Telephone: +49-4554-70210-0Telefax.: +49-4554-70210-18

Email: [email protected] 3

Date: 02.06.2009

Before beginning installation, trained professionalscarefully must read this guide carefully.

The products may only be installed if the contentsof this manual have been read and understood.

For questions, please contact:

Schwingungstechnik-Broneske GmbHGutenbergweg 3D-23812 WahlstedtDeutschland

Telephone: 04554-70210-0Telefax: 04554-70210-18

Email: [email protected]: www.broneske.de

Instruction manual




Date: 02.06.2009

The products are specially designed and producedto compensate for vibration, pressure andmovements in piping systems:

The maximum loads and the geometry of eachproduct are calculated by SB Broneske engineersin accordance with internationally valid regulations(for example engineering standards) andstandardized calculations.

Products damaged during transport or storagemay not be installed.

The manufacturer is not liable for damage sufferedas a result of transport or incorporation ofdamaged or deformed parts!

How to use




Date: 02.06.2009

During the installation or storage of products,safety and protective clothing must be worn. Theseare for example a protective suit and gloves.

Please take into account the country-specificsecurity provisions for the installation or storage ofsuch products.

Protective clothing 1




Date: 02.06.2009

During the installation or storage of products,safety and protective clothing must be worn. Theseare, for example, safety footwear.

If welding work is carried out, a welding shieldmust be used.

Please take into account the country-specificsecurity provisions for the installation or storage ofsuch products.

Protective clothing 2




Date: 02.06.2009

2.1 Protect the product from moisture

2.2 Storage

2.3 Transportation

Contents




Date: 02.06.2009

The products must be protected from moisture,from rain and water. Furthermore, the productsmust be protected from chemicals, soil or sand.

The products should be on a flat, solid, waterprooffloor and stored in a dry place. The products shouldbe stored under a roof or other rain-proof covers.

The products should be protected from highhumidity or moisture in combination with hightemperatures of over 25 ° Celsius (77°F) protected.

The products should not be stored longer than sixmonth. The products must be installed not laterthan after six month after receipt of the products.

The products should also be on site to be protectedfrom moisture on site.

For use, the products (mild steel parts) should bepainted with an appropriate coating on site toprotect them from moisture or water .

Products, which are installed outdoors, should bemade from a special corrosion-resistant material(for example stainless steel).

Protect the product against moisture




Date: 02.06.2009

Caution hollow body: When storing the expansionbellows, utmost caution should be paid. Theseproducts are components, comprising thin steelsheets.

These products are deformed at low mechanicalloads. Improper loading on the product and theproduct could be damaged or destroyed:

[1] The products may not be stacked.

[2] The products may not be entered into orstepped on.

[3] No-one should step on the products.

[4] The products should not be stored for longerthan six months.

[5] The products should be installed at thedestination (construction) after six month.

Storage




Date: 02.06.2009

Caution hollow body: When storing the expansionbellows, utmost caution should be paid. Theseproducts are components, comprising thin steelsheets.

These products are deformed at low mechanicalloads. Throwing of the product from low heightscould damage or destroy it:

To lift and transport these products, they should beheld in the holes of the flanges.

The products may not be lifted or transported onthe bellow themselves! Transportation fittings,poles for the preload of the compensator, guyropes, and gimbal joints should not be used aslifting devices.

The products must not be thrown to the ground orbe dropped.

The products must not be pushed against eachother.

Transportation




Date: 02.06.2009

3.1 Notes for design/construction

3.2 Bellow body and flanges

3.3 What is build length (BL) and InstallationLength (EL)?

Contents




Date: 02.06.2009

All modern resiliently mounted exhaust gasinstallations require stainless steel expansionbellows to:

a) Compensate for thermal expansion of the pipesand silencers (axial and lateral).b) Absorb shock and vibration forces at enginestart-up and engine shut-down.c) Limit reactive forces on the resilient fix points.

The resilient exhaustgas installation supports andthe thermal expansion bellows must work togetherand should be calibrated as one system to achievethe maximum reduction in structure born noiseand vibration.

Notes for design/construction




Date: 02.06.2009

SB Broneske expansion bellows type SBF are ofmulti-ply construction, which provide lowerreactive forces and longer service life.

SB Broneske stainless steel expansion bellows areexhaust gas resistant and heat resistant to 550°C(1000°F).

SB Broneske standard: The flanges or weld-endsare ST-37-2 steel. Various materials are suppliedon request.

All expansion bellows SBF flanges are borderedand rotate for easy installations.

Flanges are manufactured to DIN PN 6dimensions. The most common flange type onboard of ships is DIN86044.

Alternative flange sizes are readily available.

Bellows body and flanges




Date: 02.06.2009

Expansion bellows are designed and manufacturedto compensate the heat extension of exhaust pipesystems.

The expansion bellows operate if the engines arerunning and the exhaust pipe systems are hot. Theexpansion bellow should operate at its naturallength (=build length BL).

If the expansion bellow should operate at it naturallength (build length BL) in the hot pipe, theexpansion bellow must be installed pre stressed inthe cold pipe.

The expansion bellows must be installed in thecold pipe. The expansion bellows must be installedand prestressed, so that the hot pipe presses theexpansion bellow together and the expansionbellows will be able to operate at his natural length(=build length BL).

BL: The build length of the expansion bellow is thenatural length of the expansion bellow.

EL: The installation length of the expansion bellowis the length of the expansion bellow inprestressed condition. The stated maeasurementEL is the installation length of the sprecificcompensator in a COLD condition.

The distance from counterflange to counteflange isEL plus the thickness of the gaskets. SB Broneskegaskets are 2 mm thick. That means that thedistance from counter flange to counter flange isEL plus 4 mm, if SB Broneske gaskets are used.

What is Build Length (BL) and Installaton Length (EL)?




Date: 02.06.2009

The nut/bolt of the flanges must never touch thebellow itself.

The expansion bellows are designed so that thebolt/nut do not touch the bellow.

Please, choose the length of the nuts so that thenuts /bolt do not touch the bellow!

SB Broneske produces the expansion bellow withenough space between bolt/nut and bellow for freemovement.

Please check: After installation, the distancebetween the nut/bolt and the bellow must be atleast 8mm.

Please, check this distance during initial operation:If the pipes are installed correctly, the bellow willnot touch the nuts.

Only if the pipe are installed incorrect nuts mighttouch the nuts.

Please, pay very special attention while thenuts/bolts are mounted! The tools should nevertouch the bellow!

Allow bellow and nut/bolt to move without touching




Date: 21.05.2010

4.1 Life time of expansion bellows

4.2 Before assembling: Resilient suppport (elasticsupport)

4.3 Before assembling: Inspection of the pipe andthe compensator

4.4 Assembly - steps [1] to [5]

4.5 Assembly - steps [6] to [7]

4.6 Protection of the bellows during the assembly

4.7 Insulating at the expansion bellows

Contents




Date: 02.06.2009

A compensator has a calculated lifetime. This lifetime is calculated with the help of computationalmethods and certified standards that areinternationally recognized.

Prerequisite for the achievement is that thecompensator is not overloaded.

If this installation requirement is not met, thelifetime of the compensator can fall.

A reduced lifetime of the expansion bellows maydamage or breake the function of the pipingsystem.

Lifetime of expansion bellow




Date: 02.06.2009

The exhaust piping is a system which, due to thehigh temperatures of the exhaust gas, heats andexpands due to heat (thermal expansion).

To compensate the thermal expansion, theexpansion bellows must be installed in the pipingsystem.

Before the assembly of the compensator is has tobe examined whether the following calculationshave been carried out:

[1] The piping system must be supported by aresilient support system (fixed points, anchoragepoints (sway braces)). The arrangement of theelastic support must be created by specially trainedengineers. SB Broneske provides freecalculations (layout proposal). SB Broneskerecommends that customers use this free service.

[2] The elastic support must be designed andcalculated taking for example the pipe weights,acceleration forces of the exhaust gases and thereaction forces of the expansion bellows inconsideration.

Before assembling: Resilient suppport (elastic support)




Date: 02.06.2009

Before assembling, examine the following of theexpansion bellows:

[1] Check up if the expansion bellows weredamaged during transport or storage. In the caseof any damage, however small, the bellows mustnot be installed. Please, report any dents, signs ofrust on the steel, bent or damage components tothe manufaturer.

[2] The pipe with the elastic support must havebeen installed before the expansion bellows areassembed.

[3] The construction inspection must approve theelastic storage and piping system before theexpansion bellows are assembled.

[4] The counterflanges must be installed before theexpansion bellows are assembled and welded tothe respective ends of pipes. This work must beperformed by professional welders.

[5] The distance between the counter flanges of thepipe sections have exactly the distance of thepreloaded mounting length EL plus gasketthickness of the corresponding expansion bellow. Ifnot, you must contact the manufacturer of theexpansion bellow consultation.

Before assembling: Inspection of the pipe and the compensator




Date: 02.06.2009

The assembly can be performed, for example, inthe following steps:

[1] The counterflanges are already welded on theends of the exhaust pipes.

[2] Expansion bellows with inner sleeve: If theexpansion bellows show an arrow, the arrow mustpoint in the same direction as the direction of flowin the exhaust pipe!

[3] Appropriate seals between expansion bellowflanges and counterflange must be used. The sealsto be used in temperature- and pressure-resistant.

[4] One seal ist attached to the right flange(rotatable flange) of the expansion bellows and isbolted to the counter flange. It is essential to centrethe seal between the flange and counter flangebefore and during the process. The screws shouldbe tightened crosswise.

[5] The bolts must be inserted from the outside ofthe counter flanges in the direction of the bellow.The nuts must be inside the bellows. Only one nutand one washer per bore hole are required tofasten the flange. No counter nut is required.

Assembly - steps [1] to [5]




Date: 02.06.2009

[6] The left flange (rotatable flange) must be rotatedso that the holes of the flange and counter flangematch. For the rotation, three extra-long screwscan be used. The left flange is supplied with theseal and the counter flange and bolted. Therefore,the seal between the flange and counterflangemust be centered.

[7] Expansion bellows for the exhaust pipe systemsmust not transmitt rotation or torque forces.

Therefore, the flange (rotatable flanges) ofexpansion bellows must be rotated, until there isno more tension on the compensator.

[8] Protection sheets and retaining bars devicesmust be removed AFTER the installation ofexpansion bellows.

Assembly - steps [6] to [8]




Date: 02.06.2009

The bellows of the expansion bellows are verysensitive and have to be particularly rotected forexample:

[1] The expansion bellows are to be protected fromwelding spatter.

[2] The expansion bellows may not be stepped on.

[3] During assembly, the bellows of expansionbellows may not be touched by assembly tools orhoisting equippment.

[3] The bellows of the expansion bellow may not beraised, stored or moved. The expansion bellowsshould only be lifted by the flanges.

[4] When bolting, screwing or welding of theexpansion bellows, please ensured that thebellows of the expansion bellow are damaged.

[5] The bellows may not be stressed to torsion(twisting) loads.

[6] Do not use a brush or steel wool on the bellows.

[7] Do not use cleaners that contain chlorides.

Protection of the bellow during the assembly




Date: 02.06.2009

The compensator must be insulated as like theexhaust pipe.

Before insulation the expansion bellows, it is thusnecessary to prevent the insulating material fromgetting between the waves of the expansionarrives.

The compensator must be equipped with a heat-resistant outer insulation around the bellowsaround it.

Insulating at the expansion bellow




Date: 02.06.2009

5.1 Prior to the commissioning and sea trial

5.2 During commissioning and sea trial

Contents




Date: 02.06.2009

The construction inspection must check theexhaust pipe system and expansion bellows beforcommissioning and sea trial.

Please, check before commissioning and sea trial:

[1] Have the expansion bellows been damagedduring installation or transportation?

[2] Has the whole elastic support been installedaccording to the requirements and designtemplates?

[3] Were the expansion bellows fitted with thecorrect assembly length EL plus gasket thickness?

[4] Have the specific expansion bellows beeninstalled in the "correct" position in the pipesystem ?

[5] Has the correct direction of the exhaust gas pipeflow been taken into account (only if expansionbellows have inner sleeves)?

[6] Are the bellows and other moving parts of theexpansion bellows free from other bodies?

[7] Have all elements of packing, protective sheetsand prestressing bars been removed from theexpansion bellows?

Prior to the commissioning and sea trial




Date: 02.06.2009

During commissioning and sea trial the expansionbellows must be inspected by means of a visualexamination:

[1] Leakage or pressure on the respectiveexpansion bellows.

[2] Prohibited movements and improper rotation ortorsion of the bellows or their components.

[3] Prohibited movements of the exhaust pipesystem.

[4] Dents or instability of the expansion bellows.

During commissioning and sea trial




Date: 02.06.2009

One of SB Broneske designed and properly builtexpansion bellows requires no specialmaintenance. However, the compensator, togetherwith the piping system be monitored on a regularbasis.

A regular inspection / maintenance once a weekincreases the life of the expansion in the existingpipeline system.

It must be verified whether the compensatorreveals signs of rust or whether the expansionbellows screws become loose.

General Notes




Date: 02.06.2009

7.1 Damage caused by transportation, handling orinstallation

7.2 Damage caused by transportation, handling orinstallation

7.3 Operational failure

Contens




Date: 02.06.2009

SB Broneske draws the customers attention to themost frequent causes of the failure of expansionjoints.

Damage caused by transportation, handling or installation




Date: 02.06.2009

The following errors during transport or assemblymust be avoided:

Transportation and handling error: bulges, dents,scratches and scrapes due to improper handling.

Position of the expansion bellow in the exhaustpipe: The respecific expansion bellow was installedin the wrong position in the piping system.

Compensation of inaccuracies: The expansionbellows are also used to offset inaccuracies of builtpipe sections .

Prestressing facility: Removing the prestressingbars (rods or flat iron) has been overseen.

Missing cover while welding: Damage caused bywelding spatter, which during happend during theassembly of the expansion bellows.

Flow in innver sleeve: The expansion bellow isfitted with the wrong opposite direction of flow.

Damage caused by transportation, handling or installation




Date: 02.06.2009

Corrosion: Corrosion damage to the expansionbellows or the installation environment, especiallythrough injection of water or chemicals (catalysts).

Fatigue by thermal expansion: Fatigue fracturesdue to accidental movements, includingmovements or lateral movements, which arelarger than those in the underlying design.

By vibration fatigue: Fatigue fractures caused byunexpected vibration.

Impurities between folds of expansion bellows:Damage caused by firmly positioned impuritiesbetween the folds of the bellows, both internal asexternal.

Pressure or low pressure in the pipe system, theexpansion bellows are determined by pressure orlow pressure in the pipe system to be heavilyburdened and bent.

Operational failure




Date: 02.06.2009

We would like to point out that the warranty is voidif the preceding instructions for assembly,verification of assembly and commissioning arenot adhered to.

We refer to the assembly instructions forexpansion, published by the EJMA.

Exclusion from the warranty




Date: 02.06.2009

09-05-26 Handbuch Flugzeug Expansion Bellows - · PDF file3.2 Design requirements Bellows body...

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