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Solving thermal expansion, building settlement movement, noise, vibration, de-aeration & dirt problems in pipes and plant
Pipe Solutions Ltd., Head Office, Hornbeam Park Oval, Harrogate, HG2 8RB Tel:01423-878888 Fax:01423-878880 Email:sales@pipesolutions.co.uk Website:www.pipesolutions.co.uk
CONTENTS
THERMAL EXPANSION PROBLEMS TO OVERCOME METHODICAL APPROACH NATURAL FLEXIBILITY SOLUTION PIPE BRANCH & OFFSET FLEXIBILITY PIPE LOOP FLEXIBILITY EXPANSION JOINT SOLUTION TYPICAL AXIAL INSTALLATIONS TYPICAL LATERAL INSTALLATIONS TYPICAL HINGED INSTALLATIONS TYPICAL GIMBAL INSTALLATIONS EXPANSION JOINT GEOMETRY STRUCTURAL / BUILDING MOVEMENT PIPE ANCHORS - FRICTION FORCE BENDING FORCE + SPRING RATE FORCE PRESSURE THRUST FORCE + CENTRIFUGAL FORCE WIND LOAD FORCE + DEAD WEIGHT FORCE PIPE GUIDES - CALCULATION OF SPACINGS PIPE GUIDES - USED WITH UNRESTRAINED EXPANSION JOINTS PIPE GUIDES - USED WITH RESTRAINED EXPANSION JOINTS TYPICAL ANCHORS, GUIDES & SUPPORTS COLD PULL (COLD DRAW) OTHER CONSIDERATION - INSULATION, INSTALLATION, COMMISSIONING, OPERATION & MAINTENANCE STEAM DATA + WATER FILLED PIPE / INSULATION WEIGHTS DIMENSIONAL PIPE DATA
This publication contains general information. If you require more detailed data then please contact us. Nothing herein constitutes a warranty of any kind, expressed or implied. We reserve the right to alter or amend any information detailed in this publication. E&OE. Disclaimer: Every effort has been made to ensure the accuracy of the information provided, however, we cannot accept any responsibility for any errors. Edition 3. Pipe Solutions Ltd. 12/2010.
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INTRODUCTION
Pipe Solutions Ltd is a wholly independent company established with the aim of providing the engineering industry with a one stop shop for solving the problems of thermal expansion, building settlement movement, noise, vibration, de-aeration and dirt removal in pipes and plant, whilst providing an unequalled portfolio of expansion joints, guides, anchors, flexible connectors, hoses, anti-vibration mounts, de-aerators, dirt separators and chemical dosing equipment. Technical expertise, quality products, professional market support and a value led pricing policy enable Pipe Solutions Ltd to achieve success in the mechanical engineering industry. A Quality Management System approved by Lloyd's Register Quality Assurance and certified to BS EN ISO 9001 enables all in house operations to be completed to the satisfaction of all Pipe Solutions Ltd clients. From a helping hand to a 'complete solution', you are assured of the highest standard. Specially developed computer software enable the whole support team to accurately deliver exactly what is required; from providing prompt product proposals and technical data to timely product despatches and invoicing. Pipe Solutions Ltd guarantee customer care. Every team member is committed to the customer. If you are made a promise, it will be honoured. Tasks that are clearly not achievable will not be taken on and you will be told immediately. We build our reputation on integrity and honesty. Pipe Solutions - put us to the test !
PIPE SOLUTIONS
Solving thermal expansion, building settlement movement, noise, vibration, de-aeration & dirt problems in pipes and plant
Pipe Solutions Ltd, Head Office, Hornbeam Park Oval, Harrogate, HG2 8RB Tel:01423-878888 Fax:01423-878880 Email:sales@pipesolutions.co.uk Website:www.pipesolutions.co.uk
MEMBER
Tel 01423 878888 PIPE SOLUTIONS LTD
THERMAL EXPANSION
All pipes and vessels expand and contract in direct proportion to a temperature change. This can be due to the temperature of the flowing media or from surrounding ambient temperature. Wind chill and solar gain are also factors that should be considered. Expansion and contraction can be calculated mathematically using the formula:X = L (T1-T2) CExp Where, X = L = T1 = T2 = CExp =
Coefficients of Thermal Expansion for Common Pipe Materials
Expansion or Contraction (m) Length of pipe or vessel (m) Starting Temperature (C) Final Temperature (C) Coefficient of Thermal Expansion
METALS Material Copper Carbon Steel Stainless Steel (Austeni tic) Stainless Steel (Ferri tic) Cast Iron Coefficient 16.4 x 10 12.2 x 10
-6 -6
PLASTICS Material ABS PVCU PVCC PE PP Coefficient 100 x 10-6 80 x 10-6 70 x 10-6 200 x 10-6 150 x 10-6
Coefficients of Thermal Expansion for various common materials are shown right:-
11.0 x 10-6
Expansion rates of common materials at various temperature changes are as follows:Temp. Change
C 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300
PROBLEMS TO OVERCOME
Exceeding Allowable Stresses When the pipe is free to move, problems tend not to exist so often. However, when the pipe is restricted from moving freely, large forces and moments are imposed on pipe supports, anchors and connections to vessels, plant, etc. As a result, the allowable stress on the pipe and the fixed points may well be exceeded, leading to premature failure. Pipe Bowing and Buckling Other expansion related problems may also start to occur, such as the pipe buckling or bowing. This is often the direct result of a pipe growing in length between two fixed points. Although the fixed points (anchors) may not be over-stressed and remain intact, the pipe is being compressed like a column and could potentially buckle. Building Settlement Movement Whenever pipes are routed across structural movement joints in buildings, roads, bridges, etc., they will be subjected to differential displacements. These must be taken into consideration when designing the pipe system. Vessel Settlement Pipes may be installed with rigid connections to vessels used for storage of fluids. These installations will probably be made whilst the vessel is empty. However, when the vessel is filled, the weight of the fluid may cause settlement of the foundations or compression of spring mountings. These must be taken into consideration when designing the pipe system. Plant Vibration and Start-up Whenever equipment that is installed on anti-vibration mountings starts-up or runs-down, it will pass through the resonant frequency of the vibration isolation system. At this point, the equipment will move more than during normal operating conditions. These movements or displacements will be imposed on the pipework connections and may overstress or fatigue the pipe and or plant nozzles. Expansion bellows can relieve these stresses and also reduce the transmission of noise and vibration to the pipe system. Water Hammer and Flow Induced Movement and Vibration Turbulent and high velocity flow of liquids in pipes can cause pipe displacements where the liquid acts upon direction changes and reductions in the pipe system. Where a system process uses automated valves, fast closure times can cause water hammer. Expansion bellows and flexible hoses can help with relieving stresses in the pipe. Wind Loading on Supporting Structures High wind speeds naturally buffer buildings, bridges, gantries, etc. The forces developed may cause the structure to sway, which will in turn displace the pipework. If there is a possibility of displacements being imposed on the pipe, then they must be taken into consideration when designing the pipe system. Seismic Loading Although rare in the UK, consider pipe displacements due to seismic activity. Careful analysis is required with due allowance for pipe shock absorbers and sway braces.
METHODICAL APPROACH
There is no such thing as a "correct solution" as many can exist. However taking a methodical approach will unveil the possible solutions that can solve the expansion problems. Many factors must be taken into consideration. The following information should be gathered before different methods are considered:Pipe Material (Expansion Coefficients) Pipe Nominal Size (and Gauge, Wall Thickness or Schedule) Pipe Length, Location and Layout Temperature (Minimum, Maximum and Starting Temperature) Pressure (Working and Test) Connection and Branch Points Building Structure (Position and Strength of Walls, Floors, Soffits, Mezzanines, etc) PIPE SYSTEM LAYOUT & LOCATION
ESTABLISH PIPE MOVEMENT PIPE MATERIAL COEFFICIENT OF EXPANSION x TEMPERATURE CHANGE x PIPE LENGTH DETERMINE EXPANSION CONSIDER ALSO BUILDING SETTLEMENT & VESSEL SETTLEMENT & PLANT VIBRATION & WATER HAMMER & WIND LOAD MOVEMENT
=
PIPE EXPANSION CONSIDER THE VARIOUS SOLUTIONS IN TURN
NO
UNRESTRAINED BELLOWS
STANDARD AXIAL EXTERNALLY PRESSURISED AXIAL
NO
RESTRAINED BELLOWS
LATERAL HINGED GIMBAL
SUPPORTS
NO
PRESSURE BALANCED BELLOWS
Tel 01423 878888
YES
SOLUTION FOUND
PIPE SOLUTIONS LTD
Force F (N)
ANCHOR POINT
Seamed carbon steel tube to EN10255 (formerly BS1387) and copper tube to EN1057-R250 (formerly BS2871 Part 1) is considered below. Note that formulae for other tube specifications differ and data from the tube manufacturer must be used. The length of pipe required to bend can be calculated mathematically using the formulae:For carbon steel pipe, L = 0.1 (D X) Where, L D X = = = For copper pipe, L = 0.06 (D X)
The force required to bend this length of pipe can be calculated mathematically using the formulae:For carbon steel pipe, F = (24 I X) L Where, F I X L = = = =
nd
The moment of inertia (2 moment of area) can be calculated mathematically using the formula:I = 3.142 (D4 - d4) 64 Where, D d = = Pipe Outer Diameter Pipe Internal Diameter
The stress developed in the bending pipe can be calculated mathematically using the formulae:For carbon steel pipe, S = (6 105 D X) L Where, S D X L = = = = For copper pipe, S = (2.1 105 D X) L Stress (N/m) Pipe Nominal Diameter (mm) Expansion (mm) Length (m) 7
PIPE SOLUTIONS LTD
COLD PULL
ANCHOR
Expansion 'X'
(mm) 1 2 3 4 5 10 15 20 25 30 35 40 45 50 60 70 80 90 100
Branch or Offset Length 'L' (m) required for the stated Seamed Carbon Steel Pipe Size
15mm 0.387 0.548 0.671 0.775 0.866 1.225 1.500 1.732 1.936 2.121 2.291 2.449 2.598 2.739 3.000 3.240 3.464 3.674 3.873 20mm 0.447 0.632 0.775 0.894 1.000 1.414 1.732 2.000 2.236 2.449 2.646 2.828 3.000 3.162 3.464 3.742 4.000 4.243 4.472 25mm 0.500 0.707 0.866 1.000 1.118 1.581 1.936 2.236 2.500 2.739 2.958 3.162 3.354 3.536 3.873 4.183 4.472 4.743 5.000 32mm 0.566 0.800 0.980 1.131 1.265 1.789 2.191 2.530 2.828 3.098 3.347 3.578 3.795 4.000 4.382 4.733 5.060 5.367 5.657 40mm 0.632 0.894 1.095 1.265 1.414 2.000 2.449 2.828 3.162 3.464 3.742 4.000 4.243 4.472 4.899 5.292 5.657 6.000 6.325 50mm 0.707 1.000 1.225 1.414 1.581 2.236 2.739 3.162 3.536 3.873 4.183 4.472 4.743 5.000 5.477 5.916 6.325 6.708 7.071 65mm 0.806 1.140 1.396 1.612 1.803 2.550 3.122 3.606 4.031 4.416 4.770 5.099 5.408 5.701 6.245 6.745 7.211 7.649 8.062 80mm 100mm 125mm 150mm 0.894 1.000 1.118 1.225 1.265 1.414 1.581 1.732 1.549 1.732 1.936 2.121 1.789 2.000 2.236 2.449 2.000 2.236 2.500 2.739 2.828 3.162 3.536 3.873 3.464 3.873 4.330 4.743 4.000 4.472 5.000 5.477 4.472 5.000 5.590 6.124 4.899 5.477 6.124 6.708 5.292 5.916 6.614 7.246 5.657 6.325 7.071 7.746 6.000 6.708 7.500 8.216 6.325 7.071 7.906 8.660 6.928 7.746 8.660 9.487 7.483 8.367 9.354 10.247 8.000 8.944 10.000 10.954 8.485 9.487 10.607 11.619 8.944 10.000 11.180 12.247
Expansion 'X'
(mm) 1 2 3 4 5 10 15 20 25 30 35 40 45 50 60 70 80 90 100
Branch or Offset Length 'L' (m) required for the stated Copper Pipe Size
15mm 0.232 0.329 0.402 0.465 0.520 0.735 0.900 1.039 1.162 1.273 1.375 1.470 1.559 1.643 1.800 1.944 2.078 2.205 2.324 22mm 0.281 0.398 0.487 0.563 0.629 0.890 1.090 1.259 1.407 1.541 1.665 1.780 1.888 1.990 2.180 2.355 2.517 2.670 2.814 28mm 0.317 0.449 0.550 0.635 0.710 1.004 1.230 1.420 1.587 1.739 1.878 2.008 2.130 2.245 2.459 2.656 2.840 3.012 3.175 35mm 0.355 0.502 0.615 0.710 0.794 1.122 1.375 1.587 1.775 1.944 2.100 2.245 2.381 2.510 2.750 2.970 3.175 3.367 3.550 42mm 0.389 0.550 0.673 0.778 0.869 1.230 1.506 1.739 1.944 2.130 2.300 2.459 2.608 2.750 3.012 3.253 3.478 3.689 3.888 54mm 0.441 0.624 0.764 0.882 0.986 1.394 1.708 1.972 2.205 2.415 2.608 2.789 2.958 3.118 3.415 3.689 3.944 4.183 4.409 67mm 0.491 0.695 0.851 0.982 1.098 1.553 1.902 2.196 2.456 2.690 2.906 3.106 3.295 3.473 3.804 4.109 4.393 4.659 4.911 76mm 108mm 133mm 159mm 0.523 0.624 0.692 0.757 0.740 0.882 0.979 1.070 0.906 1.080 1.198 1.310 1.046 1.247 1.384 1.513 1.170 1.394 1.547 1.692 1.654 1.972 2.188 2.392 2.026 2.415 2.680 2.930 2.339 2.789 3.095 3.383 2.615 3.118 3.460 3.783 2.865 3.415 3.790 4.144 3.095 3.689 4.094 4.476 3.308 3.944 4.376 4.785 3.509 4.183 4.642 5.075 3.699 4.409 4.893 5.350 4.052 4.830 5.360 5.860 4.376 5.217 5.789 6.330 4.678 5.577 6.189 6.767 4.962 5.915 6.564 7.177 5.231 6.235 6.920 7.566
Expansion 'X'
(mm) 1 2 3 4 5 10 15 20 25 30 35 40 45 50 60 70 80 90 100
Branch or Offset Length 'L' (m) required for the stated ABS / PVC Plastic Pipe Size
20mm 0.152 0.215 0.263 0.304 0.340 0.481 0.589 0.680 0.760 0.833 0.900 0.962 1.020 1.075 1.178 1.272 1.360 1.442 1.521 25mm 0.152 0.215 0.263 0.304 0.340 0.481 0.589 0.680 0.760 0.833 0.900 0.962 1.020 1.075 1.178 1.272 1.360 1.442 1.521 32mm 0.170 0.240 0.294 0.340 0.380 0.538 0.658 0.760 0.850 0.931 1.006 1.075 1.140 1.202 1.317 1.422 1.521 1.613 1.700 40mm 0.192 0.272 0.333 0.385 0.430 0.608 0.745 0.860 0.962 1.053 1.138 1.216 1.290 1.360 1.490 1.609 1.720 1.825 1.923 50mm 0.215 0.304 0.372 0.430 0.481 0.680 0.833 0.962 1.075 1.178 1.272 1.360 1.442 1.521 1.666 1.799 1.923 2.040 2.150 63mm 0.240 0.340 0.416 0.481 0.538 0.760 0.931 1.075 1.202 1.317 1.422 1.521 1.613 1.700 1.862 2.011 2.150 2.281 2.404 75mm 0.274 0.388 0.475 0.548 0.613 0.867 1.062 1.226 1.371 1.501 1.622 1.734 1.839 1.938 2.123 2.293 2.452 2.600 2.741 90mm 110mm 125mm 140mm 0.304 0.340 0.380 0.416 0.430 0.481 0.538 0.589 0.527 0.589 0.658 0.721 0.608 0.680 0.760 0.833 0.680 0.760 0.850 0.931 0.962 1.075 1.202 1.317 1.178 1.317 1.472 1.613 1.360 1.521 1.700 1.862 1.521 1.700 1.901 2.082 1.666 1.862 2.082 2.281 1.799 2.011 2.249 2.464 1.923 2.150 2.404 2.634 2.040 2.281 2.550 2.793 2.150 2.404 2.688 2.944 2.356 2.634 2.944 3.226 2.544 2.845 3.180 3.484 2.720 3.041 3.400 3.725 2.885 3.226 3.606 3.950 3.041 3.400 3.801 4.164
Expansion 'X' Branch or Offset Length 'L' (m) required for the stated Pressfit Carbon / Stainless Pipe Size
(mm) 1 2 3 4 5 10 15 20 25 30 35 40 45 50 60 70 80 90 100 12mm 0.173 0.245 0.300 0.346 0.387 0.548 0.671 0.775 0.866 0.949 1.025 1.095 1.162 1.225 1.342 1.449 1.549 1.643 1.732 15mm 0.194 0.274 0.335 0.387 0.433 0.612 0.750 0.866 0.968 1.061 1.146 1.225 1.299 1.369 1.500 1.620 1.732 1.837 1.936 18mm 0.212 0.300 0.367 0.424 0.474 0.671 0.822 0.949 1.061 1.162 1.255 1.342 1.423 1.500 1.643 1.775 1.897 2.012 2.121 22mm 0.235 0.332 0.406 0.469 0.524 0.742 0.908 1.049 1.173 1.285 1.387 1.483 1.573 1.658 1.817 1.962 2.098 2.225 2.345 28mm 0.265 0.374 0.458 0.529 0.592 0.837 1.025 1.183 1.323 1.449 1.565 1.673 1.775 1.871 2.049 2.214 2.366 2.510 2.646 35mm 0.296 0.418 0.512 0.592 0.661 0.935 1.146 1.323 1.479 1.620 1.750 1.871 1.984 2.092 2.291 2.475 2.646 2.806 2.958 42mm 0.324 0.458 0.561 0.648 0.725 1.025 1.255 1.449 1.620 1.775 1.917 2.049 2.174 2.291 2.510 2.711 2.898 3.074 3.240 54mm 0.367 0.520 0.636 0.735 0.822 1.162 1.423 1.643 1.837 2.012 2.174 2.324 2.465 2.598 2.846 3.074 3.286 3.486 3.674 76mm 0.436 0.616 0.755 0.872 0.975 1.378 1.688 1.949 2.179 2.387 2.579 2.757 2.924 3.082 3.376 3.647 3.899 4.135 4.359 89mm 0.472 0.667 0.817 0.943 1.055 1.492 1.827 2.110 2.358 2.584 2.791 2.983 3.164 3.335 3.654 3.947 4.219 4.475 4.717 108mm 0.520 0.735 0.900 1.039 1.162 1.643 2.012 2.324 2.598 2.846 3.074 3.286 3.486 3.674 4.025 4.347 4.648 4.930 5.196
Expansion X (mm)
PIPE LENGTH
Branch L (m)
COLD PULL
ANCHOR
X 2
X 2
Loop Side Length 'L' (m) required for the stated Seamed Carbon Steel Pipe Size
15mm 0.274 0.387 0.474 0.548 0.612 0.866 1.061 1.225 1.369 1.500 1.620 1.732 1.837 1.936 2.121 2.291 2.449 2.598 2.739 20mm 0.316 0.447 0.548 0.632 0.707 1.000 1.225 1.414 1.581 1.732 1.871 2.000 2.121 2.236 2.449 2.646 2.828 3.000 3.162 25mm 0.354 0.500 0.612 0.707 0.791 1.118 1.369 1.581 1.768 1.936 2.092 2.236 2.372 2.500 2.739 2.958 3.162 3.354 3.536 32mm 0.400 0.566 0.693 0.800 0.894 1.265 1.549 1.789 2.000 2.191 2.366 2.530 2.683 2.828 3.098 3.347 3.578 3.795 4.000 40mm 0.447 0.632 0.775 0.894 1.000 1.414 1.732 2.000 2.236 2.449 2.646 2.828 3.000 3.162 3.464 3.742 4.000 4.243 4.472 50mm 0.500 0.707 0.866 1.000 1.118 1.581 1.936 2.236 2.500 2.739 2.958 3.162 3.354 3.536 3.873 4.183 4.472 4.743 5.000 65mm 0.570 0.806 0.987 1.140 1.275 1.803 2.208 2.550 2.850 3.122 3.373 3.606 3.824 4.031 4.416 4.770 5.099 5.408 5.701 80mm 100mm 125mm 150mm 0.632 0.707 0.791 0.866 0.894 1.000 1.118 1.225 1.095 1.225 1.369 1.500 1.265 1.414 1.581 1.732 1.414 1.581 1.768 1.936 2.000 2.236 2.500 2.739 2.449 2.739 3.062 3.354 2.828 3.162 3.536 3.873 3.162 3.536 3.953 4.330 3.464 3.873 4.330 4.743 3.742 4.183 4.677 5.123 4.000 4.472 5.000 5.477 4.243 4.743 5.303 5.809 4.472 5.000 5.590 6.124 4.899 5.477 6.124 6.708 5.292 5.916 6.614 7.246 5.657 6.325 7.071 7.746 6.000 6.708 7.500 8.216 6.325 7.071 7.906 8.660
Expansion 'X'
(mm) 1 2 3 4 5 10 15 20 25 30 35 40 45 50 60 70 80 90 100 15mm 0.164 0.232 0.285 0.329 0.367 0.520 0.636 0.735 0.822 0.900 0.972 1.039 1.102 1.162 1.273 1.375 1.470 1.559 1.643
Loop Side Length 'L' (m) required for the stated Copper Pipe Size
22mm 0.199 0.281 0.345 0.398 0.445 0.629 0.771 0.890 0.995 1.090 1.177 1.259 1.335 1.407 1.541 1.665 1.780 1.888 1.990 28mm 0.224 0.317 0.389 0.449 0.502 0.710 0.869 1.004 1.122 1.230 1.328 1.420 1.506 1.587 1.739 1.878 2.008 2.130 2.245 35mm 0.251 0.355 0.435 0.502 0.561 0.794 0.972 1.122 1.255 1.375 1.485 1.587 1.684 1.775 1.944 2.100 2.245 2.381 2.510 42mm 0.275 0.389 0.476 0.550 0.615 0.869 1.065 1.230 1.375 1.506 1.627 1.739 1.844 1.944 2.130 2.300 2.459 2.608 2.750 54mm 0.312 0.441 0.540 0.624 0.697 0.986 1.207 1.394 1.559 1.708 1.844 1.972 2.091 2.205 2.415 2.608 2.789 2.958 3.118 67mm 0.347 0.491 0.601 0.695 0.777 1.098 1.345 1.553 1.736 1.902 2.055 2.196 2.330 2.456 2.690 2.906 3.106 3.295 3.473 76mm 108mm 133mm 159mm 0.370 0.441 0.489 0.535 0.523 0.624 0.692 0.757 0.641 0.764 0.847 0.927 0.740 0.882 0.979 1.070 0.827 0.986 1.094 1.196 1.170 1.394 1.547 1.692 1.432 1.708 1.895 2.072 1.654 1.972 2.188 2.392 1.849 2.205 2.446 2.675 2.026 2.415 2.680 2.930 2.188 2.608 2.895 3.165 2.339 2.789 3.095 3.383 2.481 2.958 3.282 3.589 2.615 3.118 3.460 3.783 2.865 3.415 3.790 4.144 3.095 3.689 4.094 4.476 3.308 3.944 4.376 4.785 3.509 4.183 4.642 5.075 3.699 4.409 4.893 5.350
10
Expansion 'X'
(mm) 1 2 3 4 5 10 15 20 25 30 35 40 45 50 60 70 80 90 100 20mm 0.108 0.152 0.186 0.215 0.240 0.340 0.416 0.481 0.538 0.589 0.636 0.680 0.721 0.760 0.833 0.900 0.962 1.020 1.075
Loop Side Length 'L' (m) required for the stated ABS / PVC Plastic Pipe Size
25mm 0.120 0.170 0.208 0.240 0.269 0.380 0.466 0.538 0.601 0.658 0.711 0.760 0.806 0.850 0.931 1.006 1.075 1.140 1.202 32mm 0.136 0.192 0.236 0.272 0.304 0.430 0.527 0.608 0.680 0.745 0.805 0.860 0.912 0.962 1.053 1.138 1.216 1.290 1.360 40mm 0.152 0.215 0.263 0.304 0.340 0.481 0.589 0.680 0.760 0.833 0.900 0.962 1.020 1.075 1.178 1.272 1.360 1.442 1.521 50mm 0.170 0.240 0.294 0.340 0.380 0.538 0.658 0.760 0.850 0.931 1.006 1.075 1.140 1.202 1.317 1.422 1.521 1.613 1.700 63mm 0.191 0.270 0.331 0.382 0.427 0.603 0.739 0.853 0.954 1.045 1.129 1.207 1.280 1.349 1.478 1.597 1.707 1.810 1.908 75mm 0.208 0.294 0.361 0.416 0.466 0.658 0.806 0.931 1.041 1.140 1.232 1.317 1.397 1.472 1.613 1.742 1.862 1.975 2.082 90mm 110mm 125mm 140mm 0.228 0.252 0.269 0.284 0.323 0.357 0.380 0.402 0.395 0.437 0.466 0.493 0.456 0.504 0.538 0.569 0.510 0.564 0.601 0.636 0.721 0.797 0.850 0.900 0.883 0.977 1.041 1.102 1.020 1.128 1.202 1.272 1.140 1.261 1.344 1.422 1.249 1.381 1.472 1.558 1.349 1.492 1.590 1.683 1.442 1.595 1.700 1.799 1.530 1.691 1.803 1.908 1.613 1.783 1.901 2.011 1.767 1.953 2.082 2.203 1.908 2.110 2.249 2.380 2.040 2.255 2.404 2.544 2.164 2.392 2.550 2.699 2.281 2.522 2.688 2.845
Expansion 'X'
(mm) 1 2 3 4 5 10 15 20 25 30 35 40 45 50 60 70 80 90 100
Loop Side Length 'L' (m) required for the stated Pressfit Carbon / Stainless Pipe Size
12mm 0.122 0.173 0.212 0.245 0.274 0.387 0.474 0.548 0.612 0.671 0.725 0.775 0.822 0.866 0.949 1.025 1.095 1.162 1.225 15mm 0.137 0.194 0.237 0.274 0.306 0.433 0.530 0.612 0.685 0.750 0.810 0.866 0.919 0.968 1.061 1.146 1.225 1.299 1.369 18mm 0.150 0.212 0.260 0.300 0.335 0.474 0.581 0.671 0.750 0.822 0.887 0.949 1.006 1.061 1.162 1.255 1.342 1.423 1.500 22mm 0.166 0.235 0.287 0.332 0.371 0.524 0.642 0.742 0.829 0.908 0.981 1.049 1.112 1.173 1.285 1.387 1.483 1.573 1.658 28mm 0.187 0.265 0.324 0.374 0.418 0.592 0.725 0.837 0.935 1.025 1.107 1.183 1.255 1.323 1.449 1.565 1.673 1.775 1.871 35mm 0.209 0.296 0.362 0.418 0.468 0.661 0.810 0.935 1.046 1.146 1.237 1.323 1.403 1.479 1.620 1.750 1.871 1.984 2.092 42mm 0.229 0.324 0.397 0.458 0.512 0.725 0.887 1.025 1.146 1.255 1.356 1.449 1.537 1.620 1.775 1.917 2.049 2.174 2.291 54mm 0.260 0.367 0.450 0.520 0.581 0.822 1.006 1.162 1.299 1.423 1.537 1.643 1.743 1.837 2.012 2.174 2.324 2.465 2.598 76mm 0.308 0.436 0.534 0.616 0.689 0.975 1.194 1.378 1.541 1.688 1.823 1.949 2.068 2.179 2.387 2.579 2.757 2.924 3.082 89mm 108mm 0.334 0.367 0.472 0.520 0.578 0.636 0.667 0.735 0.746 0.822 1.055 1.162 1.292 1.423 1.492 1.643 1.668 1.837 1.827 2.012 1.973 2.174 2.110 2.324 2.237 2.465 2.358 2.598 2.584 2.846 2.791 3.074 2.983 3.286 3.164 3.486 3.335 3.674
PIPE LENGTH
X 2
X 2
ANCHOR
Note that a loop does not have to be placed in the middle of the pipe length. The total expansion will be naturally distributed equally between the two sides of the loop.
11
12
Anchor
Primary Guides
Intermediate Guides
Anchor
Anchor
Intermediate Guide
Primary Guides
Primary Guides
Intermediate Guide
Anchor
Comparing the two diagrams above, it can be seen that the axial expansion joint may be positioned anywhere in a straight pipe run. However, the number of primary and intermediate guides required varies, so it is important to carefully consider the options available on site.
Anchor
Intermediate Guide
Primary Guides
Anchor
Primary Guides
Intermediate Guide
Anchor
Anchor
Primary Guides
Anchor
Primary Guides
Anchor
The same comparison with regard to the numbers of guides can be made for the above two diagrams. Also consider in these two cases the ease of access for periodic inspection in the future; i.e. one access point, or two access points.
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13
Anchor
Cold Pull Here the LATERAL expansion joint is used at the end of a long single pipe run. Note the planar guide allowing the upper pipe to bend to compensate for the arc-swing of the expansion joint. Intermediate Guides Planar Guide
Anchor
Anchor Here the LATERAL expansion joint is used in an offset between two pipe runs that are parallel to each other. Note the planar guide allowing the upper pipe to bend to compensate for the arc-swing of the expansion joint.
Cold Pull
Anchor
Intermediate Guides
Cold Pull
Anchor
Anchor
Here the LATERAL expansion joint is used in a vertical offset between two pipe runs that are perpendicular to each other. Note the planar guide allowing the upper pipe to bend to compensate for the arc-swing of the expansion joint. 14
PIPE SOLUTIONS LTD
2-PIN Z SYSTEM
Anchor Intermediate Guides Intermediate Cold Intermediate Guide Pull Guide Anchor
Here two HINGED expansion joints are used in an offset between two pipe runs that are parallel to each other. Anchor Intermediate Guide Cold Pull Intermediate Guide
3-PIN Z SYSTEM
Intermediate Guides Anchor
Here three HINGED expansion joints are used adjacent to a small offset between two pipe runs that are parallel to each other.
3-PIN U SYSTEM
Anchor
Cold Pull
Cold Pull Here three HINGED expansion joints are used in a loop in a very long straight pipe run.
3-PIN L SYSTEM
Here three HINGED expansion joints are used at the direction change between two long pipe runs that are perpendicular to each other.
Intermediate Guide
Cold Pull
15
Cold Pull Anchor Here two GIMBAL expansion joint are used in a vertical offset between two pipe runs that are perpendicular to each other. Note the planar guide allowing the upper pipe to bend to compensate for the arc-swing of the expansion joint. Anchor
Planar Guide
Anchor
Spring Support
Anchor
Here two GIMBAL expansion joints are used in conjunction with one HINGED expansion joint to accommodate thermal expansion in a complex multi-directional pipe system.
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Intermediate Guides
16
2-PIN Z SYSTEM
3-PIN U SYSTEM
17
These displacements can be considered to have a horizontal or vertical direction and positive or negative magnitude (+ve or -ve) as follows:-
-VE -VE
+VE
There may also be some angular rotation about any axis shown in the diagram.
Pipes will be supported / suspended from the structure on both sides of the building movement joint (BMJ) and will therefore be subjected to deflection which may cause damage to the pipe. Most often, the pipe will be horizontal and will be perpendicular to the BMJ, but on occasions, the pipe may not be horizontal and may cross at a different angle. It must be noted that these displacements can occur in combination and therefore the resultant displacements must always be calculated before considering the expansion joint solution. It is best to consider the movement of the structure on one side of the BMJ relative to the movement on the opposite side. Hence, for example, one structure could suffer from 25mm foundation settlement (vertically downwards), whilst the other structure could suffer from 10mm land heave (vertically upwards). The resultant displacement would be the sum of both, i.e. 35mm.
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18
PIPE ANCHORS
Pipe anchors are required to control pipe expansion or contraction, and for natural flexibility or expansion joints to function as designed. The forces acting on the pipe anchors will comprise one or more of the following: Friction force of the pipe moving over the supports, relative to pipe slope Bending force of the offset or branch Spring force of the bellows of the expansion joint Pressure thrust force of unrestrained expansion joints Centrifugal force of the flowing media acting on pipe direction changes Wind loading force relative to wind speed and height above ground Dead weight force of pipe, media, insulation and components
Each of these forces are considered separately over the next few pages as follows:-
Friction Force As the pipe expands or contracts over its supports, it encounters friction. The anchors must resist this friction force, which is a function of the weight of the pipe, insulation and contents, coefficient of friction and the slope of the pipe. For vertical pipes (risers), friction forces are small, but can be estimated at 15% of the anchor force multiplied by the coefficient of friction. The friction force can be calculated mathematically using the formula:Where, F M G CFriction = = = = Force (N) Mass (kg) Gravitational Acceleration (9.81m/s 2) Coefficient of Friction F = M G CFriction
Coefficients of friction vary. As a guide, use the following:Steel on P.T.F.E. Point Contact steel on steel Line Contact steel on steel Edge Contact steel on steel Face to Face Contact steel on steel
Coefficient of Frictio n
0.03 0.2 0.25 0.3 0.4
= = = = =
Friction force (N) for 1m horizontal length of water filled insulated* BS1387 heavy steel pipe
15mm 0.5 3.1 3.9 4.7 6.3 20mm 0.6 4.3 5.4 6.5 8.6 25mm 1.0 6.9 8.6 10.3 13.7 32mm 1.4 9.4 11.8 14.1 18.8 40mm 1.7 11.2 14.0 16.8 22.4 50mm 2.4 16.3 20.4 24.4 32.6 65mm 3.4 22.6 28.2 33.8 45.1 80mm 100mm 125mm 150mm 4.4 6.7 9.1 11.7 29.4 44.7 60.6 78.3 36.8 55.9 75.8 97.9 44.1 67.1 90.9 117.4 58.9 89.5 121.3 156.6
*Insulati on is 50mm thi ck and has a density of 200k g per cub ic metr e
19
Bending Force As the pipe expands or contracts it may try to bend offsets at the end of the run, or branches off the main pipe. The anchors must resist this bending force, which is a function of the moment of inertia of the pipe, the amount of expansion, and the length of pipe able to bend. The bending force can be calculated mathematically using the formulae:For carbon steel pipes, F = (24 I X) L Where, F I X L = = = = Force (N) Moment of Inertia (cm4) Expansion (mm) Length (m) For copper pipes, F = (8.4 I X) L
Expansion (mm)
1 2 3 4 5 10 15 20 25
Force (N) to bend a 2m length of BS1387 heavy steel pipe by the stated expansion
15mm 2.4 4.7 7.1 9.5 11.9 23.7 35.6 47.4 59.3 20mm 5.3 10.5 15.8 21.0 26.3 52.5 78.8 105.0 25mm 12.9 25.7 38.6 51.5 64.4 128.7 193.1 32mm 27.5 55.0 82.4 109.9 137.4 274.8 40mm 41.9 83.9 125.8 167.8 209.7 419.4 50mm 92.4 184.8 277.2 369.6 462.0 65mm 193.5 387.0 580.5 774.0 967.5 80mm 100mm 125mm 150mm 342.0 816.0 1560.0 2586.0 684.0 1632.0 3120.0 5172.0 1026.0 2448.0 4680.0 1368.0 3264.0 1710.0
Spring Rate Force As the pipe expands or contracts it may need to deflect expansion joints installed in the pipe system. The anchors must resist the force required to overcome the spring of the bellows, which is a function of the amount of expansion and the linear or angular spring rate of the bellows, which can be found on expansion joint data sheets. The spring force can be calculated mathematically using the formulae:For axial expansion joints, F = DLin SLin Where, F DLin SLin = = = Force (N) Linear Deflection (mm) Linear Spring Rate (N/mm)
For hinged expansion joints, F = (DAng SAng) L Where, F DAng SAng L = = = = Force (N) Angular Deflection* (deg) Angular Spring Rate (Nm/deg) Length of pipe between bellows centres (m) * Angular Deflection is calculated -1 using the formula:- DAng = sin (a b)
b
a
1
DAng
It is often easier to use the maximum force to deflect when it is stated on the expansion joint data sheets, even though the expansion joint is not being fully deflected.
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20
Pressure Thrust Force As the pipe expands it may need to deflect axial expansion joints installed in the pipe system. The anchors must be able to resist the pressure thrust force which is present whenever unrestrained (axial) expansion joints are used. This force is a function of the effective area of the bellows and the working or test pressure at the expansion joint location. The pressure thrust force can be calculated mathematically using the formulae:For working conditions, F = AE Pworking 0.1 Where, F AE PWorking PTest 0.1
(bar ) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 20 24
= = = = =
Force (N) Effective Area (cm2), taken from data sheets 2 Working Pressure (kN/m ) Test Pressure (kN/m2), often 1.5x working pressure Correction Factor, due to measurement units used
20mm 80 160 240 320 400 480 560 640 720 800 880 960 1040 1120 1200 1280 1600 1920 25mm 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 2000 2400 32mm 190 380 570 760 950 1140 1330 1520 1710 1900 2090 2280 2470 2660 2850 3040 3800 4560 40mm 230 460 690 920 1150 1380 1610 1840 2070 2300 2530 2760 2990 3220 3450 3680 4600 5520 50mm 350 700 1050 1400 1750 2100 2450 2800 3150 3500 3850 4200 4550 4900 5250 5600 7000 8400 65mm 530 1060 1590 2120 2650 3180 3710 4240 4770 5300 5830 6360 6890 7420 7950 8480 10600 12720 80mm 100mm 125mm 150mm 720 1110 1690 2340 1440 2220 3380 4680 2160 3330 5070 7020 2880 4440 6760 9360 3600 5550 8450 11700 4320 6660 10140 14040 5040 7770 11830 16380 5760 8880 13520 18720 6480 9990 15210 21060 7200 11100 16900 23400 7920 12210 18590 25740 8640 13320 20280 28080 9360 14430 21970 30420 10080 15540 23660 32760 10800 16650 25350 35100 11520 17760 27040 37440 14400 22200 33800 46800 17280 26640 40560 56160
Pressure
(kN/m) 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 2000 2400
Pressure Thrust Force (N) exerted by Axial Expansion Joints at the stated pressure
15mm 60 120 180 240 300 360 420 480 540 600 660 720 780 840 900 960 1200 1440
Centrifugal Force As the media flows through the pipe, it encounters bends. At these bends the flowing media exerts a centrifugal force on the pipe. The anchors (and guides) may have to resist this centrifugal force, which is a function of the media density, media velocity, area of the bend and bend angle. The centrifugal force can be calculated mathematically using the formula:- F=(DV ASin BAng) Where, F D V A BAng = = = = = Force (N) Density of the media (kg/m3) Velocity (m/s) 2 Area of the bend on which the flowing media acts (m ) Bend Angle (degrees)
2
Centrifugal force (N) for water flowing round a 90deg steel pipe bend at the stated velocity Velocity (m/s)
1.0 2.0 3.0 4.0 5.0 6.0 15mm 0.2 0.8 1.8 3.3 5.1 7.4 20mm 0.4 1.5 3.3 5.9 9.2 13.2 25mm 0.6 2.3 5.3 9.4 14.7 21.1 32mm 1.0 4.1 9.1 16.3 25.4 36.6 40mm 1.4 5.5 12.4 22.0 34.4 49.5 50mm 2.2 8.8 19.8 35.3 55.1 79.4 65mm 3.7 14.8 33.3 59.2 92.5 133.2 80mm 5.1 20.5 46.0 81.8 127.9 184.1 100mm 8.7 34.7 78.1 138.9 217.0 312.5 125mm 13.3 53.0 119.3 212.0 331.3 477.0 150mm 19.0 75.8 170.6 303.2 473.8 682.2
21
Wind Loading Force Wind loading forces occur significantly at high wind velocity on exposed sites. The anchors (and guides) have to resist this wind loading force, which is a function of the wind velocity, height above ground, and area of the side of the pipe (and insulation). The wind loading force can be calculated mathematically using the formula:- F = Fwind AEffective Where, F = FWind = AEffective = Force (N) 2 Lateral Wind Force (N/m ) 2 Effective Area (m )
Lateral Wind Loading Force (N) pe r metre le ngth of Insulated BS1387 Heav y Steel Pipes
15mm 0.122 2.0 7.7 17.0 30.5 47.6 68.7 92.8 122.0 20mm 0.127 2.0 8.0 17.7 31.8 49.5 71.5 96.6 127.0 25mm 0.134 2.1 8.4 18.6 33.5 52.3 75.4 102.0 134.0 32mm 0.143 2.3 9.0 19.9 35.8 55.8 80.5 108.8 143.0 40mm 0.149 2.4 9.4 20.7 37.3 58.1 83.9 113.4 149.0 50mm 0.161 2.6 10.1 22.4 40.3 62.8 90.6 122.5 161.0 65mm 0.177 2.8 11.2 24.6 44.3 69.0 99.7 134.7 177.0 80mm 0.189 3.0 11.9 26.3 47.3 73.7 106.4 143.8 189.0 100mm 0.215 3.4 13.5 29.9 53.8 83.9 121.0 163.6 215.0 125mm 0.241 3.9 15.2 33.5 60.3 94.0 135.7 183.4 241.0 150mm 0.266 4.3 16.8 37.0 66.5 103.7 149.8 202.4 266.0
Dead Weight Force Dead weight forces must always be taken into account when designing anchors, guides and supports. The anchors (and guides when used to support the pipe) have to resist these dead weight forces. This is very important when designing anchors for vertical pipes (risers) in tall buildings. The dead weight forces can be calculated mathematically using the formula:F = (Mpipe + Mmedia + Minsulation) G L Where, F = Mpipe = Mmedia = Minsulation = G = L = Force (N) Mass of Pipe per metre (kg/m) Mass of Media per metre (kg/m) Mass of Insulation per metre (kg/m) Gravitational Constant (9.81) Length of pipe (m)
Mass (kg/m) for Pipe, Water Contents and Insulat ion for B S1387 He avy Steel Pipes Component
Pipe Water Insulati on TOTAL 15mm 1.45 0.18 2.30 3.93 20mm 1.90 0.33 2.40 4.63 25mm 2.97 0.52 2.60 6.09 32mm 3.84 0.93 2.90 7.67 40mm 4.43 1.27 3.10 8.80 50mm 6.17 2.07 3.50 11.74 65mm 7.90 3.53 4.00 15.43 80mm 100mm 125mm 150mm 10.10 14.40 17.80 21.20 4.91 8.38 13.05 18.70 4.40 5.20 6.00 6.80 19.41 27.98 36.85 46.70
Do not forget to add the mass of any other pipe fittings such as valves, strainers, de-aerators, etc.
22
PIPE GUIDES
Pipe guides are required to control the direction of pipe expansion or contraction, and for the natural flexibility or expansion joint solution to function as designed. They should be capable of withstanding a lateral force of 15% of the total force acting on the pipe anchor. The lateral force could act in any direction that is perpendicular to the pipe axis. This is advised in the Standards of the Expansion Joint Manufacturers Association (EJMA). The pipe guide spacings can be calculated mathematically using the formula:LGuide = (3.142 / fGuide) [ (E x I) / (F S) ] Where, LGuide fGuide E I F S = = = = = = Length between Guides (m) Guide Factor Modulus of Elasticity (109 N/m2) 4 Moment of Inertia (cm ) Total Buckling Force (N) Safety Factor (3 is recommended)
The values for Guide Factor [fGuide] for the pipe section being guided is based as follows:When both sides of the expansion joint are axially guided (close tolerance), take fGuide = 0.5 When both sides are simply supported (roller/chair), take fGuide = 1.0 Modulus of Elasticity [E] values for various common materials are shown right:The moment of inertia can be calculated mathematically using the formula:I = 3.142 (D - d ) 64 Where, D d = = Pipe Outer Diameter Pipe Internal Diameter
4 4
Modulus of Elasticity for Common Pipe Materials (Approximate) METALS Material Copper Carbon Steel Stainless Steel (Austenitic) Stainless Steel (Ferritic) Aluminium Modulus (109 N/m2) 70 200 190 190 65 PLASTICS Material ABS PVCU PVCC PE PP Modulus (109 N/m2) 1.8 3.0 2.8 0.7 to 0.9 0.9 to 1.5
The Total Buckling Force [F] for the pipe section comprises several components:For standard axial expansion joints (unrestrained) the components will usually be:Friction Force + Spring Rate Force + Pressure Thrust Force For lateral, hinged and gimbal expansion joints (restrained) the components will usually be:Friction Force + Spring Rate Force For natural flexing pipe installations, such as offsets and loops, the components will usually be:Friction Force + Bending Force Please refer to the previous section headed PIPE ANCHORS for force calculations.
23
Anchor
Intermediate Guides
Anchor
Primary Guides These are of paramount importance when considering unrestrained or axial expansion joints. There should be a maximum of 4 pipe diameters from the expansion joint to the 1st guide and 14 pipe diameters from the 1st to the 2nd guide. This is advised in BS6129. If the expansion joint is positioned adjacent to an anchor, then the distance to the anchor should be a maximum of 4 pipe diameters. Intermediate Guides These are required at intervals to prevent bowing or buckling of the pipe between the 2nd primary guide and the anchor. The spacing between these guides depends on the pipe nominal size, material, wall thickness and forces acting along the pipe. The pipe guide spacings can be calculated mathematically using the previous formula:LGuide = (3.142 / fGuide) [ (E x I) / (F S) ] As both sides of axial expansion joints must always be guided (close tolerance as detailed below), a value of 0.5 is taken for the Guide Factor [fGuide]. The Pressure Maximum is taken as the system test pressure. The Bellows Effective Area (AE) is taken from data sheets.
Test Pressure Max. (Barg)
Modulus of El astic ity, E Moment of Inert ia, I Guiding Fac tor, G Bellows Ef fect ive Area (cm2) 2.5 6 10 16 25 (Support Centres)
Intermediate Guide Spacing (m) for BS1387 Medium Steel Pipes used with Axial Exp Joints
15mm 200 0.71 0.5 6 3.5 2.3 1.8 1.4 1.1 2.0 20mm 200 1.5 0.5 8 4.4 2.9 2.2 1.8 1.4 2.4 25mm 200 3.7 0.5 10 6.2 4.0 3.1 2.5 2.0 2.7 32mm 200 7.74 0.5 19 6.5 4.2 3.3 2.6 2.1 2.7 40mm 200 11.78 0.5 23 7.3 4.7 3.7 2.9 2.3 3.0 50mm 200 26.2 0.5 35 8.9 5.7 4.4 3.5 2.8 3.4 65mm 200 54.5 0.5 53 10.4 6.7 5.2 4.1 3.3 3.7 80mm 100mm 125mm 150mm 200 200 200 200 97 231 470 787 0.5 0.5 0.5 0.5 72 111 169 234 11.9 14.8 17.1 18.8 7.7 9.6 11.0 12.1 6.0 7.4 8.6 9.4 4.7 5.9 6.8 7.4 3.8 4.7 5.4 6.0 3.7 4.1 4.4 4.8
When considering copper pipes, reduce the intermediate guide spacing by approximately 30% because copper is more flexible than steel and will tend to bow or buckle more easily. The effectiveness of pipe guides to direct the expansion movement towards an axial expansion joint depends on the clearance between the pipe and the guide. For primary guides, an annulus of 1mm (i.e. 1mm all-round clearance) is recommended for pipes up to 150mm NB. Larger pipes may have an annulus of 2mm (i.e. 2mm all-round clearance). For intermediate guides, an annulus of 2mm (i.e. 2mm all-round clearance) is recommended for pipes up to 150mm NB. Larger pipes may have an annulus of 4mm (i.e. 4mm all-round clearance). NOTE: as horizontal pipes may naturally sit on the bottom of the guide, then the clearance above the pipe will be twice the clearances stated above. Further information regarding pipe guides and supports can be found in BS3974.
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24
Pipe Guides used with Restrained Expansion Joints or Natural Flexing Pipe
See Table See Table See Table See Table
Intermediate Guides
Anchor
See Table
See Table
See Table
Planar Guide
Intermediate Guides
Anchor
Anchor
When considering pipe guides for use with restrained expansion joint systems or natural flexing pipe systems, the spacing depends on the pipe nominal size, material, wall thickness and forces acting along the pipe. The previous formula enables us to tabulate guide spacings based on the largest anchor force.
Anchor Force Max. (N)
Modulus of Elasticity, E
Guide Spacing (m) for BS1387 Medium Steel Pipes used with Restrained EJs / 'Nat' Flexing
15mm 200 0.71 0.5 1.37 0.97 0.79 0.68 0.61 0.56 20mm 200 1.5 0.5 1.99 1.41 1.15 0.99 0.89 0.81 0.75 25mm 200 3.7 0.5 3.12 2.21 1.80 1.56 1.40 1.27 1.18 1.10 32mm 200 7.74 0.5 4.51 3.19 2.61 2.26 2.02 1.84 1.71 1.60 1.50 40mm 200 11.78 0.5 5.57 3.94 3.22 2.78 2.49 2.27 2.10 1.97 1.86 1.76 50mm 200 26.2 0.5 8.31 5.87 4.79 4.15 3.71 3.39 3.14 2.94 2.77 2.63 1.86 65mm 200 54.5 0.5 11.98 8.47 6.92 5.99 5.36 4.89 4.53 4.23 3.99 3.79 2.68 2.19 80mm 100mm 125mm 150mm 200 200 200 200 97 231 470 787 0.5 0.5 0.5 0.5 15.98 24.66 35.18 45.52 11.30 17.44 24.87 32.19 9.23 14.24 20.31 26.28 7.99 12.33 17.59 22.76 7.15 11.03 15.73 20.36 6.52 10.07 14.36 18.58 6.04 9.32 13.30 17.20 5.65 8.72 12.44 16.09 5.33 8.22 11.73 15.17 5.05 7.80 11.12 14.39 3.57 5.51 7.87 10.18 2.92 4.50 6.42 8.31 2.53 3.90 5.56 7.20 3.49 4.97 6.44 4.54 5.88 5.44 3.7 4.1 4.4 4.8
Moment of Inertia, I Guiding Fac tor, G 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 20000 30000 40000 50000 60000 70000 (Support Centres)
2.0
2.4
-
2.7
2.7
3.0
3.4
3.7
Safety Factor us ed is 3
For these guides, the clearance between the pipe and the guide is not so critical as compared to those for axial expansion joints. An annulus of 2mm (i.e. 2mm all-round clearance) is recommended for pipes up to 150mm NB. Larger pipes may have an annulus of 4mm (i.e. 4mm all-round clearance).
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25
Light
Medium
Heavy
Duck-foot
Saddle / Strap
Tubular
T-Slide
Roller / Strap
Double T-Slide
27
OTHER CONSIDERATION
Pipe Insulation / Lagging
When insulating pipes that contain expansion joints, some points should be noted as follows:The movement of the expansion joints must not be restricted by the insulation material. The movement of flexing pipe must not be restricted by the insulation material. The insulation material must be removable from the expansion joint to allow for periodic inspection. Care must be taken when considering the type of insulation material to be used, as some materials contain substances that can cause corrosion of the bellows membrane under certain conditions.
Commissioning
Commissioning of a pipework system usually includes a pressure test, more often than not at a multiple of 1.5x or 2x the intended system working pressure. The pressure test will normally be at ambient temperature. Removing expansion joints from a system prior to testing is NOT good practice. This defeats the object of testing because other system components, such as anchors, guides, supports, etc are NOT subjected to the larger forces which may be encountered with expansion joints, in particular, axial expansion joints. Also, if expansion joints are not present during the test, any leaks in the expansion joint will not become apparent until the system is under working conditions. The engineer must check points as follows :Check BEFORE the pressure test: Ensure that the system test pressure does not exceed the maximum for the expansion joints. Ensure that main and intermediate anchors are strong enough to withstand the test pressure. Ensure that primary and intermediate guides are free to allow pipe movement. Ensure that expansion joint moving parts are free to allow movement. Check DURING the pressure test: WARNING: Take care when checking pressurised components ! Check for any evidence of leakage. Check for any pressure loss. Check for malfunction of expansion joints, anchors, guides and supports. Check in particular for any evidence of snaking or squirm in the bellows membrane. Investigate ALL abnormal changes or unexpected occurance. Check AFTER the pressure test: Ensure that moving components have returned to their original positions. Ensure that any necessary drain down has been accomplished. Start Up Check: Ensure that chemical additives are correct and will not damage the expansion joint bellows membrane. Ensure that the thermal expansion of the pipework causes movement in the anticipated manner. Ensure that the expansion joints absorb the movement in the manner for which they were designed. Ensure that all components are still operating within their design limits at maximum system working conditions. Ensure that the system itself is operating within design limits. Records must be made throughout ALL of the above stages. If problems arise, the procedure MUST be halted and investigated.
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STEAM DATA
Gauge Pressure (Barg) 0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 Temperature (oC) 100.0 120.2 133.5 143.6 151.8 158.8 165.0 170.4 175.4 179.9 Specific Volume (m3/kg) 1.694 0.886 0.606 0.462 0.375 0.316 0.273 0.240 0.215 0.194 Density (kg/m3) 0.590 1.129 1.651 2.163 2.668 3.169 3.666 4.161 4.653 5.144 Gauge Pressure (Barg) 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0 Temperature (oC) 184.1 212.4 233.8 250.3 263.9 275.6 285.8 295.0 303.3 311.0 Specific Volume (m3/kg) 0.177 0.100 0.067 0.050 0.039 0.032 0.027 0.024 0.020 0.018 Density (kg/m3) 5.650 10.043 15.004 20.092 25.355 30.826 36.536 42.517 48.828 55.494
15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 450 500 600
Comparative Densities:Glass Mineral Wool = 16 to 80kg/m3 , Rock Mineral Wool = 3 to 200kg/m3 , Rigid Polyurethane Foam = 50kg/m3, Phenolic Foam = 35 to 60kg/m3
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15mm 1/2" 15mm 20mm 3/4" 22mm 25mm 1" 28mm 32mm 1 1/4" 35mm 40mm 1 1/2" 42mm 50mm 2" 54mm 65mm 2 1/2" 67mm 80mm 3" 76mm 100mm 4" 108mm 125mm 5" 133mm 150mm 6" 159mm
Heavy steel Medium steel Copper (Table X) Copper (Table Y) Copper (Table Z) Heavy steel Medium steel Copper (Table X) Copper (Table Y) Copper (Table Z) Heavy steel Medium steel Copper (Table X) Copper (Table Y) Copper (Table Z) Heavy steel Medium steel Copper (Table X) Copper (Table Y) Copper (Table Z) Heavy steel Medium steel Copper (Table X) Copper (Table Y) Copper (Table Z) Heavy steel Medium steel Copper (Table X) Copper (Table Y) Copper (Table Z) Heavy steel Medium steel Copper (Table X) Copper (Table Y) Copper (Table Z) Heavy steel Medium steel Copper (Table X) Copper (Table Y) Copper (Table Z) Heavy steel Medium steel Copper (Table X) Copper (Table Y) Copper (Table Z) Heavy steel Medium steel Copper (Table X) Copper (Table Y) Copper (Table Z) Heavy steel Medium steel Copper (Table X) Copper (Table Y) Copper (Table Z)
3.25 2.65 0.70 1.00 0.50 3.25 2.65 0.90 1.20 0.60 4.05 3.25 0.90 1.20 0.60 4.05 3.25 1.20 1.50 0.70 4.05 3.25 1.20 1.50 0.80 4.50 3.65 1.20 2.00 0.90 4.50 3.65 1.20 2.00 1.00 4.85 4.05 1.50 2.00 1.20 5.40 4.50 1.50 2.00 1.20 5.40 4.85 1.50 1.50 5.40 4.85 2.00 1.50
138.7 127.7 138.7 129.8 133.25 130.4 133.25 130.4 164.1 154.3 164.1 155.3 159.25 155.4 159.25 156.4
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13. 13.1. 14. 14.1. 15. 15.1. 15.2. 15.3. 16. 16.1. 16.2. 16.3. 16.4. 16.5. 16.6. 16.7. 17. 17.1. 18. 18.1.
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TECHNICAL REFERENCE GUIDES COVER: Vibration and Noise Control De-aeration and Dirt Removal Thermal Pipe Expansion (all publications are also available in PDF format) Pipe Solutions Ltd., Head Office, Hornbeam Park Oval, Harrogate, HG2 8RB Tel:01423-878888 Fax:01423-878880 Email:sales@pipesolutions.co.uk Website:www.pipesolutions.co.uk 12/2010 3