27421-07 en

Expansion Joints
Original instructions
Installatin, Operation and Maintenance, Safety
Approved date: 06 Mar 2012
Created by: BK
Approved by: AO
Doc. No.: 27421-07-3.1

Expansion Joints
27421-07-3.1
Table of contents Page:
1 General information .............................................................................................................. 3

1.1 Scope and purpose ........................................................................................................................................... 3
1.2 Definitions and abbreviations ............................................................................................................................. 3
1.3 Legend ............................................................................................................................................................ 4
2 Design and operating principle .............................................................................................. 4

2.1 Materials overview ............................................................................................................................................ 4
2.2 Drawings and Expansion Joint Legend ................................................................................................................. 6
2.3 Bellow type ...................................................................................................................................................... 6
2.4 Assembly of expansion joint for gas duct ............................................................................................................. 8
2.5 Assembly of reinforced expansion joint ................................................................................................................ 9
2.6 Assembly of lined expansion joint ..................................................................................................................... 12
2.7 Assembly of expansion joint for chute, temp less than 500 oC .............................................................................. 14
2.8 Special joint with large transversal move for chute ............................................................................................. 16
2.9 Dedusting pipe expansion joint ......................................................................................................................... 16
2.10 Scissor .......................................................................................................................................................... 17
2.11 Lateral displaced sketches................................................................................................................................ 18
2.12 Expansion joint legend .................................................................................................................................... 18
3 Safety instructions .............................................................................................................. 19

3.1 General notes ................................................................................................................................................. 19
3.1.1 Introduction .................................................................................................................................. 19
3.2 General notes on safety for expansion joint ........................................................................................................ 19
3.2.1 Permission to work ......................................................................................................................... 19
3.2.2 Foreseen hazards to personnel ........................................................................................................ 19
3.2.3 Foreseen hazards to equipment ....................................................................................................... 19
3.2.4 Harmful media ............................................................................................................................... 19
3.3 Specific safety precautions concerning installation .............................................................................................. 19
3.3.1 Qualification .................................................................................................................................. 19
3.3.2 Electrical isolation .......................................................................................................................... 19
3.4 Specific safety precautions concerning OM ......................................................................................................... 19
4 Installation ......................................................................................................................... 20
4.1 Storage on site ............................................................................................................................................... 20
4.1.1 Bellows, insulation, glass felt auxiliaries etc. ...................................................................................... 20
4.1.2 Steel parts .................................................................................................................................... 20
4.1.3 Lining materials ............................................................................................................................. 20
4.2 Unpacking of materials .................................................................................................................................... 20
4.2.1 The bellow supply .......................................................................................................................... 20
4.2.2 The steel parts .............................................................................................................................. 20
4.3 Planning and installation procedures ................................................................................................................. 21
4.3.1 Documentation .............................................................................................................................. 21
4.3.2 Expansion joint legend.................................................................................................................... 21
4.3.3 Planning and schedule .................................................................................................................... 21
4.3.4 Scaffolding .................................................................................................................................... 22
4.3.5 Auxiliary tools ............................................................................................................................... 22
4.4 The installation task on a step-by-step basis ...................................................................................................... 22
4.4.1 Installation: Figure 7 to Figure 9 and Figure 12 to Figure 15, steel parts ............................................... 22
4.4.2 Installation for Figure 10, Figure 11, Figure 16, Figure 18 ................................................................... 26
4.4.3 Installation for Figure 19 (Scissor) ................................................................................................... 27
4.4.4 Installation for the fabric bellow. ...................................................................................................... 27
4.5 Installation tools ............................................................................................................................................. 29
4.5.1 The taptite .................................................................................................................................... 29
4.5.2 Various installation aids .................................................................................................................. 30
4.6 Detailed direction to the assembly of bellow ....................................................................................................... 31
4.6.1 Assembly of bellow materials........................................................................................................... 31
4.6.2 Mounting of large bellows (supplied open)......................................................................................... 34
4.7 Repair of bellow .............................................................................................................................................. 35
4.7.1 Repair during operation .................................................................................................................. 35
4.7.2 Emergency repair........................................................................................................................... 36
4.8 Installation documentation ............................................................................................................................... 37
4.8.1 Quality documentation .................................................................................................................... 37
5 Operation ........................................................................................................................... 37
5.1 Pre-operational check ...................................................................................................................................... 37
5.2 Operational supervision ................................................................................................................................... 37
6 Maintenance ....................................................................................................................... 37
6.1 Preventive maintenance................................................................................................................................... 37
6.1.1 Cleaning ....................................................................................................................................... 38
6.1.2 Inspection and adjustment .............................................................................................................. 38
6.1.3 Status check ................................................................................................................................. 38
6.1.4 Replacement of spares ................................................................................................................... 38
6.1.5 Functional test ............................................................................................................................... 39
List of figures
Figure 1. HT 350 ............................................................................................................................................. 6
Figure 2. HT 100 ............................................................................................................................................. 6
Figure 3. MN 300............................................................................................................................................. 6
2/39 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
Expansion Joints
27421-07-3.1
Figure 4. MN 400 .............................................................................................................................................7

Figure 5. MN 500 .............................................................................................................................................7
Figure 6. LN 200..............................................................................................................................................7
Figure 7. Expansion joint for circular or rectangular/square section. .......................................................................8
Figure 8. Expansion joint for circular or rectangular/square section in coal grinding department. ...............................9
Figure 9. Reinforced expansion joint for chute in coal departments. Circular and rectangular. ................................. 10
Figure 10. Expansion joint for de-dusting pipe and chute. ................................................................................... 11
Figure 11. Detachable expansion joint for pipe and chute. .................................................................................. 11
Figure 12. Heat resistant lined with 114 or 214 or 264 mm thickness. Circular duct. .............................................. 12
Figure 13. Ductdensulate and ductdensit. Circular or rectangular. ........................................................................ 13
Figure 14. Chute 1 and chute 2: Rectangular and circular, axial through............................................................... 14
Figure 15. Chute 3 For large expansion: Rectangular and circular, lateral offset. ................................................... 15
Figure 16. Detachable chute expansion joint for pipe. ........................................................................................ 15
Figure 17. Chute S circular. ............................................................................................................................ 16
Figure 18. Expansion joint for cold duct. Dedusting pipe joint. ............................................................................. 16
Figure 19. Long circular expansion joint (Scissor) for duct and chute. .................................................................. 17
Figure 20. Lateral displaced sketch .................................................................................................................. 18
Figure 21. Header on Expansion Joint Legend.................................................................................................... 18
Figure 22. Documentation. ............................................................................................................................. 21
Figure 23. Bracing for lifting the expansion joint. ............................................................................................... 23
Figure 24. Stuffing of ceramic felt. ................................................................................................................... 24
Figure 25. The offset of expansion joint. ........................................................................................................... 26
Figure 26. Thermal insulation and insertion of taptites. ...................................................................................... 29
Figure 27. Auxiliary materials for installation of the bellow. ................................................................................. 30
Figure 28. Glass fabric assembly. .................................................................................................................... 31
Figure 29. Glass felt assembly. ........................................................................................................................ 31
Figure 30. PTFE foil assembly. ......................................................................................................................... 32
Figure 31. Glass fabric, silicone coated. Outside layer assembly. ......................................................................... 33
Figure 32. Multi layer bellow. Final joining procedure. Adding flange reinforcement in the splicing area. ................... 34
Figure 33. Assembly of open ends. .................................................................................................................. 35
Figure 34. Permanent repair of bellow during reduced operation. ......................................................................... 36
Figure 35. Emergency repair of bellow during operation. .................................................................................... 36
NOTE !
The present instruction manual is concerned with the situations which, according to the experience of
FLSmidth, are the most likely to occur. An exhaustive enumeration of all conceivable situations, which may
occur during manufacture, installation, operation and maintenance of the equipment, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in the instruction manual,
and which the operator is/or feels unable to handle, it is recommended that FLSmidth is contacted without
undue delay for advice on appropriate action.
1 General information
1.1 Scope and purpose
This manual includes principles and directions to the installation and maintenance of
expansion joints on ducts, chutes and pipes.
An expansion joint consists of steel parts and fabric parts for expansion. Thermal
insulation, lining with densulate, densit or casted brickwork may exist on certain
components.
Expansion joints serve to compensate for the axial and lateral movements, which occur
in connection with thermal expansion of the steel structures. An expansion joint may
serve the purpose to isolate vibrations of ducts or machines from other structures. The
expansion joint ensures that considerable forces or vibrations do not apply to
neighbour components.
1.2 Definitions and abbreviations

Authorized person An authorized person is a skilled person, who is qualified and who by the
responsible manager is entrusted with certain tasks.
GA General arrangement drawing

Hinstallation Installation measure from Expansion Joint Legend.
MSDS Material safety data sheet
N/A Not applicable.
OM Operation and maintenance.
SDS Safety Data Sheet (In US known as MSDS)
Skilled person A person, who after an education as a craftsman, is capable of doing skilled work.
The information transmitted by this document is the proprietary and confidential property of FLSmidth 3/39
Expansion Joints
27421-07-3.1
1.3 Legend
Mandatory!
This symbol appears in the instruction manual to indicate dangers which, in case of non-
observance, may cause fatal or serious injuries!
Attention!
This sign is shown in the instruction manual where specific attention and caution is needed to
avoid damage to or destruction of the equipment and/or parts of the installation.
2 Design and operating principle

2.1 Materials overview
Delivered by
steel
Expansion joint type manufacturer Delivered by the fabric manufacturer Delivered by other
Duct 1. Rectan/circular Large bellow with open ends, small as an assembled ring.
Pos numbers 4, Beam for bracing the
Duct 2. Rectan/circular MN300, MN400 or LN200, (51).
20, 21, 22, 23 expansion joint steel
Figure 7, butt weld. Taptite, (3), with fixation tool.
parts before installing
Lock washer, (5).
the bellow. The same
Duct 3. Rectan/circular Glass felt, (7).
Pos numbers 4, beam may be used for
Duct 4. Rectan/circular Insulation, 60 kg/m3 loose wool (8). lifting for installation.
20, 21, 22, 23, 24
Figure 7, flange. Or See Figure 23.
Insulation bag with 80 kg/m3 loose wool (8, 9).
Assembled ring bellow, HT100 or HT350. (52) Beam for bracing the
Taptite, (3), with fixation tool. expansion joint steel
Reinforced 1 Lock washer, (5). parts before installing
Pos numbers 4,
Rectangular/circular Glass felt, (7). the bellow. The same
20, 21, 22, 23, 24
Figure 8. Insulation bag with 80 kg/m3 loose wool (8, 9). beam may be used for
Connection wire for electrical connection to adjacent lifting for installation.
equipment. See Figure 23.
Assembled ring bellow, HT100, (53).

Reinforced 2 Taptite, (3.2). Beam for bracing the
Pos 20, 23 expansion joint steel
Rectangular Figure 9. Connection wire for electrical connection to adjacent
equipment. parts before installing
Assembled ring bellow, HT100, (53). beam may be used for
Reinforced 2 Strapping band, (3.1). lifting for installation.
Pos 23
circular. Figure 9. Connection wire for electrical connection to adjacent See Figure 23.
equipment.
Assembled ring bellow, HT100. (54)
Reinforced 3 Strapping band, extra heavy, 25x15, (3).
- Pos 4, 23
circular, Figure 10. Connection wire for electrical connection to adjacent
equipment.
Assembled ring bellow, HT100. (55)
Reinforced. 4 Strapping band, extra heavy, 25x15 with snap lock, (4).
- Pos 5, 23
circular, Figure 11. Connection wire for electrical connection to adjacent
equipment.
Large bellow with open ends, small as an assembled ring. Beam for bracing the
MN300, MN400, MN500 or LN200, (56). expansion joint steel
Taptite, (3), with fixation tool. parts before installing
Pos numbers 4, Lock washer, (5).
Lined 1, Figure 12. beam may be used for
20, 21, 22, 23, 24 Glass felt, (7).
lifting for installation.
Insulation, 60 kg/m3 loose wool (8). See Figure 23.
Or Heat resistant
Insulation bag with 80 kg/m3 loose wool (8, 9). materials (9)
Beam for bracing the
Large bellow with open ends, small as an assembled ring. expansion joint steel
MN300, MN400, MN500 or LN200, (56). parts before installing
Taptite, (3), with fixation tool.
beam may be used for
Pos numbers 4, Lock washer, (5). lifting for installation.
Lined 2, Figure 12.
20, 21, 22, 23, 24 Glass felt, (7). See Figure 23.
Insulation, 60 kg/m3 loose wool (8). Heat resistant
Or materials. (9)
Insulation bag with 80 kg/m3, loose wool (8, 9). Anchors (9)
Ceramic felt (10)
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27421-07-3.1
Delivered by
steel
Expansion joint type manufacturer Delivered by the fabric manufacturer Delivered by other
Pos numbers 4, Lock washer, (5). the bellow. The same
Lined 3, Figure 13.
20, 21, 22, 23 Glass felt, (7). beam may be used for
Insulation, 60 kg/m3 loose wool (8). lifting for installation.
Or See Figure 23.
Insulation bag with 80 kg/m3 loose wool (8, 9). Densit (11)
Pos numbers 4, Lock washer, (5). the bellow. The same
Lined 4, Figure 13.
20, 21, 22, 23 Glass felt, (7). beam may be used for
Insulation, 60 kg/m3 loose wool (8). lifting for installation.
Or See Figure 23.
Insulation bag with 80 kg/m3 loose wool (8, 9). Densulate (10)
Typical closed ends bellow.

Chute 1, Figure 14. Pos numbers 20,
MN300, MN400 or LN200, (57).
Rectangular 23
Taptite with fixation tool (3.2).
Chute 1, Figure 14.
Pos numbers 23 MN300, MN400 or LN200, (57).
Circular
Strapping band (3.1).
Typical closed ends bellow. Beam for bracing the
MN300, MN400 or LN200, (57). expansion joint steel
Rectangular 23 parts before installing
Typical closed ends bellow. beam may be used for
Chute 2, Figure 14.
Pos numbers 23 MN300, MN400 or LN200, (57). lifting for installation.
Circular
Strapping band (3.1). See Figure 23.
MN300, MN400 or LN200, (57).
Rectangular 23
Chute 3, Figure 15.
Pos numbers 23 MN300, MN400 or LN200, (57).
Circular
Chute 4, Figure 16.
- MN300, MN400 or LN200, (58). Steel parts, pos 23.
Circular
Strapping band with snap lock, (3).
Beam for bracing the
Air proof, flexible material (60). expansion joint steel
parts before installing
Air proof, flexible material (61).
Chute S, Figure 17 Steel parts the bellow. The same
beam may be used for
Strapping band (3.2). lifting for installation.
See Figure 23.
Closed ends bellow.
Dedusting 1, Figure 18. Pos numbers 20
- MN300, MN400 or LN200, (59).
Rectangular Steel parts, pos 23.
Taptite with fixation tool (3).
Closed ends bellow.
Dedusting 2, Figure 18.
- MN300, MN400 or LN200, (59). Steel parts, pos 23.
Circular
Strapping band (3).
Large bellow with open ends, small as an assembled ring.
Scissor 1, Figure 19. Steel parts. 2, 3 Bellow MN 300, MN 400, MN 500 (1). -
Hexagon head bolt with nut. (5).
Scissor 2, Figure 19. Steel parts. 2, 3 Bellow MN 300, MN 400 (1). -
Hexagon head bolt with nut. (5).
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2.2 Drawings and Expansion Joint Legend

For each project FLSmidth submits one or more specific Expansion Joint Legend(s).
This document includes a total list of all expansion joints with data and dimension.
Steel parts and the appurtenant expansion joint elements are manufactured at
different workshops and delivered separately to site for local assembly.
Auxiliaries for installation of the bellows/fabrics/internal insulation are included in the
delivery of bellows/fabrics.
Outside thermal insulation or inside lining with densit/densulate/high temperature
castables is not included with the expansion joint.
Other types than shown below in sub-section 2.3 may appear for special applications.
2.3 Bellow type

The bellow is supplied as an assembled ring.
Bellow type HT350: 7 layers bellow. Temperature direct on inside of bellow max. 350 C. Explosion
pressure shock resistant.
Pos 1 Needled glass felt. Thickness 6 mm
Pos 2 PTFE coated glass fabric. Thickness 0,4 mm, 600 g/m2 .
Pos 3.1 Glass fabric polyurethane impregnate. Thickness 1,3 mm, 980 g/m2 .
Pos 4 RST 1502 PTFE / film / fabric. Thickness 1,1 mm, 1830 g/m2 .
Pos 5 Glass fibre string. 8 mm.
Figure 1. HT 350
The bellow is supplied as an assembled ring.
Bellow type HT100: 4 layers bellow. Temperature direct on inside of bellow max. 100 C. Explosion
pressure shock resistant.
Pos 1 EPDM rubber, 2 layers reinforced. 4 mm, 4800 g/m2 .
Pos 2.1 Hypalon coated polyester fabric. 0.5 mm, 530 g/m2 .
Pos 3 Glass fibre string. 8 mm.
Figure 2. HT 100
All versions of this bellow are supplied with open ends.
Bellow type MN300: 3 layers bellow. Temperature direct on inside of bellow max. 300 C.
Pos 1 Glass fabric polyurethane impregnate. 1.1 Pos 3 Silicone coated glass fabric. 1.1 mm,
mm, 600 g/m2 . 1300 g/m2 . (Silicone 400 g/m2 outside
Pos 2 2
PTFE foil. 0.2 mm, 440 g/m . and 100 g/m2 inside).
Figure 3. MN 300
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Pos 1 Silicone coated glass fabric. 1.1 mm, 1300 g/m2 . (Silicone 400 g/m2 outside and 100 g/m2
inside).
Pos 2 PTFE foil. 0.2 mm, 440 g/m2 .
Pos 3 Needle glass felt. 13 mm, 2000 g/m2 .
Pos 4 Glass fabric polyurethane impregnate 1.3 mm, 980 g/m2 .
Figure 4. MN 400
inside).
Pos 2 PTFE foil. 0.2 mm, 440 g/m2 .
Pos 3 Glass felt. 13 mm, 2000 g/m2 .
Pos 4 Wire mesh, stainless steel.
Pos 5 Glass fabric polyurethane impregnate 1.3 mm, 980 g/m2 .
Figure 5. MN 500
Small version is supplied as an assembled ring. Other with open ends.
Bellow type LN200: 1 layer bellow. Temperature direct on inside of bellow max. 200 C.
inside).
Figure 6. LN 200
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2.4 Assembly of expansion joint for gas duct

Expansion joints for ducts with circular or square cross section for air and exhaust gas with maximum
temperatures 500 C depending on bellow type.
Rectangular dimension or outer diameter is given in the Expansion Joint Legend.
Expansion joint for duct may occur with flanged connection (see pos 24, Figure 8 and Expansion Joint Legend).
Rectangular.
Circular.
Expansion joint legend representation below: Duct 1 to 4
Pos 51 Bellows to fit the steel parts for Duct 1 Pos 9 Insulation bag (pillow). Only for chosen
to 4 models. See Figure 3, Figure 4, purpose, see Expansion Joint Legend.
Figure 6. Pos 20 Retaining iron.
Pos 3 Taptite ISO 7053, M8x45-C. Pos 21 Steel part. See mechanical drawing.
Pos 4 One round bar per 100 mm. Pos 22 Floating skirt to protect the inside of the
Pos 5 Lock washers, 30. One washer for each expansion joint from wear.
round bar. The washer must press the Pos 23 Steel part. See mechanical drawing. The
glass felt (7) firmly to avoid dust steel part to be orientated with the flow in
penetrating into the insulation. the duct/machine, see flow arrow on the
Pos 6 Installation measure is defined as drawing.
H installation in this instruction see Expansion
Joint Legend.
Pos 7 2 off 10-13 mm layers of glass felt.
Pos 8 Loose mineral wool, 60 kg/m3 .
Figure 7. Expansion joint for circular or rectangular/square section.
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2.5 Assembly of reinforced expansion joint

Expansion joint for duct in coal grinding plant with circular or rectangular cross section.
The bellow is supplied as an assembled ring. Rectangular dimension or outer diameter is given in the Expansion
Joint Legend.
To be used in gas with coal meal content and exhaust gas with maximum temperatures 500 C depending on
bellow type. The joint is pressure shock resistant.
Rectangular.
Circular.
Expansion joint legend representation below: Reinforced 1
Pos 52 Bellows Figure 1 and Figure 2 fit the steel parts Pos 9 Insulation bag (pillow) encloses the
for model, Reinforced 1. loose mineral wool.
Pos 3 Taptite ISO 7053, M8x45-C. Pos 20 Retaining iron.
Pos 4 One round bar per 100 mm. Pos 21 Steel part. See mechanical drawing.
Pos 5 Lock washers, 30. One washer for each round Pos 22 Floating skirt to protect the inside of
bar. The washer must press the glass felt (7) the expansion joint from wear.
firmly to avoid dust penetrating into the Pos 23 Steel part. See mechanical drawing.
insulation. The steel part to be orientated with
Pos 6 Installation measure is defined as Hinstallation in the flow in the duct/machine, see flow
this instruction see Expansion Joint Legend. arrow on the drawing.
Pos 7 2 off 10-13 mm layers of glass felt. Pos 24 Flange connection to duct.
Pos 8 Loose mineral wool, 60 kg/m3 .
Figure 8. Expansion joint for circular or rectangular/square section in coal grinding department.
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Chute expansion joint for temperatures less Chute expansion joint for temperatures less
than 100 oC. than 100 oC.
Rectangular: Circular:
Expansion joint legend representation below: Reinforced 2
Pos 53 Bellow according to Figure 2, HT100. Pos 20 Retaining iron.

Pos 3.1 Strapping band. Pos 23 Steel parts.
Pos 3.2 Taptites ISO 7053, 8x45-C. Pos 5 Flow direction.
Pos 4 2 off 4 mm round bar welded to the Pos 6 Installation measure is defined as
pipe. H installation in this instruction see Expansion
Joint Legend.
Figure 9. Reinforced expansion joint for chute in coal departments. Circular and rectangular.
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Maximum temperatures 350 C. The joint is pressure Pos 54 Bellow as Figure 2 supplied as an
shock resistant. assembled ring. See Expansion Joint
Circular: Legend. The bellow is explosion proof,
shock resistant.
Pos 1 Flow direction.
Pos 3 Strapping band, extra heavy, 25x15.
Pos 4 2 off 4 mm round bar welded to the
pipe.
Pos 23 De-dusting piping or chute.
This expansion joint does not include any steel part
delivery. Steel parts are delivered with the dedusting
pipes or chutes.
Expansion joint legend representation below:

Reinforced 3:
Figure 10. Expansion joint for de-dusting pipe and chute.
Circular: Pos 55 Bellow as Figure 2 supplied as an

assembled ring. See Expansion Joint
Legend. The bellow is explosion proof,
shock resistant.
(sewed into the bellow).
Pos 4 Strapping band, extra heavy, 25x15 with
snap lock (sewed into the bellow).
Pos 5 2 off 4 mm round bar welded to the pipe.
Pos 23 De-dusting piping or chute.
pipes or chutes.

Reinforced 4:
Figure 11. Detachable expansion joint for pipe and chute.
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2.6 Assembly of lined expansion joint

Heat resistant lining. Thickness 114 mm. Maximum gas temperatures < 800 oC.
Circular shown - Rectangular available. Lined 1:
Expansion joint legend

representation below:
Heat resistant lining. Thickness 214 or 264 mm. Max. gas temp. < 1100 oC.
Circular shown - Rectangular available. Lined 2:

Bellow to be selected among models shown on Figure Pos 72 off 10-13 mm layers of glass felt.
3 to Figure 6. See Expansion Joint Legend and the Pos 8Loose mineral wool, 60 kg/m3 .
marking designation on the delivery.
Pos 9Heat resistant material and anchors.
Pos 56 For heat resistant lining 114 and Pos 10
Ceramic felt. See sub-section 6.1.4.
214/264. Pos 11
Free space for expansion.
Pos 3 Taptite ISO 7053, M8x45-C. Pos 20
Retaining iron.
Pos 4 One round bar per 100 mm. Pos 21
Steel part, see mechanical drawing.
Pos 5 Lock washers, 30. One washer for each Pos 22
Floating skirt to protect the inside of the
round bar. The washer must press the expansion joint from wear and dust.
glass felt (7) firmly to avoid dust Pos 23 Steel part, see mechanical drawing. The
penetrating into the insulation. steel part to be orientated with the flow in
Pos 6 Installation measure is defined as the duct/machine, see flow arrow on the
H installation in this instruction, see drawing.
Expansion Joint Legend. Pos 24 Flange connection to duct.
Insulation, 60 kg/m3 loose wool (8) or insulation bag with 80
kg/m3 wool (8, 9).
Figure 12. Heat resistant lined with 114 or 214 or 264 mm thickness. Circular duct.
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Densit. Rectangular or outer diameter dimensions are given in the Densit.

Expansion Joint Legend. Max gas temperatures < 500 C.

Lined 3:
Densulate. Rectangular or outer diameter dimensions are given in the Densulate.

Expansion Joint Legend. Max gas temperatures < 500 C.

Lined 4:
Bellow to be selected among models shown on Pos 8 Loose mineral wool, 60 kg/m3 .
Figure 3 to Figure 6. See Expansion Joint Legend Pos 9 Insulation bag (pillow). Only for chosen
and the marking designation on the delivery. purpose, see Expansion Joint Legend.
Pos 10 50 mm Densulate.
Pos 56 For densulate and densit lining. Pos 10.1 Free space for welding of root pass.
Pos 3 Taptite ISO 7053, M8x45-C. Pos 11 20 mm Densit Wearflex 2000 HT.
Pos 4 One round bar per 100 mm. Pos 11.1 Free space for welding of root pass.
Pos 5 Lock washers, 30. One washer for Pos 20 Retaining iron.
each round bar. The washer must press Pos 21 Steel part, see mechanical drawing.
the glass felt (7) firmly to avoid dust Pos 22 Floating skirt to protect the inside of the
penetrating into the insulation. expansion joint from wear and dust.
Pos 6 Installation measure is defined as Pos 23 Steel part, see mechanical drawing. The
H installation in this instruction, see steel part to be orientated with the flow
Expansion Joint Legend). in the duct/machine, see flow arrow on
Pos 7 2 off 10-13 mm layers of glass felt. the drawing.
Insulation, 60 kg/m3 loose wool (8) or insulation bag with
80 kg/m3 wool (8, 9).
Figure 13. Ductdensulate and ductdensit. Circular or rectangular.
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2.7 Assembly of expansion joint for chute, temp less than 500 oC
Chute 1: Rectangular/circular chute expansion joint. For small expansion.
Chute 2: Rectangular/circular chute expansion joint. For large expansion.
Pos 57 Bellow according to Figure 3, Figure 4 or Pos 20 Retaining iron.

Figure 6, see Expansion Joint Legend. Pos 23 Steel parts, see mechanical drawing.
Pos 3.1 Strapping band. Pos 5 Installation measure is defined as Hinstallation
Pos 3.2 Taptites ISO 7053 8x45-C. in this instruction, see Expansion Joint
Legend.
Expansion Joint Legend representation below: Expansion Joint Legend representation below:
Chute 1. Chute 2.
Figure 14. Chute 1 and chute 2: Rectangular and circular, axial through.
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Chute expansion joint, rectangular. Chute expansion joint, circular.
Expansion Joint Legend representation below: Chute 3.

For large expansion. Lateral offset.
Offset direction is declared in the Expansion Joint Legend.
Pos 57 Bellow according to Figure 3, Figure 4 or Pos 20 Retaining iron.

Figure 6. See Expansion Joint Legend. Pos 23 Steel parts, see mechanical drawing.
Pos 3.1 Strapping band. Pos 5 Installation measure is defined as
Pos 3.2 Taptites ISO 7053 8x45-C. H installation in this instruction, see
Expansion Joint Legend.
Figure 15. Chute 3 For large expansion: Rectangular and circular, lateral offset.
Detachable chute expansion joint, circular.

Pos 58 Bellow according to Figure 3, Figure 4 or
Figure 6, see Expansion Joint Legend.
(sewed into the bellow).
Pos 4 Strapping band, extra heavy, 25x15 with
snap lock (sewed into the bellow).
pipes or chutes.
Chute 4:
Figure 16. Detachable chute expansion joint for pipe.
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2.8 Special joint with large transversal move for chute
Pos 1 Lateral movement +/- 185 mm. Pos 60 Gas-proof flexible material.
Pos 2 Axial movement +/- 55 mm. Pos 61 Gas-proof flexible material.
Pos 3 Strapping band. Temperature < 100 oC.
Pressure > minus 4 kPa.
Figure 17. Chute S circular.
2.9 Dedusting pipe expansion joint

Rectangular. Circular.
This expansion joint steel part includes retaining iron This expansion joint steel part does not include any
only. steel part delivery. Steel parts are delivered with the
The inside cone and chute must be manufactured on dedusting pipes or chutes.
site from available materials of proper dimension and The cone must be manufactured on site from
quality. The holes must be drilled on site. available materials of proper dimension and quality.
Pos 59 Air-proof bellow, flexible material as Pos 59 Air-proof bellow, flexible material as
Figure 3, Figure 4 or Figure 6. Figure 3, Figure 4 or Figure 6.
Pos 20 Retaining iron. Pos 3 Strapping band.
Pos 3 Taptites ISO 7053, 8x45-C.
Expansion joint legend representation below: Expansion joint legend representation below:
Dedusting 1: Dedusting 2:
Figure 18. Expansion joint for cold duct. Dedusting pipe joint.
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2.10 Scissor
Duct or chute expansion joint. Maximum temperatures < 500 oC.
Scissor 1 Scissor 2
Duct expansion joint Chute expansion joint
Pos 1 Bellow.
Pos 2 Steel parts for expansion joint.
Pos 3 M24 nut to be firmly hand-tightened and spot-welded to the bolt.
Pos 4 Washer.
Pos 5 Hexagon head bolt with nut.
Pos 6 Retaining iron.
Figure 19. Long circular expansion joint (Scissor) for duct and chute.
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2.11 Lateral displaced sketches

The Expansion Joint Legend gives additional sketches for further information on special
installation condition.
Model: Sketch 1 Model: Sketch S
Figure 20. Lateral displaced sketch
2.12 Expansion joint legend

The Expansion Joint Legend is the document presenting all expansion joints per plant
or per department. The Expansion Joint Legend may appear in several volumes for one
plant or factory. The header and table, Figure 21 show examples on the information
given in the Expansion Joint Legend.
Duct / Dimension GA Tempe- Axial Lat. Installation Installation Drawing model Remarks
chute / A x B / A Plan rature move- move- offset length
Item dedusting no. ment ment
no. pipe [mm] [C] [mm] [mm] X [mm] H [mm]
199.1 Duct 1000 1 100 10 10 - 450 Duct 1 (with insulation bag)

Densit 20 mm
199.101 Duct 1000 1 100 10 10 - 450 Lined 3
insulation bag)
199.106 Duct 3000 8 300 85 85 - 550 Duct 1 (with insulation bag)
2.1 Duct 100x100 1 200 110 110 - 650 Duct 1

Densulate 50 mm
2.3 Duct 5000x5000 3 200 110 110 - 650 Lined 4
(with insulation bag)
Shock resistant to
2.4 Duct 1000x500 4 200 30 30 - 650 Reinforced 1
200 kPa
3.1 Duct lined 2000 5 150 40 40 - 700 Lined 1 114 mm, std. flange
4.1 Chute 710 10 100 55 55 - 550 Chute2
4.3 Chute 1000 12 100 45 45 46 505 Chute 3 Compressed
4.4 Chute 1000 13 300 80 80 - 550 Chute2
4.5 Chute 1000 14 300 80 80 - 470 Chute2 Compressed
5.1 Chute 500x710 2 100 10 10 - 550 Chute2
5.2 Chute 1000x2000 3 100 10 10 - 550 Chute2
5.7 Chute 1000x1000 7 250 160 160 - 640 Chute2 Compressed
6.1 Dedusting 500 5 100 10 10 - 250 Dedusting 2
6.2 Dedusting 315 5 125 30 30 - 250 Reinforced 3 Reinforced 350 kPa

Figure 21. Header on Expansion Joint Legend.
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3 Safety instructions
3.1 General notes
3.1.1 Introduction
FLSmidth will not assume responsibility for any damage resulting from abuse or
improper operation or inadequate maintenance of the expansion joint or resulting
from its operation or maintenance by unqualified personnel, including personnel
who have not acquired the skills required to operate or maintain the equipment on
the basis of the directions provided in the technical documentation.
3.2 General notes on safety for expansion joint

3.2.1 Permission to work
It is the responsibility of the installation supervisor or maintenance supervisor to
ensure that all personnel involved have studied and fully understand:
The permission given to perform work in the specific area.
All relevant instructions concerning health and safety and the contents of this
present instructions manual.
3.2.2 Foreseen hazards to personnel
Damage on pressure resistant bellows of type HT 100 and HT 350 may cause risk
for burn or explosion. Stop the operation of the plant if any need of repair should
arise.
Dust from repair during operation of the bellow in a duct (high temperature) may
cause breathing problem or burn.
3.2.3 Foreseen hazards to equipment
Welding sparks, sharp objects etc. constitutes a risk to the bellow.
Non-conditional operation temperature and pressure may cause burst of bellow.
3.2.4 Harmful media
Certain parts of the expansion bellow and appurtenant auxiliaries (mineral wool,
silicone glue) may cause danger to health. The material safety data sheet (MSDS)
informs any danger and precautions.
The process media may include harmful dust at elevated temperatures. The
material safety data sheet (MSDS) informs any danger and precautions.
3.3 Specific safety precautions concerning installation

3.3.1 Qualification
Attention!
Any installation activity must be carried out by skilled persons and is subject to the
supervision of authorized personnel. See sub-section 1.2.
A final installation check must result in a release note to commence test or operation
of the equipment. See sub-section 4.8.1. Non-conditional installed expansion joints
may result in escape of hot air or exhaust gas with personal injury as the
consequence.
Bellow should be mounted after all welding works have been completed. Otherwise a
bellow must be protected against welding sparks, sharp objects etc.
3.3.2 Electrical isolation

The expansion joint must be electrical connected across the connection flanges due
to avoid electrical isolation of the steel parts. The connection wire is supplied for
type HT 350 and HT 100 explosion resistant expansion joint only.
3.4 Specific safety precautions concerning OM

Mandatory!
Any operational or maintenance activity must be carried out by skilled persons and is subject to
the supervision of authorized personnel. Ensure a permit to work system for work inside the
expansion joint. Wait cooling of the expansion joint before inside maintenance activity.
Attention!
Before any operation or test activity commences an authorized person (See sub-section 1.2) must
declare that installation or maintenance has been completed and that the equipment has been
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released for operation or test. See sub-section 4.8.1.
Mandatory!
In particular all kinds of combustible material constitute a risk of fire or dust explosion. Keep
the equipment cleaned from combustible material. Explosion resistant bellows of type HT 100
and HT 350 must not be repaired. Stop the operation of the plant and change the entire bellow
if any need of repair should arise.
Media flow to or through the expansion joint constitutes a risk to personnel working inside the
expansion joint. Ensure that no media rush, exhaust gas/air flow to or through the expansion
joint may occur. Gravity force may cause media rush.
Do not repair bellow in lined ducts during operation of the plant.

Use fire-resistant clothes and other relevant personal protective equipment when repairing
bellow during operation on other types of joints.
Attention!
Emergency repaired bellow must be replaced at first opportunity. See sub-section 4.7.2.
4 Installation
4.1 Storage on site
4.1.1 Bellows, insulation, glass felt auxiliaries etc.
When bellows with auxiliary materials arrive at site, they should be stored indoors
in a dry place and remain in their transport packaging until the installation
commences. Safety data sheets are enclosed and may be found among the specific
order documentation. The identification of goods on receipt must be carefully
executed. Deficiency must be registered and reported to site management. Scope
of delivery must be consistent with the Expansion Joint Legend, see Figure 21 and
Figure 22.
4.1.2 Steel parts
Steel parts for expansion joints can be stored as other large steel structure. The
steel parts must be kept free from corrosion. Keep marking labels visible during
storage and installation and operation.
4.1.3 Lining materials

Lining materials is not part of documentation on expansion joint components.
Information must be found in other relevant documentation. The lining work must
be made by qualified company with qualified personnel.
4.2 Unpacking of materials

4.2.1 The bellow supply
Check the identification label on each bellow and ensure that the bellow consists of
correct number and quality of layers (Figure 1 to Figure 6). Identification label must
always be facing outwards and visible also after installation.
Check whether the bellow is delivered with open ends or as a closed bellow and
prepare for sufficient skilled labour force for assembly of bellow ends.
The bellow is sensitive to sharp edges and folding of material. Do not expose the
bellows to damages from this kind of mistreat.
Check all parts of delivery for damage and report any non-conformity to site
management.
4.2.2 The steel parts
Transport bracing on steel parts must be kept in place until installation bracing can
be established.
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Check all parts of delivery for damage and report any non-conformity to site
management.
4.3 Planning and installation procedures

4.3.1 Documentation
General Arrangemt Legend (front page text below) Expansion joint legend (front page text below)
Plant: PT SEMEN GRESIK (PERSERO) Plant: PT SEMEN GRESIK (PERSERO)
Tbk. Tbk.
Tuban 4, EAST JAVA, INDONESIA Tuban 4, EAST JAVA, INDONESIA
Department: 321 Raw mill Department: 321 Raw mill
Contract: 0945242 Contract: 0945242
Appr. date: 20-04-2010 Appr. date: 05-Mar-10
Created by: KGG Created by: SUVR
Approved by: AC Approved by: CBOK
This example shows GA drawing with two identical expansion joints (93-2 and 93-3) placed between
the duct and the inlets to the mill. The General Arrangement Legend refers under Ref. no. 93 to the
Expansion Joint Legend number, where 93-2 and 93-3 are specified according to example shown in
sub-section 2.12, Figure 21.
The reverse reference from the Expansion Joint Legend to the relevant GA drawing is given in the
overview table of the Expansion Joint Legend.
Figure 22. Documentation.
Information on installation and maintenance work is available in the following

documents:
General arrangement drawing with matching legend. See Figure 22 above.
Expansion joint legend. See Figure 21, Figure 22 and 4.3.2.
Marking number on every single fabric/insulation delivery.
Marking number on every single steel part delivery.
Mechanical drawing of the actual expansion joint.
Packing list from supplier. See http://packinglist.flsmidth.com.
Safety data sheets on certain materials.
4.3.2 Expansion joint legend
The Expansion Joint Legend clarifies facts on data for installation and types of
expansion joints. Information about relevant documentation, pre-compression and
offsetting of joints is given specifically for each project and each factory department
in the legend. Installation sketches for non-regular installation are given in the
legend.
4.3.3 Planning and schedule

The installation of expansion joint must be co-ordinated with the construction of
adjacent mechanical equipment, buildings and steel structures. The following
measures should be considered in the planning of installation activities:
Check the availability of all materials and equipment prior to commencement of
work.
Define critical tasks and ensure that a critical task to be performed can be
completed before end of shift.
Ensure current detailed specifications and drawings are available for carrying out
the works.
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Ensure work space for the bellow and thermal insulation material.
Containers for collection of waste materials in particular insulation and sheet waste
must be prepared.
4.3.4 Scaffolding
Installation scaffolding may be needed for other activities such as thermal
insulation and lining of the duct and retightening of the flat bar clamp screws. See
sub-section 5.2. Do not remove scaffolding before relevant parties have agreed.
Ensure that scaffolds are available at the support/fixation on the duct/machine
sufficient close to the duct ends to be offset. See step I below.
4.3.5 Auxiliary tools
A large number of screw clamps must be available. Other special tools for assembly
of the bellow are included with the bellow, see Figure 27.
4.4 The installation task on a step-by-step basis

As the character of installation varies substantially from one joint type to another, the
direction to the steel parts is given in three sub-sections from 4.4.1 to 4.4.3.
The description is organised with general considerations and direction to the more
complicated works in 4.4.1. Parts of this sub-section are relevant for installation of
steel parts of the other joint types, for which description is found in following
subsections, 4.4.2 and 4.4.3. Installation of the fabric is described in sub-section 4.4.4.
Reference in below text shown as "H" refers to the Figure 7 to Figure 20 while Hinstallation
refers to the Expansion Joint Legend.
4.4.1 Installation: Figure 7 to Figure 9 and Figure 12 to Figure 15, steel parts
A. Preparation of the steel parts
Steel parts are manufactured with flange/bolt or butt weld connection.
Reinforced joints, Figure 8 and heat lined joints, Figure 12 are installed with
flange/bolt connection.
The lining of heat lined expansion joint, Figure 12 must be casted before mounting
of the steel parts in order to ensure correct gab for the ceramic felt.
Wear lined steel parts are manufactured and connected with but weld ends, Figure
13. These types can be lined before or after the installation depending on the
procedure for lining on adjacent duct/pipe.
Pos 1 Lifting line for crane transport of Pos 5 the pos 2 beam shall be welded to
expansion joint. the duct/steel part with appropriate
Pos 2 Lifting and reinforcing fixation weld dimension. Foot plate to
beam on the steel parts Se sub prevent inside fillet weld which is
section 2.1 concerning supply. difficult to remove.
The number of beams on the
circumference must match the Attention: Do not deform expansion joint
diameter or rectangle size. flange (3) or the pre-drilled holes.
Typical the beam shall be able to
lift the entire structure from
ground. Attention: The fixation and lifting beam must
be removed immediately before installing the
Pos 3 Expansion joint flange with
bellow in order to ensure that the duct and
predrilled holes for the bellow.
steel structures are stress free and remain in
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Pos 4 Welding of lifting device to duct. correct position.

Ensure sufficient strength for
lifting force.
Figure 23. Bracing for lifting the expansion joint.
Attention, lining
Lining before installation of steel parts with butt weld ends must have 30 mm un-lined
pipe/duct ends for the sake of weld of the root pass, see Figure 13, (10.1) and (11.1).
Steel parts delivered split-up:

Large steel parts may be delivered in two or more parts considering limited item
width due to road transport legislation. The assembly of such parts must constitute
the requirements on the steel parts mechanical drawing.
Steel parts to be installed (lowered) transversal to duct axis (see step G) in one
assembled unit. Maintain transport bracing and if necessary establish additional
bracing (Figure 23) to keep the parts (23.1 and 23.2) in the position shown as "H"
on the Expansion Joint Legend.
Attention: Completion of the above mentioned fixation bracing, pos 2 on Figure 23
for installation on Figure 12 of thickness 214/264 only after insertion of ceramic
felt, see F and Figure 24.
Check connection dimensions on the duct/machine and the steel parts of the
expansion joint.
B. Flanges
Flanges may be a FLSmidth standard flange or a special flange type. Information to
flanges is given in the Expansion joint legend in the Remarks column and in
relevant section of the legend and mechanical drawing.
C. Flow direction
Check the gas-flow direction in the duct/machine (see GA drawing) and mount the
expansion joint steel parts accordingly. See flow direction in Expansion joint legend
or Figure 7 to Figure 20 or on the mechanical steel part drawing.
D. The bellow
Attention
The bellow may be supplied with closed ends. Such bellows must be hung over the
duct ends before installing the steel parts. Keep the bellow away from welding splatter
and sparks.
Aids for measuring the position of the duct/machine must be established. Such aids
must be kept available during the entire installation work. Measuring aids may be
useful for commissioning for which reason the removal must be agreed in writing with
the site management.
E. Preparation of duct ends

Duct ends are often delivered and installed with surplus length.
Ensure that the duct/machine ends are concentric positioned (any transversal offset
is described under I below).
If necessary, loosen the duct supports and move the duct ends to a position where
the dimension, Hinstallation can be achieved and where further axial and transversal
move for fine-tuning of the position is possible alternatively cut the duct ends to
appropriate length. See Hinstallation in the Expansion Joint Legend.
Ensure that the duct ends are concentric fixed and cannot move of other reason
than the expected operational movements.
Note: H on mechanical drawing and in the Expansion Joint Legend may be different
with respect to any pre-compression or pre-withdrawal. This manual defines the
installation measure, Hinstallation as the distance between the expansion joint
connection surfaces in installation state (20 C).
F. Installation of the ceramic felt
The ceramic felt (Figure 12) must be inserted while the steel parts are drawn apart
150-200 mm to bare the space for ceramic felt (thickness "a" mm) see Figure 24.
Ensure that the lining is finished on the flanged steel parts so that the ceramic felt
can be established in gap "a" and gap "c".
Before bracing the parts (pos 23.1 and pos 23.2 Figure 12) in position Hinstallation,
retract (pos 9.2, 21, 22, 23.2 Figure 12) 150-200 mm and insert suitable bits of felt
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(pos 10 Figure 24) into the gap "a" until the full circumference is covered. Hint:
Glue the felt to the lining (hatched pos 9.1 Figure 24).
Assemble the steel parts (pos 23.1 and pos 23.2) concentric and brace to obtain a
rigid body to overall length of "Hinstallation" mm.
Insert glass felt in the inside "c" opening from inside. The felt itself allows for 50 %
compression in operational state.
Hoist and lower the braced and assembled steel part into the final position.
Connect, weld or bolt (pos 23.1 Figure 24) first.
The steel part and duct/machine should now be ready for fine-tuning to fit the (pos
23.2 Figure 24).
Adjust axial pre-compressing and transversal offset if necessary (Figure 25).
Connect, weld or bolt (pos 23.2 Figure 24).
Remove the bracing between (pos 23.1 Figure 24) and (pos 23.2 Figure 24).
Maintain the measuring aids in place and observe that the expansion joint is in
place after release of bracing.
If not - Adjust to foreseen position.
This type of joint is normally connected with flanges. Here shown without flanges.
The glass felt can as maximum be compressed to 50 % thickness due to pre-compression or
operational state. Likewise it should be expected, that pre-compressed glass felt can expand to
operational state. See further instructions in Expansion Joint Legend.
Pos 10: In the vertical gap always use ceramic felt thickness "a".
The glass felt in the horizontal gap must be of dimension "c" and implemented from inside of the
joint structure. See dimensions in the Expansion Joint Legend.
Figure 24. Stuffing of ceramic felt.
G. Installation of the steel parts (for insertion perpendicular to axis)
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The steel parts of the expansion joint shall

be installed either flanged or welded
according the drawing specification:
Pos 1 Direction of insertion of the
expansion joint.
Pos 2 Duct ends.
H. Installation of the steel parts (for axial insertion of the steel parts)
The steel parts of the expansion joint

shall be installed either flanged or
welded according the drawing
specification:
Pos 1 Direction of insertion of the
expansion joint.
Pos 2 Duct end.
Ensure sufficient space between
duct/machine ends for axial
insertion of parts.
Move the braced expansion joint to
duct and connect (23.1, Figure 24)
to duct section or machine.
Install/finish duct section.
Proceed as described above under
F.
I. Axial pre-compression and transversal offset (fine-tuning)

Before fine tuning of the duct/machine ends and before installation of the bellow
the installation bracing mentioned in Figure 23 shall be removed.
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The picture above show an offset joint both lateral and axial.
Pos a and pos b are from the point of departure approximate of same size. When offsetting
lateral the a increases and the b decreases correspondingly.
Pos c Lateral offset as given in the Expansion Joint Legend.
Pos d Represents the distance which will change (positive or negative) during start
up of the plant.
Pos H H installation as given in the Expansion Joint Legend.
Pos 4 Fastener for glass felt.
Figure 25. The offset of expansion joint.
Attention
Transversal offset of the joint shall be conducted by setting the duct ends/machine with the
expansion joint steel parts mounted according to information given in Expansion Joint
Legend in the Offset column and any explanatory sketch in the Legend. See Figure 20.
Lateral displaced sketch.
Aids for measuring the position of the duct/machine must be established.

Check dimension, Hinstallation and concentricity on (23) (flanges for bellow) and
adjust if necessary.
To be able to adjust, let loose all necessary support/fixation and move the duct
ends/machine by use of ratchet hoist to the required position (axial and lateral) and
fasten the support/fixation.
Heat treatment of duct part may be used for adjusting to aimed position of
expansion joint steel parts. A half circumference electrical heat mat may be used
for more accurate heat impact.
4.4.2 Installation for Figure 10, Figure 11, Figure 16, Figure 18
A. Chute and dedusting pipes.
A number of joints do not include any steel parts because the steel parts are
considered manufactured by the duct/pipe installation company as an integrated
part of the duct/pipe system (see sub-section 2.1). Details on steel parts are
defined on the mechanical drawing with dash/dot lines.
B. Open ends/closed ends.
Bellows delivered with closed ends must be mounted on the duct, pipe or chute
while opening is available. This exposes the bellow to damage from weld spatter.
Protection must be established.
On vertical pipes mount where possible the bellow above the steel parts to exploit
the gravity force when lowering the bellow to its final position.
C. The steel parts.
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The steel parts must be manufactured on site by the installation company,

rectangular as well as circular. The two parts can be installed separately.
Where required, cut 4 mm wire and weld to the pipe or chute. Chamfer the ends
and bend firm to the steel structure. Ensure smooth surface over the entire 4 mm
wire circumference.
D. Positioning of the bellow.
The bellows are prepared for a 50 mm clamping face. Ensure appropriate steel part.
E. Fastening with strapping band.

Strapping bands for round pipe and chute may be drawn up from two or more
bands.
F. Fastening with retaining iron and tapties.
Retaining iron is used on joints for all ducts and rectangular chutes/pipes, see Pos
20 on figures in sub-sections 2.4, 2.5, 2.6, 2.7 and 2.9.
4.4.3 Installation for Figure 19 (Scissor)
The scissor is used for large compressive movements of adjacent ducts and must
always be mounted in a vertical position.
A. Tighten the M24 nuts
The M24 nuts to be firmly hand tightened and spot welded to the bolt. The bolts
must allow for free movement of the hinges.
B. Bellow
See directions in sub-section 4.4.4.
4.4.4 Installation for the fabric bellow.

A. Preparation of the bellow, insulation and insulation bag
The bellow and thermal insulation are delivered separate from the steel parts. Each
bellow is pre-assembled from a number of layers and thermal insulation in fixed
length with open or closed ends (see sub-section 2.1) and marked with the item
number given in Expansion Joint Legend. Glass felt (7) is delivered in coils
separately with the bellow.
Check the item number and check that the length of the bellow is sufficient for the
relevant circumference and the assembly work.
Attention:
The identification label on the bellow must be visible after installation of the bellow.
B. Check the axial and transversal position of the steel parts

Before installation of the bellow: Check the dimension, Hinstallation and offset
dimensions and adjust if necessary. Check that steel parts are installed to an
appropriate state (other works disturbing installation of fabrics may be ongoing).
C. Installation of the large bellow with open ends (taptites and retaining iron)
See Figure 26.
Insert 2 layers of glass felt (7) and fasten with lock washer (5).
Insert layer of insulation, loose mineral wool packed in an insulation bag, (80 kg/m3
(8 and 9)) or Loose mineral wool (60 kg/m3 (8)).
Open end bellow must be assembled around the expansion joint steel part as
follows:
Wrap the open ends bellow around the duct:
On horizontal ducts with the open ends in an upward position (to facilitate
the assembly of the ends).
On vertical duct with the open ends where access for assembly of the
ends is the best possible.
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Ensure that identification label is facing outwards and that correct layer of the
bellow is present (see sub-section 4.2.1).
Fasten the bellow temporarily to the flanges with screw clamps (see Figure 26) as
tight as possible and keep the bellow fixed firm to the flange while taptites are set.
Every taptite is applied by mean of two screw clamps, one at opposite sides of the
taptite.
Insert the taptites through the retaining iron and the bellow in a sequence from the
centre of the open-end bellow, working alternately to the left and the right of this
position until the open ends have been reached.
For each taptite to be set the temporarily fixed bellow must be tightened firm to the
flange most likely resulting in pushing a fold towards the open ends. Ease the fold
forward to the open ends.
For the vertical duct all taptites should be set in the upper flange first.
For horizontal duct set the taptites in both flanges simultaneously.
Ensure that no askew folds across the bellow occur.
Do not apply taptites 500-800 mm over the open ends to be jointed.
Assemble the open ends following the direction given in sub-section 4.6 below and
insert the remaining taptites.
No taptites should be tightened before the bellow joint has been made and all
taptites have been inserted. Once all taptites are inserted, tightening from the side
opposite the joint may commence.
D. Installation of the small and pressure resistant closed bellow with workshop joint
Smaller bellows and pressure resistant bellows will be supplied as an assembled
ring (closed ends) which must be hung on the duct/chute/pipe or the expansion
joint steel part before installation of the steel parts.
When welding: Protect the bellow against weld splashes.
Apply screw clamps on the flanges' circumference and spread any surplus bellow
length around the entire circumference. Avoid askew folds in the bellow.
Insert the taptites as described under C above in a sequence from the workshop
joint diametrical opposite side, working alternately to the left and the right of this
position.
No taptite should be tightened before all taptites have been inserted. Once all are
inserted, start tightening from starting point, alternating left and right. Ensure that
no folds in the bellow develop.
E. Installation of the bellow with strapping band
Strapping bands used on circular joints for chute and dedusting pipes only.
Strapping bands may appear as a collection of a number of bands depending on the
length of the bellow circumference.
Strapping bands may include snap lock for dismounting the bellow.
Explosion resistant bellows are fixed by a strapping band and are equipped with a
glass fibre string, 8 mm, (Figure 1 and Figure 2) and the matching steel pipe shall
be equipped with a 4 mm round bar, (Figure 9 to Figure 11).
The strapping band must be positioned between the glass fibre string and the 4
mm round bar.
Position any snap lock in a direction for easy approach.
Tighten the bands firm observing above mentioned directions.
F. Thermal insulation and insertion of taptites
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O:\PU\Instruktioner\27421 expansion joints\Image for new version\Duct_circular_bk.dwg
Pos 1 Bellow.
Pos 3 The taptite cuts thread directly in predrilled hole in the flange, taptites and
fixation tool (magnetic) are supplied with the bellow. Standard drilling
machine to be used.
Pos 5 Use one washer for each round bar (Figure 12, pos 4) only.
Pos 7 The washer must press the glass felt firmly to avoid dust penetrating into the
insulation.
Pos 20 Retaining iron.
Pos 23 Flange for bellow.
Pos 30 Attach two screw clamps. One on each side of the taptite.
Attention!
The bellow is insulated from the inside. Do not cover the bellow outside with thermal
insulation or cladding.
Figure 26. Thermal insulation and insertion of taptites.
4.5 Installation tools

4.5.1 The taptite
The taptite cuts thread directly in predrilled hole in the flange, (taptites and fixation
tool are supplied with the bellow, standard drilling machine to be used).
7.4 mm drill applies for holes for taptites.
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4.5.2 Various installation aids
Figure 27. Auxiliary materials for installation of the bellow.
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4.6 Detailed direction to the assembly of bellow

4.6.1 Assembly of bellow materials
Glass fabric assembly.
Prepare a 100-200 mm material overlap Sew together the material ends across the
overlap with parallel stitches.
Figure 28. Glass fabric assembly.
Glass felt assembly.
Mark off a 200 mm overlap on the material.

Carefully split both material ends down to half the
thickness.
Cut away the top layer of one material end and Overlap the two material ends to form a smooth
the bottom layer of the other material end. join.
Figure 29. Glass felt assembly.
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PTFE foil assembly
Clean a 250 mm area of the material ends with Prepare a strip of self adhesive PTFE foil longer
acetone or simular. Fold down a 100 mm overlap on than the width of the material. Roll on one overlap
both material ends. to half the width of the PTFE tape.
Roll on the other overlap until the fold. Bend over both material ends, at the same time,
to half the width.
Roll on the PTFE tape hard to the joining. Avoid in

Cover the join with a second strip of PTFE tape. any order wrinkles and air bubbles.
Figure 30. PTFE foil assembly.
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Glass fabric, silicone coated. Outside layer assembly.
Clean both material ends with acetone or simular Within 1 minute, roll on the other overlap
and apply silicone glue over a width of 75 mm.
Apply a string of silicone glue onto the join. Using a lap of PTFE foil, or similar material, form a
smooth layer of glue across the material.
Important: Allow 1 hour of drying time before

installing the expansion joint and 24 hours drying
time before start-up of system.
Figure 31. Glass fabric, silicone coated. Outside layer assembly.
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Multi layer bellow. Final joining procedure. Adding flange reinforcement in the splicing
area.
Figure 32. Multi layer bellow. Final joining procedure. Adding flange reinforcement in the splicing
area.
4.6.2 Mounting of large bellows (supplied open)
Steel plate as underlay for the assembly work to be positioned directly on the flanges. Use a stabilizing
clean steel plate of appropriate thickness as the basis for assembling of the bellow ends. Maintain the
plate in position until complete finishing the assembly work.
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Figure 33. Assembly of open ends.
4.7 Repair of bellow

4.7.1 Repair during operation
Efficient repair of damaged bellows in large ducts can be made by reducing the
system temperature and establish negative duct pressure. Pos number in () refers
to Figure 34.
Example: Bellow type MN300 (3 layers bellow Figure 3):
A. Material:
Bellow material can be ordered as spare parts or an old/new bellow (same
type) can be used as spare parts, actual material to be used must be in good
condition.
B. Dismount of bellow
Dismount the expansion joint retaining iron (4) over a distance large enough to
turn the bellow (1) with the inside out enabling the repair from inside and out.
Repair work must be carried out according to the bellow type. See Figure 1 to
Figure 6.
Protect the insulation material against water and thinning during open surface.
C. Procedure (see Figure 34):
For each damaged layer in the bellow, cut out a piece of new fabric (2),
approximate 400 mm longer than the damaged length and of same width as
the damaged bellow.
Attach these pieces to the damaged bellow according to direction in sub-
section 4.6, layer by layer, inside first.
D. Mount the bellow
Position the repaired piece of bellow and mount the retaining iron (4).
E. Consequence of a repair
This type of repair can bring the bellow back in condition where its not
necessary to change the bellow at next major stop. Inspect the bellow after
repair meticulously.
Expansion Joints
27421-07-3.1
Pos 1 Bellow of the type in concern.

Pos 2 Pieces of bellow attached to the original bellow.
Pos 8 Insulation material.
Figure 34. Permanent repair of bellow during reduced operation.
4.7.2 Emergency repair

If it is not possible to reduce temperature and establish negative duct pressure as
described above an emergency repairing can be done. Select appropriate personal
protective equipment after considering the actual conditions (pressure,
temperature, leaking gas flow, dust presence etc.) see safety prescriptions sub-
section 3.4.
A. Material:
Use one layer of silicone coated glass fabric with silicone layer on outside for
the repair work.
Glass fabric from an old bellow can be used if in good condition.
B. Procedure (see Figure 35):
Cut out a piece of silicone coated glass fabric approximate 1 m longer than the
damaged length and width enough to overlap both flanges.
Leave the damaged bellow (1) in place and fix the glass fabric (2) to the
flanges with screw clamps and sewing (3).
Apply silicone glue around the damaged place between (1) and (2) and sew
the new glass fabric (2) together with the old glass fabric (1) round the glue
and where possible.
Leave the screw clamps in place until change of bellow can take place.
Pos 1 Bellow of the type in concern.

Pos 2 Pieces of glass fabric attached (glued and sewed) to the original bellow.
Pos 3 Assembly needlework.
Pos 3.1 Assembly gluing and needlework over damage.
Pos 5 Number of screw clamp to hold the repaired area.
Pos 9 Insulation material (in bag).
Figure 35. Emergency repair of bellow during operation.
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27421-07-3.1
C. Consequence of an emergency repair

This type of repair cannot bring the bellow back in condition where its not
necessary to change the bellow at next major stop.
Inspect the bellow after repair meticulously.
The repaired bellow must be replaced by a new bellow as soon as possible.
D. After repair work
Immediately after this type of repair work a new bellow should be ordered. The
emergency repaired bellow must be replaced or properly repaired during next
maintenance stop. See sub-section 3.4.
4.8 Installation documentation

4.8.1 Quality documentation
Once the installation of the expansion joint is completed, a final installation check is
needed to determine that the specified condition is fulfilled.
The installation contractor must provide documentation of this final installation
check as a specific test report outlining that the specific installation dimensions
have been fulfilled and that the installation is without insufficiency or damage.
These records must be submitted to the site inspector and filed in the maintenance
system for future evaluation. See sub-section 6.1.3.
5 Operation
5.1 Pre-operational check
Check the installation notification of completion of works. Check cancellation of permit
to work status.
5.2 Operational supervision

Taptites and flatbar clamp screws must be re-tighten after 2-3 weeks in operation so
as to avoid leakage at the flanges.
6 Maintenance
6.1 Preventive maintenance
6.1.4 Replacement of
6.1.2 Inspection and
6.1.5 Functional test

6.1.3 Status check
Equipment
6.1.1 Cleaning
Pos Job designation

description
adjustment
spares
1 Bellow of all Bellow tightness 2A A

types. Bellow damage.
2 Bellow of all Axial installation position, Hinstallation A A

types. Lateral offset
3 Bellow of all A A
Operation pressure and temperature
types.
4 Bellow of all A A
Clean the outside of the bellow for dust.
types.
5 Ceramic felt Change the ceramic felt in joint type Lined 2 A A
6 Bellow of all 3-6A

Preventive change of bellow.
types.
Lining in Lining in expansion joint.
7expansion Clean expansion space. A*) A*) Ts/A A
joint. Repair of lining if necessary.
Table 1. Maintenance
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27421-07-3.1
Explanation: D = every 8 hours of operation

S = weekly
M = monthly
A = annually
A *) = at every major stop, minimum annually
T = see explanation in text below
Ts = see separate manuals.
A preceding number to a letter in the table indicates the frequency of the activity in
question. (Example: 2M means twice a month)
6.1.1 Cleaning
4 Combustible dust
To reduce risk of fire and dust explosion, dust and to a greater extent
combustible dust must be removed from equipment and structures.
7 Lining
It is of importance to clean clearance for expansion movement. See Figure
12. Free space between linings in expansion joint, transversal and axial
must be cleaned under each maintenance stop.
6.1.2 Inspection and adjustment
1 Tightness of bellow
The first sign of disintegration is that the cover layer starts peeling off or
crackles, depending on whether it was subject to thermal or chemical
disintegration.
It takes at least a couple of months from the time the cover layer starts
coming off and until the expansion joint becomes unfit for continued
service. Repair of damaged bellow can be done according to direction in
sub-section 4.7.
Leakage may occur from excessive load on the bellow, weld spatter,
mechanical damage and check also for such.
7 Lining
Damaged lining must be repaired. Otherwise it can result in damage on
steel part and bellow.
6.1.3 Status check
2 Installation position
The dimension H is given on the steel part mechanical drawing and
Hinstallation in the Expansion Joint Legend.
Check these dimensions during standstill and compare with installation
values given on the Expansion Joint Legend. See sub-section 4.8.1.
Any departure from installation value should be evaluated and related to
operational functionality, see 6.1.5. Re-align the steel parts if necessary.
Measuring the distance, Hinstallation is not possible after insulation of the
duct. Measure the analogue dimension over the visible flanges and
calculate H on the mechanical drawing on expansion joint. The measured
dimension can be related to H and Hinstallation .
3 Operational parameter
At operation temperature and nominal load of the plant the position of the
bellow should be checked and evaluated in concern of any possibility for
damage caused by excessive load.
The pressure in the bellow and the temperature on the structures, which
the bellow shall protect are variables, which must be considered and
compared with design values.
6.1.4 Replacement of spares
5 Ceramic felt
Ceramic felt placed in the free space (expansion space) between linings
Figure 12, (10) must be changed under each maintenance stop. Observe
safety precaution, sub-section 3.4.
See direction for first establishing of the ceramic felt in installation
direction in sub-section 4.4.1.
The change of ceramic felt may follow one of two procedures of which is
considered the best:
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27421-07-3.1
A: when the steel parts are assembled:
Provide access to the gaps for felt from the inside of the expansion
joint.
Cut pieces of ceramic felt suitable for stuffing into the gab a through
gab c, see Figure 24.
Use different kinds of bended 2 or 3 mm wire with angled ends
short enough to go through gap c and long enough to stuff the felt in
gab "a" and "c".
B: The ceramic felt must be set when the steel parts are drawn apart:
Disconnect the flanges and brace the parts carefully.

Lift out the entire joint.
Dismount (56), (5), (7), and (8) see Figure 12.
Withdraw (23.2) axial 150-200 mm to bare the space for inserting
ceramic felt ("a" mm).
Insert the felt into the "a" space, see 4.4.1 step 0.
Assemble the joint expansion steel parts.
Insert felt in the inside "c" gap from inside.
Mount the expansion joint.
Check and if necessary adjust the axial and transversal position.
Mount (56), (5), (7), and (8).
6 Replacement of bellow
The expansion joint bellow belongs to the product group called wear
parts, i.e. parts which need replacement after a certain time in operation,
the length of which (3-6 years) depends on the load from the air /
exhaust gas flowing through.
7 Lining
Lining in the duct/pipe/chute must be changed as needed. Annually
change for most severe loading. 3-6 years for moderate loaded
components.
6.1.5 Functional test
The functionality of the bellow shall be considered sufficient when:
Lateral offset and Hinstallation are in accordance with design.
Operation pressure and temperature are in accordance with design values.
Bellow material is in proper state.
Non-function observations can be:

Dislocation of steel parts for the expansion joint.
The bellow stretched to its utmost ability, axial or lateral.
The bellow is folded completely.
Operational condition, temperature and pressure have not been maintained
according to specification. A redesigned bellow and/or steel parts should be
considered.
Extreme layer of dirt on the fabrics.
Missing ceramic felt.
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Expansion Joints

Installatin, Operation and Maintenance, Safety

Approved date: 06 Mar 2012

Doc. No.: 27421-07-3.1

Table of contents Page:

1 General information .............................................................................................................. 3

2 Design and operating principle .............................................................................................. 4

3 Safety instructions .............................................................................................................. 19

Figure 4. MN 400 .............................................................................................................................................7

1.2 Definitions and abbreviations

GA General arrangement drawing

2 Design and operating principle

Assembled ring bellow, HT100, (53).

Typical closed ends bellow.

2.2 Drawings and Expansion Joint Legend

2.3 Bellow type

The bellow is supplied as an assembled ring.

All versions of this bellow are supplied with open ends.

All versions of this bellow are supplied with open ends.

All versions of this bellow are supplied with open ends.

Small version is supplied as an assembled ring. Other with open ends.

2.4 Assembly of expansion joint for gas duct

Expansion joint legend representation below: Duct 1 to 4

2.5 Assembly of reinforced expansion joint

Expansion joint legend representation below: Reinforced 1

Expansion joint legend representation below: Reinforced 2

Pos 53 Bellow according to Figure 2, HT100. Pos 20 Retaining iron.

Expansion joint legend representation below:

Figure 10. Expansion joint for de-dusting pipe and chute.

Circular: Pos 55 Bellow as Figure 2 supplied as an

Expansion joint legend representation below:

Figure 11. Detachable expansion joint for pipe and chute.

2.6 Assembly of lined expansion joint

Expansion joint legend

Expansion joint legend

Densit. Rectangular or outer diameter dimensions are given in the Densit.

Expansion joint legend

Densulate. Rectangular or outer diameter dimensions are given in the Densulate.

Expansion joint legend

Figure 13. Ductdensulate and ductdensit. Circular or rectangular.

Chute 1: Rectangular/circular chute expansion joint. For small expansion.

Chute 2: Rectangular/circular chute expansion joint. For large expansion.

Pos 57 Bellow according to Figure 3, Figure 4 or Pos 20 Retaining iron.

Chute expansion joint, rectangular. Chute expansion joint, circular.

Expansion Joint Legend representation below: Chute 3.

Pos 57 Bellow according to Figure 3, Figure 4 or Pos 20 Retaining iron.

Detachable chute expansion joint, circular.

Figure 16. Detachable chute expansion joint for pipe.

2.8 Special joint with large transversal move for chute

2.9 Dedusting pipe expansion joint

2.11 Lateral displaced sketches

Model: Sketch 1 Model: Sketch S

Figure 20. Lateral displaced sketch

2.12 Expansion joint legend

199.1 Duct 1000 1 100 10 10 - 450 Duct 1 (with insulation bag)

2.1 Duct 100x100 1 200 110 110 - 650 Duct 1

4.1 Chute 710 10 100 55 55 - 550 Chute2

4.3 Chute 1000 12 100 45 45 46 505 Chute 3 Compressed

4.4 Chute 1000 13 300 80 80 - 550 Chute2

4.5 Chute 1000 14 300 80 80 - 470 Chute2 Compressed

5.1 Chute 500x710 2 100 10 10 - 550 Chute2

5.2 Chute 1000x2000 3 100 10 10 - 550 Chute2

5.7 Chute 1000x1000 7 250 160 160 - 640 Chute2 Compressed