for taking upvibrationand thermalexpansion inair and flue gasduct systems

KE-Burgmann, DKis certified

acc. toISO 9001:2000

Expansion joint technology today

Expansion joints are vital compo-nents in most industrial plants. They areinstalled as flexible connections in airand flue gas pipe and duct systems totake up or compensate for thermal ex-pansion, vibrations and misalignments.

Today, advancements in processingand generating technologies are beingcombined with high demands for effi-ciency. This, with a clear orientationtowards environmental protection, puts

higher demands on expansion jointdesigns.

In the last few years, new and im-proved materials have made it possiblefor us to meet these demands. Simulta-neously we have managed to increasefunctionality, operating reliability and ser-vice life of our expansion joints.

Many possibilities

Regardless of whether flexible ex-pansion joints are manufactured fromelastomers or fabrics, they appear instrong contrast to the steel construc-tions into which they are installed.

For this very reason they offer al-most unlimited flexibility and numerousdesign possibilities for specialdemands. Furthermore,they are easyto handle

and easy toinstall.

Fabric expansion joints offersolutions to a broad range of in-

dustrial applications. Besides power ge-nerating systems as the most import-ant field of application, expansion jointsare used in all industries where one ormore thermal processes take place.

KE -B U R GMAN N

2

FABRICE XP A NSIONJ O I N T

More than just an expansion joint

Though we have standardised our ex-pansion joint designs to a great ex-tent, we customize most fabric expan-sion joints to the customer’s individualneeds.

To be able to offer the optimum solu-tion, both in terms of technical and eco-nomical requirements, we encourageyou to contact us at the earliest possi-ble stage of the project, especially sowhen it comes to new plants. Our vastexperience, combined with our nume-rous references concerning all possibleindustrial applications, and our techni-cal knowledge ensure the best opera-ting reliability for your application. Add to this our worldwideservice: it comprisesthe whole spec-

trum fromtechnical advice,

research & develop-ment, engineering (incl. of

CAU), design, to calculation(FEM) of steel components, measure-ments, installation and end-inspection,including after-sales and ‘troubleshoot-ing’ service. We do not wish to leaveanything to chance.

KE-Burgmann Denmark, the worldleader for fabric expansion joints, offersyou a reliable and competent partnerfor the best possible quality in productand service. We are certified to the ISO9001:2000 quality standard and a fullmember of the American ‘Fluid SealingAssociation’ and the ‘European SealingAssociation’.

Structure and Applicationof single-layer and multi-layer expan-sion joints. Preassembled units readyfor installation Pages 4/5

Modern Materials and EngineeringPrinciplesMaterials & engineering principles.Research, development & tests.

Pages 6/7

Criteria for Application and DesignThe most important operating criteria for quick identification of the design. The ideal check list. Please use the in-quiry data sheet (fold-out) at the back ofthe catalogue. Pages 8/9

Basic DesignsThe most important designs of expan-sion joints and connecting flanges; sleeves (baffles), insulation, and faste-ning components. Pages 10/11

Standard Expansion JointsStandard types with application andoperating criteria. Pages 12/13/14

Special Expansion JointsExamples of expansion joints for spe-cial application areas:Chimney joint; Combine-X® Fire Skirts;Chimney Lining joint; Expanding seamjoint; KE-Acouseal®; Convoluted bel-lows. Pages 14/15

Service and Technical SupportPage 16

Tools etc.Flange gaskets, installation and joiningmaterials, foil welding and other tools.

Page 17

Application Technology: Power GenerationExamples of application in power plantsand gas turbine systems. Pages 18/19

Application Technology: Other Industrial PlantsExamples of application in the chemi-cal, pulp & paper, and offshore indu-stries etc. Pages 20/21

ABC Expansion Joint Technology Explanations of special technicaland engineering terms. Pages 22/23

Inquiry Data SheetQuestionnaire and checklist in one tomake your inquiry easy.

Fold-out page

I S O 9 0 0 1

Member of theFluid SealingAssociation and theEuropean SealingAssociation.

n C O N T E N T S

3

Flange reinforcement for protection of the expansion joint and additional insulationin the flange area

Strips of insulating fabric, for extra protection of the flange area

Insulation material

Temperature resistant and Insulating fabrics

Stainless steel bands

Outer cover, laminated with PTFE on both sides

Laminated and gas tight KE foil. As standard this sealing barrier is inte-grated in the outer cover,

but it may also beincorporated as a

separate layer forextra protection

••

•

•

•

•

•

•

•

•

•

4

Stainless steel wire mesh

Structure and

Why should you use fabricexpansion joints? Be-

cause they offer a number ofadvantages especially in plantdesign and building:

They take up movements inseveral directions simultaneous-ly, they have almost no reactiveforces, need little space for in-stallation, are easy to adapt toexisting physical conditions, andthey are easy to transport andto install.

Multi- layer expansion joints

By combining different materialsand taking into account their thermal,chemical and mechanical resistance aswell as their fatigue properties, we en-sure the optimum solution both in tech-nical and economical respect.

Basically, the design of multi-layerexpansion joints comprises four groupsof materials:

� Outer cover materialProtects the expansion joint from

pressure and temperature and guar-antees form stability. In most cases thematerial is coated or laminated andmay also function as gas sealingbarrier. Stainless steel wire mesh andsteel bands are further used for specialdesigns to give added mechanical pro-tection and dimensional stability.

� Gas sealing foilThe gas sealing foil is the actual

sealing element, usually imbedded be-tween fabric layers or integrated in theouter cover. Impermeable and chemi-cally resistant.

� Temperature-resistant fabricsVery strong and temperature resistant

fabrics are used to protect the gas seal-ing foil and/or the insulation materials.

� Insulating materialsProtect both the gas sealing foil and

the other expansion joint materials fromhigh temperatures of the medium.

� Variables to considerThe following considerations will in-

fluence the design and the choice of theright expansion joint type.

� MediumThe choice of expansion joint type

is determined, among other things, bypossible chemical influences. Abrasionfrom solid matter is largely preven- ted by using a sleeve/baffle construction.

� TemperatureA specific number

of insulating materialsare required for reducing the temperature. Our Tech-nical Department determi-nes the insulating effect bycalculating and measuring thetemperatures in a complete ex-pansion joint. The exact tempe-rature flow is found by means oftemperature probes and recorders.Temperature range:–60 ...+1,200 °C (–76 ...+2,192 °F)(dependant on design)

� PressureWill the expansion joint be used in a

positive pressure or negative pressurearea? This will have influence on both

type and design of the expansion joint.The main application area covers thepressure range of � 400 mbar (� 40kPa). (Fabric expansion joints will resistpressures of up to approx. 3 bars, depen-dant on other operating parameters.)

� Tightness (sealing)The requirements for tightness have

influence on the design and especiallythe configuration of the flange area. Ifthe sealing rate must be documented(Nekal tightness or specific leakage ra-tes), the expansion joints are built withspecial flange designs. We are able todetermine leakage rates for various ma-terials and complete expansion jointstructures on our test rigs.

Example: Temperature gradient and flow in a multi-layer expansion joint

Ambient temperature 30 °C (86 °F)

Gas temperature 400 °C (752 °F)

Outer cover

Gas-tight foil

Stainless steelwire mesh

Gas fabric

Insulation

Gas fabric

100 °C (212 °F)

140 °C (284°F)

150 °C (302 °F)Dew point

320 °C (608 °F)

Appl icat ion

Expansion joint units

The use of expansion joint units, i.e.fabric part preassembled on steel com-ponents, offers many advantages:� All preassembling work is carried outin our workshop� Installation into the duct is simpleand quick� Transport brackets hold the unit inplace during transport and installation� Large units are transported in sec-tions and welded on-site, and are thuseasier to handle, to transport and to in-stall.

Single-layer expansion joints

Single-layer expansion joints consistof one material layer only.According to the applica-tion area, thelayer is manu-factured fromeither fabrics, various(fluoro) elastomers, or fluoropo-lymers with fabric reinforce-ment as composite materials.

From the very beginning,KE-Burgmann has taken an ac-tive part in the development,design and application of theseexpansion joints and their mate-rials.

Single-layer expansion joints offer theutmost tightness and chemical resi-stance as is required when exposedto heavy condensate. We are the lea-ding suppliers of expansion joints, boththe PTFE-based fluoropolymers and theoriginal virgin (FKM) fluoroelastomers,specifically designed for application influe gas cleaning systems.

The choice of the right ex-pansion joint depends on a va-riety of factors of which only afew would ever be identical.The following pages will giveyou more information on the im-portant features of single-layerand multi-layer expansion jointsas well as preassembled units.

Flange reinforcement

Elastomers fullycompounded with fabric reinforcement

Due to our modern production facili-ties, machinery and tools, we are ableto manufacture expansion joints of al-most any form and design, independentof the size of the duct. Approvals to ISO

9001 quality standards ensure a uni-form, high level of quality throughoutthe production processes.

We use modern computer softwareand methods (CAE, CAU) for the design,construction and analysis of complex

expansion joints and the influenceson them. On the basis of our ex-

tensive theoretical and practical expe-rience, KE-Burgmann has developed itsown FEM (Finite Element Methods) mo-dels in ANSYS® to analyse both thecomplete construction of which the ex-pansion joint is a part, and the expan-sion joint itself. The analysis includesthe temperature distribution in steelcomponents and insulation, the gradientof both pressure and stress in steelcomponents, and the heat loss in thecomplete expansion joint.

On this basis it is possible to calcu-late the expected service life, to opti-mize the design and to choose themost suitable steel quality. FEM analy-ses can be part of the package solutionwe offer.

Optimum design and engineering

5

6

Materia ls & Appl icat ion Technology,Research & Development

Materials Technology

KE-Burgmann expansion joints aremade from materials, some of whichhave been in practical use for decades,and others which have been developedin recent years on the basis of technolo-gical advancement and customer de-mands. Raw materials, semi-finishedproducts and complete expansion jointconstructions undergo both general andcomprehensive tests and control proce-dures.

These tests and control proceduresinclude recognized standard tests ac-cording to f. ex. DIN norms etc. and moreadvanced tests which simulate the actual conditions, under whichthe expansion joint construction mustoperate. As standard, all materials aretested with regard to:� flexibility� temperature resistance� tensile, abrasive and tear strength� mechanical strength� chemical resistance� heat convection� recovery rate after compression� fibre size and number� weaving and the strength of same

Please ask to receive material andtest specification reports for individualmaterials, as needed.

Application Technology

On the basis of our test and re-search results, we are able to docu-ment the operational reliability and life-time of an expansion joint for a givenapplication. We also carry out customer-specific tests. As standard, all ex-pansion joint constructions can betested with regard to:� flexibility rate of the expansion joint

type� leakage rate of the expansion joint

type� sound insulation properties of the

expansion joint� temperature distribution (heat/energy

loss) through the expansion joint� FEA (Finite Element Method analy-

ses) of expansion joint and steel parts with regard to life and fatigue

The valuable knowledge of applica-tion technology gained from this re-search, combined with our many yearsof practical experience, enables us tooffer the very best in engineering andtechnical support to our customers.

This engineering support is availablein different forms:

� Documentation of expansion jointdesign, with detailed construction dra-wings and operating specifications� Documentation of construction ofunits, with measurements and instruc-tional drawings to manufacture steelcomponents� Documentation of workshop dra-wings with relevant specifications forcomponents, tolerances, weldings, in-stallation etc.� A complete documentation package,with all of the above, and FEM analy-ses of steel components, heat/energyloss through the expansion joint, insula-tion specification etc. and all other cus-tomer specified documentation

Our expertise concerning design ofexpansion joints, accumulated throughmore than 40 years, is concentrated inour own computer software, which pre-pares calculations and standard dra-wings at just a push of a button.

Research,Development, Test

KE-Burgmann is deeply involvedwith improving existing materials andfinding new materials in cooperationwith material suppliers all over theworld. Concurrently, we keep a closeeye on the technical advancements sothat we may use our many years of ex-perience and practical knowhow to develop new expansion joint types for specific applications or customerneeds.

Our test and development depart-ments are optimally suited for that pur-pose with their modern equipment.Combinations of different materials anddesigns are tested on endurance andfatigue test rigs, recommendations andlimits for actual operating conditions are established, and the quality of ex-pansion joints is constantly maintainedat the highest possible level.

High-temperatureoven for materialtests

Simulation test rigfor expansionjoints for chimneyconnection

Test for chemicalresistance

Fatigue test fortensile and torsio-nal strength

Temperature gradient(FEM analysis)

Test setup for anekal test

�

��

�

�

�

7

APlace of Installationand Conditions

Cr i ter ia for Appl icat ions and Design

he decision on the type of expansion joint to be usedand on its design is based on some fundamental consi-

derations:� Is it a new plant? In this case it is possible to design theoptimal solution, in both technical and economical respect. � Does the plant already exist? In this case it may be neces-sary to design the expansion joint to compensate for less opti-mal conditions, technically seen.

As a rule, however, it is necessary to state operating dataand other conditions as detailed as possible to ensure maxi-mum operating reliability.

T

Axial compression

Axial elongation

Angular offset

Lateral offset

Torsion

On these two pages, you will findthe most essential criteria to consider. Please use the datasheet on the fold-out page at theback of the catalogue to registerthe operating data.�

Movements

The following movements, alone orin combinations, are taken up by fabricexpansion joints:� axial compression� axial elongation� lateral offset� angular offset� torsion

The size and frequency of move-ments will affect the choice of type. Forlarge movements, convoluted andwave-form designs (moulded corners)or multi-layer expansion joints withscissor control guides should be used.They ensure controlled movements andprevent damage to the fabric or heatpockets from occurring.

Mechanical loads

Fabric expansion joints can also takeup� vibrations and� structural-borne noise

Essentially, the following should beconsidered:� overstretching� abrasion by solid matter � hardened deposits� friction along the sleeve/baffle

Pressure

In the same way as temperatureand medium, pressure will affect thedesign (type of fabric and number oflayers). The following distinctions aremade:� positive pressure (normal, peak)� negative pressure (normal, peak)� variations of pressure (pulsations)� pressure surges� design/operating pressure

Flow rate

For reasons of flow efficiency, fit-ting a sleeve/baffle may be recommen-ded (see illustration above). When flowrates are above 10 m/sec., a sleeve/baffle construction can protect the ex-pansion joint from flutter or pulsation.FLUACHEM® elastomer expansionjoints do not require a sleeve/baffleeven at flow rates of up to 40 m/sec.

B CIs the place of installation easily ac-

cessible? Is scaffolding required to in-stall the expansion joint? Is it necessa-ry to have a crane or other equipmentto lift the expansion joint in place? The-se and similar conditions must be con-sidered before choosing the expansionjoint design.

It is determined already at this earlystage whether the expansion jointshould be supplied open, to be closedon site – or closed; whether it shouldbe supplied as a preassembled unit, orjust as the fabric part, etc.

8

With outside insulstion

Medium temperature

• 160 ¡C(320¡ F)

Temperaturenot belowdew point

•200¡C (392¡F)

Corrosion

Formationof condensate

Increasedchemicalload

• 100¡C(212¡F)

Without outside insulation

• 20¡C (68

Cover plate

Medium

The design is essentially decided bythe type of the medium.

Air� clean� dust content (concentration,

grain size)� chemical load by acids, solvents, etc.

(type, concentration)

Flue gases� from coal, oil, gas firing etc.� analysis of the flue gas (content of

pollutants)� humidity (value below dew point)� contents of soot or fly ashes� flushing/washing of ducts

Leakage requirements

According to the application area andthe medium, special leakage require-ments may be necessary. In principle, adistinction is made between the tight-ness of the expansion joint and thetightness of the flange area. Pressureand temperature will also affect the de-sign, and it should be noted that flan-ged expansion joints can be sealed mo-re easily.

The following requirements can bemade:� nekal tightness� flue gas tightness� defined leakage rate� drip-proof� air tightness� dust tightness

D

Solid matter

The contamination of the mediumwith solid matter, such as dust, soot, flyashes etc. will influence both the de-sign (type of coating, thickness) andthe construction (sleeve/baffle, bolsteretc.). In principle, the expansion jointshould be protected from abrasivemedia.

The main considerations concerningsolid matter are:� content (mg/Nm3)� grain size (µm)� arrangement of duct (horizontal,

vertical, diagonal)� direction of flow (upwards,

downwards) and flow rate

Temperature

The temperature (medium, opera-ting, ambient) has important influenceon the design (insulation), the type(flanged or flat) and the construction(such as extended flanges). The outercover materials (coated with PTFE, FKMelastomer, silicone etc.) are protectedfrom thermal damage by insulating lay-ers, the thickness and numbers of whichare depending on the temperature.

The most important temperature va-lues to consider are:� operating temperature� excursion temperature (duration,

frequency)� variations in temperature (duration,

frequency)� design temperature� ambient temperature

Other temperature values, such asthe temperature at the expansion jointand in the flange area, can be documen-ted on request through tests performedby our R&D department.

External influences

Ambient temperatureThe design of expansion joints is

usually based on a given ambient tem-perature. Higher ambient temperaturesare met by adjusting the insulationthickness accordingly.

WeatheringCover plates have proved as a suita-

ble measure against the influences off.ex. rain, snow, sand storms etc. Theseplates may also serve as a protectionagainst contact. Please refer to KE-Burgmann’s insulation instructions,which also considers the effect of heatdissipation.

Temperatures belowdew point

Dependant on the process used, orif the plant is stopped, or if it is opera-ting at a partial load, operating tempe-ratures may drop below the dew point.The arising humidity results in an in-creased chemical load on the expansi-on joint and the duct work as well.

Dependant on medium temperatureand type of expansion joint, insulationof the expansion joint can be an effi-cient measure to prevent the tempera-ture from constantly falling below thedew point (see illustration above).

Temperatures below dew point willinfluence:� the choice of material

(chemical resistance)� the design of the flange area

(refer to fold-out page)� the construction (flanged expansion

joints)

Please refer to KE-Burgmann instal-lation and insulation instructions for fur-ther advice on this subject.

E

9

10

Basic Designs

Belt/flanged expansion joint

Convoluted bellows expansion joint (beltconnection)

Flanged convoluted expansion joint

Flat belt expansion joint

Flanged expansion joint (negative pressure)

Basic Forms ofExpansion Joints

Which basic form of expansion jointto use, depends on the pipe and ductconnections and naturally on the opera-ting conditions: is the plant run at posi-tive or negative pressure? will pressurechanges (pulsations) occur? is a bolsternecessary? what is the flow rate, etc.?

Sleeve/BaffleConstructions

The use of sleeve/baffle construc-tion is recommended in most cases andensures: � better flow efficiency� mechanical protection against

abrasion� prevention of duct accumulation� longer life to the expansion joint

construction� fixation of expansion joint insulation

If expansion joints are used withoutsleeve constructions, their design mustbe equally more resistant to abrasive particles and mechanical loads.Fluachem® elastomer expansion jointshave particularly proved their strengthin this respect.

As special considerations are neededwhen choosing the right sleeve/baffleconstruction (f. ex. available space, flowdirection, dust accumulation etc.), KE-Burgmann should always be consulted.

Duct/Pipe Connections

The main types of connections arelisted below, and it should be notedthat the material of the connectingcomponents does not have any influen-ce on the expansion joint. Whether thecomponents are made from steel, plas-tic or brickwork, has no bearing excepton the fastening method. As a rule,duct cross-sections are round or rectan-gular, and partly with rounded corners.Fabric expansion joints can also be de-signed to bridge between round andrectangular ducts.

distinction is made between belt and flanged expansionjoints, according to the type of connection to pipe or

duct ends. Independent of the configuration of the flangearea, however, there are a wide variety of designs accordingto the application, and you will find the basic version on thesepages. The advantage of fabric expansion joints is that thereare practically no limits as to their shape and size.

A

Single sleeve/baffle fitted with the expan-sion joint

Single sleeve/baffle welded to the ductend

Double sleeve/baffle, with overlap

Single sleeve/baffle, overlapping the oppo-site duct end

Floating sleeve/baffle

Baffle plate

Vertical flange connection on duct level

Vertical flange connection, extended

Belt connection directly on the duct

Belt connection to extended flanges

Belt/vertical flange connection

11

Bolster (insulating bag) with/withoutflanges

Insulation

The main purpose of insulating ex-pansion joints is to:� reduce the temperature to the sealingand often thermally sensitive layers� protect the expansion joint from flyash etc.� support the expansion joint in case ofpulsations in the duct� noise attenuation

There are three forms of insulatingtechniques:� insulation integrated in the actual ex-pansion joint layers� insulation bolster bag, i.e. insulationmaterials protected by wire mesh orglass fabric, forming a unity with orwithout flanges� loose insulating materials resting bet-ween the expansion joint and the sleeve/baffle

Fastening Elements

Expansion joints are fitted to the duct ends in many different ways. Forless complicated expansion joints (e. g.belt types), clamping bands canbe sufficient. The higher the requirements are with regards to pressure, temperature, tight-ness etc., the more sophisti-cated will be the fasteningmethod. KE-Burgmann expansion jointsare supplied with the necessary faste-ning elements on request.

When it may be advantageous ornecessary to use a certain type of ex-pansion joint, depends on a number offactors, such as size of the duct cross-section, site conditions, sleeve con-struction etc. but also on the type ofapplication. The three basic versionswith their essential features are listedbelow:

Closed type� for vertical flanges and flat belt con-

nections� single and multi-layer designs� accurate dimensions required� usually supplied with holes punched� steel components can be supplied

separately

Open type� only for belt connection� closed on site� not usually supplied with holes� ideal for stockkeeping as spare parts,

in rolls� quick replacement and/or assembly

in case of damage (repair work)

Standard Designs of Expansion Joints

Unit ready for assembly� for all types of connection� complete preassembled units with all

steel components, insulation etc.� quick installation

Expansion joints with integrated insulatinglayers

Various bolts; cup springs for a permanentcontact pressure without retightening

Backing flanges in sections (cut at 45 °)

Bolster without flanges, filling out the gapbetween expansion joint and sleeve

Stainless steel clamping band

Bolster fitted as part of the expansion joint

� FEM analyses are possible� can be supplied with scissor controlguides for two or more expansion jointsin line, for taking up large movements

� can be sup-plied in sectionsand joined/as-sembled on site

Max. operating limits of standard expansion joints with regard to temperature andchemical loads.

1.200(2,192)

Chemical loads

12

Standard Expansion Joints

xpansion joints are custom-ized to customer specifica-

tions. Standardization is, how-ever, possible in view of knownand recurring operating condi-tions, like specific temperatureranges and media. For all majorapplications, we can thus offerstandard solutions, most of whichidentify the application area byproduct name. Your choice ismade easy, and the expansionjoint fulfills all requirements toboth operational reliability andfast and correct delivery.

E

KE-FLEX®

KE-Flex® is a comprehensive rangeof usually single-layer expansion jointsfor temperatures below 200 °C (392 °F)and where the media are not aggres-sive. Application areas are, e. g. heatingand ventilation (HVAC) systems, separa-tors, vibrating conveyor systems,powder and granulate conveyor sys-tems etc.

KE-Flex® expansion joints are avai-lable in different versions from fabrics,plastics, and elastomers. They may beprovided with rings or reinforced fabricfor stabilization of pressure loads. KE-Flex® is supplied with sewn-in or looseclamping bands.Operating limits:Temperature: –65 ... +200 °C (–85 ° ... +392 °F)Pressure range: � 250 mbar/25 kPaMovements: axial compression: 50 %Movements: lateral offset: � 20 %

FLUAFLEX®

Multi-layer expansion joints for usein air and flue gas systems, e. g. in con-ventional power plants, gas turbineplants, incinerator plants, cementworks, petrochemical plants, pulp andpaper plants etc., where temperaturesdo not exceed 575 °C (1,067 °F). Alsosuitable for aggressive media.

Fluaflex® expansion joints are ma-nufactured in round, rectangular or co-nical forms and in combinations there-of. They can be designed for flangedand belt type connections, with sleeve/baffle and insulation.Operating limits:Temperature: –35 ... +575 °C (–31°... +1,067°F)Pressure range: � 200 mbar/20 kPaMovements (depending on temperatureand type):

axial compression: 50 %lateral offset: � 20 %

FLEX-GEN®

The new generation of expansionjoints for the future: a simple, yet dura-ble and strong expansion joint with uni-que thermal, chemical and mechanicalproperties. Flex-Gen® is manufacturedfrom our own reinforced PTFE-basedlaminates, which consist of only a fewindividual layers. We first coat and thenlaminate a glass fabric on one or bothsides with one or more layers of PTFEfoil. Flex-Gen® expansion joints arethus excellently suited for a wide varie-ty of applications in conventional powerstations, where the operating tempera-tures may reach 575 °C (1,067 °F) andthe medium is dry flue gas. Operating limits: Temperature: up to 575 °C (1,067 ° F)Medium: Dry flue gases Pressure range: � 200 mbar/20 kPaMovements (depending on temperatureand type: axial compression: 50 %, late-ral offset: � 20 % Chemical resistance: outstanding – resi-stant both on the inside and outside,as the PTFE foil is laminated to theouter cover.

FLUASTAL®

Multi-layer expansion joints, desig-ned with stainless steel wire mesh andbands on the gas side to ensure highform stability and temperature resistance.For demanding applications in gastur-bine systems, smelting works, cementplants, petrochemical plants etc.

Fluastal® expansion joints are de-signed to meet individual requirements tooperating conditions and connectionforms. Due to their special construction,Fluastal® expansion joints retain excel-lent form stability and are easy to install.Operating limits:Temperature: –35 ... +1,200 °C (–31°... +2,192 °F)Pressure range: � 200 mbar/20 kPaMovements (depending on temperatureand type):

axial compression: 40 %lateral offset: � 20 %

KE-Flex®

Fluaflex®

Fluastal®

Combine-X®

Flex-Gen®

Fluachem®

fluoropolymer

Fluachem’®elastomer

700(1,292)

575

300(572)

200(392)

80(176)

0

-35(-31) No Limited High

Tem

pera

ture

°C

(°F)

13

COMBINE-X®

The ideal special expansion joints for use in gas turbine and combined-cycle plants with high operating tempe-ratures, very high gas velocities and pulsating gas flows. Combine-X® is amulti-layer expansion joint, and its de-sign is matched exactly to the opera-ting and structural requirements of theindividual application. Specially desig-ned steel components and sleeve/baffleconstructions ensure extremely goodfunctionality and high operating relia-bility. FEM (Finite Element Method)analyses can be carried out for expan-sion joints and their steel componentsto document expected life of the designin the individual installation.Operating limits:Temperature: –35 ... +700 °C (–31 ... +1,292 °F)Pressure range:–140 ... +75 mbar/7.5 kPaMovements (depending on temperatureand type):

axial compression: 50 %lateral offset: � 20 %

FLUACHEM® Elastomer and Fluoropolymer Expansion Joints

Fluachem® are single-layer expan-sion joints, based on elastomers and fluoro-polymers, which have been speci-fically developed to withstand high che-mical loads. Recommended for use influe gas cleaning systems and otherplants with very aggressive media.Fluachem® expansion joints are mostlyused without insulation and sleeve/

baffle. They are available for flange andbelt connections, for round and rectan-gular duct cross-sections and in any di-mension. If optimum tightness is requi-red in the flange area, we recommenda design with vertical flanges. Expan-sion joints, supplied open, are closed onsite by welding or vulcanizing.

FLUACHEM® Elastomer Expansion Joints

KE-Burgmann elastomer expansionjoints are manufactured by vulcanizingthe materials under pressure and tem-perature. As a rule, the elastomers used are fluoroelastomers (FKM), ethylene-propy-lene (EPDM), Butyl®and Neoprene rubber.The elastomers are rein-forced by a tear-resistant and acid-proof mesh of fibre glass or stainless steel (1.4539). The well-balanced mesh sizeand wire thickness pro-vides an absolutely tho-rough compound in vulcani-zation. Particularly expansion joints of 100 % virgin terpolymer have excee-ded by far even high expectations at con-stant temperature loads of 200 °C(392 °F), thanks to their excellent resi-stance to acids.

Millions of hours of faultless operati-on under extreme operating conditions influe gas desulphurization plants are aconvincing proof of this fact.

Characteristics� very high resistance to acids� gas and drip tight (nekal tightness)� abrasion-proof

� withstands high me-chanical loads

� no flange gasket re-quired� low reactive forces� easy to install� pressure proof evenwith alternate loadsand pulsations (reinfor-ced version)� good flexibility

Operating limits:Temperature: –35 ... +200 °C (–31 ... +392 °F)Pressure range: � 350 mbar/35 kPaMovements (depending on temperatureand type):

axial compression: 20 % (30 %*)lateral offset: � 10 % (15 %*)

*) wave form with moulded cornersGas velocity (without sleeve/baffle)

... 40 m/sec.

FLUACHEM®-FluoropolymerExpansions Joints

The core of these single-layer expan-sion joints is very strong glass fabric,protected on the one side by a PTFE-ba-sed coating and on the other side (facingthe gas) by a PTFE foil. This materialstructure ensures excellent strength,great flexibility, and excellent chemicalresistance even at continuous tempe-rature loads of up to +300 °C (572 °F).KE-Burgmann was among the pioneersin developing expansion joints from thismaterial, and since the beginning thematerials have been constantly im-proved. Today, they more than fulfillthe requirements of giving long-lastingperformance in power stations, fluegas cleaning systems, the chemicalindustry, etc.Characteristics� high chemical resistance, equalling � PTFE (pH 0 ... 14)� extremely tear-resistant� gas-tight, non-porous � mechanically resistant� excellent tensile strength even at� high temperatures� low reactive forces� very flexible� easy to installOperating limits:Temperature: –35 ... +300 °C (–31 ... +572 °F)Pressure: � 200 mbar/20 kPaMovements (depending on temperatureand type):

axial compression: 30 %lateral offset � 15 %

Gas velocity without sleeve/baffle (depending on type): ... 30 m/sec.Dust content, without sleeve/baffle:200 mg/Nm3

Standard and Special Expansion Joints

14

Convoluted expansion joints are specially designed and manufactured assingle or multi-layer versions, incor-porating steel rings for support also in connection with high pressure loads.They are suitable for use in f. ex. coalmills, steel works, pulp and paper indu-stry etc., where compensation is nee-ded for very large movements combi-

ned with high temperatures. In case ofdouble expansion joints, uniform distri-

bution of the movements is ensured bymeans of scissor control guides.Temperature: –60 ... +600 °C (–76 ... +1,112 °F)Pressure range: � 200 mbar/20 kPaMovements: axial compression: 60 %Movements: lateral offset: � 30 %

Convoluted Expansion Joints

ACOUSEAL®

KE-Acouseal® is an elastomer ex-pansion joint which has been develo-ped specifically for the air intake side of gas turbines. It is placed betweenthe filter and the compressor and ensu-res, apart from taking up the move-ments of the air ducts, a highly efficientnoise attenuation which meets even thehighest environmental requirements.

Characteristics:� easy to install� installation tolerance � 10 mm, axial

and lateral� sound emission is reduced to a mini-

mum (see diagram)� supplied closed for vertical flange

connections� pressure resistance

� 100 mbar/10 kPa� temperature resistance

–35 ... +150 °C (–31 ... +302 °F)

� customized design for the specificapplication with documentation ofsound reduction index

KE-Masterflex®

Rubber ExpansionJoints

As part of our comprehensive rangeof expansion joints, we offer a full ran-ge of rubber bellows and fabric-reinfor-ced rubber expansion joints (up to DN2400) for high-pressure systems car-rying liquids or gas.

Connex® and Bredan®

Metal Expansion Joints

A full range of metal expansionjoints, both rectangular and round bel-lows,e . g. for exhaust gas systems, are also part of our scope of supply. Pleaseask for detailed information.

This flexible expansion joint with itsspecially-developed fastening system isused between the flue gas duct and theacid-proof brick lining of the chimney. Itensures excellent tightness and is easyto install. With this system it is possibleto dispense from expensive connectingframes, which would be in contact withthe flue gas. An important advantage ofthe KE-Burgmann expansion joint forchimney connections is its (patented)fastening system, which allows for out-side fitting to the lining brick, using aspecial configuration. The fluoroelasto-mer (FKM) expansion joint is fitted with

a special extruded profile that fits into agroove in the casing stone and is held inplace by clamps.

We established the pressure requi-red and the forces actually occurring inthe clamping area in test series perfor-med on original connections at ourworks, and from theoretical calcula-tions. Our findings were subsequentlyadopted in practice and proved correct.On the duct side, the expansion joint isfastened in the usual manner. NB: if thelining brick has not been provided withgrooves from the works, these may beground in as well.

Expansion Joints for Chimney Connections

Soun

d re

duct

ion

inde

x R

(dB)

Cycles (Hz)

1/1octave 31 63 125 250 500 1000 2000 4000 8000 31.5–8000Centre Frequency (Hz) R 33,6 30,0 48,0 30,6 18,4 28,0 35,7 37,1 43,5

15

Chimneys consisting of a concretecasing and one or more internal pipes are exposed to considerable chemicalloads of acid condensate as a result ofthe low flue gas temperatures after theflue gas cleaning system. The internalpipes, mostly made from acid-proof li-ning bricks, are arranged one on top ofthe other and rest against the outsidecasing.

The lining joints are sealed flexiblyand acid-proof with Fluachem® fluoro-

elastomer expansion joints (FKM), toavoid any leakage of condensate. Thereare comparable sealing points at the bottom of the funnel and at the openingof the chimney. The expansion joints,which are supplied open, are closed onsite by hot vulcanization. Fastening ele-ments are corrosion-proof or stainlesssteel.

Lining Joint Sealings in Chimneys

Protection of our ground water is vi-tal. That is why safety has top priorityin special waste dumps for water-pollu-tant liquids (e.g. highly concentratedAHC and CHC). A reliable and time-te-sted solution is the KE-Burgmann ex-panding seam seal of highly fluorinated elastomer with a stainless steel wiremesh. It meets the stringent require-ments of the Water Resources Act. Theexpansion joint is secured and sealedby means of sectional strips throughthreaded bolts welded to the sheet me-tal liner and an accurately defined con-tact pressure. The tightness tests moni-tored by the German (Bavarian) Boardfor Technical Supervision are carriedout with a suction bell (0.5 bar min. ne-gative pressure) and a foaming agent onthe readily mounted system and ha-ve proved a sealing rate of 100 %. Thesealing material, FKM, has been appro-ved by the ”Institute for BuildingTechnology” in Berlin.

Expanding Seam Seals in Special Waste Dumps

Combine-X® Fire Skirt expansionjoints are used as flexible, fire-proofelements of the ducting in gas turbineexhaust systems on board cruise shipsor other types of vessels.

Special requirements for fireproof-ing exist on ships for equipment used inthe fire hazard zones. These fireproof-ing requirements apply also to the fa-bric expansion joints installed on thegas turbine ducting. Combine-X® FireSkirt expansion joints are approved bythe necessary approving bodies, suchas Norske Veritas and Lloyds Registerof Shipping and fulfill requirements forprotection classes such as Jet Fire andPool Fire. Fire Skirt expansion joints arealso installed on offshore escape tun-nels, which must protect against a sud-den and explosive eruption of fire.

Combine-X® type Fire Skirts are supplied preassembled on steel parts asa complete unit.

Operating data:Exhaust gas: 600 °CPressure: 70 mbar / 7 KpA / 700 mm WG

Fire Skirt Expansion Joints

16

o supply a good ex-pansion joint is one

thing. Almost everybody willoffer you advice right up un-til the purchase has beenconcluded. We offer more atKE-Burgmann: professionalengineering and a compre-hensive service second-to-none, as you would expect it from the No. 1 supplier offabric expansion jointsworldwide.

T

1

3

4

8

6

7

Our comprehensive service offercomprises, among others, the taking ofdimensions (1), installation, supervisingof installation (6), end-inspection, tight-ness tests, inside (7) and outside (3) service inspections, thermovision mea-surements (4), analyses of failures anddamage, repairs (8).

KE-Burgmann has extensive expe-rience with installation and supervisingtasks all over the world. We have excel-lent knowledge of both the conditionsprevailing on site and the cultural diffe-rences that may exist. Troubleshootingwith existing installations requires aspecial expertise, and we have beensuccessful in analysing failures bymeans of, among others, FEM and sub-sequently recommending alternative,more reliable constructions.

As a complement to this, we offer to carry out service inspections of yourexpansion joints to ensure a continuousand dependable operation.

Please contact us. We are there foryou. KE-Burgmann – your partner forservice made to measure your needs.

Service to Measure

B 4 6 9 13 19 23 26D 0.4 0.5 0.9 1.1 1.5 1.8 2.4B 4.5 7 11 16 25 31 33D 0.3 0.4 0.6 0.7 1 1.2 1.7B 5 8 14 20 30 37 40D 0.25 0.3 0.4 0.5 0.8 0.9 1.1

17

Tools etc .

PTFE round cord (9660)Of pure PTFE, specially processed

for reduced cold flow. Resistant to al-most all media (pH 0 ... 14). Max. opera-ting temperature: 260 °C (500 °F). Short periods, up to 300 °C (572 °F).

Please note:You will find a comprehensive range

of sealing products for sealing all flan-ges and flange-like connections inBurgmann´s ”Static Seals” cataloguewhich is available on request.

Scope of supply

Flange GasketsKE-Superseal® (9654)PTFE flat gasket, self-adhesive

Pure PTFE of a stretched structure(cold flow is virtually excluded). High sealing on irregular flanges; simple fit-ting; no waste, stockkeeping of only fewdimensions as the gasket is practicallyindependent of the form and nominalwidths. Resistant to almost all media (pH 0 ...14). Max. operating tempera-ture: 300 °C (572 °F).

Application data, supply Installation caseThe installation case comprises all

tools and materials required for closingor repairing multi-layer expansion joints:Pointed pliers, universal pliers, puttyknife, screw clamps, rubber gloves,measuring tape, marking pencils, scis-sors, manual clamping device, roller,knife, PTFE welding unit with supportand backing strip, steel block, awl, as-sortment box, manual rivetting tongs,hammer 500 g, backing strip of alumi-nium sheet, sewing needles, spoolswith sewing yarn, PTFE welding tape,silicone cement, stainless-steel rivetsdia. 3 x 12, stain-less steel washersdia. 3, stainlesssteel staples, va-rious fabric strips,J o u d o l ®- ” S M ”(subject to modi-fications).

Joudol®-“SM” Universal graphite/grease compound

A combined separating and lubri-cant agent for screw connections andflanged seals on a graphite basis. TheBurgmann Joudol® “SM” is an effectivepreservative grease which preventsgaskets from burning on to iron parts,as well as threaded connections of alltypes from rusting or seizing.Scope of supply:Tins of 1 kg, tubes of 250 g (8152)Spray cans of 200 ml (8153)

Joining MaterialThe scope of supply of any expan-

sion joint delivered open includes a setof “joining materials”, matched to the specific design, as well as joining in-structions. Its contents may include, forinstance: sewing yarn (stainless steel,glass, etc.), sewing needles, cement(silicone, FKM elastomer, etc.), PTFEwelding foil, stainless steel rivets andwashers, scissors, rivetting pliers.

Universal weldingequipment for foils andelastomers

Universal welding equipment, whichcan be used for joining open expansionjoints, or for repair jobs. The materials,which can be welded, are PTFE foils

and Teflon- or elastomer-based materi-als. The welding equipment is availablein two versions:� as a welding box with the necessarythermostats, timer, etc. and two wel-ding rods to be used for the joining� as a smaller version, a portable wel-ding iron, excellently suited for smalltasks. Easy to transport (low weight)and easy to handle.

Cord dia. (mm) Roll (m)2.5 153.2 154.0 106.0 58.0 5

10.0 5

Nominal width,uncompressed

Thickness,uncompressed

Cont

act p

ress

ure

N/m

m2

10

20

30

3 5 7 10 14 17 20

1.5 2.0 2.5 3.0 5 6 7

Use upto DN

Rolllength (m)

50 200 600 1500 > 1500

25; 50 10; 25 5; 25

Dimensions in mmB = compressed widthD = residual thickness

18

Appl icat ion Technology – Energywide range of applica-tions for expansion joints

is conventional power plantsfired with coal, oil and gas. Inthe past few years, the useof gas turbines has increasedconsiderably. They are quitefrequently used in combinedcycle power stations (gasturbine and heat recoveryboiler) supplying peak demand. Here, the rapid in-crease in gas temperatureand the resulting quick ex-pansion of the ducts presentthe greatest challenge for the

A“hot” “cold area”

Boiler

Coal mills

Flue gas Preci-pitator

Preci-pitator

Air

Treated gas

Scrubber

Non-

treat

ed g

as

Bypass

DeSox

DeNox

Gas preheater

Chim

ney

stac

k

Connection for chimney stack

FGD Snox

If you consider the duct system of a po-wer plant, you can see the many differentdemands that are to be met by the expan-sion joints. Rather simplified, the power

plant may be subdivided into a “hot” and a“cold” area. On the “hot” side, the tempe-rature load and the loading of the flue gaswith fly ash is decisive. On the “cold” side

the expansion joint is, above all, affectedby the formation of aggressive condensa-te, due to the temperature falling belowthe dew point.

RWE power plant at Weisweiler/Germany(lignite fired). Location: return suctionduct. Medium: Aggressive flue gas fromcoal firingTemperature: up to 900 °C (1,652 °F).Ducts are refractory-lined.Pressure: � 10 mbar / 1 kPaAxial compression: 40 mmLateral offset: � 40 mm

Coal-fired Power Plant

There are various places of applica-tion for expansion joints in coal-firedpower plants, including the area of coalmills, e. g.� coal dust lines� secondary lines� return suction ducts

Coal dust lines and the expansionjoints installed here require a specialdesign which prevents the coal dustfrom setting and possibly being ignited.

VEW power plant ‘Gersteinwerk’, GermanyMedium: gas turbine exhaust gasTemperature: 481 °C (898 °F). Temperature peaks to 520 °C (968 °F)The temperature rises to full operating tem-perature within a few minutes (especiallyby quick start)Pressure: +100 / –50 mbar / +10/–5 kPaAxial compression: 550 mmLateral offset: 100 mm

Coal Power Plant withGas Turbine

A so-called combined cycle block,where coal is fired in the steam produ-cer and natural gas in the gas turbine.Contrary to conventional firing forsteam production, where coal dust isexclusively fired with a supply of air, inthis block the air required in the steamproducer is replaced by the oxygenousexhaust gases from the gas turbine.

In order to take up the extremely lar-ge axial movements, two or three ex-pansion joints were connected in lineand joined by means of a scissor con-trol guide. The scope of supply coveredstatics, design, steel components, ex-pansion joints and supervision of the in-stallation.

Coal dust lines in the Boxberg (VEAG) po-wer plant, Germany.FLUACHEM® expansion joints (nekal tight)with bolster made from dust-tight glass fa-bric and glass felts and additional coversfor wet cleaning of the ducts. Temperature: 130 ... 200 (300) °C (266 ... 392 [572 °F])

Expansion joints on waste heat boiler pipepenetrations in the Uran power plant, India.All 166 expansion joints were closed onsite. Temperature: ... 400 °C (... 752 °F)

The power plant ‘AsPontes’ (Endesa), AsPontes, Spain. KE-Burgmann supplied 320double FLUAFLEX® expansion joints withFKM elastomer outer cover. They are instal-led, among others, between the boiler hou-se and the steam pipes.

Reduction of NitrogenOxides (DeNox)

Finding the most suitable method toreduce nitrogen oxides (DeNox) is deci-sive for the environmental protection.Primary measures provide for the use ofexpansion joints in the burner area. Butsecondary measures are required tomeet the emission standards, and thesepose highly differentiated demands onexpansion joints.

High-dust procedure� DeNox reactor arranged between boi-

ler and air preheater� flue gas with an extremely high dust

content (up to 60 g/Nm3)� temperature 400 ... 450 °C

(752 ... 842 °F)� usually negative pressure

Low-dust procedure� DeNox reactor after the FGD system� flue gas after the FGD system� temperature between 40 ... 350 °C

(104 ... 662 °F) according to location� as a rule, these plants work at posi-

tive pressure and therefore require ab-solute gas sealing

19

expansion joints. All powerplants have one thing in com-mon: they must produce elec-tricity on call. Operating reliabi-lity and a long service life ofexpansion joints is thereforecrucial as plant shut-downscause not only a lot of troublebut are also very costly.

KE-Burgmann expansionjoints have proved their highquality standard in respect ofservice life and reliability, notleast due to the knowledge be-hind their design and the mate-rials used.

’Steweag’ district heating power plant,Mellach, Austria.Multi-layer expansion joints supplied ascompletely preassembled units.Medium: flue gas before the precipitatorTemperature: max. 450 °C (842 °F)Pressure: � 50 mbar / 5 kPaAxial compression: up to approx. 200 mmLateral offset: up to 160 mm (� 80 mm)

Flue gas desulphurization at the PreussenElektra power plant, Wilhelmshaven, Ger-many.

Flue Gas Desulphuriza-tion (FGD)

Particular care has to be observed fordesigning expansion joints for FGD, asthey are sometimes exposed to extremeoperating conditions. Leakages from ex-pansion joints may cause damage to theentire plant, e. g. on the insulation.Basically, expansion joints for FGD canbe subdivided into two groups:

Expansion joints before the scrub-ber (untreated gas side)Medium: dry untreated gasTemperature: according to the process,up to 250 °C (482 °F)

On the untreated gas side, the tem-perature and abrasive wear of the un-treated gas containing dust decide thecriteria of the design.

Expansion joints after the scrubber(treated gas side)Medium: wet treated gas with a veryhigh acid concentration (pH <1)Temperature: approx. 60 ° (140 °F)Design temperature approx. 80 °C(176 °F)

On the treated gas side, the expan-sion joint must withstand the extremechemical loads of the acidic concentra-te. Correct matching of the acid proofstructure and the configuration of theflange areas is decisive. Specifically inorder to meet these requirements, KE-Burgmann offers Fluachem® elastomerand fluoropolymer expansion joints,which are operating with considerablesuccess in a great number of FGDplants.

Gas Turbine Plants

Gas turbine stations ‘Millbank’ and ‘St.Rosé’ in New Brunswick, Canada. Ten multi-layer expansion joints with diameters of 7.2 m and 4.2 m respectively, are installedafter the turbine (ABB 11N) and in the duct leading to the chimney.Medium: Turbine exhaust gasTemperature: 600 °C (1,112 °F)

The FGD ‘RWE’ power plant Niederaussem,Germany.In this large power plant, more than 500KE-Burgmann expansion joints are success-fully operating, among others in the follow-ing areas: precipitator, scrubbers, suctionfans, chimneys, connection for chimney,connection for cooling towers. Flue gasducts of FRP are used in areas with astrong chemical load. Here, FKM elastomerexpansion joints are laminated into theduct ends by a method, developed specifi-cally for this purpose (see the photo onthe left).

Combined CyclePower Plant ‘Tan-jung Priok’, Jakarta,Indonesia. Fluastal®multilayer expan-sion joints installedafter the turbine(ABB 13E) and onthe boiler (doubleexpansion jointswith scissor controlguides).Medium: Flue gasTemperature: 600 °C (1,112 °F)Pressure: 60 mbar / 6 kPaAxial compression:up to approx. 140 mmLateral offset: � 20 mm (–60 mm)

Co-generationplant ‘Hunze-strom’, the Nether-lands. Generatesenergy and pro-cess heat for theproduction of pota-to starch. Gas tur-bine plant (ABBGT10) equippedwith KE-BurgmannCombine-X® ex-pansion joints.

Combined cycle power plants ‘Paka’ &‘Pasir Gudang’, Malaysia with SiemensV94.2 gas turbines. Combine-X® and Flua-flex® expansion joints are installed afterthe gas turbine and on the boiler.Medium: flue gas; t: ...590 °C (1,094 °F);p: –50 ... +70 mbar; Axial compression:... 170 mm; Lateral offset: ... 125 mm

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Application Technology – Other Industrialpart from power generation as one ofthe primary application areas,

KE-Burgmann expansion joints offer a widerange of solutions in many different indu-stries. You will find a small selection onthese two pages and besides the onesmentioned, we shall be happy to give youreferences from others, such as:� refineries� petrochemical industries� process industries� metallurgical plants� industrial furnaces� sludge incinerators� sintering and pelletizing plants� chimney constructions� engine industries� air separation plants

A

ChemicalIndustry

Fabric expansion jointshave many application pos-

sibilities in chemical plants, especi-ally where temperature and acid loadsare very high (sulphuric acid plants, heatrecovery plants, absorption of acid va-pours etc.). Here, Fluachem® expansionjoints of fluoroelastomer and fluoropoly-mer have proved extremely successful,thanks to their excellent chemical resi-stance. Further applications are in fluegas ducts, in the hot air lines of burnerfeeders, and in rotary kilns of special wa-ste incinerators.

Nuclear Power Plants

Fabric expansion joints can be usedin nuclear power plants in, e. g. the airducts, on emergency electricity generators,for ring gap suction, in the exhaust gassystem, as a wall penetration, or as fireprotection. Requirements to meet include:� nekal/air tightness � non-combustibili-ty � ability to decontaminate � resi-stance to radiation � difficult flammabi-lity � pressure resistance

An important factor is the possibilityto manufacture according to specificquality standards. The corresponding cer-tificates are, of course, part of the docu-mentation needed.

Pulp and Paper Industry

“Yankee-Flex” expansion joints fromKE-Burgmann are used, among others, inair dryers, in connection with YankeeHoods, fluidized bed dryers, flash dryers,combustion chambers for natural gas,fans and ventilators. “Yankee Flex” expan-sion joints cover the temperature rangesfrom 100...500 °C (212...932 °F), accor-ding to operating conditions. The expan-sion joints can be provided with steelrings for greater stability in operation.

Rotary Kilns

Rotary kilns are used for thecontinuous thermal treat-ment of a wide variety ofproducts. As incinerators,they are almost “omni-vorous“. The temperatures

reach 500 to 2000 °C (932 to 3,632 °F),dependant on the process. Used inconnection with the sealing system deve-loped by Burgmann, the fabric expansionjoints compensate for movements inthe ducts.

BurgmannRotary Kilnsealing systems

21

Plants

Cement Industry

Cement plant in Aalborg, Den-mark. 115 Fluaflex® and Fluastal® fabricexpansion joints are installed on precipi-tators, the chimney, the cyclone tower,the Folax building and the coal mills.Medium: flue gas from the cement pro-duction and drying processTemperatures: 100 ... 1,000 °C(212 ... 1,832 °F), dependant on location

“Gas Domes” on LPG ships

Fluachem® expansion joints of Neo-prene with double fabric reinforcementact as elastic seals between the gastanks, stored on deck on flexible bea-rings, and the deck itself. Available as round or rectangular expansion jointswith vertical flanges.Temperature: –48 ... +60 °C (–55 ... +140 °F)Movements:

Axial compression: ... 80 mmLateral offset: .... 70 mm

Pressure: 100 mbar max. / 10 kPa max.

Offshore

Fire seals and fabric expansion jointsare in use on all major off-shore plat-forms, e. g. Draugden, Troll, Asunto,Piper, Oseberg A, Stattfjord A, etc.

To increase safety in case of fire, single and double-sided penetration seals are installed on pipe penetrationson decks and scots.

Fabric expansion joints are used inexhaust gas ducts from gas turbines, andin heating and ventilation ducts.

Diesel Gas Engines

Diesel gas engines in the Blohm &Voss block heating power plant, Ham-burg, Germany. Seven Fluastal® expan-sion joints are installed in the duct sy-stem and directly on the turbocharger ofthe largest engine (18 cylinders) of thistype. Because of their low reactive for-ces, fabric expansion joints were prefer-red to steel expansion joints.Medium: exhaust gast: 530 °C (995 °F); p: 500 mbar/50 kPa

Ventilators

In connection with fans and ventila-tors, Fanflex single-layer and multi-layerexpansion joints are installed on bothsuction and pressure sides of the ventila-tor. Here, they prevent vibrations frombeing conveyed to the ducts, and staticoffset to occur between the ventilatorand the duct.

Incineration

The requirements to expansionjoints in incineration plants correspondmore or less to those in the general po-wer plant sector. A special factor, how-ever, is the very high percentage ofaggressive content in the flue gas.A careful selection of materials and ex-tremely good tightness in the expansionjoint design is essential.

Ventilators (Howden Variax) in the St. Gott-hard tunnel, Switzerland, with KE-Burg-mann expansion joints.

Incinerator plant with flue gas cleaning inIngolstadt, GermanyMedium: flue gas (chemically very aggressive, H2SO4, HCL, HF)Temperature: 60 ... 350 °C (140 ... 662 °F)Pressure: 35 mbar / 3.5 kPaAxial compression: 40 mmLateral offset: � 20 mm

Inside view of the duct with a specially pre-formed FKM elastomer expansion joint, inthe Bielefeld incinerator plant, Germany

The “Piper” feed unit (ELF Enterprises)equipped with Fluastal® fabric expansionjoints on the gas turbine exhaust ducts.

�

�

�

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On the following two pages you willfind, in alphabetical order, a list of spe-cial words, technical terms, and specialfeatures in connection with expansionjoint technology. The list gives brief ex-planations as well as references to therelevant pages in the catalogue, whereyou can find more information on thesubject. If you wish more detailed infor-mation, any KE-Burgmann partner willbe happy to help you. Refer to the backpage for contact addresses.

ACOUSEAL® (→ page 14)

Ambient temperature (→ page 9)

Angular offset (→ page 8)

Baffle, baffle plate (→ page 10)

Belt type expansion joint (→ page 10)

BolsterInsulation, Insulating bags (→ page 11)

Bolt torqueThe torque with which bolts have to befastened. Varies according to bolt di-mensions, bolt lubrication, flange pres-sure etc. Correct tightening and retigh-tening of flanges are important factorsto achieve gas tightness in the flange-area.

CAU Computerized calculation and designsoftware for expansion joints and steelcomponents, specially developed by KE-Burgmann. The software bases itscalculations and design on operatingdata such as dimensions, temperature,pressure, movements, and media.

Cement industry (→ page 21)

Changed lengthsof duct work due to changing tempe-ratures are calculated according to thefollowing formula:

�L = · L · � · �T

�L = changed length in mmL = length of duct work between

fixing point in mm� = coefficient of expansion on °C-1

�T = temperature difference in °C

Chemical industry (→ page 20)

Chimney joint (→ page 14)

COMBINE-X® (→ page 13)

Conventional power stations(→ page 18)Convoluted bellows/expansionjoints (→ page 14)

22

CornersIn connection with rectangular fabric ex-pansion joints, corners can be made either as moulded, pre-formed, or as radiuscorners, dependant on the type of expan-sion joint and the application. For steelcomponents radius corners have certainadvantages. The radius is calculatedusing FEM, so that the corner can takeup the exact stress and strain.

Countersunk socket head bolt Bolt where the head is countersunk to belevel with the surface of the backing flan-ge. Primarily used in connection withangle flanges.

Crystallization (kristoballit)Certain ceramic wool materials formharmful crystals at temperatures in ex-cess of 800 °C (1,472 °F).

Dew point (→ page 9, 18)

Diesel gas engines (→ page 21)

Double sleeve/baffle(→ page 10)

Drain fittingA fitting to drain the expansion joint ofcondensate or other liquids at its lowestpoint.

ElastomerDesignation for rubber and fluoroelasto-mers such as FKM, Butyl®, EPDM,NPG, etc. Frequently used to manufactu-re expansion joints in combination withwire mesh or glass fabric.

Expansion joints in lineIn order to compensate particularly ex-tensive and/or lateral movements, itmay become necessary to install two ormore expansion joints in line, which arethen combined by a scissor control gui-de system to distribute the movementsuniformly among them.(→ Scissor control guide)

Expanding seam seals (→ page 15)

External insulation (→ page 9)

External influences (→ page 9)

Fastening elements (→ page 11)

FEMFinite Element Method. A procedure forcalculating temperature areas, and car-ry out structural analyses (to determinedeformations).

FilamentsNumber of threads used for weaving.Indicates the flexibility and strength ofthe fabric.

Fixed point, bearing point (also, shifting point)Points of support for the duct system;their location is dependent on whereexpansion joints are required to take upexpansion and/or movements. It is alsoessential here that fabric expansionjoints are not supporting elements.

FlangeSteel component which is used either asduct flange, backing flange or as anangle or flat flange (flange mountingstrip) to fasten the expansion joint to theduct or pipe flange.

Flanged expansion joint (→ page 10)

Flange gasket (→ page 17)

Flange reinforcementAdditional sheath of fabric in the flangearea to protect the expansion joint fromthermal and mechanical loads.

Floating sleeve/baffle(→ page 10)

Flow velocity (→ page 8)

FLUACHEM® (→ page 13)

FLUAFLEX®, FLUASTAL® (→ page 12)

Flue gas desulphurization/cleaning(→ page 18, 19)

Fluoropolymer, Fluoroelastomer(→ page 13)

Form stabilizersStainless steel bands integrated in theexpansion joint design to fix the form andavoid torsion. Only for Fluastal® typeexpansion joints.

Gas sealing foil (→ page 4)

Gas turbine systems (→ page 18)

GlueingJoinings of e. g. silicone coated outsidecover materials are glued together toensure flexibility and strength in the joi-nings.

Infrared (camera)Used for measuring temperature diffe-rences on the outer cover of the expan-sion joint, to find possible weak pointsor leakage areas.

Installation case (→ page 17)

InsulationThermally protective material layers desig-ned to reduce the temperature of the

gas or medium to a specific value. Alsoserves as a protection against dust.

Joining material (→ page 17)

KE-FLEX® (→ page 12)

LaminationFastening method of single-layer elasto-mer expansion joints on flue gas ducts ofFRP.

Lateral offset (→ page 8)

Leakage rateRate of gas leaking through the expan-sion joint or through the flange area.It can be calculated or checked by KE-Burgmann for the individual expansionjoint or structure of materials. Specialdemands for gas sealing must be speci-fied.

The ABC of Expansion Joint Technology,

All technical specifications are based on extensive tests and our many years of experience. The diversity of possibleapplications means, however, that they can serve only as guide values. We must be notified of the exact conditionsof application before we can provide any guarantee for a specific case. Subject to change.

Fixed point Expansion joint Support

Life expectancy (fatigue)Fatigue is a condition which sets in whenfabric and/or steel components havebeen exposed to a certain amount ofstress and strain.(→ FEM, Stress analysis)

Lifting pointsPositions marked on the steel compo-nents of a unit to indicate that the unitshould be lifted at these points bymeans of special lifting tackles.

Lining joint sealing (→ page 15)

Materials technology (→ page 6)

Metal fabric (→ page 4)

Moulded expansion joint typesBy means of a special mould, the ‘wall’of the expansion joint is moulded e.g.into a ‘U’ or to form a bellows. Suchforms ensure a selective and controlledforming of the folds.

Movements (→ page 8)

Multi-layer expansion joints(→ page 4)

Nekal tightnessLeakage test carried out with a bubble-forming liquid applied to the installed ex-pansion joint which is under pressure(bubble test). It indicates whether the ex-pansion joint and specifically the flangearea is nekal tight.

Noise attenuation (→ page 14)

Nuclear power stations(→ page 20)

Offshore (→ page 21)

Outer cover (→ page 4)

OverlockA method for stitching the ends of mate-rials to obtain a good finish and to pre-vent the material from fraying.

Pipe expansionCoefficient of expansion (°C–1) of themost commonly used materials.

Material Temperature100 °C 440 °C

St 37-2 11.0 · 10-6 –1,4541 16.0 · 10-6 180 · 10-6

1,4571 16.5 · 10-6 18.5 · 10-6

23

Pipe expansion diagramme for St.37.2

Precompression/presettingThe expansion joint is precompressedwhen cold and installed in this position.This method is used when expansionjoints have to take up considerable late-ral movements or great axial extensions.

PressureAmount of pressure to which the expan-sion joint is exposed in the duct system,It is measured in Kpa, mbar or mmWG.

Pulp & paper (→ page 20)

PulsationsPressure variations in the duct systeme.g. turbulence from a gas turbine. It is amajor factor for the design and materialstructure of expansion joints.

Reactive force FR

Force (in N) from the duct system actingon the → fixed point.Determination:

FR = A · p

A = duct cross-section in cm2; p = operating pressure in N/cm2

Reactive forcesContrary to steel expansion joints, fa-bric expansion joints carry only verylow reactive forces to the duct system.This means that duct support systemsand fixtures can be practically neglec-ted.

Reactive forces in axial direction

Reactive force in lateral direction

Rotary kilns (→ page 20)

Scissor control guideA special metal construction using a‘scissor’ principle, thereby distributinglarge movements equally between twoor more expansion joints in line andcombined.(→ Expansion joints in line)

ShoreDesignation for the hardness of ‘soft’ ma-terials, such as elastomer rubbers.

Single-layer expansion joints(→ page 5)

Sleeve (→ page 10)

Sound insulation (→ page 14)

Stress (and strain) analyses (FEA)Analyses carried out to determine theheat distribution in the expansion jointsand steel components, the heat trans-mission in steel components, and thesubsequent stress or strain in the steelby means of finite elements.(→ FEM, Life expectancy)

TaptitesSpecial self-tapping threaded screwswhich do not require a nut for faste-ning.

Tensile strengthAbility of a material to resist or take uptensile loads until the breakage point.

Torsion (→ page 8)

Transit clampsClamps which are fitted to the expansionjoint flanges of complete units ready forassembly to protect them during trans-port. They also assure that the cor-rect installation dimensions are maintai-ned. They must be removed after instal-lation and before start-up of the plant. (→ page 5)

Units (→ page 5, 11)

Ventilators, fans (→ page 21)

Waste incineration (→ page 21)

Wear resistanceThe ability of a material to resist abrasiveparticles without decomposing.

Weathering (→ page 9)

Welding equipment (→ page 17)

Index

Temperature difference ∆T [¡C]

Pip

e ex

pans

ion

˘L [m

m]

Pipe length L[m]

Range fabric expansionjoint (according totype and design)

Steel expansion joint

Axi

al fo

rce

(kN

)

Expansion joint diameter (mm)

Range fabric expansionjoint (according totype and design)

Steel expansion joint

Late

ral f

orce

(kN

)

Expansion joint diameter (mm)

Company: . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Department: . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contact person: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tel.: . . . . . . . . . . . . . . . . . . . . . . . . . . . Fax: . . . . . . . . . . . . .

Inquiry no.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Requested delivery time: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nos./pcs.: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signature/date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inquiry Data Sheet� Consultant� OEM� End-user� Other

Place of Installation iA

Project name: . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location: . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type or part of plant (f.ex. flue gas ductbefore FGD): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .� New plant � Existing plantInstallation: � outside � inside

Direction of duct system:� horizontal � vertical � diagonal

Movements B

Axial compression (mm) . . . . . . . . . . . . . . . . . . . . .

Axial elongation (mm) . . . . . . . . . . . . . . . . . . . . . . .

Lateral offset Y (mm) . . . . . . . . Z (mm) . . . . . . . . .

Angular offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torsion (°) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vibration/oscillation of system components, type:

Frequency (Hz) . . . . . . . Amplitude (mm) . . . . . . .

Medium D

Medium (f.ex. flue gas from coal-firing)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solid matter content (f.ex. fly ashes) . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load (mg/Nm3) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Condition of medium � dry � wet

Chemical composition (type/concentration)(f. ex. SO2 / 5 %) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Leakage test required � yes � no

Required leakage rate . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure C

Positive press. (mbar/kPa) . . . . . Duration . . . Peak

Negative press. (mbar/kPa) . . . . Duration . . . Peak

Design pressure (mbar/kPa) . . . . . . . . . . . . . . . . . .

Flow velocity (m/s) or volume (Nm3/h): . . . . . . . . .

Flow direction

� upwards � downwards � horizontal

Temperature E

Medium temp. (°C/°F) . . . . . . Duration . . . . Peak

Design temp. (°C/°F) . . . . . . . . . . . . . . . . . . . . . . .

Ambient temp. (°C/°F) approx. from . . . . . to . . . . .

Undercutting of dew point� yes � no Temp. (°C/°F) . . . . . . . . . . . . . .Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Excursion � at each stop/start cycle � continuous. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nos. of cycles per year . . . . . . . . . . . . . . . . . . . . . .

Other influences (f. ex. external). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Desired design, accessories, other services

Expansion joint � closed � open, with prepared joining � Unit (ready-

� with pre-punched holes assembled) required

Sleeve/baffle � available on site � include in offer, if necessary

Insulation/bolster � available on site � include in offer, if necessary

Fastening elements (flanges, bolts, nuts, washers, etc.) � Include in offer

Flange gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .� include in offer

Taking of dimensions/measurements required . . . . . . . . . . . . . . . . . . . . .� no � yes

Installation � own (onsite) � Supervising required � Include in offer

Please copy these pages and enter the necessary data as detailed as possible. Refer also to pages 8/9.Use separate inquiry sheets for each different expansion joint or measurement. Please mail or fax the inquiry sheet toyour nearest KE-Burgmann partner, to KE-Burgmann in Denmark, or Burgmann in Wolfratshausen. All addresses can be found on the back of the catalogue. You will then receive an offer (with no obligation).!

Measurements of connecting pipe or duct ends

Enter measurements in mm on the relevant drawings or enloseas separate measurement sheet.

Cross-section of pipe/duct ends . . . . . . . . . . . . . . . . . . . . . . . .� Round � Rectangular � with � without

� Radius corners

� (Others) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Duct; Steel quality . . . . . . . . . . Steel thickness . . . . . . . . . . .

Duct insulation � outside � inside� Thickness (mm) . . . . . . . . . . . . . . . . . . .

Belt type connection

Directlyon thepipe

Exten-ded frompipe

�

�

Radius corners

Vertical flange connection

Belt type

Enclose drawing of steel construction for existing plants