Dupont Dow VitionH6 DESIGN ACCORDING Program TO FSA Expansion Joint.pdfPoly Tetra Fluoro Ethylene Fluoro Ethylen Propylene (PTFE)-110¡˘ 500¡˘ 700 ¡˘ 75hrs (FEP) ¡˘ 400¡˘

megaflexon

DESIGN ACCORDING TO FSA

Dupont Dow VitionProgram

메가플랙슨공업(주)

lntroduction

Application

Certificate and Warranty

Material

Dupont Dow Elastomers Products

Chemfab

Darlyn

Type of Fabric Expansion Joint

Structure/Various Application

Power Plant Schematic

Movement

Rectangular Metal Expansion Joint

Megaflexon Bellows

Technical Questionnaire

Installation View

3

3

4

5

8

10

11

13

14

18

19

21

22

25

26

2

▷▷ Table of contents

3

lntroduction

Megaflexon fabric expansion joints are desigined to providethermal stress relief in duct line systems by absorbing movementcaused by thermal changes.And also vibration, misalignment of ducting, shock absorbing. Andfabricated from variety of non metallic materials, includingsynthetic elastomers, fabrics, insulation materials andfluoroplastics, depending on the applicants.Megaflexon fabric expansion joints solve problems caused bythermal and mechanical stresses generated in complex systemand supplying variety shape. In order to any requirements and different conditions, user productsproffer for special specification.

Betterments, elevations of quality and custom satisfaction hassupplied megaflexon reputation as a leader.

Megaflexon has engineered, design and manufacturing abilitytechnology involving expansion joints as well as our team ofengineers and drawings are in prepared in cad. The design andmanufacturing are accordance with FSA.

Megaflexon has been dedicated to being the global industry leaderfor engineering and manufacturing expansion joints for¡ fossil fired power plant¡ gas turbine & heat recovery steam generators(HRSG)¡ circulating fluid bed boilers(CFB)¡ fire protection¡ energy and environmental technology¡ cogeneration power plant¡ nuclear power plant¡ petroleum refinery¡ chemical refinery¡ steel mills¡ pulp and paper industry¡ smelters¡ refuse incineration¡ cement plant¡ heat/dust recovery¡ chemical plant¡ marine¡ food processing¡ HVAC-heating, ventilating and air conditioning

In the application of fabric expansion joints to this variety rangesof industries have taken advantage of capabilities.

1. Required large movement 2. Low loads3. Corrosion resistance4. Sound and vibration elimination5. High temperature(withstand over 2000¡F̆)6. Lower system design costs. reduced engineering time7. Low material cost8. (Pre-assembled)Low shipping and installation cost9. No gasket required

Applications

FABRIC EEXPANSION JJOINTT

4

CERTIFICATE & WARRANTY

WWAARRRRAANNTTYYDEC. 05. 2000

Megaflexon co., Ltd warrants that products furnished will, at the time ofdelivery, be free from defects in material and workmanship. Megaflexonco., Ltd will repair or replace any defects which occur within one yearfrom the date of installation whichever occur first.

Purchaser shall be responsible for proper installation of the units andoperating within the design limits of each unit.

Correction of defects by repair or replacement shall constituteMegaflexon co., Ltd¡fls sole and exclusive responsibility to purchaserunder this warranty and Megaflexon co., Ltd shall in no event be liablefor injuries to persons or property or direct, incidental, liquidated orconsequential damages caused by use of the product.

COMPANY NAME : MEGAFLEXON CO., LTD.ADDRESS : 9F, SAMCHANG B/D 63-1 CHOONG JEONG

RO 3GA SEODAEMUN-GU SEOUL KOREABUYER¡flS NAME : HYUNDAI ENGINEERING &

CONSTUCTION CO.LTDBUYER¡flS PURCHASING NO : 2 07 9KIB6800WARRANTY PERIOD : 1 YEARITEM : NON METALLIC FABRIC EXPANSION JOINT

5500¡¿7000¡¿550MML-4SETS

SIGNED

megaflexon co., Ltd.EXPANSION JOINT & FLEXIBLE PRODUCTS

MATERIALS

1. EPDM(Ethylene propylene)

Ethylene propylene(EPDM)-These low cost terpolymers havehigh tensile strength and elongation with excellent resistance tooxygen and ozone. They also have good flexing characteristics,low compression set and good head resistance. Conventionalcompounding produces formulations with very good chemicalresistance. Reinforced EPDM expansion joints have been usedin power generating stations and industrial plants.

2. FKM(Fluoroelastomers)

Fluoroelastomers(FKM)-Manufactured in the U.S.A. byDuPont(Viton) and Dyneon(Fluorel):these high performanceelastomers have outstanding resistance to chemicals, oils andheat compared to any other elastomer. These elastomers areavailable as copolymers(vinylidene fluoride hexafluoropropylene)or terpolymers (vinylidene fluoride tetrafluoroethylene,hexafluoropropylene). Specifically compounded terpolymers areused in the expansion joint industry. The fluoroelastomers haveexcellent abrasion resistance and generally do not requireprotection from flue gas media. Reinforced fluoroelastomerexpansion joints have been used in power generating stationsand industrial plants since 1968.

Elastomers and coatings commonly used in expansion joint:

FABRIC EEXPANSION JJOINT MMATERIAL

5

The performance of fabric expansion joints for gas ductingsystems is determind by the severity of the environment and bythe selection of the materials for each component of theexpansion joint. Selection of materials must be used onfunctional requirements as well as temperature and chemicalcapability. A corrosive atmosphere that might not have anoticeable effect at low temperature could have a disastrouseffect at higher temperatures still within the basic heatresistance capability of the material.

Fabrics are used for the reinforcement of elastomers and othercoatings to yield the mechanical properties necessary towithstand the movements and pressures exerted upon theexpansion joint by the ducting system.

Insulating materials are used to reduce interface temperaturesto a level which permits satisfactory performance and life of theelastomeric or coated materials in the gas seal layer. Fiberglassblankets perform very well to 1000deg, F(540deg, celsius)andavailable ceramic blankets are rated above 1000deg, F but dohave mechanical and chemical limitations.

Metal flanges are used to connect the flexible element to theductwork. Metal flow liners or baffles are used to protect thegas seal membrane and insulation layers of the flexible elementfrom abrasive particles which may be present in the gasstream. A liner also helps control fly ash accumulation inexpansion joint cavity and reduce flutter of the flexible elementcaused by turbulence.

6

PROPERTIES OF ELASTOMERS AND FLUOROPLASTICS TABLE E-1

* Fluoroelastomers when reinforced with nonreactive materials have an intermittent temperature capabilityof 4 hours at 700¡F̆ and 2 hours at 750¡F̆

** Excursions at high temperatures will have a detrimental effect on useful life of the product.*** Any nuclear application should be referred to expansion joint manufacturer for specific elastomer

recommendation.

ASTM DesignationsMaterial Temperature¥ . Minimum

(Low Temperature Brittle Point)Continous**IntermittentOperating Temperature(Accumulative Time in Hours)

¥–. Chemical Resistance H'O'AcidHot(+)Less Than 50%ConcentrationH'O'Acid Hot(+) over 50%ConcentrationHCL Acid Hot(+) less than 20%ConcentrationHCL Acid Hot(+) over 20%ConcentrationAnhydrous AmmoniaNAOHLess than 20% concentrationOver 20% concentration

¥†. Abrasion Resistance

¥‡. Environmental ResistanceOzoneOxidationSunlight***Radiation

Elastomers

Neo

pren

e

Hyp

alon

EP

DM

Chl

orob

utyl

Flu

oroe

last

omer

Sili

cone

(CR)

-40¡˘180¡˘

250¡˘168hrs

(CSM)

-40¡˘225¡˘

250¡˘2,600hrs350¡˘70hrs

(EPDM) (CIR) (FKM) (SL)

-60¡˘450¡˘

-60¡˘300¡˘

350¡˘200hrs

-40¡˘300¡˘

350¡˘150hrs

-40¡˘400¡˘

550¡˘240hrs600¡˘48hrs650¡˘16hrs*700¡˘4hrs*750¡˘2hrs

(ALL Temperatures ¡F̆)

B-C

C

C

C

A

AA

A

B

B

C

B

AA

A

B-C

B

C

A

AA

A

B-C

B

C

A

AA

A

A

A

A-B

C

AB

C

C

C

C

C

AB

A A A A A A C C

BBBA

AAAA

AAAA

AAAC

AAAB

AAAB

AAAB

AAAB

A

A

A

A

A

AA

A

A

A

A

A

AA

Fluoroplastics

Pol

yT

etra

Flu

oro

Eth

ylen

e

Flu

oro

Eth

ylen

Pro

pyle

ne

(PTFE)

-110¡˘500¡˘

700¡˘75hrs

(FEP)

-110¡˘400¡˘

500¡˘100hrs

Rating Code:

A=Little or no effectB=Minor to moderate effectC=Severe effect

3. PTFE(Poly Tetra Fluoro Ethylene)

Fluoroplastics-are thermoplastic resins of general paraffinic structures which have all or some of the hydrogenreplace with fluorine. Polytetra fluoroethylene(PTFE commonly called TFE and Teflon TM) and fluorinatedethylene propylene(commonly called FEP and Teflon TM) are the two major fluoroplastics used in theexpansion joint industry. Both PTFE and FEP are available in film and latex dispersion form. The dispersionfluoroplasties are generally used as a dip coating for a variety of fabrics. These coatings can be built up tothick coatings which are sintered(thermoset) to form a chemical resistant barrier. The film form of PTFE andFEP is laminated to various materials, again for a chemical resistant barrier. The film laminates have a muchgreater resistance to permeation than the dispersion coatings. The PTFE and FEP coated materials requireprotection from abrasive media in the form of a baffle or deflector plate. Various film laminates and dispersioncoated materials have been used as a secondary ply in expansion joints for 20 years.

FABRIC EEXPANSION JJOINT MMATERIAL

MATERIALS

TABLE E-2PROPERTIES OF

REINFORCEMENT MATERIALS

Reinforcing Materials

(*)Temperature Capability(¡F̆)

Chemical ResistanceDilute H₂SO₄Concentrated H₂SO₄SO₂and SO₃Caustic

450

BCBB

700-1000

BCBB

2500

ABAB

250

BCBB

1800

AAAC

Ara

mid

Fib

ergl

ass

Cor

rosi

onR

esis

tant

Allo

y W

ire

Pol

yest

er

Cer

amic

Rating Code: A - Little or no effectB - Minor to moderate effectC - Severe effect

(*)These temperatures are the maximum continuous temperatures that thereinforcement material can handle.

7

Reinforcing Materials Commonly Used in Expansion Joints

TABLE E-2 defines the capabilities of commonly used reinforcing materialsin the manufacture of expansion joints. The capabilities listed below areconsidered important to product application in flue gas systems. Chemicalcompatibility on an uncoated fabric is critical in a composite type joint.

⊙ Expansion Joint Units

8

DuPont Dow elastomersProducts

Flue Duct Expansion Joints Made from Viton Make Grade at theDrax Flue Gas Desulphurization Project

The largest flue gas desulphurization (FGD) project in theworld, a staggering billion dollar investment, is under way inthe united kingdom. When selecting suppliers and materialsfor this massive projet long-term, reliable performancetogether with a competitive price v** mandatory. The supplier of choice for flue duct expansion joints(FDEJs)manufactured from DuPont Viton fluoroelastomer ¡ B-types¡–

⊙ Demanding SpecificationsPerformance was the bottom line. National Power¡fls DraxPower station in North Yorkshire, the largest coal fired powerplant in western europe at 4000 MW, was challenged toreduce its emissions by 60% due to european clean airinitiatives.A flue gas desulphurization system was necessary to scrubsulphur dioxide from the flue gases. Sulphur dioxide emissionsneedle to be reduced by 90% for 97.5% of the time andscheduled outages had to be no less than 38 months apart.

FDEJs are a flexible seal connecting the ductwork in utilitiesand FGD plants. They allow room for dynamic motion in theductwork as well as thermal expansion and contraction. Atypical power plant may have hundreds of FDEJs made fromeither metallic, fiberglass-reinforced PTFE, or compositeelastomeric materials.In the joints require frequent maintenance due to the highlycorrosive conditions, they can significantly impact theenvironmental that performance and profitability of the powerplant. Babcock Energy Ltd., the primary contractor, wantedFDEJs made of a material that had a proven track record as anoutstanding performer and was easily capable of meeting theengineering performance criteria.

Interior of Flue Duct with Expansion Joint

Modle Completed Flue Gas DEsulphurizationProject at Drax Power Station

DuPont Dow elastomersPPrroodduuccttss

■■ The SolutionViton B-Types

FDEJs made of Viton B-type met the demanding performancerequirements specified by babcock. In fact, the drax power station hadsuccessfully used viton for more than 10 years as a liner for chimneys, sothey were well aware of the advantages of using Viton. Unlike metallicexpansion joints, Viton B has excellent resistance to sulphur dioxide, hotsulphuric acid, and other aggressive components of flue gas. Fiberglass-reinforced PTFE joints might perform adequately in this corrosiveenvironments, but they cannot withstand flex fatigue from flutter or theabrasiveness of fly ash. Viton not only provides superior resistance to flexfatigue, but also has very good abrasion resistance.And compared to exotic metal alloys, FDEJs made from Viton are Iessexpensive, light weight, flexible, and easy to install.

The combinations of excellent chemical and heat resistance, abrasionresistance, and its retention of mechanical properties made Viton B-typethe material of choice for the flue duct desulphurization project at Drax.

■■ Viton is the choice around the worldManufactured the first expansion joint made from a Viton B-type for Drax in1991. More than 350 expansion joints will be installed by the time it iscomplete in 1996.

ƒRViton B-type¡–refers to a family of terpolymer fluoroelastomers containing 68%fluorine by weight. Additional test data is available which supports the applicationof ¡ B-types¡–in flue duct expansion joints.

9

megaflexon is proud to have the distinction as DuDont dow elastomers in genuine Viton B.

CHEMFAB

Permeation Rates at steady state

are acceptably low for laminates.

Little benefit is obtained at film

thickness greater than 0.10mm

while increased thickness adversely

affects composite stiffness. Wear

characteristics of products in

current use were evaluated in a

1996 tribological study. Contact

CHEMFAB for details.

Perfluoroplastics, such as Teflon

PTFE, are resistant to a wide range

of chemicals even at elevated

temperatures.

However, due to their crystalline

nature they exhibit a degree of

stiffness (less long term flex-

endurance). To overcome this

shortcoming, since flexibility and

durability are necessary for long

service life.

We incorporated a fluoroelastomer

into the coating matrix. This results

in a unique fluorinated elasto-plastic

which combines the most desirable

properties of both. More than 10

years of operating experience has

proven the reliability and durability

of DARLYN in the most severe

corrosive environment.

PRODUCT

Construction

Gas-side PTFE filmthickness/color

Weight, g/m2

Thickness, mm

Breaking (tensile) strength,N/cm(warp ¡¿fill)

Trapezoid tear strength,N(warp ¡¿fill)

DARLYN TYPICAL NOMINAL PROPERTIESGS-4HT

Laminate bondedto fiberglass insulation

0.10 mm/black

3850

1.39

1800¡¿1600

710¡¿845

GS-4

Laminated

0.10 mm/black

2000

1.27

1800¡¿1600

710¡¿845

1100

Coated

N/A

2100

1.1

1920¡¿1920

890¡¿1000

1100 CB

Laminated

0.10 mm/orange

2420

1.42

1920¡¿1920

890¡¿1000

Temperature rating(continuous) 500¡£F(260¡ )100 hrs. @ 1 hr. intervals (excursion) 650¡£F (343¡ )

A thorough understanding of the application is required for selection of any material. Factors to considerinclude temperature, presence of humidity or moisture, particulate loading in the gas stream, and theexpected level of vibration, flutter or pressure fluctuations.

1⃞ Corrosion Inhibited Woven Fiberglass Substrate

2⃞ Perfluoroplastic Protection of Yarn3⃞ Elasto-plastic Coating Alloy4⃞ Top Coat Perfluoroplastic5⃞ PTFE Chemical Barrier Film

FABRIC EXPANSION JOINTT

CONSTRUCTION ATTRIBUTES

DARLYN FEATURES AND BENEFITS

10

KEY: E=ExcellentS=Superior

FEATURES

Fluorinated elasto-plastic(PTFE fluoroelastomer alloy)

Corrosion inhibitedwoven fiberglass

PTFE cast filmchemical barrier

BENEFITS

Chemical and corrosionresistance balanced withlong term flex-endurance

Strength retention at hightemperature over time

Protects the reinforcementfrom highly corrosive andtoxic fluids Strength retentionin sulfuric acid over time

GS-4HT

E

E

E

GS-4

E

E

S

1100

S

S

N/A

1100 CB

S

S

S

TABLE E-3

TABLE E-4

ƒ

ƒØ

ƒŁ

ƒ

ƒ

Administrator

사각형

11

DARLYNFABRIC EEXPANSION JOINT MMATERIAL

QUALITY

CHEMFAB assures the quality of DARLYN 1100 CB throughevery step of its construction, utilizing in-house manufacturingfor all aspects:

Weaving: CHEMFAB weaves the proprietary engineeredwoven fiberglass construction to meet DARLYN 1100 CB¡flsstrength and flexibility requirements.

Coating: Samples from each roll of our coated substratedundergo extensive physical destructive testing to assurequality.

Lamination: CHEMFAB uses its patented laminationtechnologies to assure that the substrate and film will notseparate or crack--even after severe f lexing and acidcondensate exposure.

Films: CHEMFAB manufactures CHEMFILM, the multilayerPTFE cast film used as the additional chemical barrier layer inDARLYN 1100 CB.

Quality assurance during weaving includes physicaltesting and 100% visual inspection of each greige goodroll.

In addition to physicaltests, every completedroll of DARLYN 1100 CBundergoes 100% visualinspection as a f inalquality assurance step.

This magnified cross section of DARLYN 1100 CB2shows the consistant film lamination and uniform filmthickness. CB2 utilizes CHEMFILM PTFE cast filmslaminated to both sides of the coated substrate.

This photo shows the multiple thin layers in 4 mil thickCHEMFILM. Each layer fills any possible imperfections in theprevious layer. This assures a uniformly thick, non-porouschemical barrier film.

Weaving

Coating

Lamination

Films

DARLYNFABRIC EEXPANSION JOINT MMATERIAL

MIT flex tester is used to show the exceptional strengthretention of DARLYN-typically over 90% after 30 flex cyclesof 270¡£rotation.

FLEXIBILITY

DARLYN 1100 CB utilizes a patented alloy coating of PTFE andfluoroelastomers. DARLYN thus avoids a problem common toconstructions that use 100% PTFE coating: stiffness and theresulting strength loss this stiffness can induce upon flexing.

How the Alloy Works: The PTFE/ fluoroelastomer alloy fills the¡ windows¡–(area between the yarns)of the woven fiberglassreinforcement, and is more compliant than PTFE alone. Thus, the fiberglass yarns bend in a more pliable matrix, andtherefore maintain significantly more of their strength afterrepeated flexing.Further, the alloy coating better resists cracking during repeatedflexing.

CHEMICAL RESISTANCE

DARLYN 1100 CB utilizes both PTFE and PTFE/fluoroelastomeralloys to coat the high strength woven fiberglass substrate. Thisquality, multiple-pass coating is essential for long-term protectionof the fiberglass from attack by low rates of acid gas permeation.

Additionally, an orange PTFE cast film is laminated to the interiorsurface, providing further protection from acid attack.

PTFE is one of the most chemically inert substances known toman-certainly the most corrosion resistant to the widest class ofchemicals.Fluoroelastomer is the most chemically resistant elastomer.

A technician cuts an exposed belt fabric sample for strengthanalysis in our lnstron machine (inset photo). Even after 5 years ofextremely harsh service on the inlet joint of a FGD scrubber, theDARLYN 1100 CB consistantly tested above the 1100 lb/in (1930N/cm) minimum strength specification for new material. Plantpersonnel removed the fabric in order to repair corroded metalframework.

FLEXIBILITY

How the Alloy Works

12

13

SINGLE LAYER TYPE

This type is comprised of one or more reinforcement plies with coating of elestomers orfluoroplastics to form a homogenous material.

Type of fabric expansion joint

COMPOSITE TYPE

A layered product that consists of various plies of materials which are laid one over the otherand are usually bonded, sewn or mechanically fastened together in the clamped flange area.

INTEGRALLY FLANGED TYPE EXPANSION JOINT

BELT TYPE EXPANSION JOINT

ANATOMY OF TYPE

METAL LINEROR BAFFLE

METAL FLANGESOR FRAME

BACK-UPBAR

FASTENERS(BOLT NUT,WASHERS)

FLEXIBLE ELEMENTSEE ILLUSTRATION

CAVITY PILLOW

METAL LINER OR BAFFLE

FLEXIBLE ELEMENT

FASTENERS(BOLT NUT,WASHERS)

BACK-UP BARS

METAL FLANGESOR FRAME

FFTYPE

BBTYPE

MF-01

megaflexon provides from designs forvarious application.

Standard internal flanged type(F type) expansion

▶ Low to moderate temperatures application.▶ Primary used for field installation application.▶ Lower initial cost and shipping cost.▶ Molded corners provided for rectangular.

OPTION(flow liner)

ECONOMIC BELT TYPE EXPANSION JOINT

■ High temperature ductwork applications■ Pre-fabricated flame reduce cost■ Easy accepts pillow design■ Large lateral movement■ Outside belt assembly

OPTION

MB-02

BELT TYPE EXPANSION JOINT

○ Suitable normality temperature applications○ Frequently fan application○ Economic and Standard frame○ Facilitate belt replacement

(OPTION) SHOP WELD

14

MB-01

STRUCTURE

A.Gas Seal Membrane

B.Insulating Layers

C.Insulating Retainer Layer

D.Back up Bar

E.Metal Liner or Baffle

F.Accumulation Bag

G.Metal Frame(Flange)

H.Gasket

megaflexon provides fromdesigns for various application.

OPTION (double liner shop weld)

▲ Low temperature applications with low level▲ Future belt replacement▲ Used frequently with fan application▲ Shop welded flow liner

MB-04

▶ High temperature application and high level▶ Large Lateral Movements▶ Intergral telescopic flow liners▶ Provide protection for belts and pillows▶ Pillow design▶ Future belt and pillow replacement

MB-05

◆ Single Integral-flow liner◆ Low level and vertical duct work applications◆ Provide protection for belts and pillows◆ Future belt and pillow replacement◆ Large lateral movements

MB-06

OPTION (braid seramic seal)

OPTION (field weld liner)

15

◇ Well suitable field assembly installation◇ Utilized for all temperature ratings◇ Economic frame◇ Facilitates field assembly

MB-07

OPTION(field weld liner)

megaflexon provides fromdesigns for various application.

▶ Flanges are not present ▶ Future belt and pillow replacement▶ Standard structural steel channel▶ Field assembly is required and fill up OPTION(field weld liner)

The Cavity Pillow fills the cavity between the flexibleelement and the metal liner or baffle and helps preventthe accumulation of particulate matter, and in someapplications unburned fuel, from becoming trapped inthe expansion joint cavity.If there is no cavity pillow, fly ash or other solidparticulates can accumulate in the expansion jointcavity in such quantities that they can cause damageto the flexible element if they solidify to a cementatiousstate. Also, certain noncementatious particles (fly ash)can create a severe corrosive (acidic) environment

when subjected to cooling (below H'SO' dew point)during a maintenance outage.

16

MB-08

Cavity Pillow

Back up Bar

The Back-up Bars are metal bars used for the purpose of clamping theflexible element of the expansion joint to mating ductwork flanges or tometal adapter flanges. Standard size back-up bars are 2¡–x3/8¡–. Back-up bar selection depends upon the bolt spacing, bolt hole size andexpansion joint flange height or width.

TABLE D1:BOLT HOLE SPACING

Bolt Size

1/2¡–bolt5/8¡–bolt

Flange Bolt Hole Spacing

4 inch C-C4 or 6 inch C-C

Liner or Baffles

Metal Liner or Baffles are metal shields designed to protect the flexible element and cavity pillow(if present).Metal liners or baffles reduce fluttering caused by air turbulence as it passes over the flexible element.

STRAIGHT STYLE

AIRFOIL STYLE

SEMI-AIRFOIL STYLE

TELESCOPIC STYLE

SHOP WELDED TO EXPANSION JOINT

FIELD WELDED TO DUCT PLATE

BOLTED TO DUCT FLANGE

INTERGRAL WITH EXPANSION JOINT FRAME

Design Installations

17

GAS FLOW

(2)AIRFOIL STYLE

GAS FLOW

(1)STRAIGHT STYLE

GAS FLOW

(3)SEMI-AIRFOIL STYLE

GAS FLOW

(4)TELESCOPIC STYLE

GAS FLOW

(1)SHOP WELDED TO EXPANSION JOINT

TYPICALCOMT

TYPICALCOMT

GAS FLOW

(2)FIELD WELDED TO DUCT PLATE

GAS FLOW

(3)BOLTED TO DUCT FLANGE

GAS FLOW

(4)INTERGRAL WITH EXPANSION JOINT FRAME

PPoowwer Plant Scer Plant Schemahematictic

18

FOSSIL FIRED POFOSSIL FIRED POWER PLANTWER PLANT

1.Boiler Furnace Area2.Silencer3.Economizer Ash Hopper4.Coal Tripper5.Coal Silo6.Pulverizer7.Forced Draft Fan8.Air Preheater9.Electrostatic Precipitator10.Flue Gas Desulpherizer11.Stack12.Turbine13.Generator14.High Pressure Heater15.Degenerator16.Condenser17.Boiler Feed Water Pump18.Condensate Pump19.Control Room20.Main Transformer

MOVEMENT

¡ Breach Opening Tolerances: Axial1/4¡–(6mm), extension 1/2¡–(13mm)compression Lateral:1/2¡–

¡ Lateral movements exceeding 3¡–(75mm) should be pre-offset one half the required movement.

19

FABRIC EEXPANSION JJOINT

Movement CapabilitiesNon metallic ducting movements can be calculated at both thedesign and maximum excursion temperatures.Fabric expansion joints can handle combined axial, lateral, angularand torsional movements with just one unit, the expansion jointlocations should be carefully selected to keep the number ofexpansion joints in the system to a minimum and still absorb all ofthe duct movements.Should an expansion joint location have very large axial and/orlateral movements, consult manufacturers for a recommendation onhow these large movements can best be handled.

AXIAL Compression Extension

LATERAL MOVEMENT

Torsional Deflection

ANGULAR Deflection

In general, by increasing the active length of expansion joint, greater movements can be accommodated.

BELT TYPE

Single LayerElastomer orFluoroplastic

Flexible Element

Composite TypeFlexible Element

<TYPICAL MOVEMENT CHART>

ACTIVE LENGTH

6¡–(150mm)9¡–(230mm)

12¡–(305mm)16¡–(405mm)

6¡–(150mm)9¡–(230mm)

12¡–(305mm)16¡–(405mm)

AXIALCOMPRESSION

2¡–(50mm)3¡–(75mm)4¡–(100mm)5¡–(125mm)

1¡–(25mm)2¡–(50mm)3¡–(75mm)4¡–(100mm)

AXIAL EXTENSION

1/2¡–(13mm)1/2¡–(13mm)1¡–(25mm)1¡–(25mm)

1/2¡–(13mm)1/2¡–(13mm)1¡–(25mm)1¡–(25mm)

LATERIALMOVEMENT

+/-1¡–(25mm)+/-11/2¡–(38mm)

+/-2¡–(50mm)+/-2 1/2¡–(63mm)

+/-1/2¡–(13mm)+/-1¡–(25mm)

+/-1 1/2¡–(38mm)+/-2¡–(50mm)

Set Back Requirements

The distance the expansion joint is moved outward from the gasstream to allow for lateral movements and to prevent the jointfrom protruding into the gas stream when operating undernegative pressures.Proper setback also reduces the thermal transfer effect on theinner face of the expansion joint from particles in the gas stream.

MOVEMENT

6¡–(150mm)

3¡–(75mm)

4¡–(100mm)

1¡–(25mm)

2¡–(50mm)

ACTIVE LENGTH

lllustration pressure9¡–(230mm)

3¡–(75mm)

6¡–(150mm)

1 1/2¡–(38mm)

3¡–(75mm)

12¡–(305mm)

4¡–(100mm)

6¡–(150mm)

2¡–(50mm)

4¡–(100mm)

16¡–(405mm)

6¡–(150mm)

7¡–(175mm)

2 1/2¡–(63mm)

5¡–(125mm)

FABRIC EEXPANSION JJOINT

20

ACTIVE LENGTH

Rectangular Metal Expansion Joint

21

Megaflexon multi-ply rectangular expansion jointwith round corners are dimensioned to match theduct. Megaflexon rectangular expansion jointswith integral multiply-walls and round corners forlarge dimensions.These expansion joints are welded together onjob site.

Rectangular Expansion Joint in a flue gas scrubber Material : InconelDimension : 2,200mm¡¿2,000mm

The service l i fe of an expansion joint isinfluenced by following factors:- number of cycles- movement to the taken up- operating temperature- pressure load- pressure pulse- thermal transients during operation- corrosion- vibration

The permissible movements can be calculatedsubject to relevant factors and according tooperating conditions. A cycle is represented bythe total movement from the initial position, toone extreme value, to the other extreme valueand back to the initial position.

Metallic Rectancular Expansion Joint200¡¿570mm, type fruMaterial SS316,P=2bar, T=450¡Bellow : Corten Steel

Metallic Rectangular expansion joint for flue gas line11182¡¿3482¡¿3000mmLDouble miter corner typeIntermediate pipe, sleeve:A387Gr12Bellows : Corten Steel

22

MEGAFLEXON BELLOWSBellows walled megaflexon circular or rectangularbellows are menu featured from a multi-ply cylindrical package.To this end, strip sheet is compactly coiled around alongitudinally-seam welded liner cylinder, in as manylayers as required for pressure stability.By pressing out undulations the cylindrical package isformed in to a bellows.

The multi-ply bellows stands for the principle of thebreaking up a single-wall bellows into multiple walls.This method meets the requirements for high movementabsorption in a short built-in length.

MEGAFLEXON BELLOWS

SpecificationTravel<movement>: Axial, Lateral, Angular Materials of the bellows,Materials/600Incoloy 800/ operating tempertureIncoloy 800H/900Incoly 825/450Incoly 600/450Incoly 600H/900Hastelloy C4/400Hastelloy C276/400Monel/425Nickel/600Titanium/250Zirconium/

Rectangular Universal Expansion Joint 200¡¿570mm,type FruMaterial Inconel,P=2bar,T=450 ℃

Multy-ply Bellows Round Corner Rectangular ExpansionJoint with fixed flange

F-1. Storage

The storage environment and storage time can be important factors

in the condition and performance of a fabric expansion joint. The

materials used in fabric expansion joints exhibit excellent resistance

to various forms of environmental attack; however, recommended

storage practices must be observed and an awareness of deviations must

be maintained. After prolonged storage(over one year), inspection by the

expansion joint manufacturer can assure that performance will not be affected. In

cases of storage abuse, expansion joint warranties may be invalid. Special storage

methods should be used when long-term field storage is anticipated for spare expansion

joints.

F-1.1. Length of StorageThe storage warranty period is specified by the maunfacturer based upon the expansion joint style.

Notify the manufacturer for inspection if storage period exceeds one year. Inspections should be made

at least sixty(60)days before anticipated installation. Notify the manufacture if the start-up date is to be

more than twelve(12)months after the installation of the expansion joints. Notify the manufacturer,

regardless of storage time, if any unusual appearances are noticed when unpacking or installing the

expansion joints.

F-1.2. Indoor Storage RecommendationsDo store the expansion joints in their original shipping containers. Do protect the containers from physical

damage and abuse. Do store in cool, dry areas. Do Not store where the temperature will exceed 150¡£

F(65¡ ). The ideal storage temperature is between 50¡£and 70¡£F(10¡£to 20¡£). Expansion joints should not

be stored near sources of heat such as radiators and base board heaters.

F-1.3. Outdoor Storage RecommendationsDo store the expansion joints in their original shipping containers. Do protect the containers from physical

damage and abuse. Do store at least one(1) foot above the ground in a dry area where flooding will not

occur. Do cover the containers with a tarpaulin or heavy plastic to protect them from the weather. Do Not

store where the temperature will exceed 150¡£F(65¡£). The ideal storage temperature is between 50¡£and

70¡£F(10¡£to 20¡ ). Expansion joints should not be stored near sources of heat.

F-2. Handling and InstallationExpansion joints, whether ordered assembled, unassembled or as components, must be packaged to

arrive at the job site in good condition. The purchaser should, immediately upon receipt at the job site,

verify that all parts shown on the packing slip have been received undamaged. All expansion joint

manufacturers provide detailed instructions with each shipment and these instructions should be reviewed

before installation. To insure proper performance and service life it is important to prevent damage by

careful handling and by supporting the expansion joint during installation.

23

SECTION FSTORAGE, HANDLING, INSTALLATION, and

COMMISSIONING

F-2.1. Pre-Erection Requirements:The breach opening and ducting should be checked for proper alignment. The opening should not exceed the

following tolerances; Axial+1/4¡–, -1/2¡–, Lateral 1/2¡–. If the breach opening exceeds these tolerances then the

expansion joint manufacturer must be notified. Mounting flanges or expansion joint attachment area of the ductwork

must be smooth, clean, flat, and parallel. All welded areas must be ground smooth at attachment points. The area

around the ductwork must be cleared of any sharp objects and protrusions. If not removable they should be marked

for avoidance. The expansion joint and components should be kept packaged until immediately before installation. If

any handling devices such as crane hooks or fork lifts are utilized in handling the expansion joints, the contact surface

must be protected by cushioning materials. If welding or burning operations are being performed in the vicinity of the

exposed expansion joint, fabric welding blankets or other protective covering must be used. These covers must be

removed before system start-up.

F-2.2. Installation

F-3. CommissioningIt is very desirable to have a representative of the manufacture provide a ¡ Final Walk Down¡–inspection of the

installation prior to system start-up. This inspection should consist of verifying installed dimensions, bolt torques, and

general condition of installation.

Non-Metallic EExppansion JJoint

24

It is important that the expansion joints be installed at the proper face-to-face dimension

as specified by the manufacturer. Never extend, compress or laterally distort expansion

joints to compensate for dimensional errors without the manufacturer¡fls concurrence.

When an expansion joint must be precompressed or laterally preset, follow the

manufacturer¡fls detailed instructions for installation. All expansion joints provided with

baffles or liners should have flow arrows or other suitable means of assisting the installer

to properly orient the expansion joint to flow direction. Care must be taken to assure that

back-up bar ends butt up to each other without overlapping or allowing large space

between ends. Follow the manufacturer¡fls specific instructions. Installers must follow the

manufacturer¡fls bolt installation and torque recommendations. If impact tools are used

then they must have torque limiting devices properly set before use. Do not install

insulation over the expansion joint or mounting area unless it is in accordance with the

manufacturer¡fls instructions. In areas where coal dust can collect on the expansion joint outercover, protective

shields may be required. Coal dust can cause spontaneous combustion, resulting in burning outer covers of

expansion joints. Consult the expansion joint manufacturer for details and requirements for a shield. Proper

installation of the expansion joint is critical to the service of the product and should be checked by the installer.

1.Medium¡ Flue gas ¡ Air ¡ Waste gas ¡ Others:¡ Composition according to enclosed analysis¡ dry¡ moistdust ¡ no ¡ yes: content: mg/m'łsolid particles ¡ no ¡ yes: content: mg/m'łgrain size mmFlow rate: mn'ł/h Flow velocity: m/sDirection of flow ¡ horizontal ¡ vertically up ¡ vertically down

¡ diagonally up ¡ diagonally downDew point: _ ¡Condensate ¡ strongly acid ¡ slightly acid ¡ neutral ¡ slighty basic ¡ strongly basic

2. TemperaturesTemperature of medium: ¡ Design temperature: ¡ Excursion temperature: ¡

Duration of individual excursions days: hours: minutes:

Duration of excursions per year days: hours: minutes:

Ambient temperature: ¡ (standard value:50¡ with a free convection)

Radiation impeded ¡ no ¡ yes,by:

Passive radiation by components ¡ no ¡ yes,by:

External insulation ¡ no ¡ yes!Has to be confirmed by manufacturer

The Quality Committee of the Quality Association for Fabric Expansion Joints.

3. PressureOperating pressure: mbar Neg.op.pressure: mbar Design pressure: mbar

Transient pressure ¡ no ¡ yes,from mbar to mbar Frequency:

Surge load ¡ no ¡ yes,from mbar to mbar Frequency:

Excursion pressure: mbar Neg.exc.pressure: mbar duration of excursion:

Frequency of excursions: per: at a temperature of: ¡

4. Specified tightness¡ without ¡ flue gas tight acc. to MG-002 ¡ nekal tight acc.to MG-003

5. MovementsAxial compression Axial elongation Lateral offset

Angular movement Torsion Vibration

- Z : mm + Z : mm X : mm y : mm

∂χ: 。 ∂χ: 。 ∂z: 。

¡ no ¡ yes

frequency : S-1

amplitude : mm

6. DesignType of connection ¡ tubular connection ¡ flange connection

Delivery ¡ open ¡ endless

Baffle/sleeve ¡ no ¡ yes ¡ welded ¡ bolted

Insulation between expansion joint and baffle/sleeve ¡ yes ¡ no

Technical Questionnaire

26

View of round “F”type fabric expansion joint after installation

View of rectangular “F”type fabric expansion jointafter installation

View of round type metal expansionjoint under construction

View of rectangular type fabricexpansion joint after installation

View of fabric expansion joint which is installedfront of stake

INSTALLAION & APPLICATION

27

View of Viton-B expansion joint which is installed in FGD flue gas duct line

View of Viton-B expansion joint underconstruction fossil power plant

View of produce rectangular metalexpansion joint at Kimpo plant

View of operating fabricexpansion joint at 390 ¡C̆flow gas line

View of fabric expansion joint which is installed inFGD flue gas duct line

INSTALLAION & APPLICATION

View of storage after completeproduction rectangular & roundtype expansion joint

megaflexonHEAD OFFICE :#262-2, CHOWONJEE-RI,DAEGOT-MYEUN KIMPO-CITY, KOREATEL : 82-341-981-0981~3 FAX : 82-341-981-0986

HEAD OFFICE :#262-2, CHOWONJEE-RI,DAEGOT-MYEUN KIMPO-CITY, KOREATEL : 82-341-981-0981~3 FAX : 82-341-981-0986

































SEOUL OFFICE :서울시 서대문구 충정로 3가 63-1 BLDG 9층9FL, SAMCHANG BLDG. #63-1, CHOONGJEONGRO 3-GA,SEODAEMUN-GU, SEOUL, KOREATEL : 82-2-743-6411,2,3, 2277-2788 FAX : 82-2-2277-2789Email:[email protected]//www.megaflexon.com


































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