MA-PQP-PQ-MAN-038 C OFFSHORE 32 MANBW BOF eee DOCUMENTO CONTROLADO Made By: Vivian AguilarBaw Table of Contents 4 Mechanical equipment 4.1 List of mechanical equipment CASCADE/ i MAN 42 Heat data for cooling water systems MAN 4.3 Engine cooling and sypply systems 4.3.0 General safety notes MAN 4.3.1 Lubrication oil system MAN 4.3.2 Fuel oil system MAN [433 Cooling water system MAN 4.3.4 Steam and condensate system MAN 4.3.5 Intake air system MAN 4.3.7 Starting air- control air - working air system MAN 44 Auxiliary systems for barge operation 4.4.1 Ballast system CASCADE 44.2 Fresh water system CASCADE 4.4.3 Domestic hot and cold water system CASCADE 444 Black and grey water system CASCADE 445 Sewage system CASCADE 4.46 Fire fighting system CASCADE 4.4.7 __| Ventilation system CASCADE 4.4.7-1 Ventilation of main engine hall CASCADE 4.4.7-2 Ventilation of separator room CASCADE 4.4.7-3 Ventilation of forward pump room CASCADE 4.4.7-4 Ventilation of aft pump room CASCADE 4.4.7-5 Deckshouse ventilation CASCADE 4.4.7-6 Alternator exhaust system CASCADE 4.4.8 Air conditioning system CASCADE 44.9 Oily water, dirty oil and sludge system CASCADE 4.5 Other systems 4.5.1 Communications system CASCADE 4.5.2 Alarm system CASCADE 4.5.3 Tank vents CASCADE 4.5.4 Sounding tubes CASCADE 4.5.5 Safety systems CASCADE 4.5.5-1 Fire detection system CASCADE 4.5.5-2 General alarm system CASCADE 4.5.5-3 CO,/Ventilation shut down system CASCADE 4.5.6 Wireway system arrangements CASCADE 4.5.7 Exterior deck drains CASCADE POWER BARGE Drafted: 31.08.1999 Revision: 01.08.00 Page 1/9 ESPERANZA TAT/TKU TKU(sa3\ Exhaust System Cc 4.3.6 Table of Contents: 4.3.6 -1 Safety regulations 4.3.6 -2 System description 4.3.6 -2.1 Operating points and design of the system 4.3.6 - 2.1.1 Pressure 4.3.6 - 2.1.2 Temperatures 4.3.6 - 2.1.3 Design 4.3.6 -2.1.4 Exhaust silencer 4.3.6 -2.1.5 Waste-heat boiler 4.3.6 - 2.1.6 Expansion fittings and system supports 4.3.6 -3 Monitoring system 4.3.6 -4 Commissioning, operation and maintenance of the plant 4.3.6 - 4.1 Commissioning 4.3.6 -4.2 Maintenance 4.3.6-5 Possible system malfunctions and corrective measures Drawings: 4.3.6-6 Exhaust schematic MBD- C11.83032-0017 Exhaust system MBD- B11.68000-0560, Sheet 1-3 43.6-7 Description of accessories see Plant Accessories appendix POWER BARGE ESPERANZA Issued: 09.02.2000 Revision: Page 1 of 10 Dr. SanticMaw Exhaust System CG 4.3.6 4.3.6-1 SAFETY REGULATIONS General: e The plant must only be used for the intended purpose for which it has been constructed, and which is given in the technical specifications. Any other use beyond that shall be considered not a proper use. The manufacturer accepts no liability for any damage resulting therefrom; any risks involved shall be borne by the operator. . ° The proper intended use also includes following the assembly, disassembly, commissioning, operating, and maintenance instructions issued by the manufacturer. e No alterations may be made to the system without the explicit permission of MBD and the accessory manufacturer. In particular, adding or removing parts is not permitted. e Repairs must only be made using OEM parts. Any use of components from other manufacturers which have not been explicitly approved by the equipment manufacturer is not permitted. DANGERS IF SAFETY REGULATIONS ARE NOT OBSERVED e Not observing the safety instructions can mean danger to people, the environment, or the system. Not observing the safety instructions can also lead to the loss of any guarantees on system components. Safety notes: e The system must only be operated, serviced, and repaired by personnel trained and instructed for this. e Actions which impair the safety of the system are not permitted. e The insulation on the exhaust pipe near the controls must not be removed, because of the risk of fire or accidents. e Observe fire-prevention regulations concerning distances to flammable objects. e The insulation on the exhaust pipe within the engine room must not be removed (to prevent injury and increased thermal radiation). POWER BARGE Issued: 09.02.2000 Revision: Page 2 of 10 ESPERANZA Dr. Santic(aN Exhaust System G 4.3.6 4.3.6-2 SYSTEM DESCRIPTION The exhaust gas system is shown in the following drawings: MBD Exhaust schematic No. C11.83032-0017 MBD Exhaust system No. B11.68000-0560, Sheet 1-3 The function of the exhaust system is to vent the waste gases from combustion to the atmo- sphere. Diesel engines No. 2, 4 and 6 are each provided with a waste-heat boiler, in which part of the usable heat in the exhaust gases is utilized for steam generation. OPEN-AIR Exhaust system schematic diagram There are two exhaust systems of different types in the plant: e Exhaust system with waste-heat boilers — Engines 2(B), 4(D) and 6(F) e Exhaust system without waste-heat boilers — Engines 1(A), 3(C), 5(E) and 7(G) POWER BARGE Issued: 09.02.2000 Revision: Page 3 of 10 ESPERANZA Dr. Santic(max Exhaust System C 4.3.6 The exhaust system with waste-heat boilers consists of the following main components: — Silencer (SLO02) for muffling the exhaust noises; attenuation factor 35 dB(A) — System drains — Waste-heat boiler (1HE006) (see Section C 4.3.4 "Steam system”) — Expansion fittings (EB) after each turbocharger and ahead of the boiler inlet to absorb fluctuations in length of components due to temperature stresses and vibrations — Y-shaped pipe to combine the exhaust pipes from two rows of cylinders — Insulation as protection against body contact, and to reduce thermal radiation losses The exhaust system with waste-heat boilers consists of the following main components: — Silencer (SLO02) for muffling the exhaust noises; attenuation factor 35 dB(A) — System drains — Expansion fittings (EB) after each turbocharger and ahead of the boiler inlet to absorb fluctuations in length of components due to temperature stresses and vibrations — Y-shaped pipe to combine the exhaust pipes from two rows of cylinders — Insulation as protection against body contact, and to reduce thermal radiation losses 4.3.6 -2.1 Operating points and design of the system 4.3.6-2.1.1 Pressure The back-pressure of the exhaust gases in the exhaust system without waste-heat boilers will amount to about 1800 Pa (18 mbar). The precise values must be determined during commissioning. The maximum permissible resistance in the system (exhaust back-pressure after the turbocharger) in the exhaust system without waste-heat boilers should not exceed 25 mbar. The maximum permissible resistance in the system (exhaust back-pressure after the turbocharger) in the exhaust system with waste-heat boilers should not exceed 30 mbar for fouled boilers. The resistance is determined during commissioning. If the resistance registered exceeds the maximum permissible values given above, consult MBD. If the resistance increases beyond the permissible value in operation, the boiler and possibly other internals must be cleaned on the exhaust-gas side. Note that, as the exhaust back-pressure increases, the fuel consumption and the exhaust gas temperatures rise, which results in greater thermal stresses on the engine. Therefore, the waste-heat boiler should be cleaned at regular intervals (see Section C 4.3.4, "Steam System” concerning this). POWER BARGE Issued: 09.02.2000 Revision: Page 4 of 10 ESPERANZA Dr. Santic(mas Exhaust System © 4.3.6 4.3.6 -2.1.2 Temperatures The temperatures, as a function of engine load, are given in the operating instructions or in the engine's acceptance record. The exhaust temperature measuring facility is not able to do absolute measurements of temperature; only comparative measurements are possible. Deviations between the individual cylinders can be determined in this way. In order to avoid conditions in the exhaust heat exchanger (waste-heat boiler) dropping below the dewpoint, the exhaust outlet temperature should not be allowed to fall below about 220°C when running on high-sulphur HFO (and about 180°C in LFO operation). The outlet temperature increases relatively rapidly with increasing fouling of the boiler heating surface, and reaches a steady state at a certain thickness of deposit. The intervals between cleaning are determined by the plant operator (see Section C 4.3.4 "Steam System”). 4.3.6-2.1.3 Design The exhaust gas pipe is appropriately insulated with respect to thermal losses, exhaust temperature, and accident prevention. The temperature difference between full load and standstill creates a thermal expansion of the exhaust system. The system is designed so that it can expand freely without any major internal stresses. The expansion fittings are installed prestressed. The specified initial tension must be observ- ed when installing a replacement expansion fitting. The expansion fittings (Item 04) ahead of the boiler and the silencer are prestressed in the axial direction; installed dimension 454 mm (for details, see B11.68000-0560 Sheets 1-3). The expansion fittings (Item 03) after the turbocharger are installed with a lateral initial tension of -25 mm, as shown in the diagram. Laterale pretension -25 mm +25 mm (cold operation condition) (warm operation condition) Lateral prestressing of expansion fitting after turbocharger POWER BARGE issued: 09.02.2000 Revision: Page 5 of 10 ESPERANZA Dr. SanticES Exhaust System © 4.3.6 Js 49.0 i 4 pele 4 i z g +-—1Ts5 z + 27.00 a / 4 8 4 1520%6. L+ 23,7 Ke I f ] Wy sit a J+ 18,75 | gE F | + 14,233 i q 3 4 ps ; he_39 30 Bal | op | sus | @@@raz| saa i =, PG Ly e \XTli@ 5 Kf las 1 | SN 1 own % = = + 8,00 HEP conan aca = | 3 ap 05-06 q Exhaust system with waste-heat boiler POWER BARGE ESPERANZA Issued: 09.02.2000 Revision: Dr. Santic Page 6 of 10(sass Exhaust System Cc 4.3.6 An expansion pipe and a sliding support are installed between the turbocharger and the fixed point in the boiler fastening (or the elbow fastening in the case of the system without waste- heat boilers). Thus the displacements are determined, ensuring an optimum effect of the expansion pipe downstream from the turbocharger (see drawing "Exhaust Gas System", No. B11.68000-0560, Sheet 1-3). 4.3.6-2.1.4 Exhaust silencer SL-002 The function of this absorption silencer is to muffle the exhaust noise by 35 dB(A). 4.3.6 -2.1.5 Waste-heat boiler 1HE006 See Section C 4.3.4, "Steam system”. 4.3.6 - 2.1.6 Expansion fittings and system supports See the drawing ,Exhaust Gas System", B11.68000-0560, Sheets 1-3. POWER BARGE Issued: 09.02.2000 Revision: Page 7 of 10 ESPERANZA Dr. SanticMA eee Exhaust System SC 4.3.6 4.3.6-3 MONITORING SYSTEM A monitoring system is provided. The monitoring facilities for the exhaust system consists of several local indicating instruments and a remote-monitoring system. In the exhaust systems with waste-heat boilers, each waste-heat boiler has its own temperature monitoring system. The essential temperatures, such as the exhaust-gas inlet and outlet temperatures, can be monitored visually with this system. The degree of fouling of the boiler can be determined from the exhaust outlet temperature. During commissioning, the temperatures are noted in the boiler manual. As fouling of the heating surfaces increases, the exhaust outlet temperature rises and the steam generation decreases. See also the List of Measuring and Control Devices, $11.99400-0651, Sheets 41-43, and the Engine Description. A number of the exhaust parameters are monitored in the EDS system (CoCos) for the purpose of system diagnosis and plant logs. See Section C 3.85 Monitoring System - EDS (CoCoS). POWER BARGE Issued: 09.02.2000 Revision: Page 8 of 10 ESPERANZA Dr. SanticBaw Exhaust System Cc 4.3.6 4.3.6-4 START-UP, OPERATION AND MAINTENANCE OF THE PLANT 4.3.6 - 4.1 Start-Up The following points must be observed during start-up and operation: e Maintain any distances to flammable objects prescribed by fire-safety regulations. e The insulation of the exhaust pipe near the controls must not be removed, for reasons of fire and accident prevention. e The insulation of the exhaust pipe within the engine room must not be removed (to prevent injuries and increased thermal radiation. In the exhaust system with waste-heat boilers, note that a shut-down waste-heat boiler must not be put into operation until the temperature of the exhaust pipe has dropped to ca. 150- 480°C. This means that the engine must be switched off first, followed by a period of waiting for the system to cool. Then the engine can be re-started. (See Section C 4.3.4, Steam System.) e This procedure prevents possible steam hammering in the boiler system. e Before starting, fill the drain traps with water. The entire system is designed for continuous operation. Due to the use of HFO, special attention must be paid to the possibility of sulphur corrosion. For this reason, the exhaust temperature during continuous operation must be kept higher than 220°C. 4.3.6 - 4.2 Maintenance The following points must be observed when operating the plant: e The drain traps in the exhaust pipes of all engines must be cleaned mechanically at regular intervals. e Make sure to fill the traps with water whenever they are cleaned. TENTION! If drain traps are dry, the exhaust gases will escape through the drain pipe. e The supports (fixed and sliding points) of the exhaust pipe must be checked once a year. The fixed point is at the bottom of the boiler, or on the pipe bend ahead of the silencer. All other supports or fastenings are sliding points. The fixed points are labelled FP, and the sliding points SP (see Drawing B11.68000-0560, Sheets 1-3). e As fouling of the heating surfaces increases, the exhaust outlet temperature rises and the steam generation decreases. So the waste-heat boiler must be cleaned of soot at regular intervals (intervals for soot washing are given in the description of the waste-heat boiler, Section 4.3.7-7, Plant Accessories). This soot washing should only be done during operation, if possible. This will ensure that the soot particles are ejected to the surroundings with the flow of exhaust gas. Maintenance of the boiler consists mainly of thorough cleaning of the heating surfaces. If these are very fouled, mechanical cleaning is advisable. POWER BARGE Issued: 09.02.2000 Revision: Page 9 of 10 ESPERANZA Dr. SanticMaw Exhaust System C 4.3.6 4.3.6-5 POSSIBLE SYSTEM MALFUNCTIONS AND CORRECTIVE MEASURES (TROUBLE SHOOTING) If the engine has been shut down for a longer period, condensate and rainwater can collect in the exhaust pipe. Therefore it is necessary to blow out the engine before start-up. See the engine operating manual, and Section A 4.9 "Blowing Out of Engine”. With regard to possible system malfunctions and corrective measures, please consult the operating instructions in the Engine Descriptions. POWER BARGE Issued: 09.02.2000 Revision: Page 10 of 10 ESPERANZA Dr. SanticROHRLISTE PIPING SCHEDULE n EEEENT RAPS TEGHITEAL DATA 7 Lon) SUSEATEEARO. ; eat 7 eowusr ong, gyeary ax [296 _[ 97 oe | oe bo xo. [BE ROFRLETTUNG/PIPING apeen, ¢ Hi asc | 136 700 | t00x lea Jeger | sezercwmanscescerrrion — |vewvenon] e15/70 (ey | D 7 ze | save | took Sas TS Tanne ToRBSeNatER ‘SEG: sso10 i 14 [SAGs Gas PIPE tnette 1100 p ase | see = : OPEN-AIR << soe _| [5+ ARRAS Gat orer ia $500 MAX PERMISSIBLE PRESSURE DRO: 260 16 W.C_(25 YEAR) P H SunESSENE Tag Ly a Gos 7 [oRAIN PIPE "SL002 so Bo» Beh scorer eens 1 Teaatt Sipe ap 100 SIN? PS ROEs 2.5.5.6 : 3 5 | IGASLETL lL. Gals 7 [eiritisr cas PIPE ne RT 1600 E | ' | ZUBEHOERLISTE EQUIPMENT LIST els Bow. /LIEFERT ‘$L0028] || QUIEN tbe SUPPLY. BENENNUNG TECHNISCHE DATEN | Veawese. 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Howe Z jai essoecoese at eon - Grown 2m oxo¢ = a opens nish = Bienen 19 iy SERRE ast ang EE EE fore VERONLNGSELEDH 10M THICK ANSICHT V E COVERING SHEET AND VIEW V 3 baie ict Techical Services | DETAIL K DETAIL L/M pooner & |_ muss cena | an a 3 Cate eeeeee-e EE a4 2-23 ain Ife 4 Bouarsaguann 1 : 0 ow unten Ty Pemonsa msiel rs sauna he 2 | A asta cee Bross 2 m once MM, 1305, A | Tu Ly o4 02/29 | gece THEY 2 oH FE A | j—_BIcaTung_ 2 ra Bre LN $4 % segseumesrren 22-23 Pee ¥ + i r Bie % ggorsuntssay.sen | ; | sneha | 4 ee O2/aa— | | | een Rebngtgreenen™ = | a Os, TYP 482, 91.1600.216.0 \BGASSYSTEM ANORDNUNG} 5 g o'r 8 ON 1100/1600 t 1 Mieesecas, |EXHAUST GAS SYSTEM, ARRANGEVENT | q lIa11 68000-0540 [eAo]{ ua Exhaust gas system C 4.3.6 Accessories Annexe Designation Ident No. 680 A |Pipe silencer WILLICH&GERBER Drawing SE99-060 Drawing, supporting legs SE99-061 680 C_ | Universal expansion joint WITZENMANN/HYDRA = DN1100 Installation instructions sheet 1-4 Dimension drawing E11.68019-0288 680 D_ | Axial expansion joint WITZENMANN/HYDRA DN1600 Installation instructions sheet 14 Installation instructions 8201, 2 sheets Dimension drawing 1067446 7 Exhaust gas system Power Barge Issued: 22.02.00 Revision: Esperanza Simon TKU Page 1/1WITZENMANN Installation instructions Preliminary remarks Expansion joints are specially designed to absorb movement, which is compen- sated by the elastic forming of the bellow corrugations. Damage to the bellows reduces the service life and the pressure reliability, and may cause a expansion joint to fail prematurely. The instructions below, which apply to standard expansion joints 1), should be observed exactly in the interests of avoiding frequently made installation errors. If in doubt, please consult our team of specialists. We cannot accept any liability for damaged or incorrectly installed expansion joints. General - Check the expansion joint prior to installation for any damage, e. g. damage caused in transit - Take care not to damage the bellow — avoid severe shocks and knocks and do not throw - Do not fix any chains or ropes to the bellow section - Protect the bellow from weld spatters — cover over witha non-conducting material ~ Take steps to prevent electrical short-circuits from welding electrodes, ground ca- bles etc. — they may destroy the bellow - Keep foreign bodies (dirt, cement, insulating materials) away from both the inside and outside of the bellow corrugations — check inside before assembly and out- side after assembly ~ Remove the pretensioning brackets and transportation safety guards after installa- tion — not before ~ Fit a metal cover before insulating with mineral wool. ee ')Altemative or additional measures may be necessary for special designs.Hydra WITZENMANN — Take great care to avoid torsional strain during installation (and later during opera- tion; Figs. 19.1 and 19.2) — Never exceed the permissible test pressure — HYDRA expansion joints are maintenance-free. Guide bearing SY] IN - Anchor Fig. 19.1 Fig. .19.2 Pipe with axial expansion joint Pipe with lateral expansion joint Distance between guides Leinmm s+ ze Ar 7 sf acacel |! 3 = Po PT ra pi i | i 2 t — ~ - : ; ; iy i ah pif i > - 5 25 50 80 100 150 200 300400 io d : Fig. 19.3 Nominal diameter ON Distances between pipe guides SeEE eH Hert ee eee eee eee eee Eee eed ee eer Herero enero eEee- eee Haare EeeHydra WITZENMANN Axial and universal expansion joints — Provide adequately sized anchors at the ends of the pipe sections, to enable the axial reaction force at test pressure, the adjusting force of the expansion joint and the frictional forces of the pipe supports to be absorbed — Install one expansion joint only between two anchors — If several axial expansion joints are fitted along a straight pipe section, they must be separated by means of (light) intermediate anchors. — Thé pipe with the axial expansion joints must be guided (see Figs. 19.3 and 19.4 for distances). Guides are required on both sides of the axial expansion joint at a distance of approx. 3 DN (the guide function is performed adequately by a anchor). Inner sleeves and outer protective sleeves are not normally suitable for guiding pipes. — The pipe must be flush at the point at which the expansion joint is installed — Do not use the expansion joint to compensate for misalignment — Pretension axial expansion joints after assembly (apart from the designs which are pretensioned in the factory) — normally to 50% of the movement — taking into account the direction of the movement and the assembly temperature. Fig. 19.4 Fig. 19.5 Guide distances for pipes Vibrating aggregate with with axial expansion joints axial expansion joint— anchor fitted directly at expansion jointHydra WITZENMANN — Pretension the pipe by displacing as necessary it close to an anchor and then sec- uring it — Before applying pressure to the pipe, secure the anchors and guides in position — the expansion joint will otherwise be elongated and become useless — Axial expansion joints are only permitted at machines and aggregates (e.g. to ab- sorb vibrations) if the stability of the aggregate is sufficient to absorb the axial reac- tion force (see P. 481 ff.) — Caution is necessary with flexibly supported aggregates (anchored expansion joints!) — Secure the pipe directly after the expansion joint (Fig. 19.5) — Use only expansion joints without inner sleeves (or possibly with special inner sleeves) to absorb vibrations. Anchored expansion joints — Provide adequately sized anchors for the pipe sections, to allow the adjusting forces of the expansion joint and the frictional forces of the pipe supports to be ab- sorbed — Use only one compensation system (lateral expansion joint, double-hinge system or triple-hinge system) between two anchors — If more than one compensation system is installed in the same pipe, it must be split up with intermediate anchors — Provide suitable pipe guides or suspensions in the region of the compensation system, to allow the forces due to weight to be absorbed — note the transversal movement of the pipes! — When installing hinged expansion joints, make sure that the pivots are correctly positioned — parallel to one another and perpendicular to the direction of movement — Take care to fit the tie rods in a position where they can function correctly (see Chapter 11, “Positioning expansion joints”). — Pretension hinge systems after assembly — normally to 50% of the movement — taking into account the direction of movement and the assembly temperature Pretension the pipe by displacing it close to an anchor and then securing it.Bock DIESELABGASLEITUNG-BETRIEBSDATEN DIESEL EXHAUST PIPING SERVICE DATA 2 1210 (32 BOHRUNGEN BETRIEBSDRUCK p= 25 mbar o @ 1180 SERVICE PRESSURE el® a 222 BETRIEBSTEMPERATUR t= 550 °C 5 y i SERVICE TEMPERATURE a i 1 HYDRA UNIVERSAL-KOMPENSATOR TYP UBZ 01.1100.504.0, PN 1 = A | STEHE_ZETCHNUNG.NR. z a OHNE INNERES ROHR, MIT BEIDSEITIGEN BOERDELFLANSCHEN z 2 AUS STAHL GEBOHRT NACH DIN 86044-1100 < ze BALG VIELWANDIG AUS EDELSTAHL 1.4541 a8 HYDRA-UNIVERSAL COMPENSATOR TYPE UBZ 01.1100.504.0, PN 1 Be 6] oS SEE DRAWING NO. m8 WITHOUT INSIDE PROTCTIVE SLEEVE, WITH FLOATING FLANGES E ON BOTH SIDES FROM STEEL TO DIN’ 86044-1100 BELLOW MULTI WALL FROM STEEL ALLOY 1.4541 KOMPENSATOR-BETR | EBSDATEN a COMPENSATOR SERVICE DATAS il 5 ALTERNATION e| BS OF LOAD 4 9 au al BENENNUNG TITLE AXIAL F1 | LATERAL F3] LASTSPIELE é mB a yee @ 1200 WAERMEDEHNUNG THERMAL EXPANSION 504 mm | 300 mm 1000 3 3 & SEEGANGBEWEGUNG | SHIP*S MOTION AT SEA [+ 22,8mm = 45 mm | 2108 DS MOTORSCHWINGUNG ENGINE VIBRATION + 15,2mm [+ 15,2mm | 2*108 2 AN-UND ABSTELLEN TURN ON / TURN OFF + 45 mm 76 mm 108 a FEDERRATEN SPRING RATE 41 N/mm | 34 N/mm a BETRIEBSBEWEGUNG OPERATING MOVEMENT 40 mm 55 mm MAX. ZUL. KRAFTE- MAX. ADMISIBLE-FORCES- @ 1111 MOMENTE AM TURBOLADER | MOMENTS ON TURBINE B000"N || 2400 _N VORSPANNUNG PRETENSION 50 % 50 % é | WIRKS . QUERSCHNITT EFFECTIVE AREA BELLOW © 10468 cm? Y T I FUER SENKRECHTEN - UND WAAGERECHTEN EINBAU. 8 1113 FOR VERTICAL AND HORIZONTAL INSTALLATION. + LATERAL (MM) MaBe ohne Toleranzangabe: B, mittel,nach DIN 7168 |}Kanten nach DIN 6784] Oberfl.nach DIN ISO 1302 q ss 150-¢2150 MM THEOR.KOMPENSATOR-DEHNUNG 550°C. Dimensions vithout tolerance indication: B,mediun acc. DIN 7168 |Edges acc. DIN 6784 | Surface acc. DIN ISO 1302 ze EXPANSION THEORETICALLY PREMISSIBLE 550°C. [rctcnanirurtrcggeter 7 custoner Org.to:] Aottraggeber 7 Customer: [Verwendungabereich 7 Range of application: 2 22 ALLGEMEIN / GENERAL =< hot Pe ALLGEMEIN i Zchg.-Nr. Lizenz / Org.No. Licence: |Werkstoff,Halbzeug/Mater ial = mm Seceee Ww) 1004 i Grp.-Zehg tr. —_| — z 50 « DEHNUNGSDIAGRAM Srp.Ora. Ho. votsteb / Scale: Behtetl-Sochnn: emameat| | z as EXPANSION DIAGRAM _Thodet oder Gesenk-Ne: 197 S| oe Datum None [Pattern or die No = 26 1999 Bate” | None = & PS gasim|50 05 [HueceLe AUNT VERSAL-KOMPENSATOR Geprurt su Checked [27.05 |HUE . DN { 100 : 1356 MM ee . Si ws 252 MM = [11 1397799 [31.05 HUE! z He tae ioe | [outa COMPENSATOR Zo State] Revision-No Date Name ee + AXIAL (MM) MAN ha 0 | | 1 Thtetonden eve 7 ertanated from MAM \ [E11 .68019-0288 Ale Wo 0 50 100 150 200 250 NEU Fis OF] | 9 . FEDEREATE. waa at ee HE : SPRING RATE AXIAL 41 N/MM oA /04 Zeichnung ist Eigentum der MAN B8¥ Diesel AG u. dem onvertraut dem HAN BBW sie ousgehdndigt hat.Gebrouch nur mit schriftl. Einvill igung der MAN B&W gestottet q 8 7 6 5 This draving is the property of MAN BEN Diesel AG ond is entrusted to those to vhom MAN BAM has handed it.Its use is subject to the written consent of MAN B&W. 7Hydra WITZENMANN Installation instructions Preliminary remarks Expansion joints are specially designed to absorb movement, which is compen- sated by the elastic forming of the bellow corrugations. Damage to the bellows reduces the service life and the pressure reliability, and may cause a expansion joint to fail prematurely. : The instructions below, which apply to standard expansion joints 1), should be observed exactly in the interests of avoiding frequently made installation errors. If in doubt, please consult our team of specialists. We cannot accept any liability for damaged or incorrectly installed expansion joints. General - Check the expansion joint prior to installation for any damage, e. g. damage caused in transit - Take care not to damage the bellow — avoid severe shocks and knocks and do not throw - Do not fix any chains or ropes to the bellow section - Protect the bellow from weld spatters — cover over with a non-conducting material - Take steps to prevent electrical short-circuits from welding electrodes, ground ca- bles etc. — they may destroy the bellow ~ Keep foreign bodies (dirt, cement, insulating materials) away from both the inside and outside of the bellow corrugations — check inside before assembly and out- side after assembly - Remove the pretensioning brackets and transportation safety guards after installa- tion — not before ~ Fita metal cover before insulating with mineral wool. ')Altemative or additional measures may be necessary for special designs. -1-Hydra WITZENMANN — Take great care to avoid torsional strain during installation (and later during opera- tion; Figs. 19.1 and 19.2) — Never exceed the permissible test pressure — HYDRA expansion joints are maintenance-free. ame e— Guide bearing AVN a Fig. 19.1 Fig..19.2 Pipe with axial expansion joint Pipe with lateral expansion joint 5 — g al a le = oT | a 7 I I 8 (ay zB | 1 | 35 4 5 ' | | 8 fe Poy 2° POST | 1 8, I | id 8 Y i ryt 5 i} On I—1—t t—+t { 5 25 50 80 100 150 200 300 400 ils Fig. 19.3 Nominal diameter DN Distances between pipe guidesHydra WITZENMANN Axial and universal expansion joints — Provide adequately sized anchors at the ends of the pipe sections, to enable the axial reaction force at test pressure, the adjusting force of the expansion joint and the frictional forces of the pipe supports to be absorbed — Install one expansion joint only between two anchors — If several axial expansion joints are fitted along a straight pipe section, they must be separated by means of (light) intermediate anchors. — The pipe with the axial expansion joints must be guided (see Figs. 19.3 and 19.4 for distances). Guides are required on both sides of the axial expansion joint at a distance of approx. 3 DN (the guide function is performed adequately by a anchor). Inner sleeves and outer protective sleeves are not normally suitable for guiding pipes. — The pipe must be flush at the point at which the expansion joint is installed — Do not use the expansion joint to compensate for misalignment — Pretension axial expansion joints after assembly (apart from the designs which are pretensioned in the factory) — normally to 50% of the movement — taking into account the direction of the movement and the assembly temperature. Fig. 19.4 Fig. 19.5 Guide distances for pipes Vibrating aggregate with with axial expansion joints axial expansion joint - anchor fitted directly at expansion jointHydra WITZENMANN — — Pretension the pipe by displacing as necessary it close to an anchor and then sec- uring it - Before applying pressure to the pipe, secure the anchors and guides in position — the expansion joint will otherwise be elongated and become useless — Axial expansion joints are only permitted at machines and aggregates (e.g. to ab- sorb vibrations) if the stability of the aggregate is sufficient to absorb the axial reac- tion force (see P. 481 ff.) — Caution is necessary with flexibly supported aggregates (anchored expansion joints!) — Secure the pipe directly after the expansion joint (Fig. 19.5) — Use only expansion joints without inner sleeves (or possibly with special inner sleeves) to absorb vibrations. Anchored expansion joints — Provide adequately sized anchors for the pipe sections, to allow the adjusting forces of the expansion joint and the frictional forces of the pipe supports to be ab- sorbed — Use only one compensation system (lateral expansion joint, double-hinge system or triple-hinge system) between two anchors — If more than one compensation system is installed in the same pipe, it must be split up with intermediate anchors — Provide suitable pipe guides or suspensions in the region of the compensation system, to allow the forces due to weight to be absorbed — note the transversal movement of the pipes! — When installing hinged expansion joints, make sure that the pivots are correctly positioned — parallel to one another and perpendicular to the direction of movement — Take care to fit the tie rods in a position where they can function correctly (see Chapter 11, “Positioning expansion joints”). — Pretension hinge systems after assembly — normally to 50 % of the movement — taking into account the direction of movement and the assembly temperature — Pretension the pipe by displacing it close to an anchor and then securing it. Le |NY UNA Expansion somes Important general instructions valid for every application: © jr weld-on or braze-on expansion joint: Protect bellows section of the expansion joint against splashes of weld (or filler) metal by covering it up. © For flanged expansion joint: tighten bolts crosswise; gasket must be centred; flange bolt holes must be aligned. Healer are Selmi sion during installation or later in use through un- favourable piping stresses. anchor © Protect bellows part of the expansion joint against severe mechanical stresses (hard knocks, throwing etc.). © After installation, check that the bellows corrugations are free from foreign particles (dirt, cement, insulating material etc.). © Provide enough anchors at pipe extremities and deflections, (The main factor for anchor loading is the force of reaction as ) product of the effective cross-section in cm? and operating pressure in atm.g.p.). Instructions for usa: © Avoid excessive pressure surges (result of wrong connections, water hammer ete.). © Prevent the penetration of aggressive media, although our standard expansion joint with an internal lining in stainless steel Material no. 4541 offers considerable safety in this respect. Additional instructions (supplement to page 1) when installing HYDRA Expansion Joints for absorbing axial movements: © Attach pipe supports (not only brackets) at the necessary intervals in such a way that the moving piping sections are in [Pp line (that the pipe thrust is co-axial). © Only one axial expansion joint must be inctalled between two anchors. When aral axial expansion joints are in- stalled, the straight section must be sub-divided by light intermediate anchors. © Ensure correct pre-setting, taking into account the installation temperature. E [bun 2+ nom.dia. 2+ nom.dia, anchor or guide total expansion absorbed guide I rn I CU = An [| Ht © The piping must not be subjected to either test pressure or Static pressure before anchors and guides have been fixed; otherwise the expansion joint will stretch and may be “-maged beyond repair. © ‘ne protective or guide sleeve, if fitted, is used to protect and/or stabilize the internally pressurized bellows; it never replaces the guides and supports normally needed for the piping. movements: ‘Bly, 3 “gp Huy lateral © Only one expansion joint must be installed between two anchors. When installing several expansion joints, the straight section must be sub-divided by light intermediate anchors. © Ensure correct pre-setting, taking into account the installation temperature. © The piping must not be subjected to either test pressure or static pressure before anchors and guides have been fixed; the expansion joint will otherwise stretch and may be damaged beyond repair. @ The angular rotation or lateral (offset) deflection possible in - each case, as well as the then still possible maximum pressure stress must be clarified with us as the manufacturer before installation. An expansion joint which absorbs angular or lateral movements does not normally have en internal or external protective sleeve. Additional instructions (supplement to page 1) when installing HYDRA Expansion Joints for absorbing vibrations in all directions: © As shown in the sketch, the output piping must be provided with an anchor anchor behind the expansion joint. © The vibrating assembly itself e.g. — a pump, must have enough stability to absorb the force of reaction as the product of the effective cross- section in cm? and operating pres- sure in atm. g. p. An expansion joint intended for ao absorbing vibration does not nor- vibrations in mally have an internal or external all directions Protective sleeve. ses These brief installation instructions cover the most important points for installing HYDRA Expansion Joints. If you require further information, please consult our Hand book no. 456 E. All HYDRA Expansion Joints are inspected and tested for leaktightness, WITZENMANN GMBH Metallschlauch-Fabrik Pforzheim D-7530 Pforzheim, Postfach 1280 Tel. (07231) 581-1, Telex 783828-0 englisch 82 01 miTUNA expansion somnts Important general instructions valid for every application: © _rweld-on or braze-on expansion joint: protect bellows section of the expansion joint against splashes of weld (or filler) metal by covering it up. © For flanged expansion joint: tighten bolts crosswise; gasket must be centred; flange bolt holes must be aligned. S @ Take care that the expansion joint is not subjected to tor- 10001 sion during installation or later in use through un- favourable piping stresses. © Protect bellows part of the expansion joint against severe mechanical stresses (hard knocks, throwing etc.). © After installation, check that the bellows corrugations are free from foreign particles (dirt, cement, insulating material etc.). © Provide enough anchors at pipe extremities and deflections. {The main factor for anchor loading is the force of reaction as (product of the effective cross-section in cm? and operating Pressure in atm.g.p.). Instructions for use: © Avoid excessive pressure surges (result of wrong connections, water hammer etc.). © Prevent the penetration of aggressive media, although our standard expansion joint with an internal lining in stainless steel material no, 4541 offers considerable safety in this respect. anchor Additional instructions (supplement to page 1) when installing HYDRA Expansion Joints for absorbing axial movements: © Attach pipe supports (not only brackets) at the necessary intervals in such a way that the moving piping sections are in line (that the pipe thrust is co-axial). f a @ Only one axial expansion joint must be i--talled between two anchors. When tal axial expansion joints are in- Stalled, the straight section must be sub-divided by light intermediate anchors. © Ensure correct pre-setting, taking into account the installation temperature, €2-nomdia. S2-nomdia. bl A rT CI ee total expansion absorbed guide HE bel anchor or guide © The piping must not be subjected to either test pressure or Static pressure before anchors and guides have been fixed; otherwise the expansion joint will stretch and may be C aged beyond repair. © ‘ine protective or guide sleeve, if fitted, is used to protect and/or stabilize the internally pressurized bellows; it never replaces the guides and supports normally needed for the piping. FOr Capanorun une for auoUrUIy anyurE: anu rascrer movements: ie oi S -£F = YS § — ee ot — angular lateral © Only one expansion joint must be installed between two anchors. When installing several expansion joints, the straight section must be sub-divided by light intermediate anchors. © Ensure correct pre-setting, taking into account the installation temperature. © The piping must not be subjected to either test pressure or static pressure before anchors and guides have been fixed; the expansion joint will otherwise stretch and may be damaged beyond repair. © The angular rotation or lateral (offset) deflection possible in - each case, as well as the then still possible maximum pressure stress must be clarified with us as the manufacturer before installation. An expansion joint which absorbs angular or lateral movements does not normally have an internal or external protective sleeve. Additional instructions (supplement to page 1) when installing HYDRA Expansion Joints for absorbing vibrations in all directions: © As shown in the sketch, the output piping must be provided with an anchor anchor behind the expansion joint. © The vibrating assembly itself e.g. = @ pump, must have enough stability to absorb the force of reaction as the product of the effective cross- section in cm? and operating pres- sure in atm. g. p. An expansion joint intended for 7 absorbing vibration does not nor- vibrations in mally have an internal or external all directions protective sleeve. Fea en nanan an Enna nn nnan ssn nan assess ane e Sra o Sa oaESSTESEEEOTONEIETEIEY These brief installation instructions cover the most important points for installing HYDRA Expansion Joints. If you require further information, please consult our Hand book no. 456 E. All HYDRA Expansion Joints are inspected and tested for leaktightness. WITZENMANN GMBH Metallschlauch-Fabrik Pforzheim 0-7530 Piorzheirn, Postfach 1280 Tel. {07231) 581-1, Telex 783828-0 E englisch 82 01