INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS
FIGURE 40A
FLEXIBLE CONNECTORS
150# FLANGED END SINGLE SPHERE CONNECTOR
INTRODUCTION
This instruction sheet includes installation, operation and maintenance procedures for flexible connectors.
APPLICATION
Flexible connectors are used to absorb thermal and seismic movement, absorb hydraulic shock, provide vibration and noise dampening, make installation easier and correct minor misalignment of piping and components.
STORAGE
Store the joint flat in a dry location, avoiding humidity and extreme temperatures. Place flanges face down and do not stack any heavy items on top of the expansion joints.
INSTALLATION
1. Specifications
Make sure that the expansion joint you are using meets the system's required ratings for pressure, temperature, vacuum, elastic materials and movements.
2. Alignment
Expansion joints are not intended to correct pipe misalignment, which should be no more than 1/8" in any direction. Using an expansion joint to make up for piping misalignment errors will reduce the rated movements and cause premature failure. If the pipe is misaligned, adjust fixation points, keeping in mind axial compression or elongation, as well as transverse movement and angular deflection when trying to make up for misalignments. Please see diagram and chart below.
BRAID LIMITS
Diagram illustrating four types of movement for flexible connectors: Axial Compression (showing the connector compressed), Axial Elongation (showing the connector stretched), Transverse Movement (showing the connector bending sideways), and Angular Deflection (showing the connector bending at an angle).
| Size | Maximum Axial Compression | Maximum Axial Elongation | Maximum Transverse Movement | Maximum Angular Deflection |
|---|---|---|---|---|
| 2-1/2 | 0.500" | 0.375" | 0.50" | 15° |
| 3 | 0.500" | 0.375" | 0.50" | 15° |
| 4 | 0.625" | 0.375" | 0.50" | 15° |
| 5 | 0.625" | 0.375" | 0.50" | 15° |
| 6 | 0.625" | 0.375" | 0.50" | 15° |
| 8 | 0.625" | 0.375" | 0.50" | 15° |
| 10 | 0.625" | 0.500" | 0.75" | 15° |
3. Anchoring
The alignment of the piping system should be adjusted and secured with fixation points as close as possible on each side of the rubber joints at a distance less than three times the pipe's nominal diameter. These fixation points must be installed when mounting a rubber joint with control rods or in the case of an elbow pipe. If there is considerable distance between two fixation points, guiding points can be installed to support and guide the pipe. Expansion joints should be installed on straight runs between anchors. Control rods should be used on all expansion joints to prevent excessive movements due to pressure thrusts or other circumstances.
Diagram showing a section of piping with a flexible connector. It illustrates the placement of anchors on the upstream and downstream pipes, control rods connecting the pipes to prevent excessive movement, and fixation points for securing the system. A separate view shows a cross-section of the piping with control rods and anchors.
4. Pipe Support
Do not carry any pipe weight on the expansion joint. The piping must be supported. When installing, take care that the rubber joint does not support compression or extension due to the weight of the upstream or downstream pipe. See note above for alignment that the joint isn't compressed or extended in service.
Mounting order:
- 1-Upstream pipe: anchor.
- 2-Downstream pipe: anchor.
- 3-Rubber joint.
When installing the rubber joint, take care that it is not twisted in any way. Verify that the upstream and downstream pipe alignment do not deviate more than 1/8" (3mm) and that the rubber joint does not support heavy weight.
CONTROL RODS – CONTROL OF EXTENSION
Schematic diagram labeled 'CONTROL RODS – CONTROL OF EXTENSION' showing an installation scheme with numbered points: 1) Anchor, 2) With control rods, 3) Fixation points, 4) Guiding points. The visual shows how these elements are applied to the piping system around the flexible connector.
5. Mating Flanges
Verify that the surfaces meeting the joint are perfectly clean, flat-faced type, and without cutting edges (pipe), thus avoiding damage to the joint surface. Insert the bolts on the arch side of the joint, thus avoiding direct contact with the rubber. The breech opening must match the flange-to-flange dimension of the expansion joint. Composite gaskets are required when attaching beaded end flange expansion joints to raised face flanges. Expansion joints are never to be installed next to butterfly or check valves.
6. Bolting Torque
Recommended torque values are in Table 8 for the flexible connector. Properly tighten the bolts per the sequence chart while following the torque values in Table 8. Do not overtighten as this can cause metal-to-metal contact. Due to installation offsets, environmental conditions, flange surfaces and operating pressures, the torque values are approximate.
| Nominal Pipe Size Expansion Joint I.D. Inch/(mm) | Step 1 FT-LBS (Nm) | Rest | Step 2 FT-LBS (Nm) | Rest | Step 3 FT-LBS (Nm) |
|---|---|---|---|---|---|
| 2.5 (65) | 18 (25) | 30 min. | 35 (50) | 60 min. | 50-60 (70-80) |
| 3 (80) | 25 (35) | 30 min. | 45 (60) | 60 min. | 60-75 (80-100) |
| 3.5 (90) | 25 (35) | 30 min. | 45 (60) | 60 min. | 60-75 (80-100) |
| 4 (100) | 25 (35) | 30 min. | 45 (60) | 60 min. | 60-75 (80-100) |
| 5 (125) | 25 (35) | 30 min. | 45 (60) | 60 min. | 60-75 (80-100) |
| 6 (150) | 30 (40) | 30 min. | 50 (70) | 60 min. | 60-75 (80-100) |
| 8 (200) | 30 (40) | 30 min. | 50 (70) | 60 min. | 60-75 (80-100) |
| 10 (250) | 30 (40) | 30 min. | 50 (70) | 60 min. | 75-85 (100-115) |
SEQUENCE CHART
Tighten opposing nuts/bolts gradually according to the following sequence:
Diagram illustrating the sequence for tightening bolts on the flexible connector. It shows a circular pattern with numbers indicating the order in which opposing bolts should be tightened, starting from 1 and proceeding through 12.
Do not paint or cover the joint with insulation. Covering the expansion joint prevents the detection of flange leaks and can also cause premature failure to the elastomer. If insulation is necessary, bring it up to the pipe flanges and leave the expansion joint exposed.
When performing heat-producing work, such as welding or burning, that is carried out within close range, cover or dismount the rubber joint. The heat can cause damage to the elastomer, resulting in premature failure.
MAINTENANCE
Bolt tightness should be checked daily within the first month after services and checked periodically thereafter. Retighten if necessary.
WARRANTY
- LIMITED WARRANTY: Subject to the limitations expressed herein, Seller warrants that products manufactured by Seller shall be free from defects in design, material, and workmanship under normal use for a period of one (1) year from installation but in no case shall the warranty period extend longer than eighteen months from the date of sale. This warranty is void for any damage caused by misuse, abuse, neglect, acts of God, or improper installation. For the purpose of this section, “Normal Use" means in strict accordance with the installation, operation, and maintenance manual. The warranty for all other products is provided by the original equipment manufacturer.
- REMEDIES: Seller shall repair or replace, at its option, any non-conforming or otherwise defective product, upon receipt of notice from Buyer during the Manufacturer's warranty period at no additional charge. SELLER HEREBY DISCLAIMS ALL OTHER EXPRESSED OR IMPLIED WARRANTIES, INCLUDING, WITHOUT LIMITATION, ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS OR FITNESS FOR A PARTICULAR PURPOSE.
- LIMITATION OF LIABILITY: UNDER NO CIRCUMSTANCES SHALL EITHER PARTY BE LIABLE TO THE OTHER FOR INCIDENTAL, PUNITIVE, SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY KIND. BUYER HEREBY ACKNOWLEDGES AND AGREES THAT UNDER NO CIRCUMSTANCES, AND IN NO EVENT, SHALL SELLER'S LIABILITY, IF ANY, EXCEED THE NET SALES PRICE OF THE DEFECTIVE PRODUCT(S) PURCHASED DURING THE PREVIOUS CONTRACT YEAR.
- LABOR ALLOWANCE: Seller makes NO ADDITIONAL ALLOWANCE FOR THE LABOR OR EXPENSE OF REPAIRING OR REPLACING DEFECTIVE PRODUCTS OR WORKMANSHIP OR DAMAGE RESULTING FROM THE SAME.
- RECOMMENDATIONS BY SELLER: Seller may assist Buyer in selection decisions by providing information regarding products that it manufactures and those manufactured by others. However, Buyer acknowledges that Buyer ultimately chooses the product's suitability for its particular use, as normally signified by the signature of Buyer's technical representative. Any recommendations made by Seller concerning the use, design, application, or operation of the products shall not be construed as representations or warranties, expressed or implied. Failure by Seller to make recommendations or give advice to Buyer shall not impose any liability upon Seller.
- EXCUSED PERFORMANCE: Seller will make a good faith effort to complete delivery of the products as indicated by Seller in writing, but Seller assumes no responsibility or liability and will accept no back-charge for loss or damage due to delay or inability to deliver, caused by acts of God, war, labor difficulties, accidents, inability to obtain materials, delays of carriers, contractors or suppliers or any other causes of any kind whatever beyond the control of Seller. Under no circumstances shall Seller be liable for any special, consequential, incidental, or indirect damages, losses, or expense (whether or not based on negligence) arising directly or indirectly from delays or failure to give notice of delay.
