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STAMPED is an industry-accepted acronym used to determine the 7 detailed specifications required for a quality hose assembly.
S stands for SIZE: Inside Diameter (I.D.), Outside Diameter (O.D.) and Length
T stands for TEMPERATURE of the material being conveyed and the environmental conditions
A stands for APPLICATION: the conditions of use
M stands for the MATERIAL being conveyed, type and concentration
P stands for the PRESSURE to which the assembly will be exposed
E stands for ENDS: the style, type, orientation, attachment of the hose ends
D stands for DELIVERY: requirements for testing, quality, packaging and shipping
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Open in new tab Rubber, Metal, PTFE, and Fabric Expansion Joints
WARNING:
Failure to follow the installation instructions may cause premature failure and/or rupture of the unit resulting in property damage, serious personal injury, or even death.
Service Conditions
Ensure the expansion joint rating for temperature, pressure, vacuum and movements match the system requirements. Contact UIP International, Inc. for advice if system requirements exceed those of the expansion joint selected. Make sure the elastomer selected is chemically compatible with the process fluid or gas.
Alignment
Expansion joints are not typically designed to compensate for piping misalignment errors. Piping should be lined up within 1/8”. Misalignment reduces the rated movements of the expansion joint and can induce severe stress and reduce service life. Pipe guides should be installed to keep the pipe aligned and to prevent undue displacement.
Anchoring
Solid anchoring is required wherever the pipeline changes direction, and expansion joints should be located as close as possible to anchor points. If anchors are not used, the pressure thrust may cause excessive movements and damage the expansion joints.
Pipe Support
Piping must be supported so expansion joints do not carry any pipe.
Mating Flanges
Install the expansion joint against the mating pipe flanges and install bolts so that the bolt head and washer are against the retaining rings. If washers are not used, flange leakage can result–particularly at the split in the retaining rings. Flange-to-flange dimensions of the expansion joint must match the breech type opening. Make sure the mating flanges are clean and are flat-face type or no more than 1/16” raised face type. Never install expansion joints that utilized split retaining rings next to wafer type check or butterfly valves. Serious damage can result to a rubber joint of this type unless installed against full face flanges.
Tightening Bolts
Tighten bolts in stages by alternating around the flange. If the joint has integral fabric and rubber flanges, the bolts should be tight enough to make the rubber flange O.D. bulge between the retaining rings and the mating flange. Torque bolts sufficiently to assure leak-free operation at hydrostatic test pressure. Bolt torquing values are available. If the joint has metal flanges, tighten bolts only enough to achieve a seal and never tighten to the point that there is metal-to-metal contact between the joint flange and the mating flange.
Storage
Ideal storage is a warehouse with a relatively dry, cool location. Store flange face down on a pallet or wooden platform. Do not store other heavy items on top of an expansion joint. Ten-year shelf life can be expected with ideal conditions. If storage must be outdoors, joints should be placed on wooden platforms and should not be in contact with the ground. Cover with a tarpaulin.
Large Joint Handling
Do not lift with ropes or bars through the bolt holes. If lifting through the bore, use padding or a saddle to distribute the weight. Make sure cables or forklift tines do not contact the rubber. Do not let expansion joints sit vertically on the edges of the flanges for any period of time.
Anchoring & Guiding the Piping System
It is generally stated that the proper location of rubber expansion joints is close to a main anchoring point. Following the joint in the line, a pipe guide or guides should be installed to keep the pipe in line and prevent undue displacement of this line. This is the simplest application of a joint, namely, to absorb the expansion and contraction of a pipeline between fixed anchor points.
Control Units
Control Units Used in Restraining the Piping System Control units may be required to limit both extension and compression movements.
Extension
Control units must be used when it is not feasible in a given structure to provide adequate anchors in the proper location.
In such cases, the static pressure thrust of the system will cause the expansion joint to extend to the limit set by the control rods which will then preclude the possibility of further motion that would over-elongate the joint. Despite the limiting action that control rods have on the joint, they must be used when proper anchoring cannot be provided. It cannot be emphasized too strongly that rubber expansion joints, by virtue of their function, are not designed to take end thrusts and, in all cases where such are likely to occur, proper anchoring is essential. If this fact is ignored, premature failure of the expansion joint is a foregone conclusion.
Compression
Pipe sleeves or inside nuts can be installed on the control rods. The purpose of the sleeve is to prevent excessive compression in the expansion joint. The length of this pipe sleeve should be such that the expansion joint cannot be compressed beyond the maximum allowable compression.
Specifications
The exact number of control rods should be selected on the basis of the actual design/test pressure of the system. Always specify the mating flange thickness when ordering control unit assemblies.
Control Unit Assemblies
When an elastomeric expansion joint with a control unit assembly is to be installed directly to a pump flange, special care must be taken. Make sure that there is sufficient clearance behind the pump flange not only for the plates, but also for the nuts, bolts and washers. In cases where there is not sufficient clearance, the control rod plates on the pump end can be mounted behind the expansion joint flange if the expansion joint flange has a metal flange. If the elastomer expansion joint has an integral flange with split retaining rings, this method is not usually recommended as the split retaining rings may not have enough strength to withstand the total force encountered.
Control Unit Installation
- Assemble expansion joint between pipe flanges to the manufactured face-to-face length of the expansion joint. Include the retaining rings furnished with the expansion joints.
- Assemble control rod plates behind pipe flanges. Flange bolts through the control rod plate must be longer to accommodate the plate. Control rod plates should be equally spaced around the flange. Depending upon the size and pressure rating of the system, 2, 3 or more control rods may be required.
- Insert rods through top plate holes. Steel washers are to be positioned at the outer plate surface. An optional rubber washer is positioned between the steel washer and the outer plate surface.
- If a single nut per unit is furnished, position this nut so that there is a gap between the nut and the steel washer. This gap is equal to the joint’s maximum extension (commencing with the nominal face-to-face length). Do not consider the thickness of the rubber washer. To lock this nut in position, either “stake” the thread in two places or tack weld the nut to the rod. If two jam nuts are furnished for each unit, tighten the two nuts together, so as to achieve a “jamming” effect to prevent loosening. Note: Consult UIP International, Inc. if there is any question as to the rated compression and elongation. These two dimensions are critical in setting the nuts and sizing the compression pipe sleeve.
- If there is a requirement of compression pipe sleeves, ordinary pipe may be used and sized in length to allow the joint to be compressed to its normal limit.
- For reducer installations, it is recommended that all control rod installations be parallel to the piping.
- Location: The expansion joint should always be installed in an accessible location to allow for future inspection or replacement.
Split Metal Rings
Retaining rings must be used to distribute the bolting load and assure a pressure tight seal. They are coated for corrosion resistance and drilled as specified.
The rings are installed directly against the back of the flanges of the joint and bolted through to the mating flange of the pipe. Steel washers are recommended under the bolt heads against the retaining rings; at a minimum at the splits. Rings are normally 3/8” (9mm) thick, but can vary due to conditions. The ring I.D. edge installed next to the rubber flange should be broken or beveled to prevent cutting of the rubber.
Additional Tips for Installation
- For elevated temperatures, do not insulate over a non-metallic expansion joint
- It is acceptable, but not necessary to lubricate the expansion joint flanges with a thin film of graphite dispersed in glycerin or water to ease disassembly at a later time
- Do not weld in the near vicinity of a non-metallic joint
- If expansion joints are to be installed underground, or will be submerged in water, contact UIP International, Inc. for specific recommendations
- If the expansion joint will be installed outdoors, make sure the cover material will withstand ozone, sunlight, etc. Materials such as EPDM and CSM are recommended. Materials painted with weather resistant paint will give additional ozone and sunlight protection
- Check the tightness of leak-free flanges two or three weeks after installation and re-tighten if necessary
- Inspect for damage during shipment, i.e. dents, broken hardware, water marks on carton, etc.
- Store in clean dry area where it will not be exposed to heavy traffic or damaging environment
- Use only designated lifting lugs
- Make the piping system fit the expansion joint by stretching, compressing or offsetting the joint to fit the piping, it may be overstressed when the system is in service
- It is good practice to leave one flange loose until the expansion joint has been fitted into position. Make necessary adjustments of loose flanges before welding.
- Install joint with arrow pointing in the direction of flow
- Install single Van Stone liners pointing in the direction of flow. Be sure to install a gasket between the metallic liner and Van Stone flange as well as between the mating flange and liner.
- With telescoping Van Stone liners, install the smallest I.D. liner pointing in the direction of flow
- Remove all shipping devices after the installation is complete and before any pressure test of the fully installed system
- Remove any foreign material that may have become lodged between the convolution
- Refer to EJMA standards for proper guides.
WARNING:
Expansion joints may operate in pipelines or equipment carrying units and/or gasses at elevated temperatures and pressures and may transport hazardous materials. Precautions should be taken to protect personnel in the event of leakage or splash.
Non-metallic joints should not be installed in inaccessible areas where inspection is impossible. Make sure proper drainage is available in the event of leakage when operating personnel are not available.
FLANGE BOLT TORQUE SPECIFICATIONS
When assembling flange connections, it is recommended that a full complement of clean, new and high-strength A193-B7 bolting is consistently utilized. When Stainless Steel bolting is used, it should consist of the following:
- A 320/A320M Class 2 B8 (304 SS)
- Class 2 B8M (316 SS) with A 194/A194M
- Grade 8 or 8A Nuts (for 304 SS)
- Grade 8M or 8MA (for 316 SS)
When other bolting materials are employed, user should ensure new bolting material strength properties exceed the calculated bolt stress values generated in establishing the piping connection.
The following practices are strongly recommended:
- Always utilized flat washers on both sides of the connection
- Ensure that the flange bolts are tightened with a calibrated torque wrench expressly for the specified bolt torques. Note: For anti-seize compounds, the torque values may vary. Please contact UIP International, Inc. for more information
- Firmly secure the flange bolts with a torque wrench utilizing a “criss-cross” pattern that alternately tightens the bolts located 180 degrees apart
- Employing the above mentioned pattern, tighten the bolts in 20% increments of the final bolt torque until 80% of the final bolt torque has been accomplished
- To tighten the final torque values, firmly tighten bolts sequentially clockwise one time around the flange. This procedure ensures the bolts have been evenly stressed
- Extreme caution should be taken to avoid over-torqueing which can result in damage to plastic sealing surfaces
NOTE: When bolting dissimilar materials, always tighten to the lowest recommended torque of the components in the joint. Employing higher torques may cause excessive deformation of the “softer” material contained in the joint. Position a ½” thick spacer between UIP International, Inc. PTFE-lined pipe or fittings and other plastic-lined components, particularly valves, should differences in the diameters of the raised plastic faces occur. *Belleville washers are not recommended for use with PTFE-lined products.
Retorquing
A retorque should be applied a minimum of 24 hours after the initial torque or after the first thermal cycle. Retorquing enables seating of the plastic and allows for the relaxation of the bolts. In the event that the system is intended to perform at elevated temperatures, hot water should be circulated at the maximum operating temperature of the process (if possible) for at least 24 hours. This process will allow the pipe system to experience one full thermal cycle.
After cool-down, retorquing of the system should be completed. Torqueing need only be completed on the system in the ambient, cooled state and never while the process is at an elevated temperature. This could cause excessive force to be exerted to the plastic faces. Never attempt to disassemble a flange joint in a hot system. Wait until the system has cooled to ambient temperature.
Hydrotesting
Typically after initial torque and retorque, a hydrotest should be carried out utilizing ANSI requirements. Experience has demonstrated that if the aforementioned procedure is adhered to, very few, if any flange joints will fail the hydrotest. If a flange joint leaks, first re-check the torque values and tighten in 10% increments over the specified bolt torques until completely sealed. If, however, 150% of the specified torque value has been reached and the flange joint continues to leak, stop the process and disassemble the flange joint. It is likely that something else is wrong, i.e, a scratched plastic face. The hydrotest must be successfully completed, and any existing leaks corrected before the pipeline can be approved and commissioned.
Regular Inspection
Regular inspection for leaks and periodic bolt tightening in accordance with good maintenance practice is recommended. Never attempt this process at an elevated temperature as damaging excessive force may be applied to the plastic faces.
Below are suggested Torque Values. The amount of torque required is different for all applications. They can change depending on media, temperature, pressure, material type, mating flange type and surface, specialty joints, if lubricant is used, installation offsets and environmental conditions.
Bolt Torque Values
Size = ft./lbs of torque
1″ to 2-1/2″ = 25 lbs. to 75 lbs.
3″ to 6″ = 40 lbs. to 85 lbs.
8″ to 12″ = 45 lbs. to 95 lbs.
14″ to 18″ = 50 lbs. to 110 lbs.
20″ to 28″ = 60 lbs. to 150 lbs.
30″ to 40″ = 75 lbs. to 200 lbs.
42″ to 48″ = 90 lbs. to 250 lbs.
Above 48″ to 144″ can vary greatly from 100 lbs to 500 lbs. depending on the application. See disclaimer above.
ADDITIONAL CONSIDERATIONS FOR METAL BELLOWS EXPANSION JOINTS
Single | Double Metal Bellows Expansion Joints are designed to absorb a specified amount of movement by the flexing of the thin-gauge convolutions. If proper care is not taken during installation, it may reduce the cycle life and the pressure capacity of the expansion joints, which could result in a premature failure of the bellows element or damage to the piping system. The following recommendations are included to avoid the most common errors that occur during installation When in doubt about an installation procedure, contact the manufacturer for clarification before attempting to install the Expansion Joints.
ADDITIONAL CONSIDERATIONS FOR PTFE STYLE EXPANSION JOINTS
- Do not remove flange covers (and spacer sleeves) until expansion joint is to be bolted into position or sealing forces may become warped or damaged.
- Limit bolts with elastic stop nuts are factory set at the maximum travel position to prevent over-extension. Severe damage or personal injury can result if the limit bolts and stop nuts are removed, replaced, or altered to exceed the factory setting, or if non-locking nuts are installed. Install expansion joint and nominal setting except, when used to handle hot material, the units should be installed at nearly extended length to permit compression when piping expands due to heat. If used in chilled line, install at nearly compressed length to permit piping to contract.
- Sealing faces of expansion joints and adjacent flanges must be clean and smooth. Sharp corners and burrs on adjacent flange faces, and any extended scratches in either face, should be removed with fine emery cloth. If surface irregularities cannot be completely removed, it may be necessary to install at 1/16” thick gasket to obtain adequate sealing. Gaskets are recommended when connecting to flanges of dissimilar materials.
- Do not install nuts or connecting bolt heads behind expansion joint flanges or accidental wrench damage may occur to the TFE element. Expansion joint flanges are tapped with thread sizes to accommodate ANSI class 150 or optionally glass pipe bolt sizes. At most, two bolt threads should extend behind expansion joint flanges to prevent interference and possible damage when expansion joint is compressed. Do not bore cut threads.
- Do not over tighten bolts
- Expansion joints should not be tested to more than 1-1/2 times the working pressure as indicated in the following pressure/temperature curves. Anchors must also be designed to withstand test pressure conditions and all anchors and guides must be installed and checked prior to testing.
ADDITIONAL CONSIDERATIONS FOR FABRIC EXPANSION JOINTS
There are a couple of fundamental considerations when deciding the type of expansion joint to be used:
Is it a new plant?
If this is the case, it is more easily possible to create an optimal solution with respect to economic and technological concerns.
Does the plant already exist?
If this is the case, your expansion joint may need to be designed to operate in less than optimal conditions.
Questions for consideration:
Is the location of installation easily accessible? Do you require scaffolding or other complex equipment to install the expansion joint? Is a crane or other heavy equipment necessary to lift the expansion joint into place?
It is imperative that these and other similar conditions be considered prior to selecting the expansion joint design. It is at this stage that determination should be made on whether the expansion joint should be supplied open, closed on site, or supplied as a pre-assembled unit.
Movements:
The following movements, alone or in combinations, are compensated for by fabric expansion joints: Axial compression, axial elongation, lateral offset, angular offset and torsion.
The size and frequency of movements will affect the choice of expansion joint type. For large movements, convoluted and wave-form designs (moulded corners) or multi-layer expansion joints with scissor control guides should be used. They ensure that movements are controlled and help prevent damage to the fabric or heat pockets from occurring.
Mechanical Loads:
Fabric expansion joints can also compensate for vibrations and noise.
Consider the following when selecting an expansion joint: over stretching, abrasion by solid matter, hardened deposits and friction along the sleeve/baffle
Pressure:
Pressure affects the design (type of fabric and number of layers) of an expansion joint in the same way that temperature and medium do.
The following distinctions are made:
- Positive pressure (normal, peak)
- Negative pressure (normal, peak)
- Variations of pressure (pulsations)
- Pressure surges of design or operating pressure
Flow Rate:
To allow for greater flow efficiency, fitting a sleeve/baffle may be recommended. When flow rates exceed 10 m/sec., a sleeve/baffle construction can protect the expansion joint from flutter or pulsation. Elastomer expansion joints, however, do not require a sleeve/baffle even at flow rates of up to 40 m/sec.
Medium:
The flow, or medium, is a major factor in the design of an expansion joint.
- 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 v. Flushing/washing of ducts
Temperature:
Varying temperatures play an important role in the design and construction of the expansion joint. The external covering materials are protected from thermal damage by the utilization of insulating layers; the thickness and number of layers depends upon the temperature.
The most important temperature values to consider are:
- Operating temperature
- Excursion temperature (duration, frequency)
- Variations in temperature (duration, frequency)
- Design temperature
- Ambient temperature
External influences
Ambient temperature
Expansion joint designs are typically dependent upon a given ambient temperature. Higher ambient temperatures can be tolerated by adjusting the thickness of the insulation accordingly.
Weathering
Cover plates have been shown to provide an effective measure of protection against rain, snow, sand storms, and other forces of nature. They also protect the joint from falling objects and build-up of debris along the top of the joint.
Temperatures below dew point
When temperatures are below dew point, the resulting increase in humidity also increases the chemical load on the expansion joint, and the duct work. Temperatures may drop below dew point as a result of the process being utilized, the shut-down of the plant, or if the plant is at partial operating capacity.
When temperatures are below dew point, they will affect:
- Material choice for the purpose of chemical resistance
- Flange area design
- Construction
Proper use of insulation inside the expansion joint, and around the joint frame’s external surfaces can be very effective in controlling the negative consequences of consistently cycling through dew point.
Installation Do’s
- Inspect for damage during shipment, i.e., dents, broken hardware, water marks on carton, etc.
- Store in clean dry area where it will not be exposed to heavy traffic or damaging environment.
- Use only designated lifting lugs.
- Make the piping system fit the expansion joint. By stretching, compressing, or offsetting the joint to fit the piping, it may be over stressed when the system is in service.
- It is good practice to leave one flange loose until the expansion joint has been fitted into position. Make necessary adjustment of loose flange before welding.
- Install joint with arrow pointing in the direction of flow.
- Install single Van Stone liners pointing in the direction of flow. Be sure to install a gasket between the liner and Van Stone flange as well as between the matting flange and liner.
- With telescoping Van Stone line, install the smallest I.D. liner pointing in the direction of flow.
- Remove all shipping devices after the installation is complete and before any pressure test of the fully installed system.
- Remove any foreign material that may have become lodged between the convolutions.
- Refer to EJMA Standards for proper guide spacing and anchor recommendations.
Installation Don’ts
- Do not drop or strike carton.
- Do not remove shipping bars until installation is complete.
- Do not use hanger lugs as lifting lugs without approval of manufacturer.
- Do not use chains or any lifting device directly on the bellows or Bellows cover.
- Do not allow weld splatter to hit unprotected bellows. Protect with wet chloride-free asbestos.
- Do not use cleaning agents that contain chlorides.
- Do not use steel wool or wire brushes on bellows.
- Do not force-rotate one end of an expansion joint alignment of bolt holes. Ordinary bellows are not capable of absorbing torque.
- Do not hydrostatic pressure test or evacuate the system before proper installation of all guides and anchors.
- Pipe hangers are not adequate guides.
- Do not exceed a pressure test of 1-1/2 times the rated working pressure of the expansion joint.
- Do not use shipping bars to retain the pressure thrust if tested prior to installation.
The manufacturer’s warranty may be void if improper installation procedures have been used.
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Flange Installation
In addition to choosing the correct gasketing material, proper installation is crucial to ensure a leak free BFJA (Bolt Flange Joint Assembly). Most commonly, when there are leaks in a flange, it is assumed that it is due to a “gasket failure” however, that is rarely the case. The vast majority of the time, leakage occurs as a result of improper installation. Follow these basic guidelines when installing a gasket in a BFJA:
1) Properly inspect the gasket to ensure it is in good condition. The dimensions should be verified including the I.D., O.D., Bolt pattern (if applicable), and the thickness of the gasket. A visual inspection of the flange sealing surface should also be done to ensure it is free of any debris, lubricants and/or defects. All fasteners should meet the requirements including material, length, thread pitch and nut thickness. Lubricants should not be used to temporarily hold a gasket in place.
2) Align the gasket properly to be concentric with the flange ID and avoid protrusion into piping flow path, ensure gasket remains in proper place during assembly and that flanges are properly aligned and parallel to each other.
3) Bolts must be tightened in incremental steps to arrive at the target stress level using a properly calibrated load control device such as a torque wrench, or a stud tensioner. During the incremental torqueing steps, it is good practice to measure the flange gap at a minimum of four points at 90 degrees to each other around the flange OD at each step to assure even loading.
**UIP strongly encourages the reader to reference FSA/ESA document (FSA0009) FSA/ESA . Gasket Installation Procedures
How to Bolt Flanges
Bolting should be of sufficient strength to achieve proper compression of the gasket, to not only seal the joint, but to maintain the seal without exceeding the yield strength of the bolts being used. Torque values are based on using ASTM A193 Grade B7 studs and 2H heavy hex nuts lubricated with never seize. Since sheet gasket materials have micropores, they must be sufficiently compressed to reduce porosity. Without adequate compression the system pressure can force the contained fluid into the gasket and degrade it. Therefore, when installing the gasket it is important that good technique be followed including cleaning the flanges, inspecting the flange face and the bolts and bringing the flanges together parallel and in stages. Many field problems arise from improperly installed gaskets. According to the Fluid Sealing Association (FSA,) incorrect tightness is the leading reason gasketed joints fail. This can be prevented by following good bolting practice.
TORQUE
After installing a new gasket or seal it’s essential to tighten the fasteners with a torque wrench that’s been recently calibrated. Without this it’s impossible to know if the joint has been tightened to the required level. Friction between the nut, washers, flange faces and thread increases the torque measured at the wrench, possibly resulting in insufficient clamping force being applied to the gasket. Avoid this by applying a thin, uniform coating of high quality lubricant to the underside of bolt heads, nuts and washers and the thread itself. Take care to keep it off the gasket.
GASKET COMPRESSION
The gasket must be compressed uniformly to avoid material displacement. It’s also important to avoid deforming the flange faces. There are two aspects to consider: the bolt pattern and the tightening sequence.
BOLT PATTERN
To bring the joint together, fasteners should be tightened in opposite pairs. Start at 12 o’clock and then move to 6 o’clock. Then halve the angle between them, moving to the 3 and 9 o’clock pair. Halve the angle again, going to the pair closest to 1:30 and 7:30. Keep repeating until every bolt has been tightened.
TIGHTENING SEQUENCE
Following the pattern described above, insert the bolts and run up the nuts by hand.
Set the torque wrench to 30% of full torque and, using the pattern, tighten each fastener.
Repeat with the torque wrench at 60%.
Repeat again with the torque wrench at 100%.
Make a final pass, this time in a circumferential direction, ensuring each fastener is at the required torque.
GOOD BOLTING PRACTICE
Replacing gaskets and seals can be expensive, so whenever joints are made in pipes and ducting it’s important to ensure they don’t leak. One factor in achieving a good joint is to follow good bolting practice. Control the torque applied, the bolting pattern and the tightening sequence to avoid leaks.
ASME Bolt Torque Values
Bolt Torque Values for ASME B16.5 Series A Class 150# Flat Flanges
with A193 Grade B7 Bolts
For Full Face Homogenous Elastomeric Gaskets
| 0.50 | 4 | 0.50 | 9 | 14 | 19 |
| 0.75 | 4 | 0.50 | 12 | 17 | 23 |
| 1.00 | 4 | 0.50 | 14 | 21 | 28 |
| 1.25 | 4 | 0.50 | 16 | 24 | 32 |
| 1.50 | 4 | 0.50 | 19 | 28 | 37 |
| 2.00 | 4 | 0.63 | 33 | 49 | 66 |
| 2.50 | 4 | 0.63 | 45 | 67 | 90 |
| 3.00 | 4 | 0.63 | 49 | 73 | 97 |
| 3.50 | 4 | 0.63 | 49 | 73 | 97 |
| 3.50 | 8 | 0.63 | 30 | 45 | 60 |
| 4.00 | 8 | 0.63 | 33 | 49 | 66 |
| 5.00 | 8 | 0.75 | 41 | 61 | 82 |
| 6.00 | 8 | 0.75 | 46 | 69 | 92 |
| 8.00 | 8 | 0.75 | 66 | 99 | 132 |
| 10.0 | 12 | 0.88 | 64 | 96 | 128 |
| 12.0 | 12 | 0.88 | 93 | 140 | 186 |
| 14.0 | 12 | 1.00 | 134 | 201 | 268 |
| 16.0 | 16 | 1.00 | 120 | 181 | 241 |
| 18.0 | 16 | 1.13 | 132 | 198 | 264 |
| 20.0 | 20 | 1.13 | 124 | 187 | 249 |
| 24.0 | 20 | 1.25 | 173 | 260 | 347 |
Bolt Torque Values for ASME B16.47 Series A Class 150# Flat Flanges
with A193 Grade B7 Bolts
For Full Face Homogenous Elastomeric Gaskets
| Nominal Pipe Size (in) | # of Bolt Holes (in) | Size of Bolts (in) | Minimum Torque (ft. lbs.) | <70 durometer Shore A Preferred Torque (ft. lbs.) | >70 durometer Shore A Preferred Torque (ft. lbs.) |
|---|---|---|---|---|---|
| 26 | 24 | 1.25 | 238 | 238 | 318 |
| 28 | 28 | 1.25 | 224 | 224 | 299 |
| 30 | 28 | 1.25 | 248 | 248 | 331 |
| 32 | 28 | 1.5 | 309 | 309 | 412 |
| 34 | 32 | 1.5 | 283 | 283 | 377 |
| 36 | 32 | 1.5 | 309 | 309 | 411 |
| 38 | 32 | 1.5 | 356 | 356 | 474 |
| 40 | 36 | 1.5 | 328 | 328 | 438 |
| 42 | 36 | 1.5 | 354 | 354 | 472 |
| 44 | 40 | 1.5 | 339 | 339 | 452 |
| 46 | 40 | 1.5 | 354 | 354 | 473 |
| 48 | 44 | 1.5 | 342 | 342 | 456 |
| 50 | 44 | 1.75 | 470 | 470 | 626 |
| 52 | 44 | 1.75 | 502 | 502 | 669 |
| 54 | 44 | 1.75 | 535 | 535 | 713 |
| 56 | 48 | 1.75 | 528 | 528 | 705 |
| 58 | 48 | 1.75 | 561 | 561 | 747 |
| 60 | 52 | 1.75 | 530 | 530 | 707 |
NOTE 1: This torque table applies for 1/16” and 1/8” thick homogenous elastomeric gaskets. The pressure rating of the material may vary depending on the grade.
NOTE 2: The above-mentioned torque values are based on the maximum bolt stress of 60,000 psi. Bolt yield should be at least 80,000 psi.
NOTE 3: This table does not take flange strength into consideration. We recommend consulting the flange manufacturer to confirm the suitability of the above-mentioned values.
NOTE 4: Apply torque in increments. When the gasket extends past the O.D. of the flange by 1/4:” to 3/8”, stop tightening.
TORQUE
After installing a new gasket or seal it’s essential to tighten the fasteners with a torque wrench that’s been recently calibrated. Without this it’s impossible to know if the joint has been tightened to the required level. Friction between the nut, washers, flange faces and thread increases the torque measured at the wrench, possibly resulting in insufficient clamping force being applied to the gasket. Avoid this by applying a thin, uniform coating of high quality lubricant to the underside of bolt heads, nuts and washers and the thread itself. Take care to keep it off the gasket.
ASTM D2000 SPECIFICATIONS BROKEN DOWN
ASTM D2000, “Standard Classification for Rubber Products in Automotive Applications”, which is identical to a second standard, SAE J200, “Classification System for Rubber Products”. Once the fundamentals are broken down, ASTM D200 is easy to understand.
Line call outs include, the document number (D 2000), the revision year, the prefix letter “M”, the grade number, type and class designation, the hardness and tensile strength, and the suffix requirements if any.
Special requirements can be added using a “Z” call-out. This is typically done after the last call-out and number. Below are a few examples that we have seen over time:
Z1 – A14 Use Grade 4 requirements (Since grade 2 does not have A14 call outs, this designates which to use)
Z2 – Color Blue (Specific Color is required for a project)
Z3 – FDA 21 CFR 177.2600 complaint (Regulatory requirements need to be met)
The various callouts can be used to meet specific needs of an application. They can be used to specifically assure a given polymer time like, Z1- polymer EPDM, or to assure a specific grade–like Z1 – Medical Silicone.
Even without additional callouts, using the ASTM D2000 will give basic requirements. Typically, it is a minimum physical requirement for a heat age, oil age (depending on polymer), and a compression set test. Solely using these minimum callouts can help put controls in place to assure quality compounds are used — leading to a more robust part. An example would be ASTM D2000 M2BG710.
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UIP INTERNATIONAL, INC. FREIGHT POLICY
UIP International’s prepaid freight policy is as below:
Seller prepays freight to any one continental U.S. location for shipments totaling over $1,500 for camlocks or $5,000 for any combination of products thereof.
Prepaid freight includes one initial shipment and one backorder shipment. Any additional shipments made would be shipped at the Buyer’s expense including any additional backordered items. Buyer may choose to wait for all backordered items to ship together to be eligible for free freight.
For any questions regarding our freight policy, please contact us at sales@uipintl.com.
ONLINE PAYMENT PROCESSING
UIP International, Inc. accepts online payments. Please note: all credit card transactions are charged a 3.5% processing fee.
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EXPANSION JOINT TERMINOLOGY
Abrasion Resistance: The ability to withstand the wearing effect of a rubbing surface. In elastomers, abrasion is a complicated process, often affected more by compounding and curing than by the elastomer. Soft, resilient compounds, such as pure gum rubber are frequently specified.
Adhesion: The strength of bond between cured rubber surfaces or cured rubber surface and a non-rubber surface.
Ambient Temperature: The environment temperature surrounding the object under consideration.
Anchor: Terminal point or fixed point in a piping system from which directional movement occurs.
Angular Movement: The movement which occurs when one flange of the expansion joint is moved to an out of parallel position with the other flange. Such movement being measured in degrees.
Arch: That portion of an expansion joint which accommodates the movement of the joint.
ASTM INTERNATIONAL: This organization has developed methods of testing and classifying elastomers as well as setting standards, such as ASTM F 1123-87, Standard Specification for Non-Metallic Expansion Joints.
Atmospheric Cracking: Cracks produced on surface of rubber articles by exposure to atmospheric conditions, especially sunlight, ozone and pollution. Chlorobutyl, EPDM, CSM, Neoprene and Fluorelastomers are all highly resistant compounds.
Average Burst: Used by a manufacturer to determine Maximum Allowable Working Pressure. The average burst pressure is determined from a large number of burst tests on specimens of equal size, construction and grade.
Axial Compression: The dimensional reduction or shortening in the face-to-face parallel length of the joint measured along the longitudinal axis.
Axial Elongation: The dimensional increase or lengthening of face-to-face parallel length of the joint measured along the longitudinal axis.
Axial Extension: The dimensional lengthening of an expansion joint parallel to its longitudinal axis. Such movement being measured in inches or millimeters.
Baffle: A sleeve extending through the bore of the expansion joint with a full face flange on one end. Constructed of hard rubber, metal or Fluoroplastic, it reduces frictional wear of the expansion joint and provides smooth flow, reducing turbulence.
Bellows: See Arch or Expansion Joint.
Bench Test: A modified service test in which the service conditions are approximated, but the equipment is conventional laboratory equipment and not necessarily identical with that in which the product will be employed.
Bending Modululs: A force required to induce bending around a given radius; hence a measure of stiffness.
Blister: A raised spot on the surface or a separation between layers, usually forming a void or air-filled space in the rubber article.
Bloom: A natural discoloration or change in appearance of the surface of a rubber product caused by the migration of a liquid or solid to the surface. Examples: sulphur bloom, wax bloom. Not to be confused with dust on the surface from external sources.
Body: Carcass of the expansion joint.
Body Rings: Wire or solid steel rings embedded in the carcass used as strengthening members of the joint.
Bolt Hole Pattern or Drill Pattern: The systematic location of bolt holes in the expansion joint flanges, where joint is to be bolted to mating flanges.
Bore: A fluid passageway, normally the inside diameter of the expansion joint.
Burst Test: A test to measure the pressure at which an expansion joint bursts.
Capped End: A seal on the end of a sleeve joint or flange to protect internal reinforcement.
Carcass: Body of the expansion joint.
Cemented Edge: An application of cement around the edges of an expansion joint with or without internal reinforcement for protection or adhesion.
Cemented End: A capped end accomplished by means of cement.
Chalking: Formation of a powdery surface condition due to disintegration of surface binder or elastomer, due in turn to weathering or other destructive environments.
Coefficient of Thermal Expansion: Average expansion per degree over a stated temperature range, expressed in a fraction of initial dimension. May be linear or volumetric.
Cold Flow: Continued deformation under stress.
Compensator: See Expansion Joint
Compression Set: The deformation which remains in rubber after it has been subjected to and released from a specific compressive stress for a definite period of time, at a prescribed temperature.
Concurrent Movements: Combination of two or more types (axial or lateral) of movement.
Conductive: A rubber having qualities of conducting or transmitting heat or electricity. Most generally, applied to rubber products capable of conducting static electricity.
Connector: See Flexible Connector.
Control Rods or Units: Devices usually in the form of tie rods, attached to the expansion joint assembly whose primary function is to restrict the bellows axial movement range during normal operation. In the event of a main anchor failure, they are designed to prevent bellows over-extension or over-compensation while absorbing the static pressure thrust at the expansion joint, generated by the anchor failure.
Convolution: See Arch.
Coupling: See Expansion Joint.
Cracking: See Atmospheric
Cracking, Flex Cracking Crazing: See Atmospheric Cracking
Design Pressure: The maximum high temperature that the expansion joint is designed to handle during normal operating conditions. Not to be confused with excursion temperature.
Design Temperature: The maximum high or low temperature that the expansion joint is designed to handle during normal operating conditions. Not to be confused with excursion temperature.
Diameter, Inside: The length of a straight line through the geometric center and terminating at the inner periphery of an expansion joint.
Directional Anchor: A directional or sliding anchor is one which is designed to absorb loading in one direction while permitting motion in another. It may be either a main or intermediate anchor, depending upon the application involved. When designed for the purpose, a directional anchor may also function as a pipe alignment guide.
Drill Pattern: They systematic location of bolt holes on the mating flange to which the expansion joint will be attached. Usually meets a specific specification.
Duck: A durable, closely woven fabric.
Durometer: A measurement of the hardness of rubber. (also see Hardness).
Eccentricity: A condition in which the inside and outside of two diameters deviate from a common center.
EJMA: Expansion Joint Manufacturers Association (Metal Expansion Joints).
Elasticity: The ability to return to the original shape after removal of load without regard to the rate of return.
Electrical Resistivity: The resistance between opposite parallel faces of material having a unit length and unit cross section. Typically measured in Ohms/cm.
Elongation: Increase in length expressed numerically as a fraction or a percentage of initial length.
Enlarged End: An end with inside diameter greater than that of the main body of an expansion joint.
Excursion Temperature: The temperature the system could reach during an equipment failure. Excursion temperature should be defined by maximum temperature and time duration of excursion.
Face-to-Face (F/F): Dimension between the pipe flange faces to which the expansion joint will be bolted. This is also the length of the expansion joint when the system is in the cold position. Also see Pre-Compression and Pre-Set.
Fatigue: The weakening or deterioration of a material caused by a repetition of stress or strain.
Flange: See Integrally Flanged Type Expansion Joint.
Flanged End: Turned up or raised end made so that it can be bolted to an adjacent flange.
Flexible Connector: See Expansion Joint.
Flex Cracking: A surface cracking induced by repeated bending or flexing.
Flex Life: See Cycle Life.
Floating Flange: Metal flange which is grooved to contain the bead on each end of an expansion joint. The flange floats until lined up with mating bolt holes and bolted in place, and is used on spherical expansion joints.
Fluorelastomers: Highly resistant compounds.
Free Length: The linear measurement before being subjected to a load or force.
Friction: A rubber compound applied to an impregnating a fabric, usually by means of a calender with rolls running at different surface speed; hence the name “friction”. The process is called “frictioning”.
Frictioned Fabric: A fabric with a surface treatment which will bond two surfaces together when interposed between the surfaces. Also may be used to adhere to only one surface.
Hardness: Property or extent of being hard. Measured by extent of failure of the indentor point of any one of a number of standard hardness testing instruments to penetrate the product. (Also see Durometer.)
Heat Resistance: The ability of rubber articles to resist the deteriorating effects of elevated temperatures.
Helix: shape formed by spiraling a wire or other reinforcement around the cylindrical body of a rubber pipe.
Hydraulic Pressure: A force exerted through fluids.
Installed Length: See Face-to-Face.
Integrally Flanged Type Expansion Joint: An expansion joint in which the joint flanges are made of the same rubber and fabric as the body of the joint.
Lateral Deflection or Lateral Movement: Movement ore relating displacement of the two ends of the joint perpendicular to its longitudinal axis.
Lateral Offset: Refer to Lateral Deflection or Lateral Movement.
Limit Rods: Rods placed across an expansion joint from flange to flange to minimize possible damage to the expansion joint caused by excessive motion of the pipeline.
Lined Bolt Hole: A method of sealing exposed fabric in a bolt hole.
Liner: A sleeve extending through the bore of the expansion joint with a full face flange on one end. Constructed of hard rubber, metal or Fluoroplastic, it reduces frictional wear of the expansion joint and provides smooth flow, reducing turbulence.
Main Anchor: A main anchor is one which must withstand all of the thrust due to pressure, flow and spring forces of the system.
Mandrel: A form used for sizing and to support the expansion joint during fabrication and/or vulcanization. It may be rigid or flexible.
Mandrel Built: An expansion joint fabricated and/or vulcanized on a mandrel.
Maximum Burst: The theoretical (predetermined) burst pressure of an expansion joint.
Metal Reinforcement: Wire or solid steel rings embedded in the carcass used as strengthening members of the joint.
Misalignment: The out of line condition that exists between the adjacent faces of the flanges.
Movements: The dimensional changes which the expansion joint is designed to absorb, such as those resulting from thermal expansion or contraction. See Angular Movement, Concurrent Movement, Resultant Movement, Lateral Movement, Torsional Movement, Thermal Movement, Transverse Movement.
NMEJ: Non-Metallic Expansion Joint Division, Fluid Sealing Association.
O-A-L: Alternative term for the face-to-face dimension of the overall length of an expansion joint.
Oil Resistant: The ability to withstand the deteriorating effects of oil (generally refers to petroleum) on the physical properties.
Oil Swell: The change in volume of rubber due to absorption of oil.
Open Arch: Rubber face flange of sufficient thickness to form a tight seal against the metal flanges without the use of gaskets.
Operating Temperature: The temperature at which the system will generally operate during normal conditions.
Permeability: The ability of a fluid or gas to pass through an elastomer.
Permanent Set: The deformation remaining after a specimen has been stressed in tension or compression a prescribed amount for a definite period and released for a definite period.
Pipe Alignment Guide: A pipe alignment guide is framework fastened to some rigid part of the installation which permits the pipeline to move freely in only one direction along the axis of the pipe. Pipe alignment guides are designed primarily for use in applications to prevent lateral deflection and angular rotation.
Pipe Sleeve: See Compression Sleeves.
Ply: One concentric layer or ring of material, such as fabric plies in an expansion joint.
Pre-Compression: Compressing the expansion joint (shortening the F/F) so that in the cold position the joint has given amount of compression set into the joint. The purpose of pre-compression is to allow for unexpected or additional axial extension. This is performed at the job site.
Pre-Set: Dimension that joints are deflected to insure that desired movements will take place. See Lateral.
Proof Pressure Test: See Hydrostatic Test.
Pump Connector: See Expansion Joint.
Reducers: Expansion joints used to connect piping of unequal diameters.
Reinforcement: Flexible and supporting member between tube and cover; wire or solid steel rings embedded in the carcass as strengthening members of the joint.
Resultant Movement: The net effect of concurrent movement.
Retaining Rings: Used to distribute the bolting load and assure a pressure tight seal.
RMA: The Rubber Manufacturers Association, Inc. now known as American Rubber Products Manufacturers
SAE: The Society of Automotive Engineers. This organization has developed methods of testing and classifying elastomers.
Service Test: A test in which the expansion joint is operated under service conditions in the actual equipment.
Soft Cuffs: Designed to slip over the straight ends of the open pipe and be held securely in place with clamps.
Soft End: An end in which the rigid reinforcement of the body, usually wire, is omitted.
Specific Gravity: The ratio of the weight of a given substance to the weight of an equal volume of water at a specified temperature.
Static Wire: A wire incorporated in an expansion joint for conducting or transmitting static electricity.
Straight End: An end with inside diameter the same as that of the main body.
Sun Checking: See Atmospheric Cracking
Tapers: Reducing expansion joints used to connect piping of unequal diameters.
Temperature: See Ambient Temperature, Design Temperature, Excursion Temperature, Operating Temperature.
Tensile Strength: the force required to rupture a specimen. “Dumbbell” specimens are cut from flat stock by a die of specified shape. Large elongations require special considerations in holding specimens and measuring the test results.
Testing: See Bench Test, Burst Test, Hydrostatic Test, Service Test.
Thermal Movements: Movements created within the piping system by thermal expansion. Can be axial, lateral or torsional.
Top Hat Liner: Consists of a sleeve extending through the bore of an expansion joint with a full face flange on one end.
Torsional Movement: The twisting of one end of an expansion joint with respect to the other end about its longitudinal axis.
Tube: A protective, leak proof lining made of synthetic or natural rubber as the service dictates.
Under Gauge: Thinner than the thickness specified.
Van Stone Flange: A loose, rotating type flange, sometimes called a lap-joint flange.
Wire Reinforced: A product containing metal wire to give added strength, increased dimensional stability or crush resistance. See Reinforcement.
Wrap Marks: Impressions left on the cover surface by the material used to wrap the expansion joint during vulcanization. Usually shows characteristics of a woven pattern and wrapper with edge marks.
Gaskets are available in many types of materials. Here is a very basic list of material properties to help you in the selection of the proper gasket type. At UIP, we carry a vast selection of sheet rubber and gasket materials. Ask one of our experts for help in determining the best gasket material for your application!
RUBBER
NEOPRENE (CHLOROPRENE):
A general purpose elastomeric compound with low temperature flexibility and good oil resistance. Good resistance to weather, ozone, natural aging, alkalis, salts and acids. Cloth-inserted also available.
NITRILE (BUNA-N):
Strong resistance to petroleum-based and hydraulic fluids, aromatic and aliphatic hydrocarbons and gasoline over a wide range of temperatures. Good resistance to caustics and salts. Cloth-inserted also available.
EPDM:
Ethylene propylene diene monomer rubber, better known as EPDM, exhibits excellent resistance to extreme temperatures, acids, ozone, oxygen, sunlight, alkalis, and keytones.
FKM/VITON®:
A versatile and popular high-performance synthetic rubber, Fluorocarbon elastomer has good resistance to oils, fuel, chlorinated solvents, aliphatic and aromatic hydrocarbons and strong acids. Highly flexible and oxidation resistant with low gas permeability.
SILICONE:
Highly resistant to extreme temperatures with excellent UV and ozone resistance. Non-toxic, chemically inert and fungus resistant.
CSM/HYPALON®:
CSM has high resistance to most chemicals. It resists weathering, sunlight, ozone, oils and commercial fuels such as diesel and kerosene.
SBR RED RUBBER:
An economical and general purpose co-polymer of Styrene and Butadiene, exhibiting excellent abrasion, heat and impact resistance. Highly impermeable, serving as an excellent barrier against gases and liquids.
SBR RED RUBBER CI:
Cloth inserted red rubber offers maximum conformity and deformation resistance. Fabric reinforced rubber presents good dimensional stability under high compression loads.
TAN PURE GUM RUBBER:
Gum rubber is extremely flexible, elastic and durable. Resistant to salts, ammonia, acids and alkalis, it offers good tear strength and is made from FDA approved ingredients.
BUTYL:
Exceptionally low gas and moisture permeability and outstanding resistance to heat aging, weather, ozone, chemical attack, flexing, abrasion and tearing. Resistant to hydraulic fluids and has excellent electrical insulation performance.
CLOSED CELL FOAM (SPONGE RUBBER):
An economical rubber with excellent compression properties. Absorbs shock and vibration. Impermeable to air and water with good resistance to solvents.
FDA GRADE RUBBER
WHITE FDA GRADE NEOPRENE:
A non-toxic and non-marking elastomer made from FDA grade material. Versatile option for food and beverage, pharmaceutical and cosmetics manufacturing. Good abrasive qualities and excellent resistance to weathering and ozone conditions.
WHITE FDA GRADE NITRILE:
FDA rated material compatible in the food service, pharmaceutical and cosmetic industries. Good oil and abrasion resistance, non-toxic and non-marking. it has a superior level of resistance against synthetic and natural grease products and increased durability making it the rubber of choice for food safety.
WHITE FDA GRADE EPDM:
Made from FDA-approved ingredients, White EPDM offers a smooth finish, good resiliency to abrasion and repels oily and greasy food products.
FDA GRADE SILICONE:
While silicone is inherently non-toxic, only our specially formulated grade of silicone is made for consumables. Food grade silicone is often used in food processing, packaging and preparation applications. It can also be found in laboratory and medical environments.
OTHER MATERIALS
SPIRAL WOUND GASKETS:
Precision-engineered solution for flanged joints, heat exchangers, boiler handholes, manholes and other high temperature, high pressure applications—providing resistance to virtually every known corrosive and toxic element.
PTFE/TEFLON®:
Highly flexible, strong, and able to perform in extreme temperatures. Strong chemical and corrosion resistance. Long product life. Often used in the chemical industry.
GRAPHITE (TANG/FOIL):
Excels in extreme conditions, withstanding heat, pressure, and aggressive chemicals. High dimensional stability in high temperatures and pressure fluctuations. Tang-inserted, foil-inserted and other types available.
CORK/CORK RUBBER BLEND:
A hybrid family of materials combined with rubbers such as silicone, nitrile or neoprene. Compressible, flexible, with excellent anti-vibration characteristics and oil, solvent and fuel resistance.
COMPRESSED FIBER:
There are many types of compressed fiber gasket options offering a wide temperature range for various applications. Blended non-asbestos fibers with elastomeric binders.