When the temperature of the transported and the environment changes, deformations of the pipeline may occur. It lengthens at high temperatures and shortens at low temperatures. Existing connections due to this process begin to collapse, and pipes acquire bends.
Rubber products allow you to replace such changes and maintain the integrity of the structure. The work of compensators is based on elasticity - these devices can both compress and decompress. The load on the pipeline is thereby minimized and compensated, most often due to the elasticity characteristics of the metal used for the production of pipes. Supports restrict compensating flow to prevent pinching.
Classification
In the industry today, the U-shaped and corrugated type rubber compensator has become widespread. The latter are divided according to the type of flexible part into lens, bellows and wavy. There are also gland expansion joints, but they have not become widespread.
Corrugated parts are divided into axial, angular, rotary and semi-flattened.
Due to axial compressionelongation is absorbed by axial and semi-balanced compensators. Angled devices do this by bending, while rotary devices do this by lateral displacement of the elastic part.
Destination
When designing equipment and industrial facilities, the intervals of working divisions, vibrations and fluctuations, the amount of compensated displacement, aggressive chemical environments should be taken into account.
Flange compensator is made from special rubber. The set of advantages of the device gives the chance of use of a product in various situations. There is an elastic part made of elastomers, which is not subject to fatigue and thinning. The main task of the compensator is to remove the vibration load from the equipment. Also, the elastic pliable bellows compensates for the temperature movement of the equipment and pipeline. No special equipment is required for mounting the device.
For each task, optimal solutions, conditions of use and certain sizes are needed. Therefore, high-quality expansion joints must be both functional and cost-effective.
Vibration inserts are made of synthetic or natural materials, they are light in weight, high resistance to shock loads, easy to install and maintain. They are designed for a long period of operation.
Anti-vibration compensator is implemented in several types, for different media in pipelines. It is not affected by rust and can be used with significant mechanicalloads.
Gland expansion joints
Operation is carried out in a temperature range of up to 300 degrees and a pressure of not more than 1.7 MPa. The device is a tube inserted into the housing. For tightness, the gap that occurs between the base and the pipe is sealed with a ring having a grand axle box.
This type of compensator can be one-sided and two-sided. It has small dimensions and has a good compensating characteristic, but it is difficult to achieve proper sealing, because of this it is less in demand than the others. Among the shortcomings, it is worth noting rapid wear, which is why it requires systematic inspection and preventive care.
Wavy compensator
This device has the highest compensating characteristic in combination with small size. The flexible part of the compensator is a corrugated elastic sheath. Can be used in the temperature range from -80 to +800 degrees.
Through the use of such devices, the consumption of pipes, the available hydraulic pressure and the number of fixed supports are reduced. The latter is achieved by transferring minimal forces to the support structure.
Bellow expansion joint
The device has gained its distribution on pipelines with a diameter of 10 to 1000 mm, which transport liquid and vaporous media. The main elastic part is the bellows, which is a metalcurved part with hollow content. Due to the special design of the bellows, the rubber compensator is capable of bending, elongating and squeezing with a large displacement under the influence of longitudinal, transverse and angular moments, while deformation occurs in the transverse direction while maintaining tightness.
Can be used at significant pressure and temperature for corrosive environments, and good sealing performance is also noted. The compensator has become widespread in the chemical, oil, gas, energy industries.
Lens compensators
They consist of several lenses with a specific connection to the pipeline. These are elements consisting of the thinnest steel half-lenses. The principle of operation of devices of this type is based on a slight compression of the elements, each of which has a compensatory capacity in the range from five to eight millimeters. The most popular are designs with multiple lenses. There is also a division into rectangular and round, suitable for the corresponding shape of the gas pipeline.
Lens expansion joints are installed on pipelines with a diameter of 100 to 1500 mm. It is worth noting among the advantages of this type of small size and weight. Weaknesses lie in the low compensating characteristics and the possibility of using only at a fairly low pressure.
U-type compensator
The U-shaped compensator differs in the greatest compensating characteristic. He acquiredextensive distribution in technological elevated pipelines with any conditional passages. These types of expansion joints are produced using bent, bent with a large angle and welded bends.
Among the main advantages are ease of production and ease of use. But for the use of such devices, additional construction of supporting elements is required, they are also characterized by increased hydraulic resistance and require a large consumption of pipes during installation.
Fabric compensator
Most often used in systems with a temperature of no more than 1300 degrees, which transport gaseous media.
Such devices are made from one or more layers of insulating or gas-tight matter, assembled together to create a dense base. A gas-tight material is produced from various coatings, it has a distinctive resistance to chemical attack, surpassing even stainless steel in some cases. Various types of mounting are possible, for example, under the clamp or flange type 101. The design with internal insulation is used for temperatures above 600 degrees.
Rubber expansion joint
Applied mostly in piping systems pumping liquid media. The transported liquid can have a temperature of up to 200 degrees. The rubber compensator is connected to the pipeline using a flange method. A fire-resistant cover is used to increase resistance to negative external influences.
The devices are made of rubberof various types and have cord reinforcement. An appropriate elastomer is installed depending on the purpose and type of working medium.
Today, the flanged bellows expansion joint is produced by a number of European manufacturers, it is made of special rubber, due to which there is the possibility of operation in the food industry.
Distribution area
The compensator can be used to transport the working water medium, oil and products of its processing. A special material is used for working environments with high chemical activity. To increase the resistance to chemical attack, a special Teflon coating is also used. Corner stops and connecting rods are designed to increase the reliability of the connection.
Rubber products are most widely used in the organization of water supply, sewer pipelines and the oil industry. They are recommended for installation between the pump and pipes by most pump manufacturers. Due to this, it is possible to compensate for the vibration coming from the pump, respectively, the reliability and the period of operation of both the system and the equipment connected to the pipeline increase.
Terms of use
If properly installed and operated under suitable conditions and environmental parameters, no special care is required, except for a routine inspection at the installation site. After starting the pipelines, it is necessary to re-bolt tightening.
Temperature deformations of the bellows, such as tears, cracks, hardness and swelling are not allowed. It is important to conduct a systematic inspection for the presence of displacement, rust and to control the strength of the elements. Inspection frequency is affected by unexpected vibrations, system functions and loads.
During use, do not clean the surface with brushes or steel wool. Cleaning should be done with a special low alkali solution and rinsing with plain water.
The rubber flange compensator KMS has a certain service life, which provides for the absence of excess temperature and mechanical influences. Installation is possible only in those places of pipes that are predetermined by the project.
It is important that there is no twisting with the use of a significant force of the elements of the device. If the piping system is designed for a conductive light medium and is hydrotested with a heavier type of medium, precautions must be taken to carry more than the specified weight.
The rubber compensator is a non-repairable product and must be replaced if stable and tight characteristics are lost.
