Compensator Maintenance Manual: Follow these 6 steps and the equipment will last several years

Step 1: Find out which compensator you are using first-different materials, maintenance points are very different

Don't come up thinking about how to wipe and how to screw. You have to look down and see what the stuff you have in your hand is made of. YesMetal corrugated expansion joint？ StillNon-metallic expansion joints (fabric fiber expansion joints)？ Or maybe you're usingrubber compensator？ Even if it's all bellows,Universal corrugated expansion jointAndHigh temperature axial expansion jointThe temperature resistance range is quite different. If you wipe the metal with rubber oil, it may accelerate the aging.

PTFE-lined hoseAndPTFE compensatorThe surface looks smooth, but it is actually particularly afraid of sharp objects scratching. WhileSleeve type pipe expansion jointThere is padding inside, and the maintenance focus is on the seal. So – go through the nameplate on your device first, or check the purchase order to confirm the model number. After this step is completed, the subsequent maintenance will be accurate. Otherwise, it's like filling a diesel car with petrol, wasting your effort.

Step 2: Daily inspection to see these 3 places, 90% of the problems can be found in advance

• Welds and troughs: especiallyCorrugated expansion joint for power station industryAndMetal Corrugated Expansion Joints in Cement Industry, the welds are most prone to fine cracks under high temperature and high pressure. Take a magnifying glass, or use a penetration test, don't be lazy.
• Flange connection: Is there any leakage? Are the bolts loose? EspeciallyDirect buried (fully buried) type expansion jointIt is difficult to check if it is buried in the soil, but the flange on the ground must be tightened regularly.
• Guide brackets and limiting devices: likeLarge tie rod expansion jointIs the tie rod nut loose?Rotary compensatorIs the rotating part stuck? These three places, see at least once a week. And guess what? I met a customer two days ago and said that they had aCompound hinge transverse expansion jointI used it for three years without any accident because someone took a wrench and screwed the nut once a week.

Step 3: Cleaning is not as simple as wiping dust. Different parts have different wiping methods

Hey, don't flush it directly with the hose! EspeciallyNon-metallic expansion jointFabric fiber is afraid of water and oil, and it is easy to delaminate when flushed. Correct way to do this:

• Metal bellows section(includingMetal hose、External pressure single axial expansion joint): Use a soft bristle brush with neutral detergent, brush along the direction of the ripples, don't scrape horizontally. Blow dry with compressed air after brushing, otherwise the accumulated water will rust in the trough.
• Rubber（rubber compensator、Rubber PTFE compensator): Just wipe it with a damp cloth. Don't use organic solvents (such as gasoline and alcohol). That thing will make the rubber hard and crack.
• Tetrafluorine（PTFE-lined hose、PTFE compensator): PTFE itself is not sticky, but hard scale is easy to attach to the surface. Gently shovel it off with a plastic scraper, don't use steel wire balls.
• Baffle category（Flue gas baffle door、Double-sealed single-axis circular baffle door): the emphasis is on cleaning the ash accumulation on the blade, especially under the desulfurization working condition,Desulfurization flue gas baffle doorThe blades are easy to form gypsum, so you have to use a high-pressure water gun with a brush.

Cleaning is not to look good, it is to not bring dirt into the sealing surface and movable joints. Tsk, you think you're wiping dust, you're actually renewing the device.

Step 4: Keep an eye on the temperature, pressure and displacement during operation, and don't wait for it to be broken before repairing it

This step is the easiest to overlook. Many people think that "as long as there is no leak, it can be used", but one day the pipe suddenly burst. You say it was wrong or not?

• TemperatureEspeciallyHigh temperature axial expansion jointAndDouble hinge expansion joint for air-cooled island vacuum pipelineThe design temperature is the red line. If the temperature exceeds, the bellows will deform permanently. It is recommended to stick a temperature measurement patch on the wall of the pipe, so that you can know if it exceeds the standard at a glance.
• pressure：Straight pipe pressure balanced expansion jointAndCurved tube pressure balance expansion jointParticularly sensitive to pressure fluctuations, if the pointer of the pressure gauge jumps back and forth, stop the machine quickly for inspection.
• displacement: Take a ruler to measure the expansion and contraction of the expansion joint, and compare it with the design value. Such asUniversal corrugated expansion jointThe allowable axial displacement is ± X mm. If the actual displacement is close to the upper limit, it means that the piping system may be out of position.

Buy an infrared temperature measuring gun and vernier caliper and put them in the duty room. Take two minutes to measure them for each inspection and record them in a notebook. Data doesn't deceive.

Step 5: What should I change for regular maintenance? As soon as these signals appear, immediately take action

Not that you have to wait until a planned overhaul to change parts. If you see any of the following signals, it is time to change:

• Visible cracks or corrosion spots on the surface of the bellows— especiallyLarge diameter thick wall expansion jointThe wall thickness is large but it is troublesome once the corrosion penetrates.
• Non-metallic expansion joints (fabric fiber expansion joints)The layers of fiber froth, delaminate, or harden-that is aging, don't hesitate.
• rubber compensatorBulging or sticky surfaces-the internal cord may have broken.
• Sleeve type pipe expansion jointThe packing box began to leak frequently, and the tight bolts couldn't hold it down-change the packing, or change the sleeve directly.
• Significant deformation of tie rod or hinge— For exampleCompound straight pipe bypass pressure balanced expansion jointThe tie rod in is bent, which is not a trivial matter, indicating that the pipe stress is abnormal.

What about that? Stop the machine immediately and find the original factory or professional maintenance. Don't weld it yourself. The high temperature of welding will destroy the heat treatment state of the bellows, and the more you weld, the more brittle it will be.

Step 6: The 5 Most Common Wrong Operations, See How Many Pits You Have Stepped On

I have worked for more than ten years, and I have seen too many wonderful operations. List it, and you compare it:

• Error 1: Forgot to remove transport screw during installation— especiallyUniversal corrugated expansion jointAndExternal pressure single axial expansion jointIn order to prevent deformation, several screws will be welded when they leave the factory. Some people turn on the machine directly by screwing it on. As a result, the expansion joint can't move at all, and the pipeline stress is all held elsewhere. Correct practice: After installing the pipe, loosen or remove the screw.
• Error 2: The pipes on both sides of the compensator are misaligned-Forcibly tighten the flange with bolts, causing the bellows to twist. This is more common inMetal hoseInstallation. Correct practice: Ensure that the pipeline is naturally aligned and does not stifle.
• Mistake 3: Painting the rubber compensator-The solvent in the paint will swell the rubber, soften it and fail. The right thing to do: Leave it as it is, and don't do it unnecessary.
• Mistake 4: Clean the PTFE surface with a metal brush-PTFE soft, one brush is all scratches, and then the medium penetrates along the scratches. Proper way to do it: Use a plastic scraper or scouring pad.
• Error 5: Unauthorized installation of liner or guide tube— — Some users think that "adding a sleeve is more wear-resistant", which destroys the original flow channel and causes eddy vibration. Correct way to do this:expansion joint guide tubeIt was designed when it left the factory, so don't blindly change it yourself.

Is that the truth? How many pits have you stepped on? Welcome to your seats. Anyway, I dare say that as long as these 6 steps are implemented, your compensator will live at least two years longer.