Why do you need a split type? — — The scene can't be installed, the old parts can't be replaced, this thing is here to save the scene
The pipes had been welded to death, and the equipment was squeezed between the corners and the pillars. After measuring for a long time, it was found that the conventional non-metallic compensator couldn't fit in at all. Or the desulfurization tower has been running for three or five years, and its skin is rotten, so you want to replace it with a new one-it loses hundreds of thousands a day after shutting down production, but you have to dismantle the whole pipeline before you can install the integrated compensator. At this time, the split non-metallic compensator is the only solution. It makes the flange and skin into two separable halves, and assembles them on site, without moving the pipe or waiting for production to stop.
Structural disassembly: What does the split non-metallic compensator look like?
To put it bluntly, it is a "non-metallic expansion joint that can be detached". It is structurally divided into three pieces:
flange split— and this site'sRectangular non-metallic expansion jointSimilarly, the flange is also cast or welded in sections, and the two halves of the flange are butted by high-strength bolts. Note that the sealing surface of the profile flange must be finished, otherwise air leakage.
Fabric skin-a core component, andNon-metallic expansion joint (fabric fiber expansion joint)The same temperature-resistant coating fabric is used, and silicone cloth, fluororubber cloth or PTFE cloth are selected according to the working conditions. The split skin is cut whole, wrapped on the flange frame on the spot, and fixed with pressing strips and bolts.
insulation layer-Filled with ceramic fiber blanket or aluminum silicate wool, thermal insulation and noise reduction. The split insulation layer is also prefabricated in blocks, stuffed in on the spot, and then sealed with stainless steel wire mesh or metal guard plate.
First, weld the lower half flange to the pipe interface, lay the lower half for heat preservation, then cover the skin, then buckle the half flange, tighten the bolts, and finally press the skin edge. There is no need to cut pipes or build scaffolding to disassemble the whole process.
Is it really better than all-in-one? — — Hardcore advantages and unavoidable pits
Non-stop replacement— — For example, the non-metallic compensator burned through the kiln tail flue of the cement plant. With a split structure, the materials were prepared during the day, the furnace was shut down for two hours in the night shift, the old skin was removed, new parts were installed, and the burning continued at dawn. One-piece? At least down for a full day.
Adapt to special-shaped pipes— — Circular, rectangular, square and polygonal pipes, split flanges can be designed in sections according to the actual shape. Last year, a hexagonal split compensator was made for the outlet of a desulfurization tower, and it was impossible to do it in one piece.
Convenient transportation— — Oversized rectangular compensator, the whole piece is super wide, super high and overweight, and it can be split into two halves, which can be pulled by ordinary trucks and assembled on the spot.
But there are also pits, don't step on them:
The sealing surface of the split structure is twice that of the integrated structure, and the number of bolts is also twice that of the integrated structure. When the bolts are screwed, they must be tightened multiple times in diagonal order with a torque wrench-if the installation is not flat, the skin cannot be pressed tightly, and air leakage will take minutes to run ash. In addition, the split type cannot be used in high-pressure working conditions. Generally, the design pressure does not exceed 0.1MPa, and the temperature andNon-metallic expansion joint (fabric fiber expansion joint)Similarly, the temperature resistance range depends on the skin material. Silicone cloth is within 200 ℃, fluororubber cloth is 250 ℃, and polytetrafluoroethylene can reach 300 ℃.
Where can I use it? — — Cement plant flue, desulfurization system, boiler outlet... split type is just needed
Where the maintenance space is tight and the production line can't be stopped, the split non-metallic compensator is standard.
Cement industry: preheater export, kiln head and kiln tail flue, powder separator import and export. The temperature is high and the dust is large. If the compensator is broken, it must be replaced online.Flue gas baffle doorOrManual plug-in type insulation door isolates the air duct, which is safe and hassle-free.
Desulfurization system: absorption tower inlet and outlet, clean flue. Wet desulfurization is highly corrosive, and it is the norm to change the skin every two years. The split type can be replaced in sections without dismantling the whole tower body.
Boiler outlet: tail flue of power station boiler, waste heat boiler. The operating pressure of the boiler is low but the temperature fluctuates greatly. The split fabric compensator can absorb three-dimensional displacement and does not produce metal fatigue.
By the way, this site'sRound Flap Door (Double Seal) andElectric plug-in insulation doorIt is often used with a split compensator, and it works well with each other in structure.
Selected Lightning Protection Guide
Select the split type non-metallic compensator, and the parameters should be calculated clearly:
Pressure temperature— — As mentioned earlier, below 0.1MPa and within 300℃. Beyond this range, honestly and practicallyNon-metallic expansion joint (fabric fiber expansion joint)OrMetal rectangular expansion joint.
Compensation amount— — The displacements in the axial, transverse and angular directions should be provided to the manufacturer separately. Because the split type has two more seals, the compensation ability will be slightly lower than that of the integrated type of the same size, usually with a coefficient of 0.8.
Interface Size— — The flange screw hole must match the pipeline on site. If your site plumbing isThe power station industry uses the old flange on the corrugated expansion joint. When ordering the split type, send the size diagram of the old flange. Don't take it for granted.
You can also take a look at this station'sRectangular non-metallic expansion jointAndNon-metallic expansion joint (fabric fiber expansion joint)Their technical parameters are basically the same as the split type, but the flange structure is different.
Installation and maintenance: Experience of front-line masters
There are three cores for installing a split compensator:
How to screw bolts— — First pre-tighten to 70% torque with an electric wrench, then cross-twist diagonally from the middle to both sides with a torque wrench, and add it to the design value in three times. Don't screw it to death once to save trouble. If the flange is deformed, it will definitely leak.
How to press the edges of skin— — When cutting the skin, leave a margin of about 30mm. After wrapping the edge of the flange, press it with a press bar, and the spacing between bolts should not be more than 150mm. Strip and skin contact surface can be coated with a layer of silicone rubber sealant, insurance.
How often to change— — Depends on the working conditions. Generally, the kiln tail of cement plant is 1-2 years, the desulfurization clean flue is 2-3 years, and the boiler tail flue is 3-5 years. Check whether the skin is aging and brittle, whether the insulation layer collapses, and whether the flange bolts are loose every time the machine is shut down for maintenance. If you find cracks or bulges on the skin surface, arrange replacement immediately. Don't wait for leaks before repairing.