Application Guide

CompensatorsHose AssembliesExpansion Joints

FLEX-WELD.COM

FLEX-WELDI N C O R P O R AT E D

Manufactured By:

Application Guide

What we need to know.......

A. Physical / System ParametersA. Physical / System ParametersA. Physical / System ParametersA. Physical / System Parameters

1Size of Assembly:

Measure Pipe size (ID) of the system

Inches Inches

2Type of Piping Material

Determine piping material being used

Carbon Steel

Copper

Carbon Steel

Copper

3Installed Length (OAL):

Length of pipe measured from anchor to anchor

Inches Inches

4Type of Media:

Indicate if liquid, steam, gas, exhaust, slurry, solids, etc.

5Design Pressure of the System:

Highest/Most severe pressure during operation

Positive PSIG Negative HG

6Operating Pressure:

Acutal Pressure which system works under in normal conditions

Positive PSIG Negative HG

7Temperature of Flowing Media:

Indicate both operating and maximum temperatures of the system

Operating °F Maximum °F

8Temperature of Surrounding Atmosphere:

Indicate both min. & max. termperatures of atmosphere at the expansion joint

Minimum °F Maximum °F

9Velocity of Flowing Media:

In feet/Sec or Gallons/Min

Feet/Sec Gal/Min

10Axial Movement (Compression/Extension):

In inches as a result of system extension/expansion

Compression in Inches Extension in Inches

11Lateral Deflection/Offset:

In inches

Inches Inches

12Angual Movement:

In degrees

Degrees Degrees

Application Guide

B. Product RequirementsB. Product RequirementsB. Product RequirementsB. Product RequirementsB. Product RequirementsB. Product Requirements

1PRODUCT TYPE PRODUCT TYPE PRODUCT TYPE PRODUCT TYPE PRODUCT TYPE

1 COMPENSATOR BRAIDED HOSE EXPANSION JOINT GENERAL PURPOSE PUMP CONNECTOR

2END 1END 1END 1END 1END 1

2 FLANGED ENDS GROOVED ENDS WELD ENDS MALE NPT THREADS FEMALE SWEAT ENDS

Straight

Loop

308

311

10MC

30MC

1207

1407

150#

300#

Plate

Raised Face

Sch 40

Sch 80

Sch 40

Sch 80

Sch 40

Sch 80

Copper

(Compensators & braided hose only)

(Compensators & braided hose only)

(Compensators & braided hose only)

END 2END 2END 2END 2END 2

FLANGED ENDS GROOVED ENDS WELD ENDS MALE NPT THREADS FEMALE SWEAT ENDS

150#

300#

Plate

Raised Face

Sch 40

Sch 80

Sch 40

Sch 80

Sch 40

Sch 80

Copper

(Compensators & braided hose only)

(Compensators & braided hose only)

(Compensators & braided hose only)

Application Guide

Double

3CONNECTION MATERIAL (Expansion Joints, General Purpose & Pump Connector only)

Carbon Steel 304 SS 316L SS

4WETTED MATERIALS (Expansion Joints, General Purpose & Pump Connector only)

5MOVEMENT

1 1/2” 4”

(Ke-loop Only)

Other

(Please Specify)

6HOSE & BRAID MATERIAL (Braided Hose & Ke-loop Only)

Bronze

(End fittings must be copper sweat ends)

304 SS 316L SS 321 SS Monel(Contact Factory)

Inconel(Contact Factory)

SS

7BRAID REQUIREMENT (Braided Hose & Ke-loop Only)

Single

8NESTING REQUIREMENTS (Ke-loop only, see worksheets)

9

OTHER PRODUCT REQUIREMENTS & NOTES:

Application Guide

Thermal Expansion of Pipe in Inches per 100 Feet Thermal Expansion of Pipe in Inches per 100 Feet Thermal Expansion of Pipe in Inches per 100 Feet Thermal Expansion of Pipe in Inches per 100 Feet Thermal Expansion of Pipe in Inches per 100 Feet Thermal Expansion of Pipe in Inches per 100 Feet Thermal Expansion of Pipe in Inches per 100 Feet Thermal Expansion of Pipe in Inches per 100 Feet Saturated Steam Vacuum in HG below 212°F, Pressure, PSIG above 212°F

Temp. °F Cast Iron Carbon Steel or Steel

Wrought Iron 4-6% Cr. Alloy Steel

18 Cr.-8Ni Stainless Steel

Copper

-200 -1.058 -1.282 -1.289 -1.25 -2.03 -1.955

-180 -0.982 -1.176 -1.183 -1.15 -1.85 -1.782

-160 -0.891 -1.066 -1.073 -1.03 -1.67 -1.612

-140 -0.797 -0.948 -0.955 -0.97 -1.48 -1.428

-120 -0.697 -0.826 -0.833 -0.8 -1.3 -1.235

-100 -0.593 -0.698 -0.705 -0.7 -0.9 -1.04

-80 -0.481 -0.563 -0.57 -0.5 -0.88 -0.835

-60 -0.368 -0.428 -0.435 -0.43 -0.67 -0.63

-40 -0.248 -0.288 -0.295 -0.92 -0.45 -0.421

-20 -0.127 -0.145 -0.152 -0.145 -0.225 -0.21

0 0 0 0 0 0 0

20 0.128 1.148 0.18 0.14 0.223 0.238

32 0.209 0.23 0.28 0.234 0.356 0.366

40 0.27 0.3 0.35 0.28 0.446 0.451

29.39 60 0.41 0.448 0.54 0.43 0.669 0.684

28.89 80 0.55 0.58 0.71 0.5 0.892 0.896

27.99 100 0.68 0.753 0.887 0.65 1.115 1.134

26.48 120 0.83 0.91 1.058 0.8 1.338 1.366

24.04 140 0.97 1.064 1.24 0.95 1.545 1.59

20.27 160 1.11 1.2 1.42 1.1 1.784 1.804

14.63 180 1.24 1.36 1.58 1.25 2 2.051

6.45 200 1.39 1.52 1.75 1.4 2.23 2.296

0 212 1.48 1.61 1.87 1.5 2.361 2.428

2.5 220 1.53 1.68 1.94 1.55 2.46 2.516

10.3 240 1.67 1.84 2.12 1.72 2.68 2.756

20.7 260 1.82 2.02 2.3 1.88 2.92 2.985

34.5 280 1.97 2.18 2.47 2.05 3.15 3.218

52.3 300 2.13 2.35 2.67 2.2 3.39 3.461

74.9 320 2.268 2.53 2.85 2.37 3.615 3.696

103.3 340 2.43 2.7 3.04 2.53 3.84 3.941

138.3 360 2.59 2.88 3.23 2.7 4.1 4.176

180.9 380 2.75 3.06 3.425 2.86 4.346 4.424

232.4 400 2.91 3.23 3.62 3.01 4.58 4.666

293.7 420 3.09 3.421 3.82 3.18 4.8 4.914

366.1 440 3.25 3.595 4.02 3.35 5.05 5.154

451.3 460 3.41 3.784 4.2 3.53 5.3 5.408

550.3 480 3.57 3.955 4.4 3.7 5.54 5.651

664.3 500 3.73 4.151 4.6 3.86 5.8 5.906

795.3 520 3.9 4.342 4.81 4.04 6.05 6.148

945.3 540 4.08 4.525 5.02 4.2 6.28 6.41

1115 560 4.25 4.73 5.22 4.4 6.52 6.646

1308 580 4.43 4.93 5.43 4.56 6.78 6.919

1525 600 4.6 5.13 5.62 4.75 7.02 7.184

1768 620 4.79 5.33 5.84 4.92 7.27 7.432

2041 640 4.97 5.53 6.05 5.1 7.52 7.689

2346 660 5.15 5.75 6.25 5.3 7.77 7.949

2705 680 5.33 5.95 6.47 5.48 8.02 8.196

3080 700 5.52 6.16 6.67 5.65 8.28 8.472

720 5.71 6.36 6.88 5.85 8.52 8.708

740 5.9 6.57 7.1 6.03 8.78 8.999

760 6.09 6.79 7.32 6.22 9.05 9.256

780 6.28 7 7.53 6.41 9.3 9.532

800 6.47 7.23 7.73 6.61 9.58 9.788

820 6.66 7.45 7.96 6.8 9.82 10.068

840 6.85 7.66 7.18 7 10.1 10.308

How to Use the Thermal Expansion Table: Example: Find the expansion 0f 105ft. Of any diameter carbon steel pipe carrying steam at 138 PSIG and at a lowest surrounding ambient temperature of 40°F. ▶ Maximum temperature = 360°F (138 PSIG saturated steam)

▶ Calculated traverse (from table) Expansion per 100 ft. of carbon steel at 360°F = 2.88”

▶ Less expansion per 100 ft. of carbon steel pipe at 40°F = 0.30”

▶ Expected traverse per 100 ft. = 2.58”

Expansion of 105 ft. = (105 / 100) x 2.58” = 2.71” Conclusion: Since an expansion joint is normally set at 80% in compression and 20% in extension, an expansion joint with 4” total axial movement should be selected.

NOTE: The shaded area indicates the maximum and minimum recommended temperature for each material. For applications requiring lower or higher temperatures, consult the factory. From the Piping Handbook by Sabin Crocker, McGraw-Hill Publishing Co. & Acme Paper No. 53-A-52, 1954.

NOTE: Expansion joints are not designed to absorb torsional movement or stress. Subjecting an expansion joint to torsion of any amount may drastically affect operating life and will void the warranty. Consult factory if torsion is present.

Ke-Loop™ L-Flex Nesting Worksheet

Ke-Loop™ V-Flex Nesting Worksheet

V-Flex Nest Position

Pipe ID (inches)

End Fitting

MovementMovementMovement Max . Service

PSI/Temp

Insulation Thickness OAL V-Flex

Distance Between

Pipe Centers

V-Flex Nest Position

Pipe ID (inches)

End Fitting Seismic All

Directions Axial

Compression Axial

Extension

Max . Service

PSI/Temp

Insulation Thickness OAL V-Flex

Distance Between

Pipe Centers

Inner Y1

Middle 1 Y2

Middle 2 Y3

Middle 3 Y4

Outer Y5

L-Flex Nest Position

Pipe ID (inches)

End Fitting

MovementMovementMovement Max . Service

PSI/Temp

Insulation Thickness OAL

Distance Between

Pipe Centers

L-Flex Nest Position

Pipe ID (inches)

End Fitting Seismic All

Directions Axial

Compression Axial

Extension

Max . Service

PSI/Temp

Insulation Thickness OAL

Distance Between

Pipe Centers

Inner

Middle 1

Middle 2

Middle 3

Outer

Application Guide

Consult factory for quiding recommendations

Ke-Loop™ U-Flex Nesting Worksheet

U-Flex Nest Position

Pipe ID (inches)

End Fitting

MovementMovementMovement Max . Service

PSI/Temp

Insulation Thickness OAL U-Flex

Distance Between

Pipe Centers

U-Flex Nest Position

Pipe ID (inches)

End Fitting Seismic All

Directions Axial

Compression Axial

Extension

Max . Service

PSI/Temp

Insulation Thickness OAL U-Flex

Distance Between

Pipe Centers

Inner Y1

Middle 1 Y2

Middle 2 Y3

Middle 3 Y4

Outer Y5

Application Guide

Recommended Positioning of Guides, Anchors, & Compensators

▶ System design must not create torque on expansion compensators. See diagrams for typical installation practices.

▶ Piping centerlines should be precisely aligned.▶ All set pins must be removed after installation.

Expansion compensators must be both correctly selected and properly installed for effective performance in service. The reactions created by pressure and movement within the piping system should be carefully considered and the following precautions taken at installation:

Anchors must be of sufficient strength to withstand the thrust pressure of the pipe section.

Anchoring and Guiding KEFLEX™ Compensators

Compensators used in risers and radiation lines require adequate anchoring and guiding. Main anchors are necessary at the end of each pipe run, with guides installed to prevent the line from bowing, buckling or becoming misaligned because of thermal expansion or internal pressures. Pipe hangers and rollers are not considered to be adequate as guides. The main anchors must restrain the ends of the pipe so that all expansion is directed into the compensator. The main anchors must also withstand the end thrust force of the internal pressure. This force is shown in the Thrust Force Data Table.Compensators should not be subjected to hydrostatic pressure tests beyond their rated working pressures. If a higher pressure test is required, the factory should be advised. The inside of all piping must be clean before installing and testing compensators. Before the pipe lines are hydrostatically tested, all anchors and pipe guides must be secured.The contractor installing sweat end type compensators is advised to use a soft solder. Excessive heat used to make the solder joint may have a detrimental effect on the compensator. Soldered joints should be washed thoroughly so as to neutralize or remove acids used in solder fluxes

Keflex 7Q Compensator Anchor

1st Guide 2nd Guide All Other Guides (Refer to “Slide Guide Chart)

4 X D 14 X D Additional Guides

D = Pipe O.D. FLEX-WELD.COM800-323-6893MADE IN USA

KEFLEX1425 Lake AvenueWoodstock, IL 60098

flex-weld.comPh: 800-323-6893

Fax: 815-334-3689MADE IN THE USA

Application Guide

Tube Size 4 X D 14 X DMaximum Spacing for Intermediate Guides for Copper

Water Tube Maximum Spacing for Intermediate Guides for Copper

Water Tube Maximum Spacing for Intermediate Guides for Copper

Water Tube Tube Size 4 X D 14 X D@ 25 PSI @50 PSI @70 PSI

3/4” 3” 10 1/2” 7’ 6’ 5’

1” 4” 1’ 2” 9’ 8’ 6’

1 1/4” 5” 1’ 5 1/2” 14’ 11’ 9’

1 1/2” 6” 1’ 9” 14’ 11’ 9’

2” 8” 2’ 4” 19’ 14’ 12’

2 1/2” 10” 2’ 11” 23’ 17’ 15’

3” 1’ 3’ 6” 27’ 20’ 18’

4” 1’ 4” 4’ 8” 31’ 23’ 21’

Pipe Size Max Distance EJ to 1st Guide or

Anchor

Approx. Distance

Between 1st & 2nd Guide

Approximate Distance Between Additional Pipe Guides

Approximate Distance Between Additional Pipe Guides

Approximate Distance Between Additional Pipe Guides

Pipe Size Max Distance EJ to 1st Guide or

Anchor

Approx. Distance

Between 1st & 2nd Guide @ 50 PSI @150 PSI @300 PSI

3/4” 3” 10 1/2” 14’ 8’ 6’

1” 4” 1’ 2” 21’ 12’ 10’

1 1/4” 5” 1’ 5” 23’ 13’ 12’

1 1/2” 6” 1’ 9” 28’ 17’ 13’

2” 8” 2’ 4” 32’ 18’ 15’

2 1/2” 10” 2’ 11” 35’ 22’ 20’

3” 1’ 3’ 6” 38’ 23’ 17’

4” 1’ 4” 4’ 8” 52’ 31’ 22’

5” 1’ 8” 5’ 8” 63’ 38’ 25’

6” 2’ 7’ 68’ 40’ 28’

8” 2’ 8” 9’ 4” 87’ 45’ 38’

10” 3’ 4” 11’ 8” 107’ 60’ 48’

12” 4’ 14’ 118’ 70’ 50’

Pipe Guide Spacing Guidelines for Copper Tube

Pipe Guide Spacing Guidelines for Standard Weight Carbon Steel Pipe