IOM_redflex

7/31/2019 IOM_redflex

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Red Valves complete line of Redflex Expansion Joinrubber pipe, and rubber fabricated product s includesingle and multiple arched expansion joints with flangor threaded end connections, concentric and eccentrireducers, rubber vibration pipe in flanged and s lip-onmodels, and rubber fittings which are built to meet oucustomers exact specifications. All Redflex productsare available in a variety of elastomers to insure chem

compatibility with the fluid.The Redflex product line is used in applications suchWastewater t reatment facilities, Power plants, M iningChemical plants, and Pulp and Paper mills. Redf lex

Expansion Joints and rubber fittings are manufacturedsizes up to 108".

IMPORTANT

Please take a moment to review this manual. Before performing any maintenance on thisproduct be sure the pipeline has been de-pressurized. The improper installation or use of this

product may result in personal injury, product failure, or reduced product life. Red Valve Co., Inc.can accept NO liability resulting from the improper use or installation of this product. If you haveany questions or problems, please call the customer service department at (412) 279-0044. We

appreciate your comments. And thank you for choosing Red Valve.

REDFLEX

Rubber Expansion Joint

Installation, Operation, and M aintenance M anua


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GENERAL DESCRIPTIONRedflex Expansion Joints are designed to alleviatestresses caused by thermal expansion and contraction inpiping systems and reduces noise and vibration. Theflexibility of these durable expansion joints permits theconnecting of misaligned piping which is caused by wornparts, foundations settling or in the operating of system sand mechanical equipment.

Red Valve Companys Redflex Expansion Joints are manu-factured like a heavy duty truck tire. The abrasive resistant,all elastomer expansion joints are designed for maximumflexibility and are available in sizes 1" - 108". Redflex

Expansion Joints are reinforced with st eel wire or s olid steelreinforcing rings and synthetic fabric for additional strength.

The construction of the Redflex Expansion Joints includes:a tube, body cover, and flanges. The tube is a protectiveleakproof liner made of an elastomer, and is the only wettedpart. The body consists of fabric and various rubber com-pounds and is reinforced with steel w ire or rings forstrength. The cover is formed fro m the desired elastomer,normally Neoprene or Butyl. The flanges are made of rubberconstructions to resist stresses and provide a tight sealwith the companion pipe flanges, eliminating the need forgaskets. The flanges are full face AN SI Class 125 #.

ANCHORINGIt is absolutely necessary that rigid metal pipe on both endsof the expansion joint or any flexible connector be properlyanchored to eliminate the danger of excessive movement. Itcannot be emphasized too strongly that rubber expansionjo int s and co nnect ors, by vir tue of their design and function ,are not designed to take end thrusts and in all cases wheresuch forces are likely to occur, proper anchoring is essen-

tial. Anchors should always be installed. An expansion jointshould never be used to support the piping.

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J- 1 EXPANSION J OIN T

STORAGE AND HANDLINGRed Valve Redflex Expansion Joints and rubber fittingshould be st ored in a cool, dry locatio n on original shippallet or a wooden platform with the flanges down (Fig#1). Do not drop, bend or twist Redflex rubber produor damage may oc cur.

1. Do not allow joints to be in contact with the ground.jo int is to be st ored outdoors, co ver it with a t arpaulprevent weather and sun damage.

2. Avoid exposure to light, electric motors, dirt or chem

cals. Redflex

rubber products are subject to deteriotion when exposed to ozones and non-compatiblechemicals. Ozone especially causes age hardening othe elastomer.

3. Do not sto re other heavy items on t op of an expansjo int .

4. Store Installation Operation M anual with product so will be readily available fo r installation.

5. Do not lift joints or pipe by bo lt holes. Tearing of the flaand bolt holes or deformation of the bolt holes can occThey should be handled w ith a padded sling or a piece pipe longer than the face-to-face of the joint w ith a cabthrough it so as not to cut into the rubber joint or pipe

(Figure #2).

FIGURE 2

FIGURE 1

NEVER cut or modify Expansion Joint or rubber fitting.

NEVER operate rubber Expansion Joint or pipe above specifiepressure and temperature rating.

DO keep Expansion Joints and rubber fittings on pallet unready to install.

DO install expansion joints at recommended length, even arch is slightly compressed.


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INSTALLATION INSTRUCTIONSREDFLEX EXPANSION JOINTS AND RUBBER FITTINGS

Review the application to which the expansion joint is going tobe applied. Special attention should be paid to t he pressure/vacuum, temperature, and movements to ensure that theexpansion joint meets t he system requirements.

1. INSPECT PIPE AND PRODUCTCheck flange faces of pipe and Redflex expansion jointfor rough/ damaged areas. Pipeline flanges must be flat,properly spaced, and parallel to achieve proper seal.M ating flange I.D. must match the Redflex I.D.. Flangeswith an oversized I.D. can cut the Redflex f lange. Grindor file any sharp edges of t he pipeline flange to preventdamage to the Redflex expansion joint. StandardRedflex expansion joints are built to Schedule 40 pipeI.D. and ANSI Class125/ 150# f lange andbolt c ircle specifica-

tions.For slip-on joints andfittings, check that theI.D. of the joint orfitt ing is slightly largerthan the O.D. of themating pipe, and thatthe mating pipe edgesare clean and free ofsharp edges.

2. M EASURE LENGTH OF JOIN T NEEDED

M easure the distance between the two flanges to be con-nected. Measurements should be taken at ambient tempera-ture. M ake sure that the flanges are properly aligned, and thatany misalignment does not exceed 1/ 8".

3. SET JOINT IN PLACEInstall Redflex in recommended face-to-face dimensions,avoiding expansion or elongation. Arch may be slightlycompressed if distance betw een flanges necessitates. Athin film of graphite dispersed in water or glycerin may beapplied to the face of the rubber flange before installing.This prevents the rubber from adhering to the metal flangeso that if dismantling is ever necessary, the joint can beremoved easily.

4. FOR RAISED FACE FLANGESIt is recommended that the mating flanges are flat and fufaced. Raised face mating fl anges are not recommendeinstalling to a raised faced flange, use a serrated ring gasbetween the mating flange and the expansion joint f lange

5. FOR NON- M ETALLIC FLANGESWhen installing an Expansion Joint to a PVC or synthetmating flange, use a split back-up retaining ring behind tPVC or synthetic flange. If this is not done, the matingflange will yield prior to generating enough force on theflange faces for a proper seal. It is recommended that aserrated metal gasket be installed between the PVC fla

and the rubber expansion joint flange to insure propersealing between the tw o.

PipelineFlange

Expansion

JointFlange

I.D. 1 = I.D. 2

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6. INSTALL THE RETAINING RINGSOne set of split st eel back-up retaining rings is used for eachflange of the expansion joint, to insure a tight, even seal andto prevent hardware from damaging the rubber flange. Boltswith integral washers should be inserted from the steelretaining ring side of the joint. Flat washers should be used inconjunction with hex bolts at all splits in the steel rings.

7. TIGHTENING BOLTSWhen tightening bolts, two wrenches should be used toprevent damage to t he rubber flange. Always use a starpattern when bo lting an expansion joint or rubber pipe.Initially, torque t he bolts t o t he recommended values shownin the Torque Values chart. Pressurize the line. Retorque thebolts to the proper torque. If processfluid leaks, increase the t orque inincrements of 50% of the tabu-lated values. During installationyou may need to retorque theflange bolts several times for aproper seal. This will overcome

any leaks due to the cold flow o fthe rubber expansion joint flange.Check bo lt torque and retighten ifnecessary several days after initialoperation and then periodically thereafter.

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8. INSPECT COVER AFTER INSTALLATIONAfter the unit is securely bolted into position, carefully inspthe cover of the expansion joint for any cuts or gouges cauby tools or bolts. These should be sealed with rubber cemto prevent oil or water from penetrating the elastomeric co

RubberCement

1

2

34

5

6

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TORQUE VALUES

STANDARD PRESSURE HIGH PRESSURE

FLANGE PRESSURE TORQUE PRESSURE TORQSIZE RATING RATING

( inches) (PSI ) ( f t - pounds) (PSI ) ( f t - pou

1/2 165 13 200 16

3/4 165 25 200 30

1 165 20 200 25

1.25 165 25 200 30

1.5 165 25 200 30

2 165 40 200 50

2.5 165 55 200 65

3 165 60 200 75

4 165 40 200 50

5 140 45 190 60

6 140 55 190 75

8 140 75 190 100

10 140 70 190 95

12 140 105 190 142

14 85 80 130 125

16 65 55 110 90

18 65 70 110 120

20 65 70 110 115

24 65 90 100 135

30 55 65 90 110

36 55 90 90 145

42 55 109 80 150

48 55 100 80 150

54 55 125 80 185

66 55 160 80 230

72 45 145 70 225


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9. CONTROL UNITSCo ntrol rods must be installed where piping is not suffi-ciently anchored to prevent excessive axial movement.

Install the gusset plates first, to the pipeline flange.

10. INSERTING THE CONTROL RODThe control rod bolt is passed through holes in the gusset

plates and secured using steel and rubber washers o r rubber-backed steel washers to properly set the spacing of the rod.This rod limits the expansion of the joint to set limits.

W hen adjusting the control rod bolt take the following intoconsideration:

1. The free standing face-to-face dimension of the joint;2. The required elongation capabilities of the joint;3. The flange thicknesses of both mating flanges;4. The thickness of the gusset plates;5. Unless the joint is installed at the maximum elongated

state (NOT RECOMMENDED), or you do not want thejo int to elongat e, the rod will be loose;

6. If you do not want the joint to elongate, adjust HANDTIGHT O NLY.

11. COM PRESSION SLEEVEAn opt ional compression sleeve can be used to limit thecompress ion of the expansion joint. The control rod ispassed through the sleeve before being inserted through

the second gusset plate.

12. CONCENTRIC REDUCERSIf a reducing joint becomes necessary, it is recommendethat the m aximum reducing drop betw een the flangesshould not exceed 10 or tw o pipe sizes. For concentricreducers and concentric reducing expansion joints, twodifferent sized gusset plates are used, as shown. Installtion is the same as for standard expansion joints, but us

caution not to o vertighten the control rod. Overtighteninthe control rod will cause the longer gusset plate to act

lever and may bend the flange and/ or plate.

13. ECCENTRIC REDUCERSW hen using eccentric reducers and eccentric reducinexpansion joints, cont rol rods and gusset plates can be installed in one correct orientation for the flanges mate. Use caution not to overtighten the control rod

the large gusset plate.

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14. THREADED END EXPANSION JOINTSFor threaded end expansion joints, thread one end to pipe afew turns only. If pipe ends to be connected are misaligned,bend joint and begin to thread second coupling a few turns.Continue to thread both couplings, alternating sides every fewturns until both are snug.

15. SLIP-ON EXPANSION JOINTS

Be sure that ends of pipe are clean and free of oil or debrisbefore installing slip-on style rubber expansion joints orpipe. Coarse sandpaper may be used to roughen the pipesurface to prevent t he joint from slipping or rotating.

15 A. INSTALLIN G SLIP-ON J OIN TSlide one end of t he joint over one exposed pipe end. Bsure that the hose clamp is on the joint, but not tightene

Slide the joint into place over the other pipe end and cethe joint arch between the pipe ends. M ake sure that thpipe is only inside the cuff area of the joint. Rotate the bclamps 180 from each ot her and tighten the band clamsecurely.

16. OTHER FITTINGS

Other styles of Redflex rubberfittings, such as elbows and

tees, are installed in thesame way as expansio

jo int s. The sam ecautions apply.

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Rubber WasherGusset Plate

Steel Washer

Compression Sleeve

REDFLEX CONTROL UNITSExpansion Joints, Vibration Pipe, and Reducers installed inpiping systems must be rigidly anchored on both sides o fthe unit to control expansion and contraction. The illustra-tion below exhibits the details of a properly installed set ofcontrol units.

Co ntrol rods do not protect the expansion joint and piping

system against lateral offsets and are not a replacement forproper system anchors, guides and supports.

Co ntrol rods should not be used w ith non-metallic flangessuch as PVC, FRP and other flanges which do not havesufficient strength.

The table below indicates the number of rods to be useby size and test pressure ratings. The calculation of therods is based on an allowable stress of 65% of yield of rod from ASTM A-307-68 steel.

M AXI M UM SURGE OR TESCONTROL UNIT PRESSURE OF THE SYSTEM

NOM INAL NUM BER OF CONTROLPIPE SIZE PLATE ROD RODS RECOM M ENDEDEXP.J T. I D THICKN ESS DI AM ETER

( i nches) ( inches) ( i nches ) 2 3 4 6

1 3/8 1/2 949 -- -- --1-1/4 3/8 1/2 830 -- -- --1-1/2 3/8 1/2 510 -- -- --

2 3/8 5/8 661 -- -- --2-1/2 3/8 5/8 529 -- -- --

3 3/8 5/8 441 -- -- --3-1/2 3/8 5/8 365 547 729 --

4 3/8 5/8 311 467 622 --5 3/8 5/8 235 353 470 --6 1/2 5/8 186 278 371 --

8 1/2 3/4 163 244 326 --10 3/4 7/8 163 244 325 48812 3/4 1 160 240 320 48114 3/4 1 112 167 223 33516 3/4 1-1/8 113 170 227 340

18 3/4 1-1/8 94 141 187 28120 3/4 1-1/8 79 118 158 23622 1 1-1/4 85 128 171 25624 1 1-1/4 74 110 147 22126 1 1-1/4 62 93 124 186

28 1-1/4 1-3/8 65 98 130 19530 1-1/4 1-1/2 70 105 141 211

32 1-1/4 1-1/2 63 94 125 18834 1-1/2 1-5/8 72 107 143 21536 1-1/2 1-3/4 69 103 138 207

38 1-1/2 1-3/4 63 94 125 18840 1-1/2 1-1/2 42 63 85 12742 1-1/2 1-5/8 48 72 96 14444 1-1/2 1-5/8 44 66 88 13346 1-1/2 1-5/8 41 61 82 122

48 1-1/2 1-3/4 40 60 81 12150 1-1/2 1-3/4 37 56 75 11252 1-1/2 1-3/4 35 53 70 10554 1-1/2 2 43 64 86 12856 1-1/2 2 40 60 80 120

58 1-1/2 2 38 56 75 11360 1-3/4 2 35 53 71 10662 1-3/4 2 33 50 66 100

66 1-7/8 2 30 44 59 8972 1-7/8 2 25 38 50 75

78 2 2-1/4 28 42 56 8484 2-1/4 2-1/4 24 37 49 7390 2-1/2 2-1/2 26 40 53 7996 2-1/2 2-3/4 29 43 58 86

102 2-1/2 2-3/4 25 33 51 76

108 2-1/2 2-3/4 23 34 46 75120 2-1/2 2-3/4 18 28 37 56132 2-1/2 2-3/4 15 23 31 46144 2-1/2 2-3/4 13 19 26 39

CONTROL UNIT DIM ENSIONS AND RATIN GS


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RED VALVEWARRANTYRED VALVEWARRANTYRED VALVEWARRANTYRED VALVEWARRANTYRED VALVEWARRANTY

WARRANTIES - REMEDIES - DISCLAIMERS - LIMITATION OF LIABILITYUnless otherwise agreed to in writing signed by Red Valve, all Products supplied Valve will be described in the specifications set forth on the face hereof.

THE WARRANTIES SET FORTH IN THIS PROVISION ARE EXCLUSIVE ALIEU OF ALL OTHER WARRANTIES WHETHER STATUTORY, EXPRESSEIMPLIED (INCLUDING ALL WARRANTIES OF MERCHANTABILITY AND FITFOR A PARTICULAR PURPOSE AND ALL WARRANTIES ARISING FROM COOF DEALING OR USAGE OR TRADE).

Red Valve Products are guaranteed for a period of one year from date of shipagainst defective workmanship and material only, when properly installed, opand serviced in accordance with Red Valve's recommendations. Replacement foof Red Valve's manufacture will be made f ree of charge if proved to be defectivesuch year; but no claim for transportation, labor or consequential damages sallowed. We shall have the option of requiring the return of the defective producfactory, with transportation charges prepaid, to establish the claim and our liabilibe limited to the repair or replacement of the defective product, F.O.B. our factorValve will not assume costs incurred to remove or install defective products nowe incur backcharges or liquidated damages as a result of warranty work. Reddoes not guarantee resistance to corrosion erosion, abrasion or other sources of fnor does Red Valve guarantee a minimum length of service, or that the producbe fit for any particular service. Failure of purchaser to give prompt written noticealleged defect under this guarantee forthwith upon its discovery, or use, and possthereof after an attempt has been made and completed to remedy defects therfailure to return product or part for replacement as herein provided, or failure toand operate said products and parts according to instructions furnished by Red or failure to pay entire contract price when due, shall be a waiver by purchase

rights under these warranties. All orders accepted shall be deemed accepted sto this warranty which shall be exclusive of any other or previous warranty, and sthe only effective guarantee or warranty binding on Red Valve, anything on the cocontained in purchaser's order, or represented by any agent or employee of Redin writing or otherwise, not withstanding implied warranties. RED VALVE MAKWARRANTY THAT THE PRODUCTS, AUXILIARIES AND PARTS ARE MERCABLE OR FIT FOR ANY PARTICULAR PURPOSE.

700 N. Bell AvenueCarnegie, PA 15106(412) 279-0044FAX (412) 279-7878

website: www.redvalve.com

Redflex IOM 1/00

TROUBLESHOOTINGSYMPTOM:

Flange leakage

Check bolt t ightness. Check mating flange surface area for grooves, scratches, or

distorted areas. Overextension may indicate need for control units.

SYMPTOM:Cracking at base of arch and/ or flange

Check installed face-to-face dimensions for overextension orovercompression.

Chec.k for proper pipe alignment to within 1/ 8".

SYMPTOM:

Liquid weeping from bolt holes

Check t ube portion of joint for leaks. Replace joint or rubberfitting, if neces sary.

SYMPTOM:

Excessive ballooning of arch

M ay indicate distortion or deterioration of joint strengtheningmembers, or may indicate excessive system pressure.

Reevaluate service conditions and install a new joint.

NEVER WELD NEAR REDFLEX EXPANSION JOINTS ORRUBBER FITTINGS!Intense light and sparks from welding can damage theprotective cover o f rubber joints and fittings.

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IOM_redflex