Field Engineering
To insure good performance of the inlay, the inlay fi ller metal
should be compatible with the bellows material and base
metal. The fi nished inlay should receive 100% dye penetrant
examination. The inlay can be post weld heat treated if the
Chrome Moly base metal is to be heat treated in accordance
with the fabrication specifi cation. However, the inlay itself is
adequate insurance against leakage through the heat-affected
zone. An additional heat treatment specifi cally for the inlay
is not considered necessary for reliable bellows attachment
weld performance.
- Avoidance of future problems, unplanned shutdowns
and safety hazards
- Fast track response from SFP in emergencies working
from accurate site data
- Opportunity to purchase spare parts on a nonemergency
basis if developing problems are identifi ed
which could cause an unplanned shutdown
- Early identifi cation of work for planned maintenance
SFP provide broadly 4 levels of site inspection and reporting for clients
covering all types and manufacturers' expansion joints.
- Level 1 - Walk through of plant
- Level 2 - On line inspection
- Level 3 - Off line inspection
- Level 4 - Full pipe stress and line condition study
Level 1 - Walk through of plant on-line or off-line
This inspection would be carried out by an experienced engineer from
SFP to provide an overall visual assessment of the joints and piping
conditions in the plant.
Scope:
- Visual inspection using existing permanent access
routes, walkways and platforms for access
- No covers removed or physical intervention on the
joints
- Any existing, permanent test points accessible would
be checked
- Position of pipe hangers and overall line conditions
noted
- External condition of joints noted including hardware,
obvious signs of leakage and apparent movement of
joint
A brief visit note would be issued highlighting any concerns and suggestion
further action required.
Level 2 - On line inspection
This inspection would be carried out by an experienced Engineer from
SFP to provide a detailed external assessment of the joints and piping
conditions in the plant.
We recommend prior to the survey the following is arranged:
- Good physical access to all expansion joints
(scaffolding work, platforms etc)
- Removal of covers and insulation and/or lagging
- Applicable drawings for subject expansion joints to
be inspected or SFP references prior to visit.
- General arrangement of piping system drawings, if
applicable.
- Identity and tag each expansion joint per location
and type of expansion joint.
- Visually inspect each expansion joint bellows for the
following: leaks, dents, convolution uniformity,
discoloration, foreign materials, longitudinal and
bellows attachment weld cracking.
- Visual inspection of all piping components associ
ated with an expansion joint, i.e. spring supports,
guides and anchors where accessible. All acces
sible guides and spring supports will be marked in the
hot condition.
- Pressure test of two ply bellows to confi rm integrity where
access allows
- Dimensionally inspect the bellows with regard to overall
length, tie rod nut gaps, slotted hinge gaps, angular rotation
(for gimbal and hinged units) and comment on the
measured movement versus the design movement of the
expansion joint.
- Temperature reading (whenever applicable) on various
locations of the bellows and pipe wall.
- Inspect hardware welds where accessible.
- Inspect for general distortion of hardware, missing hardware,
etc.
- Full written report of fi ndings per joint and recommendations
for action
Level 3 - Off line Inspection
This inspection extends the Level 2 scope with internal and weld
inspections.
We recommend prior to the survey the following is arranged:
- As per Level 2 plus:
- Man way accessibility, lighting and ventilation, when applicable.
Scope:
- As per Level 2 plus:
- All accessible welds both dye penetrant tested and visually
inspected.
- Sampling and analysis of any foreign material found in
expansion joint.
- Magnetic particle testing, positive material identifi cation
utilizing Texas Nuclear Analyser, ultrasonic testing and
replicate testing, when applicable.
- Visually examine all accessible wetted surfaces from
inside the expansion joint.
- Inspect liner cavity, packing, refractory and liners, when
applicable
- Verify design movements versus actual movements when
reference is available.
- Extended written report of fi ndings per joint and recommendations
for action
Level 4 - Full pipe stress and line condition study
The inspection and engineering analysis will be undertaken by one of
SFP’s fully qualifi ed pipe stress engineers:
Scope:
- Pipe stress analysis using CAESAR pipe stress analysis
programme
- Finite Element Analysis (FEA) using the COSMOS or ALGOR
FEA programme
- Customer developed engineering programmes for the analysis
and design of expansion joints, supports, anchors and guides
- Training seminars
- Fully detailed written report and output.
SFP Site Service Solutions are deigned to reduce both cost and operational
risk and ensure your maintenance investment delivers best value
over many years of successful and trouble free operation.