Blog Archives | US Bellows

Rectangular Fabric Expansion Joint for a Ventilation Air Filter System at a Gas Turbine Facility

November 12, 2024

Type:	Rectangular Fabric Expansion Joint
Size:	153″ long x 55″ wide x 21″ face-to-face
Material:	PTFE fiber glass reinforced / A572 Gr.50 high strength steel frame & liner
Design:	-20°F to +200°F at +/- 100″ water column
Testing:	100% Dye-Penetrant

U.S. Bellows designed this rectangular fabric expansion joint for a ventilation air filter system at a gas turbine facility. The dimensions for the expansion joint are 153" long x 55" wide x 21" face-to-face. The fabric belt is made from PTFE fiber glass reinforced, while the frame and liner are fabricated from A572 Gr.50 high strength steel. The expansion joint is designed for -20°F to +200°F at +/- 100" water column. A dye penetrant examination on the welds was performed prior to shipment.

PT&P REF. ORIGINAL POST 10182016

42″ Single Expansion Joints for an Exhaust Duct Application at a Gas Turbine Facility in Indiana

October 8, 2024

Usbellows single expansion joint 132974

Type: Single Expansion Joints

Size: 42″ ID | 24″Face-To-Face

Material: Inconel 600 | 304 Stainless Steel | Carbon Steel

Design: 350°F Operating Temp. @ 100 psig | 0.75″ Lateral

Testing: Hydro-tested

These single expansion joints were custom-designed by U.S. Bellows for an exhaust duct application at a gas turbine facility in Indiana. The units have a 42″ ID and are 27″ face-to-face. The bellows were fabricated from Inconel 600, the liners from 304 stainless steel, and the cover, limit rods, and hardware from carbon steel with red oxide primer on all exposed carbon steel. It is important to note that our manufacturing and production abilities around mixed metallurgy are unique in that we can isolate and manage different metals in our production but also have the experience depending on the client’s need.

These units are designed for an operating temperature of 350°F at 100 psig, 0.625″ of axial compression, and 0.75″ of lateral deflection. The expansion joints were hydro-tested prior to shipment.

Over 60-65% of the expansion joints we provided replace existing units. US Bellows is not necessarily the OEM in all cases however we have the experience to manufacture, repair, or audit our designs and others as we are members of EJMA with deep expertise in expansion joint design and manufacturing for over 50 years with an in-house Field service team. Our expansion joint engineers use the EJMA (Expansion Joint Manufacturers Association) latest edition to maintain a calculations-based spreadsheet and a stand-alone engineering design software program for the ASME ( American Society of Mechanical Engineers) code section VIII-based calculations to design expansion joints.

Applications for expansion joints include:

Fossil Fuel Power Plant Chemicals and Petrochemical Stationary Engine Exhaust Pulp, Paper, Wood pellets

Power (Nuclear/Fossil fuel/Renewables) Heat Exchangers Municipal Water Districts Space Aviation/Aerospace Engine Exhaust

District Energy FCC Units Wastewater Treatment Truck Exhausts

Gas Turbines Navy Biofuels/Solid Waste Incineration Steel Mills/Blast Furnaces/Mining

Steam Distribution Kilns Solar/Environmental applications Marine Piping and Exhaust

Geothermal Power Plants Furnace Sealing Bags HVAC Building and heating systems Liquefied Natural Gas Service (LNG)

Refineries Education/Labs Food processing Cement manufacturing

PT&P REF. ORIGINAL POST 11252019

11 Foot Long Universal Gimbal Expansion Joints Designed for an Oil Refinery in Canada

September 10, 2024

Type:	Universal Gimbal Expansion Joint
Size:	102″ – 133″ L \| 41.5″ W \| 41.75″ H \| 32″ diameter
Material:	Carbon Steel \| 304 Stainless Steel
Design:	100°F @ 285 psig \| 102 lb/in/degree Rotational Spring Rate \| 15.4″ Lateral Deflection
Testing:	Hydrotested @ 428 PSIG

U.S. Bellows custom designed these universal gimbal expansion joints for an oil refinery in Canada. The bellows and liners are fabricated from 304 stainless steel, and the remainder of the components are fabricated from carbon steel. The units range from 102" to 133" long respectively, and sizes supplied are 12"NPS with a gimbal box 27" wide, 27.5" tall and 24"NPS with a gimbal box 41.25" wide, 41.75" tall. They are designed for an operating temperature of 100°F at 285 psig, with a 102 lb/in/degree rotational spring rate and 15.4" of lateral deflection. The expansion joints were 100% dye-penetrant tested and hydro-tested at 428 psig prior to shipment.

Gimbal expansion joints are used in a variety of industrial applications where piping systems experience multidirectional movements due to thermal expansion, vibrations, or other external forces. Here are some common areas where gimbal expansion joints are utilized:

Power Plants: In both fossil fuel and nuclear power plants, gimbal expansion joints are used in the steam, water, and exhaust systems to accommodate thermal expansion and prevent stress on the piping.

Refineries and Petrochemical Plants: These joints are essential in refineries and petrochemical facilities to manage the thermal expansion in pipelines carrying various fluids, including high-temperature hydrocarbons, to ensure safe and efficient operations.

Oil and Gas Industry: Gimbal expansion joints are employed in pipelines that transport oil, gas, and other fluids, especially in offshore drilling platforms, to handle the dynamic movements caused by waves, currents, and thermal effects.

Shipbuilding: In marine applications, gimbal expansion joints are used in the exhaust systems of ships to absorb vibrations and accommodate thermal expansion caused by the operation of engines and other machinery.

Aerospace and Defense: These joints are also found in aerospace applications, such as in rocket propulsion systems, to absorb the significant thermal expansion and mechanical stresses during launch and flight.

PT&P REF. ORIGINAL POST 10012018

Fabric Expansion Joints Designed for a Textile Sheets, Polymer and Fiber Plant

August 6, 2024

Type:	Fabric Expansion Joint
Size:	36″ L \| 24-1/2″ W \| 24-1/2″ L
Material:	1-Ply ReinForced Silicone Fabric \| Carbon Steel
Design:	300°F @ 3 psig \| 6″ Lateral Movement
Testing:	100% Dye-Penetrant

U.S. Bellows designed fabric expansion joint for a textile sheets, polymer, and fiber plant in Virginia. The dimensions for the expansion joints are 36" long, 24-1/2" wide, and 24-1/2" long. These fabric expansion joints are fabricated of carbon steel flanges with 1-ply reinforced silicone fabric. The expansion joints are designed for 300°F with an operating pressure of 3 psig, and movement of 6" lateral. A dye penetrant examination on the welds was performed prior to shipment.

Fabric expansion joints are used in a wide array of applications playing a crucial role in preventing damage to equipment, ensuring system reliability, and maintaining overall safety in industrial processes. Some examples of where they are used are:

Cement plants for ducts and exhaust systems associated with high temperature operations.
Mining industry for mineral and material handling including smelting.
HVAC systems for duct work to address any thermal movements or vibrations.
Marine and shipbuilding applications where exhaust systems, engine piping and other critical areas movement and vibrations must be managed.
Renewable energy facilities such a waste to energy or bioenergy plants in which the incineration operations are critical.
Paper and Pulp mills for ducting systems in drying and paper manufacturing processes.
Steel Mills for blast furnace systems and exhausting ducts.
Chemical plants to handle dynamic forces associated with chemical reactions, temperature variations and corrosive environments.
Power plants Fossil Fuel and Nuclear plants to manage vibrations and thermal axial expansion that could stress components and fixed equipment.

We have a 24/7 field service team that works on fabric expansion joints. One of our loyal customers, a North American-based energy company, reached out to us for warranty work on one of our Fabric Expansion Joints and our fierce Fabric Expansion Joint team lead, stepped in and stepped up! She flew up to West Virginia and completed the work. We are dedicated to the success of our products in the field even after they leave our plant.

PT&P REF. ORIGINAL POST 02052019

Universal Hinged Fabric Expansion Joints for a Chemical Plant in Delaware

May 7, 2024

U.S. Bellows designed these hinged universal fabric expansion joints for a chemical plant in Delaware. The expansion joints are 84″ in diameter and 60″ OAL. The fabric belt is made with PTFE while the rest of the components are from carbon steel. The expansion joints are designed for an operating temperature of 650°F at 1 psig and 1/2″ of angular movement. The units were 100% dye-penetrate examined was performed prior to shipment.

PT&P REF. ORIGINAL POST 02292016

Custom Designed Externally Pressurized Expansion Joints for a Flare Header Application at a Mississippi Refinery

April 9, 2024

Type:	Externally Pressurized Expansion Joint
Size:	133 11/16″ and 120.5″ Long \| Both Have 42″ Pipe Dia.
Design:	Inconel 625 \| Carbon Steel
Material:	450°F at 108 psig & 31″ and 25″ Axial Compression
Testing:	Hydro-tested at 167, PMI, 100% X-Ray, and Dye-Penetrant

U.S. Bellows custom designed these externally pressurized expansion joints for a flare header application at a refinery in Mississippi. One unit measures 133-11/16" long and the other measures 120-1/2" long and both are manufactured for a 42" pipe diameter. The bellows were fabricated from Inconel 625 and used in conjunction with a carbon steel pipe per A671-CC-60 CL.22. The carbon steel pipe is finished with a 2-coat paint system for corrosion protection. They are manufactured for a design pressure of 108 psig at 450°F with 31" and 25" of axial compression. All alloy material was PMI inspected. The units were hydro tested at 167 psig, 100% dye-penetrant tested, and the bellows and pipe weld seams were 100% X-ray tested prior to shipment.

Expansion joint applications are varied depending on the type of plant. Some applications include:

Exhaust systems for Aerospace, Trucks, Marine Piping
Solid waste incineration for Renewables and Biofuel plants
Waste Water Treatment plants for Municipal water districts as well as manufacturing plants
Kilns in Mining, Food, and Plastics plants
Geothermal Plants
Gas Turbines
FCC units
Heat exchangers
Steam distribution in Geothermal plants
Water cooling systems for Nuclear power plants such as inlet of condenser cooling water from lakes or large bodies of water
Thermal Oxidizer systems in polymer processing
Boller Duct Expansions
Vacuum Jacketed piping systems in LNG

We have built, supplied, installed, replaced, audited, repaired, and tested expansion joints for most piping systems applications. Our in-house expertise in handling different types of materials needed for expansion joints made of carbon steel, stainless, alloy steel, high nickel alloys, and aluminum spans over our 48 years of work. Welding specialties include TIG, pulse-arc MIG, SMAW, SUB-ARC, and Aluminium. Our qualifications for expansion joints are ASME Section IX, AWS D1.1, NS, and MIL-STD-248. Testing can specified to include any or all of the following depending on project and application requirements:

magnetic particle-dry method
Liquid penetrant-visible and fluorescent
Ultrasonic and radiography
Hydrostatic and Pneumatic testing

US Bellows, a subsidiary of Piping Technology and Products, is a member of the EJMA association which maintains a set of standards for quality expansion joint design and manufacturing. The standards are used as a worldwide reference for the proper selection and application of expansion joints.

PT&P REF. ORIGINAL POST 02202018

Fabric Expansion Joint for an Inlet Duct Application at a Gas Turbine Facility

February 6, 2024

Type:	Fabric Expansion Joint
Size:	143″ long x 61″ wide x 12″ face-to-face
Material:	PTFE Fiberglass Reinforced Fabric Belt & 304 Stainless Steel
Design:	-20°F to 600°F , +/- 100″ water column, 0.5″ Axial & 1″ Lateral
Testing:	Dye-Penetrant

U.S. Bellows fabricated this rectangular fabric expansion joint for an inlet duct application at a gas turbine facility. The unit is 143″ long x 61″ wide x 12″ face-to-face. The fabric belt is made from reinforced PTFE fiberglass and the frame and liner from 304 stainless steel. It is designed for an operating temperature ranging from -20°F to 600°F with a pressure of +/- 100″ water column, with 0.5″ of axial compression and 1″ of lateral deflection. A dye-penetrant examination was performed on all the structural frame welds prior to shipment.

- Cement plants for ducts and exhaust systems associated with high temperature operations.

- Mining industry for mineral and material handling including smelting.

- HVAC systems for duct work to address any thermal movements or vibrations.

- Marine and shipbuilding applications where exhaust systems, engine piping and other critical areas movement and vibrations must be managed.

- Renewable energy facilities such a waste to energy or bioenergy plants in which the incineration operations are critical.

- Paper and Pulp mills for ducting systems in drying and paper manufacturing processes.

- Steel Mills for blast furnace systems and exhausting ducts

- Chemical plants to handle dynamic forces associated with chemical reactions, temperature variations and corrosive environments.

Power plants: Fossil Fuel and Nuclear plants to manage vibrations and thermal axial expansion that could stress components and fixed equipment.

PT&P REF. ORIGINAL POST 06252018

Rectangular Expansion Joints Custom Designed for an Air Fan Ducting Application in Texas

January 8, 2024

Usbellows rectangular expansion joint 166850

Type: Rectangular Expansion Joints

Size: 37-3/8″ Wide | 65″ Long | 16″ FTF

Material: 304 Stainless Steel | Carbon Steel

Design: 250°F Operating Temperature @ 5 psig

Testing: 100% Dye-Penetrant

U.S. Bellows custom-designed two of these rectangular expansion joints for an air fan ducting application at a chemical facility in Texas. They are 37-3/8″ wide, 65″ long, and 16″ face-to-face. The bellows and liner were fabricated from 304 stainless steel, with the rest of the components from carbon steel. The units are designed for an operating temperature of 250°F at 5 psig. The expansion joints were 100% dye-penetrant tested prior to shipment.

Rectangular expansion joints have many applications in which they are used. They can be used in blast furnaces in steel processing facilities, APH Air preheaters in refineries, and for ducting in large systems in many industries in petrochem, mining, LNG and steel mills. We have built over 400 such units over the last couple of years of varying metallurgy ranging from carbon steel to stainless to inconel. We currently have inconel units in production for a large LNG facility to meet the newly established FERC requirements around spillage, environmental considerations, and, most importantly, safety.

Manufacturing expansion joints involves a precise blend of scientific principles and manufacturing craftsmanship. Rectangular expansion joints present distinctive challenges, particularly in relation to edge welding requirements. Without the necessary expertise, there is a risk of encountering issues such as sugaring—a form of oxidation that arises when an inadequate amount of purging gas is utilized during welding.

It’s worth noting that circumferential welds in typical round expansion joints, which are both welded and formed simultaneously, do not face the same concerns. In contrast, rectangular expansion joints undergo a two-step process where they are first formed and then welded, introducing unique considerations.

We conduct thorough in-house testing for all our expansion joints, encompassing a comprehensive range of assessments:

Burst Testing

Dye Penetration testing

Fatigue/Cycle Testing

Hydrostatic testing

Helium Leak testing

Ultrasonic Testing

Radiography Testing

PMI Testing

Pneumatic Testing

Magnetic Particle Testing

Leak Detection Testing.

Rectangular expansion joints represent a subset of the assessments conducted for typical round expansion joints. Specifically, for rectangular expansion joints, we perform leak, hydro, and pneumatic testing.

PT&P REF. ORIGINAL POST 07222019

Fabric Expansion Joints for a Carbon Gas Application at an Oil and Gas Facility

November 7, 2023

Type:	Fabric Expansion Joint
Size:	20″ Diameter & 18″ Length
Material:	1-Ply PTFE Fabric Belt/Carbon Steel Framework
Design:	-20°F/+600°F with a +/- 20″ Water Column, and +/- 1″ of Axial Compression & Lateral Offset
Testing:	100% Dye-Penetrant

U.S Bellows fabricated these fabric expansion joints for a carbon gas application at an oil and gas facility in Louisiana. These units are 20″ in diameter and 18" in length. The 1-ply fabric belt is made from PTFE, and the framework is carbon steel. They are designed for an operating temperature of -20°F/+600°F with a +/- 20" water column and +/- 1" of axial compression and lateral offset. The welds of the units were dye penetrant tested prior to shipment.

US Bellows and its subsidiaries have served as leading global suppliers of carbon black worldwide. Material from these plants is made to exacting standards for tires, coatings, ink, batteries, plastics, and numerous other specialty high-performance applications. Carbon black is produced from the thermal decomposition of heavy petroleum raw materials, such as coal tar, ethylene cracking tar, or FCC tar. It is widely utilized owing to its various beneficial characteristics, including surging tire tread wear and rolling resistance, effectively absorbing ultraviolet (UV) light and converting it into heat, improved thermal conductivity, and superior UV protection. Several processes, such as oil furnaces and thermal, are mainly used to manufacture carbon black. In addition to providing expansion joints, we have provided the following products from our portfolio of manufactured in our facility in Houston, Texas:

Constant Spring Hangers
Metallic Expansion Joints
Pipe Shoes, Guides, and Anchors
Insulated Supports
Paddle Blinds and Spacers
Pipe Hangers Hardware
Slide Bearing Plates
Instrument Supports
Variable Spring Hangers

PT&P REF. ORIGINAL POST 08122017

Fabric Expansion Joint Designed for a High-Temperature Duct Application

August 8, 2023

Type:	Fabric Expansion Joints
Size:	67″ Long x 67″ Wide x 14″ Tall
Material:	3-Layer Fabric Belt with Kaowool Insulation 304 Stainless Steel Angle Flanges
Design	Operating Temp: 2012°F at +/- 100″ Water Column 1″ of Lateral Deflection
Testing:	100% Dye Penetrant Testing & Q.C. Inspection

Fabric pipe expansion joints are often used in ducts that carry hot gasses at low pressures. The major design parameters are the temperatures and flow rates of the gasses and the amount and abrasiveness of solids suspended in the gasses. This fabric expansion joint utilizes a bulky flexible material, also called an Insulation Pillow, to shield against high temperatures protecting the belting material. Refractory is also used in the construction of this joint but is designed so that it does not interfere with movement. Our experienced engineers know that every element of this expansion joint plays a role in its rating for certain temperatures and the number of hours of operation. View Fabric Expansion Joints Product Section.
Fabric expansion joints are key in the systems supporting power and refining plants focused around renewable carbon-neutral product offerings. We have worked with the new entrants in the marketplace but also helped our long-term clients transition their older fossil fuel-based assets to green technology. These plants include biochar from biomass processing, carbon black, clean hydrogen, styrene, and cement.

PT&P REF. ORIGINAL POST 03182020

Newer posts

Fossil Fuel Power Plant	Chemicals and Petrochemical	Stationary Engine Exhaust	Pulp, Paper, Wood pellets
Power (Nuclear/Fossil fuel/Renewables)	Heat Exchangers	Municipal Water Districts	Space Aviation/Aerospace Engine Exhaust
District Energy	FCC Units	Wastewater Treatment	Truck Exhausts
Gas Turbines	Navy	Biofuels/Solid Waste Incineration	Steel Mills/Blast Furnaces/Mining
Steam Distribution	Kilns	Solar/Environmental applications	Marine Piping and Exhaust
Geothermal Power Plants	Furnace Sealing Bags	HVAC Building and heating systems	Liquefied Natural Gas Service (LNG)
Refineries	Education/Labs	Food processing	Cement manufacturing