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13 Foot Universal Expansion Joint Custom Designed with Incoloy Bellows and Manufactured in the USA for Service in a Chemical Plant
June 6, 2023

Usbellows universal expansion joint 150651v2

 

 Type:  Universal Expansion Joint
 Size:  157″ Long x 28″ Diameter
 Material:  Incoloy 825 |  321 SS | 304 SS
 Design:  Operating Temp: 842°F a t 190 psig
Movement 8.875″ Lateral Deflection
 Testing:  Dye Penetrant Examined | 100% X-Rayed Bellows
Longitudinal Seams | PMI Examined | Hydro-tested

This 13′ long universal expansion joint was custom designed for a chemical plant that manufactures products such as amines, glycol, polyurethanes (isocyanates and polyol), butanols, polyethylene, and hydrogen peroxide. The bellows were fabricated from Incoloy 825, the welds and liner from 321 stainless steel, and the cover tie rods from 304 stainless steel. The 157″ long unit is 28″ in diameter. It is designed for an operating temperature of 842°F at 190 psig and 8.875″ of lateral deflection. Prior to shipment, the units were 100% dye penetrant tested, and the bellows longitudinal seams were 100% X-rayed, PMI examined, and hydro-tested.

Piping Technology and Products and its subsidiaries are the only global provider of engineered supports and expansion joints in the world. Our manufacturing facilities and processes are set up to support the manufacturing of different materials should the project need it. For this project, the client requested the bellows be made of a combination of Incoloy and stainless steel. We have the experience to work with an extraordinarily broad range of materials, including high-strength steel, a full range of stainless steel, super alloys, thermoplastics, and insulation isolation materials.

PT&P REF. ORIGINAL POST 07142020

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81″ Diameter Pressure Balanced Tee Expansion Joints Custom Designed for a Chemical Plant
February 7, 2023

81” Diameter Pressure Balanced Tee Expansion Joints Custom Designed for a Chemical Plant

Type: Pressure Balanced Tee Expansion Joints
Size: 352″ OAL | 81″ Dia. | 90″ Centerline to Bevel End
Material: 304 Stainless Steel | CS
Design 392°F at 15 PSIG | 6″ Axial Compression
Testing: 100% Dye Penetrant | Air Soap and Bubble test

US Bellows custom-designed pressure-balanced tee expansion joints for a chemical plant in Texas. The units were 352″ overall length, 81″ diameter, and 90″ center line to the bevel-end of the tee. All assemblies were fabricated from 304 stainless steel.

They were designed for an operating temperature of 392°F at 15 PSIG, with 6″ of axial compression and 1.25″ of lateral deflection. The expansion joints were 100% dye-penetrate tested, as well as air soap and bubble tested prior to shipment.

We can also design and manufacture refractory lined expansion joints for these types that are able to expand and contract as conditions move from hot to cold. These units can be installed in refineries, power plants, and various green energy facilities where no other option is practical.

Our team of engineers and manufacturing staff are ready and willing to assist in helping solve any design and/or manufacturing challenges. We can also refurbish existing units to help decrease the time operations are shut down. We assure you that our 24×7 web-based emergency and quick-turn-around service can help when you need it most.

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PT&P REF. ORIGINAL POST 04192019

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Tied Universal Elbow Expansion Joint Custom-Designed for Ammonia and Waste Processing for a Liquid Nitrogen Fertilizer Plant
July 5, 2022

Usbellows tied universal expansion joint 143516

Type: Tied Universal Elbow Expansion Joint
Size: 20″ Dia. | 112″ Face-of-Flange to Center Line of Elbow OAL
Material: Inconel® 625 Bellows | 304 H Stainless Steel
Design Operating Temp: 1,150°F at 140 PSIG | 4″ Lateral Deflection
Testing: Dye Penetrant Examined | 100% X-Rayed Bellows | Hydro-tested

US Bellows custom-designed a tied universal elbow expansion joint for ammonia and waste processing for a nitrogen fertilizer plant. The bellows and liner are fabricated from Inconel® 625. The pipe, tie rods, and flanges are fabricated from 304 H stainless steel. It is designed for an operating temperature of 1,150°F at 140 PSIG and 4″ of lateral deflection. The assembly is 20″ in diameter and 112″ face-of-flange to the centerline of elbow OAL. The unit was 100% x-rayed, dye-penetrate examined, and hydro-tested before shipment.

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Rubber Expansion Joints for an 8” Dia. Pipeline at a Saudi Arabian Oil Company
May 11, 2022

Ptp rubber expansion joint 171379

U.S. Bellows, Inc. provided rubber expansion joints for an 8″ pipeline. This single open arch rubber expansion joint is fabricated from EPDM rubber and the retaining rings are galvanized A36 carbon steel and powder coated orange. The expansion joints were designed for an operating pressure of 250 psig with a 30″ vacuum, 1.75″ compression, 0.88″ extension, and 1″ lateral offset. Rubber pipe expansion joints are often used to compensate for minor misalignment and offset. Each unit was hydro-tested at 250°F at 75 psig. An advantage of a rubber expansion joint (also called an elastomer joint) over the metallic is the ability to prevent the transmission of vibration and to do this without significant harm to the joint. They can be utilized for pump inlets and discharges solely to stop vibration and noise from the pump. They have an integrally flanged design where no gaskets are required. Metal reinforcing rings can also be added to help resist pressure and flexing during operation. Fabric reinforcement within the rubber can also be added for applications to take the load of fluid pressure. At U.S. Bellows, our engineers are professionally trained and qualified to both design and manufacture units specifically for your application per expansion joint manufacturing association (EJMA).

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96″ Dia. Thick Wall Expansion Joint Designed for a Sulfuric Acid Plant
April 12, 2022

Us bellows thick wall expansion joint 169673

US Bellows designed this thick-wall flanged and flued head expansion joint at a sulfuric acid plant in Louisiana. Sulfuric acid plants are located throughout the industrialized world, and we have worked with most of them, including market leaders. Most are located near their product acid’s point of use, i.e., near fertilizer plants, copper ore leach plants, and petroleum refineries. This is because elemental sulfur is cheaper to transport than sulfuric acid.

By far the largest amount of sulfuric acid is used to make phosphoric acid, which is, in turn, used to make the phosphate fertilizers, calcium dihydrogenphosphate, and ammonium phosphates. It is also used to make ammonium sulfate, which is a particularly important fertilizer in sulfur-deficient soils. In various concentrations, the acid is used in the manufacture of fertilizers, pigments, dyes, drugs, explosives, detergents, and inorganic salts and acids, as well as in petroleum refining and metallurgical processes.

The expansion joint was fabricated from A516-70 carbon steel and painted with a special epoxy coat for protection from corrosion. The unit is 96″ x 124-1/4″ O.D. All of the butt welds for this expansion joint were 100% liquid-penetrant, 100% radiographic, and soap and air bubble tested prior to shipment. This type of joint can be used as a “clamshell” joint in conjunction with shell and tube heat exchangers, steam exhaust, hot water return lines, or chilled water lines.

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26′-10″ Long Universal Expansion Joint & Ductwork for a Chemical Plant
February 16, 2022

 

Us bellows universal expansion joint 144495

Type: Universal Expansion Joints with Ductwork
Size: 322″ Centerline-to-Centerline | 48″ Diameter
Material: 304 Stainless Steel | Carbon Steel
Design 400°F Operating Temp. @ 91 psig | 3.3″ Lateral
Testing: 100% Dye-Penetrant | PMI | Hydro-tested

U.S. Bellows custom designed this 26 ft. -10 in. long universal expansion joint with ductwork for a chemical plant. The bellows, ductwork, and flanges were fabricated from 304 stainless steel and the rest of the components from carbon steel. The unit is designed for 48″ diameter piping with an operating temperature of 400°F at 91 psig and 3.3″ of lateral deflection. The expansion joint was completed in 12 weeks and was 100% dye-penetrant, PMI, and hydro-tested before shipment. Chemical plants for which these are typically required process chemicals such as ethylene oxide/glycols, toluene diisocyanate, methylene diphenyl isocyanate, hydrochloric acid, polyether polyols, butanediol, GBL, n-methyl pyrrolidone, tetrahydrofuran, 2-pyrrolidone, PVP/PVPi, specialty amines, aniline, acetylene, surfactants, polytetrahydrofuran, and methylamines. The end products include furniture, automotive antifreeze, foams, carpets, construction, steel pickling, oil well acidizing, biodegradable plastics, lithium-ion battery production, pharmaceuticals, agriculture, gas treatment, water treatment, toothpaste, detergent, spandex fibers, engineered high-performance plastics, and animal feed.

U.S. Bellows has the scale and manufacturing agility to produce expansion joints and ductwork ranging in order size from a small scale of sub-1000 of dollars to upwards of 1M dollar large capital projects. We regularly support overnight lead times and tight project deliverables with evolving project requirements per the client and site needs. Last month, over half of our production capacity, was dedicated to this kind of work. A glimpse into our capabilities is outlined below from some projects we did last year:

– Refurbished 6, 48″-64″ diameter refractory-lined expansion joints for a large Houston refinery during a 45-day turnaround
– Completed a large ducting project for a major chemical facility in Texas with on-time delivery
– In the last 6 months, 40% of our expansion joint jobs have shipped in 2 weeks

We invite you to visit our facility and meet our team to get a first-hand look at our capabilities for your upcoming projects.

US-B REF. ORIGINAL POST 11122019

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Neoprene Expansion Joints for a Combined Cycle Power Plant
January 18, 2022

Neoprene Expansion Joints for a Combined Cycle Power Plant in Western Europe

These neoprene expansion joints were custom-designed for a gas turbine facility in Western Europe. Neoprene expansion joints are typically used in turbine inlets and turbine exhaust and can accommodate the full temperature of hot gas flows while absorbing the thermal expansion and reducing stresses in the system. Neoprene expansion joints can be lined with different materials such as metal, fiberglass, or PTFE for increased temperatures. These types of expansion joints can also absorb contraction in cryogenic lines and assist in reducing vibration. In addition to gas turbines, these units can be used in coal-fired plants, renewable energy plants such as Biofuels Green energy plants, geothermal plants, chemical and other types of power plants where high-pressure pulsations and turbulent flow conditions exist.

Some other end applications for these types of expansion joints include:

  • Engineered wood building products (such as OSB)
  • Building materials such as cement, concrete, and aggregates
  • Carbon blacks for industrial, automotive, and conductive coatings, pigments, tire components, mechanical/industrial rubber goods (including membrane roofing, automotive rubber parts)
  • Metal ore mining

The expansion joint is a conical design and is 42” x 36” and 12” face-to-face. The fabric belt is made from reinforced neoprene and the framework is made from stainless steel and incorporates the use of stainless steel bolting to prevent corrosion. Units can be supplied with several different bolting patterns and configurations to accommodate various operation/installation requirements or allow access for periodic maintenance. They are designed for an operating temperature range from-30-120°F with a +/- 100” water column and 1” of axial compression and 1.25” lateral deflection. A 100% dye-penetrant test was performed before shipment. US Bellows, a subsidiary of Piping Technology and Products, has a long history of providing neoprene and fabric type expansion joints to meet the parameters, temperatures, and flow rates of gases and can be designed to operate when there are abrasive solids that could be suspended in the gases. Due to our experienced staff, we offer the special ability to both assist in the design and development of expansion joints along with the ability to manufacture these units at our 450,000 Square feet facility to meet your specifications. Our expansion joint capability has been greatly expanded production and allowed us to meet customer expectations on the most demanding projects from refurbishments to replacements, to new innovative designs for emerging verticals such as waste-to-energy plants aimed at reducing carbon footprint. In the last 6 months, we shipped over 40% of our expansion joints in two weeks or less to meet customer timelines and deliverables.

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Expansion Joint with “Testable” Bellows for Auxiliary Column Overhead Line
December 14, 2021

Custom Universal Tied Expansion Joint with 2-Ply "Testable" Bellows for an Auxiliary Column Overhead Line

U.S. Bellows, a division of PT&P, custom-designed universal tied expansion joints with oversized, testable bellows for an auxiliary column overhead line in a refinery. This design can also be used in BioFuels plants, Wastewater Treatment Plants, and various Green Energy facilities. The expansion joint pictured is 100″ long and fabricated with carbon steel flanges, liner, cover, and hardware. The bellows are 36″ diameter and formed utilizing Inconel-625 LCF material. The expansion joints are designed for an operating temperature of 650°F at 50 psig with 2.75″ lateral movement. Tests included dye Penetrant examination of all welds, x-ray test of butt-welds, and bellows long seams. We conducted PMI tests on all alloys along with the welds, as well as, a pneumatic test and bellows ply leak test.

The bellows, being two-ply, provide for 100% redundancy; therefore, if a leak occurs in the inner ply (which can be detected by a leak detection system), the outer ply is designed for the full pressure and temperature. Pipe strain, misalignment, and vibration can affect the lifecycle of expansion joints located near pumps, compressors, and other rotating equipment. This design allows for the critical piping system to continue operating while plans for replacement can be formulated. This can prevent unexpected shut-downs saving field maintenance valuable time and money. Two-ply bellows also make it possible to pressure test (using the installed test ports) and inspect for leaks during field inspections and in some cases, if conditions permit, the expansion joint can be tested while in service. Most expansion joints in oil refineries, especially FCC units use two-ply bellows, but they are also ideal for regenerated catalyst standpipe, spent catalyst standpipe, recirculation cooled catalyst flue gas piping, and hot gas expanded piping.

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Universal Elbow Expansion Joints for Glycol Heat Transfer Piping
November 22, 2021

Universal Elbow Expansion Joints for Glycol Heat Transfer Piping
U.S. Bellows, a division of PT&P, custom-designed universal elbow expansion joints for glycol heat transfer piping for one of the largest chemical and refining companies in the world. Such industrial complexes produce chemicals such propylene oxide used for making plastic goods, tertiary butyl alcohol used in making flavors, perfumes, and as a solvent, ethylene oxide is used as an intermediate product in the production of fabrics and antifreeze, polypropylene is used for making consumer products such as those for automobiles, and Catalloy process resins which are used in packaging and automotive production. Glycol heat transfer enables effective process cooling. The bellows, flanges, plates, pipe, nuts, and threaded rods are all fabricated from 304 stainless steel and the units were painted for added protection. The expansion joints are designed for a 16” NPS and are 68-3/8” long. They are designed for an operating pressure of 67 psig at 378°F with 854 lb/in. axial spring rate and 0.2” of axial compression and with 205 in/lb lateral spring rate and 1.51 in lateral movements. Both expansion joints were hydro-tested at 101 psi and QC inspected before shipment. Generally, a universal expansion joint is composed of two bellows connected by a common pipe or center spool. This type of assembly allows any combination of the three basic movements: axial, lateral, and angular allowing for safe absorption of temperature-induced expansion and contraction of building materials, and vibration, or to allow movement due to ground settlement or seismic activity. In addition to expansion joints, PT&P provides a full range of engineered pipe supports, pre-insulated supports, shock control, restraint, and support devices, ASME fabricated vessels, tanks, pig launchers, and more.

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Externally Pressurized X-Flex Expansion Joints for a Overseas Facility
September 14, 2021

Externally Pressurized X-Flex Expansion Joints for a Overseas Facility

“Decarbonation” and “Carbon Neutral” are two key terms used to describe efforts to lower the amount of greenhouse gasses emitted into the atmosphere. Efforts are now underway to gradually convert existing Coal-Fired, HRSG (Heat Recovery Steam Generated or Natural Gas Powered) and other power plants utilizing fossil fuels onto plants that emit far fewer greenhouse gasses into the atmosphere. U.S. Bellows, Inc. received unique specifications to design and manufacture externally pressurized expansion joints for a facility overseas. The bellows are fabricated from 316 stainless steel and all other components are carbon steel. They are designed for a temperature of 200°F at 150 psig with 8″ axial compression. The units are 4″ NOP x 63″ L, 6″ NPS x 61.44″ L, and 12″ NPS x 64″ L.

3d drawing externally pressurized ej 171063Externally pressurized pipe expansion joints, also known as X-Flex expansion joints, are suited for piping systems that require large amounts of axial compression or extension. In externally pressurized pipe expansion joints, the bellows elements are arranged so that the media flow is on the external surface of the bellows. Externally pressurizing the bellows eliminates pressure instability as a limitation to the design and permits the absorption of large amounts of axial expansion. Our QC department conducted various NDT examinations (X-Rays, PMI, Penetrant Tests, and Hydro Tests). Also provided were “weld maps” and MTR’s for client review and inspection. At U.S. Bellows, we are constantly developing and assisting client engineers in this effort toward decarbonation by designing innovative products to accommodate new and unusual design specifications.

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