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Safety

Piping Technology highly recommends that our customers thoroughly understand the uniqueness of pipe expansion joints and their application. The following safety recommendations are paraphrased from the Fifth Edition of The Standards of the Expansion Joint Manufacturers Association, 1980.

SAFETY RECOMMENDATIONS FOR PIPING SYSTEMS CONTAINING BELLOWS EXPANSION JOINTS

Bellows pipe expansion joints are employed in piping systems to absorb differential thermal expansion while containing the system pressure. They are being successfully used in refineries, chemical plants, fossil and nuclear power plants, shipboard applications, heating and cooling systems, pulp and paper plants, and cryogenic plants. Typical service conditions range from pressures of full vacuum to 1,000 psig (70 kg/cm3) and -420F to +1,800 F (-251C to +968 C). Thus, pipe expansion joints must be specified as a highly engineered product. They cannot and should not be purchased and used as commodity items if the pipe expansion joints are to perform their intended function safely and reliably. The system operating requirements, the pipe expansion joint design and manufacturing quality, the installation, test and operating procedures must all be considered for all pipe expansion joint installations.

Unlike most commonly used piping components, a bellows is constructed of relatively thin gauge material in order to provide the flexibility needed to absorb mechanical and thermal movements expected in service. This requires design, manufacturing quality, nondestructive examination, handling, installation and inspection procedures which recognize the unique nature of this product.

In general, the most reliable and safe bellows pipe expansion joint installations have always involved a high degree of understanding between the user and manufacturer. With this basic concept in mind, the following recommendations are given in order to better inform the user of those factors which many years of experience have shown to be essential for the successful installation and performance of piping systems containing bellows pipe expansion joints.

Custom-Designed Single Flanged Expansion Joints
December 10, 2024

Us bellows single expansion joint 157943

Type: Single Flanged Expansion Joint
Size: 6″ to 18″ Dia. Range
Material: 321 Stainless Steel | 304 SS | 316 SS
Design 1055°F | 2 psig | 5/8 ” Axial Travel | 5/8″ Lateral Offse
Testing: 100% Dye-Penetrant | Air, Soap, & Bubble

U.S. Bellows provided single expansion joints custom-designed for an oil refinery. The 12″ diameter bellows are fabricated from 321 stainless steel, the liner is 304 stainless and the flanges are fabricated from carbon steel.

Other single type expansion joints for this client’s order varied in diameter from 6″ to 18″, and were constructed using 316 stainless steel for the bellows, liners, and flanges. The design conditions were as follows: a design temperature of 1055°F, an operating pressure of 2 psig, an axial travel of 5/8″, and a lateral offset of 5/8″. Each unit underwent hydrostatic testing before shipment. U.S. Bellows offers expansion joint solutions for a wide range of industries, including biofuels and bioenergy, carbon black, paper mills, sugar mills, and wastewater management.

PT&P REF. ORIGINAL POST 10142020

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Rectangular Fabric Expansion Joint for a Ventilation Air Filter System at a Gas Turbine Facility
November 12, 2024

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

 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

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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

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11 Foot Long Universal Gimbal Expansion Joints Designed for an Oil Refinery in Canada
September 10, 2024

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

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

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Fabric Expansion Joints Designed for a Textile Sheets, Polymer and Fiber Plant
August 6, 2024

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

 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

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Universal Hinged Fabric Expansion Joints for a Chemical Plant in Delaware
May 7, 2024

Hinged Fabric Expansion Joints for a Chemical Plant in Delaware
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

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Custom Designed Externally Pressurized Expansion Joints for a Flare Header Application at a Mississippi Refinery
April 9, 2024

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

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

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Fabric Expansion Joint for an Inlet Duct Application at a Gas Turbine Facility
February 6, 2024

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

 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.

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.

PT&P REF. ORIGINAL POST 06252018

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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

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Fabric Expansion Joints for a Carbon Gas Application at an Oil and Gas Facility
November 7, 2023

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

 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

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