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
U.S. 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, used, in turn, 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. 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 used in conjunction with shell and tube heat exchangers, steam exhaust, hot water return lines, or chilled water lines.
Read MoreRectangular Fabric Expansion Joint for a Heat Recovery System at a Cement Plant
U.S. Bellows, Inc. designed and fabricated this rectangular fabric expansion joint for a heat recovery system at a cement plant in Indiana. The unit was fabricated with a high-temperature PTFE fabric belt and carbon steel frame. The dimensions are 197″ in length, 118″ in width, and 18″ face-to-face. The expansion joint is designed for an operating temperature of -20°-400°F at +/- 60″ water column and 1″ of axial compression and lateral offset. A dye-penetrant exam was performed on all welds before shipment.
Fabric expansion joints are often used in ducts that carry hot gases at low pressures. The major design parameters are the temperatures and flow rates of the gases and the amount and abrasiveness of solids suspended in the gases. Rectangular fabric expansion joints are also used in power plant ducting that requires joints from the boiler or economizer outlet to the chimney.
Also, they can be used on ducting to the coal pulverizers and the furnace-air inlets. Combustion turbines will also use these types of joints in exhaust and heat-recovery ducts. The primary duct movement this type of joint absorbs is axial expansion and contraction due to temperature changes. The expansion joint designer can also design for lateral and angular movements. Elastomers and Plastomers are the basic flexible materials used to construct the belting material for these joints. These sheets can be used in combination with woven glass, metal wire, fluoroelastomers, insulation, and other materials for use in applications where there may be abrasive material, condensate, acids, and other particles that could reduce the expected life of the joint. Our experienced engineers are also skilled in the various methods and fasteners to connect the belting material to the metal frames of the expansion joint.
This expansion joint was designed for a cement plant for one of the largest building material manufacturers worldwide. Such facilities make products ranging from fly ash, slag, masonry, white, specialty and oil well cements for use in commercial construction, residential construction, and industrial applications.
USB REF. ORIGINAL POST 03132017
Read More26′-10″ Long Universal Expansion Joint & Ductwork for a Chemical Plant
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
Read MoreUniversal Expansion Joints Custom-Designed for a Hot Air Blower
These universal expansion joints were custom-designed with guided tie rods, internal liners, and bellows protection covers for a hot air blower. These expansion joints are used in a plant that manufactures tires for cars and light-duty trucks. High Heat is required in the manufacturing process to vulcanize rubber to components made of steel and polyester and to also cure the rubber. The universal expansion joint can allow for large amounts of lateral deflection that can occur in more than one plane. By increasing or decreasing the distance between the two bellows by varying the length of a section of pipe spool, the designer can accommodate for the given amount of lateral deflection. These expansion joints are designed for an operating pressure of 50 psig at 383 degrees F. A total of 18 were supplied with half of the units measuring 40” dia. x 74-7/8” long x 58-1/2” overall outer dia. The rest measure 36” dia. X 60-1/4” long x 53-3/4” overall outer diameter. The bellows, flange, middle pipe, liner, and lugs are fabricated from 316/316L stainless steel. The rods, nuts, and cover are 316 stainless steel. The 40” dia. unit is designed for 0.394” axial compression and the 36” dia. unit is designed for 0.20” axial compression. Both units are designed for 0.394” lateral movement. Each expansion joint was inspected by quality control and hydraulic pressure tested before shipment. We manufacture expansion joints to relieve stress in piping systems whether the thermal movement is axial, lateral, or angular in plants such as Food Processing, Automotive, Hospital Steam Lines, Semiconductors, and other types of Green Energy plants.
Read MoreU.S. Bellows Custom-Designed Tied Universal Expansion Joints for Service at a Chemical Plant
Universal expansion joints such as these are used in chemical plants that manufacture petrochemicals (such as ethylene and styrene monomer), polymers, and building products (PVC profiles for windows, doors, and decking). The units range from 26” to 48” in length and 8” to 20” in diameter. The bellows were fabricated from 321 stainless steel, the weld ends, pipe spools, and flanges from 304 stainless steel, and the tie rods and hex nuts from carbon steel. They are designed for temperatures ranging from -150°F to 800°F, operating pressures ranging from 50 to 240 psig, and 0.25” to 2.25” of lateral deflection. The expansion joints were air, soap, and bubble tested, 100% dye-penetrant tested and hydro-tested before shipment. The universal pipe expansion joint consists of two bellows separated by a pipe section or spool. The primary purpose of this arrangement is to have a unit that will accept large amounts of lateral deflection. The amount of lateral deflection they can accept is a function of the amount of angulation each bellows can absorb and the distance between the bellows. For a given bellows element, the amount of lateral deflection capability can be increased or decreased by simply changing the length of the center spool.
Read MoreGimbal Expansion Joints for Crude Oil Pipelines in Canada
U.S. Bellows custom-designed and fabricated universal gimbal expansion joints for 24” diameter crude oil pipelines at a power plant in Canada. The bellows are fabricated from A240 316 stainless steel bellows, the flanges are A105N carbon steel, and the plates are A516 70 carbon steel. The expansion joints are designed for a 10 degrees angular rotation at 285 psig up to 100 degrees F. They are designed for an angular spring rate of 4900 in-lb/dec and vertical offset of 10-1/4”. The units measure 43” x 43” x 110” and 38” x 38” x 79”.
3D Modeling was done so that our engineers can check the “fit-up” to confirm the design, perform stress analysis, or other modeling benefits prior to fabrication. We performed hydro tests, completed NDE reports, and supplied Material Test Reports per the client requirements.
Read MoreCustom-Designed Single Flanged Expansion Joints
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. The remaining bellows ranged in diameter from 6” to 18” and were fabricated with 316 stainless steel bellows, liners, and flanges. Design conditions: design temperature = 1055°F, operating pressure = 2 psig, axial travel = 5/8”, lateral offset = 5/8”. Each unit was hydrostatically tested prior to shipment. U.S. Bellows provides expansion joint solutions for all markets and applications including biofuels/bioenergy, carbon black industry, paper mills, sugar mills, and wastewater management.
Read MoreSingle Flanged Expansion Joints for a Leading Manufacturer & Designer of Transformers & Power Supplies for an Industrial Applications Company
Type: | Single Flanged Expansion Joint |
Size: | 5″ Length | 6″ ID | 11″ O.D. |
Material: | ASTM A240-316 Stainless Steel |
Design | 200°F | 150 psig | 7,942 lb/in. Lateral Spring Rate 0.625 ” Axial Travel | 803 lb/in. Axial Spring Rate 0.125″ Lateral Offset | 225 psig Test Pressure |
Testing: | 100% Dye-Penetrant | Air, Soap, & Bubble |
The single expansion joint type is simply a bellows element with end connections. It is the least expensive type but requires that the piping be controlled as to the direction of the movements required of the unit. This type of expansion joint should not be expected to control the movement of the pipe. If the piping analysis shows that the expansion joint must accept axial compression, then the piping must be guided and constrained in other locations so that only that axial movement will occur. The flanges and bellows are fabricated from ASTM A240-316 stainless steel. The units are 6″ in diameter, 5″ long, and have an 11″ outside diameter. Design conditions are: design pressure = 150 psig, test pressure = 225 psig, design temp. = 200°F, axial travel = 0.625″ compression, axial spring rate = 803 lb/in., lateral offset = 0.125″, and lateral spring rate = 7,942 lb/in. *Designed in accordance with the Standards of the Expansion Joint Manufacturers Association, 10th E, and welding per ASME Boiler and Pressure Vessel Code Section IX.
Read MoreTied Universal Elbow Expansion Joint Custom-Designed for Ammonia and Waste Processing for a Liquid Nitrogen Fertilizer Plant
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 |
U.S. Bellows, Inc. 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.
Read MoreFabric Expansion Joints Custom Designed for an Exhaust Duct at a Gas Turbine in Saudi, Arabia
Type: | Fabric Expansion Joint |
Size: | 70″ W x 126″ L x 17.5″ Face-to-Face |
Material: | PTFE Fabric Belt | Stainless Steel Framework |
Design | Operating Temp: -20°F to 600°F | Operating Pressure +/- 100″ Water Column Movement +/- 1″ Axial Compression & Lateral Offset Combined |
Testing: | Dye Penetrant Examined | Anchor Install Test& Q.C. Inspection |
U.S Bellows custom-designed a rectangular fabric expansion joint with rounded corners for an exhaust duct application at a gas turbine in Saudi, Arabia. The unit is 70″ W x 126″ L x 17.5″ face-to-face; the fabric belt is PTFE and the framework is stainless steel. The expansion joint is designed for an operating temperature range from -20°F to 600°F, an operating pressure of +/- 100″ water column, and a movement of +/- 1″ axial compression and lateral offset combined. A 100% dye-penetrate exam and anchor install test were performed before shipment.
Read MoreRubber Expansion Joints Designed for Water Cooling Loops at a Chemical Plant
Type: | Neoprene Expansion Joint |
Size: | 3×10, 6×10, 8×12, 10×14 |
Material: | Neoprene Twin Sphere Rubber Tubing with 304 SS Flanges & Covers |
Design | Operating Temp: 225°F at 225 psig | 1-3/8″ – 1-3/4″ of Lateral Offset |
Testing: | Hydro-Tested | PMI on all Rubber Joint Root-Rings |
These neoprene expansion joints were custom-designed for water cooling loops at a chemical plant in Louisiana. They have a neoprene twin sphere rubber tubing with 304 stainless steel flanges and covers. U.S. Bellows fabricated five of each of the following dimensions: 3×10, 6×10, 8×12, and 10×14. They are designed for an operating temperature of 225°F at 225 psig and 1-3/8″ – 1-3/4″ of lateral offset. The units were hydro-tested and PMI on all rubber joint root-rings prior to shipment.
Read MoreU.S. Bellows, Inc. Custom Designed a Refractory-Lined Expansion Joint for a Regenerator Application in Uruguay
Type: | Refractory-Lined Expansion Joint |
Size: | 43″ Tall x 39-1/2″ Dia. |
Material: | Carbon Steel | INCOLOY® 825 | 3.75″ Thick Refractory |
Design | Operating Temp: 653°F at 46 PSIG | 0.25″ Axial Compression |
Testing: | Hydro-tested | Q.C. Inspection |
This refractory-lined expansion joint was custom designed for a regenerator application in Uruguay. The unit is 43″ tall, 39-1/2″ in diameter, fabricated from carbon steel and the bellows are INCOLOY® 825. It is lined with 3.75″ thick insulating and abrasion-resistant refractory. It is designed for an operating temperature of 653°F at 46 PSIG and 0.25” axial compression. The expansion joint was hydro-tested at 68 psig prior to shipment.
Read MoreFabric Expansion Joint Designed for a High-Temperature Duct Application
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 |
U.S. Bellows custom designed this fabric expansion joint for a high-temperature duct application in Nebraska. The dimensions for the expansion joint are 67” long, 67” wide, and 14” tall. It has a 3 layer fabric belt with kaowool insulation pillow, 304 stainless steel angle flanges, and 6” internal module of kaowool insulation. The unit is designed for an operating temperature up to 2012°F at +/- 100” water column and 1” of lateral deflection. The expansion joint was 100% dye-penetrant tested prior to shipment.
Read MoreHinged Expansion Joints Designed for a Steam Exhaust Application
Type: | Hinged Expansion Joints |
Size: | 42″ Long | 16″ Nominal Pipe Size |
Material: | 316L Stainless Steel | Carbon Steel |
Design | 400°F at 150 psig | 4.25″ Lateral | 1° Angular |
Testing: | 100% Dye Pen. | Bellows Longitudinal Seams 100% X-rayed | Hydro-Tested at 250 psig |
U.S. Bellows custom designed hinged universal expansion joint for a steam exhaust application at a chemical plant in Texas. The units are 42″ long and have a nominal pipe size of 16″. The bellows are fabricated from 316L stainless steel. The flanges, pipe spool, and hardware are carbon steel. They are designed for an operating temperature of 400°F at 150 psig. They are capable of 4.25″ lateral deflection and 1° of angular movement. The expansion joints were 100% dye penetrant tested, the bellows longitudinal seams were 100% X-rayed, and a hydro-test at 250 psig was performed prior to shipment.
Read MoreUniversal Expansion Joint with Oversized Bellows for a Crude Oil Line Application in Saudi Arabia
Type: | Universal Expansion Joints |
Size: | 48″ Diameter | 77″ FTF |
Material: | 316 Stainless Steel | Carbon Steel |
Design | 150°F Operating Temp. @ 25 psig | 5.3″ Axial | 2″ Lateral |
Testing: | Hydro-tested @ 50 psig |
U.S. Bellows custom designed this universal expansion joint for a crude oil line at an oil refinery in Saudi Arabia. This expansion joint was specially designed with oversized bellows to keep a smooth flow of oil along the line and avoid turbulence. The bellows were fabricated from a 316 stainless steel with all of the other components from carbon steel. The unit is 48″ in diameter and 77″ face-to-face. It is designed for an operating temperature of 150°F at 25 psig, 5.3″ of axial compression, and 2″ of lateral deflection. The unit was hydro-tested at 50 psig prior to shipment.
Read More66″ Custom Designed Hinged Expansion Joint for a Chemical Plant in Saudi Arabia
Type: | Hinged Expansion Joints |
Size: | 66″ Diameter | 39 3/8″ OAL |
Material: | Incoloy 825 | 321 Stainless Steel |
Design | 986°F Operating Temp. @ 73 psig | 4.25° Angular |
Testing: | 100% Dye-Penetrant | X-Ray | Hydro-tested |
This single hinged expansion joint was custom designed for a chemical plant in Saudi Arabia. The bellows were fabricated from Incoloy 825 and the cover, weld-ends, hinges, and liner from 321 stainless steel. The unit is 66″ in diameter and 39 3/8″ OAL. It is designed for an operating temperature of 986°F at 73 psig and 4.25° of angular rotation. The expansion joint was 100% dye-penetrant tested, the bellows and pipe longitudinal seam were x-ray tested and hydro-tested prior to shipment.
Read MoreCustom Tied Universal Expansion Joints for a Chemical Plant in Texas
Type: | Universal Expansion Joints |
Size: | 108″ Length | 19.5″ ID |
Design: | 304 Stainless Steel |
Material: | 550°F Operating Temperature @ 15 psig, 5″ Lateral |
Testing: | 100% Dye-Penetrant | Air, Soap, & Bubble |
U.S. Bellows custom designed these tied universal expansion joints for a chemical plant in Texas. The units were completely fabricated from 304 stainless steel and are 108″ long with a 19.5″ ID. They are designed for an operating temperature of 550°F at 15 psig, 5″ of lateral deflection. The expansion joints were 100% dye-penetrant tested and air, soap, and bubble tested prior to shipment.
Read MoreSingle Expansion Joints Designed for an Oklahoma Pipeline
Type: | Single Flanged Expansion Joint |
Size: | 10″ & 14″ NPS | 13″ & 16-1/2″ OAL |
Material: | 304 Stainless Steel | CS |
Design | 203°F Operating Temperature |
Testing: | 100% Dye Penetrant | Hydro-tested |
U.S. Bellows designed these 10″ and 14″ NPS single expansion joints for a pipeline in Oklahoma. They have an overall length of 13″ and 16-1/2″. The bellows, liners, covers, and flanges are fabricated from 304 stainless steel, and the tie rods are carbon steel. They are designed for an operating temperature of 203°F at 15 psig. The expansion joints were 100% dye-penetrant and hydro-tested prior to shipment.
Read More81″ 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 |
U.S. Bellows custom-designed pressure balanced tee expansion joints for a chemical plant in Texas. The units are 352″ overall length, 81″ diameter and 90″ centerline to the bevel-end of the tee. All assemblies were completely fabricated from 304 stainless steel. They are 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 and air soap and bubble tested prior to shipment.
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