Ej Beginners 2

10/17/2013
U.S. Bellows, Inc.

presents:
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Attention P.E.’s: this Webinar is worth 1 PDH credit for TX P.E.’s (send request to news@usbellows.com)
U.S. Bellows, Inc.
Presenter…
John T. Demusz
Manager US Bellows, Inc.
www.usbellows.com
1
10/17/2013
U.S. Bellows, Inc.
Certifications Manufacturing Facility

• EJMA Member
• ASME U-Stamp
• ASME R-Stamp
• ASME NS Certified
• ISO 9001:2008 Certified
• Minority Business Enterprise • Houston, Texas USA

(MBE) by City of Houston
• 450,000 Square Feet of Covered
• Houston Minority Business Shop Space on a 35 Acre
Council (HMBC) Property
• Located Near the Port of Houston
www.usbellows.com
U.S. Bellows, Inc.
EJMA Members
CodeCalc program snapshot
www.usbellows.com
2
10/17/2013
U.S. Bellows, Inc.
Expansion Joint
Metallic Fabric Rubber
www.usbellows.com
U.S. Bellows, Inc.
▪ Fossil Fuel ▪ Chemical & ▪ Stationary Engine ▪ Pulp & Paper

Power Plant Petrochemical Exhaust
▪ Power ▪ Heat ▪ Municipal Water ▪ Aerospace Turbo

Exchangers Districts Engine Exhaust
▪ District ▪ FCC Units ▪ Waste Water ▪ Truck Exhaust

Energy Treatment
▪ Gas Turbines ▪ U.S. Navy ▪ Solid Waste ▪ Heavy Metal

Incineration
▪ Steam ▪ Kilns ▪ Environmental ▪ Marine Piping &
Distribution Applications Exhaust
▪ Geothermal ▪ Furnace Sealing

Power Plants Bags ▪ HVAC Building ▪ Liquefied Natural
Heating & Cooling Gas (LNG) Service
Systems
▪ Refinery ▪ Research &
Development
www.usbellows.com
3
10/17/2013
U.S. Bellows, Inc.
O Introduction
O Pipe & Duct Movement
O Metallic vs. Fabric
O Expansion Joints
O Metal
O Fabric
O Expansion Joint Failures
O Maintenance
O Conclusion
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U.S. Bellows, Inc.
Chemical Plant
Power Plant
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4
10/17/2013
U.S. Bellows, Inc.
www.usbellows.com
U.S. Bellows, Inc.
O A “flexible”
assembly, that
includes a metallic,
fabric or rubber
flexible component,
that will be installed
into a pipe, tube or
duct.
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5
10/17/2013
U.S. Bellows, Inc.
www.usbellows.com
U.S. Bellows, Inc.
Complexity Simple
Semi Really
Complex Complex
Moves in all
Movement None Moves up &
directions,
down a little bit
vibrates, & large
movements
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6
10/17/2013
U.S. Bellows, Inc.
OUTSIDE
INSIDE DIAMETER WALL THICKNESS
DIAMETER
LIVE-LENGTH OF
PITCH BELLOWS
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U.S. Bellows, Inc.
Axial Movement Lateral Movement
Angular Movement Torsional Movement
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7
10/17/2013
U.S. Bellows, Inc.
Gimbal Expansion Joint Tied Single Expansion Joint
Expansion Joint Movement
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U.S. Bellows, Inc.
Universal Expansion Joint

Tied Universal Expansion Joint
Hinged Universal Expansion Joint
Single Expansion Joint Slotted Hinged Expansion Joint
www.usbellows.com
8
10/17/2013
U.S. Bellows, Inc.
O Pipe diameter
O Type of media
O Flow media rate
O Type & amount of movement
O End fittings & extra components
O Design Pressure
O Design Temperature
O Service conditions
www.usbellows.com
U.S. Bellows, Inc.
www.usbellows.com
9
10/17/2013
U.S. Bellows, Inc.
Metallic Fabric Expansion

Expansion Joints Joints
Design Time 1-2 days 1-2 days
Project Time 8 weeks 8 weeks
Fabrication Complicated Moderately

Complexity complicated
Engineer Time Takes more time Takes less time

Alotted
Other Customer Customer

Approval, Approval
www.usbellows.com
U.S. Bellows, Inc.
Depending on the style or design of a bellows, wall

thicknesses may range from:
.010” TO .500” wall with varying

number of plies in the various alloys
• STAINLESS STEEL – T-321, T-316, L & H, T-304, L &H

• MONEL 400
• INCONEL 625
• INCONEL 625 LCF
• INCOLOY 800
• INCOLOY 825
• HASTELLOY C-276
• TITANIUM
www.usbellows.com
10
10/17/2013
U.S. Bellows, Inc.
The original Creation of the The reroll

piece of steel convolutions/bell process of the
ows bellows
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11
10/17/2013
U.S. Bellows, Inc.
www.usbellows.com
U.S. Bellows, Inc.
www.usbellows.com
12
10/17/2013
U.S. Bellows, Inc.
www.usbellows.com
U.S. Bellows, Inc.
O THE LOAD IN POUNDS REQUIRED TO COMPRESS A

BELLOWS ONE INCH (lb/in).
www.usbellows.com
13
10/17/2013
U.S. Bellows, Inc.
• Hydrostatic Testing
Burst Test
• Magnetic Particle
• Ultrasonic
• Cycle Test
• Burst Test
• Helium Leak Detection
• Liquid Penetrant
• Inspection
Dye Penetration Testing • Radiography Test
• Positive Material
• Identification (PMI) Test
• Pneumatic Testing
• Spring Rate Testing
• Fatigue Testing
www.usbellows.com
U.S. Bellows, Inc.
Stresses
Temperature Change
Repetitive Mechanical
Movements
Vibrations
Cycle Test on a 12" diameter A240-321SS Bellows with 8 convolutions.

The bellows has met the EMJA cycle life calculation of 1,000 cycles and
failed in the root of the convolutions at 1,285 cycles.
www.usbellows.com
14
10/17/2013
U.S. Bellows, Inc.
Limit Rods
It is sometimes desirable to limit the axial expansion or compression

of the expansion joint. Limit rods, shown above, provide freedom of
movement over a range determined by the location of nut stops along
the rods. In the event of a main anchor failure, limit rods are designed
to prevent bellows over-extension while restraining the full pressure
thrust of the system.
www.usbellows.com
U.S. Bellows, Inc.
24" In-line Pressure Balanced Expansion Joints designed for 175

PSIG and 610F for a petrochemical plant in Venezuela
www.usbellows.com
15
10/17/2013
U.S. Bellows, Inc.
Pressure Balanced Elbow

Expansion Joints designed for 150
PSIG and 450F for a 42" steam line
www.usbellows.com
U.S. Bellows, Inc.
54" Pressure
36" Pressure Balanced Elbow Expansion Joints Balanced Elbow
Turbine Crossover
Expansion Joint
(Refurbished)
www.usbellows.com
16
10/17/2013
U.S. Bellows, Inc.
Universal Expansion Joint

Single Expansion Joints

with Stainless Steel Flanges
www.usbellows.com
U.S. Bellows, Inc.
55" O.D. Double Gimbal Universal Expansion Joint for an FCC Unit.
The expansion joint is equipped with floating rings and Inco 625 LCF bellows.
www.usbellows.com
17
10/17/2013
U.S. Bellows, Inc.
www.usbellows.com
U.S. Bellows, Inc.
44" Universal Refractory

70" Tied Universal
Lined Expansion Joint
Expansion Joint designed
designed for 30 PSIG and
for 51 PSIG and 1460F
1400F
36" Double Hinged

Expansion Joint
designed for 50 PSIG
and 1000F
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18
10/17/2013
U.S. Bellows, Inc.
Protective Covers & Internal Liners
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U.S. Bellows, Inc.
* Ability to absorb large mounts of axial travel
* Pressure is applied externally to the bellows
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19
10/17/2013
U.S. Bellows, Inc.
Thick Wall Metallic Expansion Rectangular Expansion Joint

Joint
71" x 143" Round Corner Regular

108" Diameter Thick Wall Expansion Expansion Joint for an oil refinery in India
Joint (with 2 convolutions)
78" I.D. x 100" O.D. Thick Wall Expansion Rectangular Metallic

Joint Expansion Joint
240" x 80" and 157" x 65"
www.usbellows.com
U.S. Bellows, Inc.
www.usbellows.com
20
10/17/2013
U.S. Bellows, Inc.
Metallic Fabric
Cryogenic – high temps. High temperatures
Flexible element - bellows Flexible element - fabric belt
High pressure services Low pressure services
Maintenance free Minimal maintenance
Timely repair & preset Easy repair & preset
Limited movement More movement
Limited size restraints No size restraints
Non-combustible Combustible
No torsional movement Torsional movement
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U.S. Bellows, Inc.
Standard Fabric Expansion Joint
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21
10/17/2013
U.S. Bellows, Inc.
Fabric
Belt
Metal
Frame
Fabric EJ on
attached to duct
work
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U.S. Bellows, Inc.
Reinforced Silicone PTFE Coated Glass Aluminized Glass Silica Oxide Glass
Fabric Cloth Cloth Cloth
Chemical
Temperature Materials Advantages Pressure Applications
Resistance
High tensile strength, Hot and Cold Water, Low
Low
Butyl Rubber, Neoprene, Viton Ozone and weathering Medium High Pressure Steam, Neutral
Ambient - 250°F
resistance Solutions
Resistant to deterioration by
Medium weathering and engine oil Gaskets or Seals,
Fiberglass, Reinforced Silicone Low High
250 - 500°F remains, UV / ozone / fungus Recirculation Air, Air Intake
resistant
High tear / crease resistant,

High PTFE Impregnated Fiberglass, Smooth / low friction / non- Exhaust Ventilation, Fume
Low Medium
500 - 700°F PTFE Coated Glass Cloth stick surface / high tensile Protection, Gaskets or Seals
strength
High High abrasion resistance,

Silica Fabric Cloth Low Low Boiler Exhaust
700 - 1000°F Won't rot or mildew
High Silica/PTFE Fabric with Kaowool, Excellent resistance to

Furnaces,
1000 - 1800°F Aluminized Glass Cloth with chemicals, High temperature Low Low
Kilns
*3-layer Kaowool & PTFE stability
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22
10/17/2013
U.S. Bellows, Inc.
• FD Fan to Air Preheater

• Air Preheater to Boiler
• Air Preheater to Pulverizer
• Air Preheater to Inlet from
Boiler
• Air Preheater to
Precipitator or Bag house
• Precipitator or Bag house
to ID Fan
• ID Fan to Scrubber
• Scrubber to Stack
www.usbellows.com
U.S. Bellows, Inc.
High Temperature 3-Layer Expansion Joint
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23
10/17/2013
U.S. Bellows, Inc.
High-Temp 23 ¼" I.D. Fabric Expansion Joint Stitching the Fabric Belt on the 1st Layer
128" x 229" Rectangular Fabric Expansion Joint

(Includes a Three Layer Belt)
www.usbellows.com
U.S. Bellows, Inc.
– Emergency Response
Same-Day Emergency Service on an 8" Single Expansion Joint
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24
10/17/2013
U.S. Bellows, Inc.
O Engineering and Design

O Piping, pipe support and
structural design
O 3D modeling technology
O Pipe Stress Analysis

O ANSYS
O Finite Element Analysis

O Special stress/thermal problems
O Pro/E for 3-D Part Design
O ANSYS for Mesh Generation
+ Analysis + Results Analysis
O Field Testing
www.usbellows.com
U.S. Bellows, Inc.
Please forward any additional questions or inquiries to us at

sales@usbellows.com, call us at 877-660-1795 or visit our
website at www.usbellows.com
www.usbellows.com
25

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10/17/2013

U.S. Bellows, Inc.

U.S. Bellows, Inc.

U.S. Bellows, Inc.

Certifications Manufacturing Facility

• ISO 9001:2008 Certified

• Minority Business Enterprise • Houston, Texas USA

U.S. Bellows, Inc.

CodeCalc program snapshot

U.S. Bellows, Inc.

Metallic Fabric Rubber

U.S. Bellows, Inc.

▪ Fossil Fuel ▪ Chemical & ▪ Stationary Engine ▪ Pulp & Paper

▪ Power ▪ Heat ▪ Municipal Water ▪ Aerospace Turbo

▪ District ▪ FCC Units ▪ Waste Water ▪ Truck Exhaust

▪ Gas Turbines ▪ U.S. Navy ▪ Solid Waste ▪ Heavy Metal

▪ Geothermal ▪ Furnace Sealing

U.S. Bellows, Inc.

O Pipe & Duct Movement

O Metallic vs. Fabric

O Expansion Joint Failures

U.S. Bellows, Inc.

U.S. Bellows, Inc.

U.S. Bellows, Inc.

U.S. Bellows, Inc.

U.S. Bellows, Inc.

U.S. Bellows, Inc.

U.S. Bellows, Inc.

Axial Movement Lateral Movement

Angular Movement Torsional Movement

U.S. Bellows, Inc.

Gimbal Expansion Joint Tied Single Expansion Joint

Expansion Joint Movement

U.S. Bellows, Inc.

Universal Expansion Joint

Hinged Universal Expansion Joint

Single Expansion Joint Slotted Hinged Expansion Joint

U.S. Bellows, Inc.

O Flow media rate

O Type & amount of movement

O End fittings & extra components

U.S. Bellows, Inc.

U.S. Bellows, Inc.

Metallic Fabric Expansion

Design Time 1-2 days 1-2 days

Project Time 8 weeks 8 weeks

Fabrication Complicated Moderately

Engineer Time Takes more time Takes less time

Other Customer Customer

U.S. Bellows, Inc.

Depending on the style or design of a bellows, wall

.010” TO .500” wall with varying

• STAINLESS STEEL – T-321, T-316, L & H, T-304, L &H

U.S. Bellows, Inc.

The original Creation of the The reroll

U.S. Bellows, Inc.

U.S. Bellows, Inc.

U.S. Bellows, Inc.

U.S. Bellows, Inc.

O THE LOAD IN POUNDS REQUIRED TO COMPRESS A

U.S. Bellows, Inc.

U.S. Bellows, Inc.

Cycle Test on a 12" diameter A240-321SS Bellows with 8 convolutions.

U.S. Bellows, Inc.