Expansion & contraction

All materials expand & contract with thermal change & pressure change.
In case of piping systems, this dimension change can produce excessive
stresses throughout the piping system and at fixed points such as vessels
and rotating equipment, as well as within the pipe itself.
 Expansion Joint
Pipe expansion loop may add the required flexibility to a piping system if
space permits.
However the initial cost of the additional pipe, elbow & support must be
considered for the pipe expansion loop system.
In addition, increased continuous operating cost due to pressure drop may
result the frictional resistance of the flowing media through additional pipe &
elbow.
In some cases, pipe diameter must be increased to compensate the losses
due to pressure drop.

Pipe Expansion Loop

 Expansion Joint
A practical & cost effective means of achieving piping system
flexibility in a compact design is through the application of
“Expansion Joints’.
• The most efficient piping system is the shortest and most
directly routed system & expansion joints make it possible.
• Expansion joint provide an excellent solution for isolation of
settlement, seismic deflection, mechanical vibration and sound
attenuation transmission produced by rotating equipment.
 Expansion Joint
Metal bellows expansion joint consist of a flexible bellows element,
appropriate end fitting such as flanges or butt weld ends to allow
connection to the adjacent piping or equipment, and other
accessory items that may be required for a particular service
application.
Expansion Joint
 Expansion Joint
Bellows are manufactured from relatively thin walled tubing to form a
corrugated cylinder.
• The corrugations, commonly referred to as “Convolutions” add the
structural reinforcement necessary for the thin wall material to contains
system pressure.
• The bellow designer selects the thickness and convolution geometry to
produce a bellow design that approaches, and often exceeds the
capacity of adjoining pipe to contain system pressure at a specific
design temperature.
• Flexibility of the bellows is achieved through bending the convolution
side walls, as well as flexing within their crest & root radii. In most
cases, multiple convolutions are required to provide sufficient flexibility
to accommodate the expected expansion and contraction of the piping
system.
What metallic expansion Joint DO
Expansion Joint
 Expansion Joint
Axial movement is the change in dimensional length of
the bellows from its free length in a direction parallel to
its longitudinal axis.
Compression is always expressed as negative (‐) and
extension as positive (+). The units for axial spring rates
displayed in N/mm.
 Expansion Joint
Lateral movement is the relative displacement of one end of the bellows to
the other end in a direction perpendicular to
its longitudinal axis (shear). Lateral movement can be imposed on a single
bellows as depicted below but to a limited degree.
A better solution is to incorporate two bellows in a universal arrangement
as shown  This results in greater offset movements
and much lower offset forces.
The units for lateral spring rates displayed in N/mm
 Expansion Joint
Angular movement is the rotational displacement of the longitudinal axis of the
bellows toward a point of rotation.
The convolutions at the inner most point are in compression (‐) while those
furthest away are in extension (+).
The angular capability of a bellows is most often used with a second bellows.
The units for angular spring rates displayed in Nm/deg
 Expansion Joint
Torsional movement is the rotation about the axis through the centre of a bellows
(twisting).
Many expansion joint manufacturers DISCOURAGES ANY TORSIONAL
ROTATION OF METAL BELLOWS EXPANSION JOINTS.
Torsion destabilizes an expansion joint, reducing its ability to contain pressure and
absorb movement.
If torsion is present in a piping system, hinges, slotted hinges or gimbals are
recommended to combat the torsion.
Torsional spring rates are in Nm/deg and maximum torsional limits in degrees for
computational modelling only.
Piping software such as CAESAR II and COADE often require these spring rates for
nodal input.
Pressure thrust
Pressure thrust
Single bellow expansion Joint
 Single bellow expansion Joint
The simplest type of expansion joint consists of a single Bellows element
welded to end fittings, normally flange or pipe ends.
The single bellows can absorb small amounts of axial, lateral and angular
movement with ease, but adequate anchors and guides must be provided
Single bellow expansion Joint
 Axial type bellow expansion Joint
Unrestrained expansion joint must be used in anchored & guided systems
which require anchors at each end of a pipe run that are sufficient to react to
pressure thrust at the highest pressure anticipated.
• These fixed points (anchors) insure that the pipe grows (or contracts) &
compressed (or extends) the expansion joint.
• The guides insure the motion is axial only.
Axial type bellow expansion Joint
Axial type bellow expansion Joint
Pipe anchor & Pipe support/guide

Pipe anchor Pipe support/guide
Universal expansion joint
 Universal expansion joint
This expansion joint consists of two bellows connected by a centre spool
piece with flange or pipe ends.
The universal arrangement allows greater axial, lateral and angular
movements than a Single Bellows
Increasing the centre spool length produces increased movement
capability.
Like the single, adequate anchors and guides must be provided.
Externally pressurized expansion joint
Externally pressurized expansion joint
Line pressure acts externally on the bellows by means of a Pressure
chamber.
This allows a greater number of convolutions to be used for large axial
movements, without fear of bellows instability.
Externally Pressurized Expansion Joints have the added benefit of
self‐draining convolutions if standing media is a concern.
Anchors and guides are an essential part of a good installation.
Single tied bellow expansion joint
 Single tied bellow expansion joint
The addition of tie rods to a Single Bellows Assembly adds design flexibility
to a piping system.
The tie rods are attached to the pipe or flange with lugs that carry the
pressure thrust of the system, eliminating the need for main anchors.
With the assembly tied, the ability to absorb axial growth is lost.
Only lateral and angular movement can be absorbed with the tied
expansion joint.
The addition of tie rods does not eliminate the need for a well‐planned
guide system for the adjacent piping.
Tied universal expansion joint
 Tied universal expansion joint
Similar in construction to a Universal Assembly except that tie rods absorb
pressure thrust and limit movements to lateral offset and angulation.
Large offset movements are possible in a Universal Assembly by increasing
the distance between the two bellows
Tied universal expansion joint
Hinge expansion joint
 Hinge expansion joint
When a Hinged Expansion Joint is used, movement is limited to Angulation in one plane. 
Hinged Assemblies are normally used in sets of two or three to absorb large amounts of 
expansion in high pressure piping systems. 
Only low spring forces are transmitted to the equipment. 
The hinge hardware is designed to carry the pressure thrust of the system, and often times, 
used to combat torsional movement in a piping system. 
Slotted Hinged Expansion Joints are a variant of the standard Hinged Expansion Joints that 
allow axial and angular movement. 
Important note: 
Once a Slotted Hinge is introduced, torsion in the piping system is still resisted but the hinge 
no longer carries pressure thrust.
Hinge expansion joint
Gimbal expansion joint
 Gimbal expansion joint
The gimbal restraint is designed to absorb system pressure thrust And
torsional twist while allowing angulation in any plane.
Gimbal Assemblies, when used in pairs or with a Single Hinged unit, have
the advantage of absorbing movements in multi‐planer piping systems.
The gimbal works the same as an automobile's universal drive shaft.
Gimbal expansion joint
Pressure balanced elbow expansion joint
Pressure balanced elbow expansion joint
These assemblies are used in applications where space limitations
preclude the use of main anchors.
Pressure thrust acting on the line bellows (bellows in the media flow) is
equalized by the balancing bellows through a system of tie rods or
linkages.
The only forces transmitted to equipment are low spring forces created by
the axial, lateral, or angular movements.
An elbow must be present in the piping network to install this style of
expansion joint.
Inline pressure balanced expansion joint
Inline pressure balanced expansion joint
If an elbow is not present in a piping network and pressure thrust Must be
absorbed by the expansion joint, an In‐Line Pressure Balanced expansion
joint is the solution.
An equalizing bellows with twice the effective area as the line bellows is tied
in the expansion joint through a series of tie rods.
The opposing pressure forces cancel each other leaving only the low spring
forces generated from the bellows deflection.
 Externally pressurized
pressure balanced expansion joint
If large amounts of axial movement in a system are needed and the
expansion joint must absorb pressure thrust, an Externally Pressurized
Pressure Balanced expansion joint is the solution.
The opposing force balancing theory is similar to the In‐Line Pressure
Balanced Assembly except the opposing forces are generated from
pressure acting on the outside of the bellows
Pressure balanced expansion joint
 Pipe Stress Analysis
± Some pipes are subjected to high pressure and high
temperature. Also pipes carry the load of the flowing fluid.
± We need to check and confirm the pipe is not going to fail
with these loading.
± This process of checking the stress developed in the
piping due to various loading is called Pipe Stress
Analysis/Flexibility analysis.
± In the process of Analysis we apply various postulated
loading on the pipe and find out the stress resulted from
these loading.
± Then we check with governing codes if those stresses
generated are acceptable or not.
 Pipe Stress Analysis
± We have to check support load & movement for various
loading condition.
± We also have to check out the terminal point loading
generated from pipe to the equipment connected to the
pipe. This loading are to be within acceptable limits of the
equipment suggested by the vendors.
± We also have to find out the pipe (expansion) and need to
keep the movement of pipe within acceptable limits.
± Pipe Stress Analysis is an Interactive and Iterative
process. Each step is checked
± If a check fails we have to go back, modify the layout and
restart the analysis.
± There are many piping stress analysis software in the
market to help us to design a correct piping design
 Expansion Joint
A design specification shall be prepared for each pipe expansion joint
application.
Prior to writing the pipe expansion joint design specification it is imperative
that the system designer completely review the piping system layout, flowing
medium, pressure, temperature, movements, and other items which may
effect the performance of the pipe expansion joint.
Particular attention shall be given to the following items.
• The piping system should be reviewed to determine the location and type
of pipe expansion joint most suitable for the application. Both the EJMA
(expansion joint manufacturer association) standards and most reliable
pipe expansion joint manufacturers' catalogues provide numerous
examples to assist the user in this effort. The availability of supporting
structures for anchoring and guiding of the piping, and the direction and
magnitude of thermal movements to be absorbed must be considered
when selecting the type and location of the pipe expansion joint. Torsional
rotation of the bellows should be avoided or special hardware should be
incorporated into the design to limit the amount of torsional shear stress
in the bellows.
 Expansion Joint
• The bellows material shall be specified by the user and must be
compatible with the flowing medium, the external environment and the
operating temperature. Consideration shall be given to possible
corrosion and erosion. The 300 Series stainless steels may be subject
to chloride ion stress corrosion. High nickel alloys are subject to caustic
induced stress corrosion. The presence of sulphur may also be
detrimental to nickel alloys. The material chosen shall also be
compatible with the environment surrounding the pipe expansion joint,
water treatment and cleaning materials. In some cases, leaching of
corrodents from insulating materials can be a source of corrosion.
• Internal sleeves shall be specified in all applications involving flow
velocities which could induce resonant vibration in the bellows or cause
erosion of the convolutions resulting in premature failure.
 Expansion Joint
• The system design pressure and test pressure shall be specified
realistically without adding arbitrary safety factors. Excess bellows
material thickness required for unrealistic pressures will often produce
an adverse effect on the bellows fatigue life or increase the number of
convolutions required which may reduce the stability of the bellows. In
the case of high temperature applications, it may not be possible to test
the expansion joint to 1.5 times the equivalent cold pressure rating of
the system. This results from the various materials employed in the
construction of the pipe expansion joint, temperature gradient utilized in
the design, pressure stability criteria, anchor strength, etc. The
manufacturer must be consulted.
• The maximum, minimum and installation temperatures shall be
accurately stated. Where the ambient temperature can vary
significantly during pipeline construction, pre-positioning of the pipe
expansion joint at installation may be required.
• The pipe expansion joint manufacturer shall be advised if the pipe
expansion joint will be insulated. Insulation details shall be furnished to
the manufacturer in order to properly design the component parts.
 Expansion Joint
• .The movements which are to be absorbed by the pipe expansion joint
shall include not only piping elongation or contraction, but also
movement of attached vessels, anchors, etc. and the possibility of
misalignment during installation. Unless included in the design
requirements, misalignment of the pipe expansion joint must be avoided.
Where movements are cyclic, the number of cycles expected shall be
specified. Similar to pressure, the movements specified must be
realistic. An excessive safety factor can often result in an expansion joint
which is unnecessarily flexible; thus its stability under pressure is
unnecessarily reduced
• If the flowing medium can pack or solidify, provisions shall be made to
prevent entrapment or solidification of the material in the convolutions
which could result in damage to the pipe expansion joint or pipeline.
• Internal sleeves are usually installed in the direction of flow. If the
stagnant flow medium trapped behind the sleeve is undesirable, drain
holes in the sleeve, purge connections, or packing shall be specified.
Where backflow will be encountered, an extra-heavy sleeve shall be
specified to prevent buckling of the sleeve and possible damage to the
bellows.
 Expansion Joint
• The predicted amplitude and frequency of external mechanical vibrations
to be imposed on the bellows, such as those caused by reciprocating or
pulsating machinery, shall be specified. A resonant condition in the
bellows will result in a grossly reduced fatigue life and must be avoided.
The pipe expansion joint designer will attempt to provide a non-resonating
design; however, the ability to always assure non-resonance is
impossible. Therefore, field modifications to the pipe expansion joint or
other system components may be necessary
• The piping system drawings shall specify the location of all anchors,
guides, supports and fixed points.
• Both the anchors and guides must be suitable for the highest pressures
to be applied to the system.
• IN MOST CASES THE TEST PRESSURE WILL BE SIGNIFICANTLY
HIGHER THAN THE SYSTEM OPERATING PRESSURE
 Expansion Joint
The system designer shall specify those special features which best
accomplish personnel protection in his particular system.
Piping systems containing high pressure and/or hazardous materials which
are located in close proximity to personnel shall be provided with additional
safety features which will protect such personnel in the event of a failure in
the system.
 Expansion Joint
• Extra-heavy covers which could serve to impede the effect of a jet flow
produced by a failure; however, such covers will not prevent the
escaping medium from expanding and filling the surroundings in which it
is located.
 Expansion Joint
• Limit rods designed for dynamic loading can be employed to
restrain the longitudinal pressure
 Expansion Joint
• A two-ply or two concentric bellows design may be employed with each
ply or bellows designed to contain the full line pressure. The annular
space between the plies or concentric bellows can be monitored
continuously for leakage by means of suitable instrumentation. A change
in pressure in the annulus could be used to detect bellows leakage.
 Expansion Joint
• The system designer shall provide for the accessibility of
components (anchors, expansion joints, guides, etc.) in the
piping system for periodic inspection after initial start up.
Expansion Joint
Expansion Joint
 Shipping bar
Shipping Bars ‐ These are temporary
attachments that "hold" the expansion joint at its
correct installed length during shipping and
installation.
Angle iron or channel section is used and is
always painted bright yellow.
Shipping bars must never be removed until
after the unit has been correctly welded or
bolted into the piping system.
Caution:
Tie rods or limit rods are sometimes mistaken
for shipping bars.

NOTE:
Great care must be taken when removing the
shipping bars. If a welding or burning torch is
used, ALWAYS protect the bellows element from
burn splatter with a flame‐retardant cloth or
other shielding material.
Expansion Joint
Expansion Joint
Anchor
Anchor
Pipe guide