Guide to Selecting and Using Expansion Joints

Guideline for Expansion Joints Mott MacDonald Consultants (India) Pvt.Ltd.
Guideline for Expansion Joints
Revision O
Mott MacDonald Consultants (India) Pvt.Ltd.

Kothari House, CTS No. 185
Off Andheri - Kurla Road,
Andheri (E)
Mumbai 400 059, India
Tel 09122 3083 5000
Fax 09122 2825 3779
E-Mail Sharad.Ashtikar@mottmac-india.com
P:\Andheri\Management\Ashtikar\Piping Guidelines\PIPDG016\PIP-DG- i
016.doc
List of Contents Page
1 Introduction 1
2 Definition of Expansion Joints 1
3 Why Expansion Joint is used in Piping System? 1
4 Hazards of usage of Expansion Joints 1
5 Where Expansion Joints shall not be used? 1
6 Where Expansion Joints are recommended? 1
7 Different Types of Expansion Joints 2
8 Characteristics of each type of Expansion Joint 2

8.1 Rubber Expansion Joint 2
8.2 Fabric Expansion Joint 3
8.3 Metallic Expansion Joints 3
9 End Connection Details of Expansion Joints 4
10 Metallic Expansion Joint as per EJMA 5

10.1 Typical Cross Section of Expansion Joint & Accessories 5
10.2 Expansion Joint Movements 8
10.3 Generation of forces & moments by metallic expansion joints in
piping network 9
11 Various Type of Metallic Expansion Joints 12

11.1 Definition & Application 12
11.2 Importance of selection of Pipe Support & proper supporting of
Piping Network for optimum usage of Expansion Joints 19
11.3 Type of Pipe Supports 19
11.3.1 Rest Support 20
11.3.2 Guide Support 20
11.3.3 Restraints Support 20
11.3.4 Anchor Support 20
11.3.5 Causes of Bellow Failure 20
Appendix A: Case Study 20
Appendix B: Example from EJMA 22
Appendix C: Rubber Bellow Catalog 23
Appendix D: References 24
P:\Andheri\Management\Ashtikar\Piping Guidelines\PIPDG016\PIP-DG- iii

016.doc
1 Introduction
The purpose of this Document is to establish the Guidelines for the selection of Expansion Joints.
This Guideline shall be adopted in the absence of the Guideline from Client.
2 Definition of Expansion Joints
Expansion joint is a flexible element in the form a convoluted metallic tube or in a non-metallic
convoluted form such as rubber expansion joint or simple fabric cloth.
3 Why Expansion Joint is used in Piping System?
If a line or duct operating at elevated temperature cannot be made flexible due to various Process
& space constraints or curbing of excessive forces and moments at equipment nozzles and supports
would warrant a use of expansion joint. Also, expansion joints are provided for the purpose of pipe
alignment & to avoid the transfer of vibrations.
4 Hazards of usage of Expansion Joints
As per Code & Experience of refinery, petrochemical, fertilizer complexes etc.usage of expansion
joint as far as possible shall be avoided or in other words to be implemented in a Piping System
only subsequent to approval of process licensor and client, this is mainly due to :
For Toxic & Hazardous Chemicals which are handled at elevated temperature and pressure, if
flexible element such as expansion joint not properly selected, designed, manufactured, supported
and erected can always be considered as weak link in a Piping System & failure of which may
cause catastrophe in a Plant.
5 Where Expansion Joints shall not be used?

• Where toxic, volatile and hazardous chemicals in liquid, gaseous and two-phase form are
handled.
• Steam Network at high pressure and temperature.
• Jacketed Piping Network.
• Large diameter, high pressure pipelines and ducts.
• Lines handling viscous fluids which may congeal below desired temperature.
• Lines handling slurry or suspended fluids.
• Lines operating at pressure close to full vacuum.
6 Where Expansion Joints are recommended?

• Large diameter pipes and ducts handling fluids operating at low pressure but at elevated
temperature.
• At suction and discharge nozzle of rotating equipment such as blowers, fans etc.
• Pneumatic conveying system handling two-phase fluid flow at elevated temperature and
moderate pressure.
P:\Andheri\Management\Ashtikar\Piping Guidelines\PIPDG016\PIP-DG- 1
016.doc
• At suction nozzle of large cooling water pumps.

• On gravity transfer chutes and operating at elevated temperature.
• Gravity transfer chutes and ducts hooked up to equipment mounted on load cells.
• On shell side of shell and tube type heat exchangers.
7 Different Types of Expansion Joints

• Rubber Expansion Joint
• Fabric Expansion Joint
• Metallic Expansion Joint
8 Characteristics of each type of Expansion Joint

8.1 Rubber Expansion Joint
(i) These can be used on low pressure, low temperature piping network mainly on innocent
fluids such as water on pump suction line.
(ii) The type of rubber used for expansion joint shall be compatible with fluid handled.
(iii) The can absorb pretty low movement in axial and lateral direction in light of its basic
structure
(iv) They are mainly selected to absorb the mismatch in a straight configured pipeline installed
between an equipment nozzle and suction nozzle of pump.
(v) They can be used on pump discharge line operating at a reasonable pressure to eliminate the
discharge network piping load on pump nozzle.
(vi) This unit is usually equipped with tie rods which may allow lateral movements. It is not
suitable when exposed to torsional movements.
(vii) No authentic Codes & standards are available to design such bellows. The experience of
manufacturer and industries where it is used is the only guideline applicable to its selection
for specific duty condition. Manufacturer should be consulted for its use & installation.
Refer Appendix C for the sample catalog of the rubber Expansion Joint
016.doc
8.2 Fabric Expansion Joint
(i) Maximum pressure withstanding capability of such expansion joint is up to 50 KPa.

(ii) Selection of fabric shall be suitable to meet the elevated temperature of process fluid
handled (say up to 200°C)
(iii) A care should be taken when using a Fabric expansion joint for fluid handled such as acids.
This may affect the property of fabric used
(iv) This type of expansion joint has limitations on absorbing axial and lateral movements
(v) Generally it fails if torsional movements are expected in piping network & hence torsional
movement of expansion joints are not acceptable.
(vi) No authentic Codes & Standards are available to design such bellows. The experience of
manufacturer and industries where it is used is the only guideline applicable to its selection
for specific duty conditions. Manufacturer should be consulted for its use & installation.
8.3 Metallic Expansion Joints
(i) Metallic Expansion Joint covers wide range of design parameters like pressure, temperature
and compatibility of bellow material with respect to fluid being handled
(ii) Installation of joint in horizontal plane may allow entrapment of liquid or suspended solids
when system is not in operation
016.doc
(iii) Metallic bellows are designed as per Expansion Joint Manufacturers Association
(EJMA) as well as ASME B31.1 & ASME B31.3 as appropriate.
(iv) Manufacturer’s guide lines should be followed for installation.
9 End Connection Details of Expansion Joints

(a) Rubber expansion joint is sandwiched between two flanges when installed in a pipeline.
(b) Fabric joints are available in plain end form as well as flanged end form.
(c) Plain end fabric bellows can be wrapped around on pipes and ducts with clamping device.
(d) Flanged end fabric expansion joint can be installed in between two line flanges. However,
joint between fabric cloth and flange is quite fragile if mishandled during transportation or
erection.
(e) Metallic expansion joints are available with flanged as well as butt welding ends
(f) Flanges of large diameter (normally 14” & above) Metallic Expansion Joints shall be plate
type with thickness of flange to suit the design of pressure and temperature of piping system.
Bulky flanges welded to expansion joint tube may develop a weak joint to rupture during
transportation or erection.
(g) Type of flange facing i.e. R.F. or F.F. & Finish i.e. serrated or smooth to suit the type of
gasket used in piping network.
(h) In order to economise the flanges welded to expansion joint of Superior material a lined
flange concept need to be adopted e.g. slip on plate f1ange of suitable CS material shall have
a liner welded to gasket face of flange to ensure the fluid contact surface of SS. The Liner
may be of 2 to 3 mm thick properly welded to CS flange. Adequate care to be taken while
executing inside fi1let weld between flange and expansion joint tube.
(i) For large diameter slip on plate flange 26" NB and above due to economic reasons flanges
are made out of number of segments of plate cut in a shape to form a flange. The plate
flange such formed needs to be stress relieved prior to its welding to bellow tube.
(j) In case of butt welded expansion joint thickness of butt welding end to match with pipe/duct
thick to which it need to be welded. This is to avoid any chamfering work at site which may
damage the bellow.
(k) Butt welding joint is preferable where systems are operating at very high
temperatures such as temp of 400°C and above.
(l) Standard flange drilling shall be used to avoid special counter flanges to be installed to
match with expansion joint flange. Standards such as ASME B16.5 up to 24" NB and ASME
B16.47 for Lines 26" NB and above can be used. However this shall match with the Line
Spec.
016.doc
10 Metallic Expansion Joint as per EJMA

10.1 Typical Cross Section of Expansion Joint & Accessories
The basic unit of every expansion joint is the bellow. However, by adding additional components
expansion joints of multiple capability and complexity are created to cater the wide range of
applications warranted by the user industries.
1 Bellows
The flexible element of an expansion joint consisting of one or more convolutions, formed
from thin material.
In few cases multi ply bellows are also used. Multi ply bellows have the distinct advantage
of containing the same pressure as an equivalent thick single ply design, but with much
lighter spring rates and much higher cycle life.
2 Liner
A device which minimizes the effect on the inner surface of the bellows by the fluid flowing
through it. Liners are primarily used in high velocity applications to prevent erosion of the
inner surface of the bellows and to minimiser the likelihood of flow induced vibration.
Liners come in single tapered or telescoping configurations according to the application
requirements. An expansion joint if provided with liners, must be installed in the proper
orientation with respect to flow direction. Liners are sometimes referred to as internal
sleeves.
016.doc
3 Cover
A device used to provide external protection to the bellows from foreign objects, mechanical
damage, and/or external flow. The use of a cover is strongly recommended for all
applications. A cover is sometimes referred to as a shroud. Cover is provided even for
insulated bellow.
4 Weld End
Ends of an expansion joint equipped with pipe for weld attachment to adjacent equipment or
piping. Weld ends are commonly supplied bevelled for butt welding.
5 Flanged End
The ends of an expansion joint equipped with flanges for the purpose of bolting the
expansion joint to the mating flanges of adjacent equipment or piping.
6 Collar
A ring of suitable thickness which is used to reinforce the bellows tangent or cuff from
bulging due to pressure.
7 Hollow Reinforcing Rings
Devices used on some expansion joints, fitting snugly in the roots of the convolutions. The
primary purpose of these devices is to reinforce the bellows against internal pressure.
Hollow rings are usually formed from a suitable pipe or tubing section.
8 Solid Root Rings
Identical in function to hollow reinforcing rings, but formed from solid bar stock for greater
strength.
9 Equalizing Rings
"T" Shaped in cross-section, these rings are made of cast iron, steel, stainless steel or other
suitable alloys. In addition to resisting internal pressure, equalizing rings limit the amount of
compression movement per convolution.
10 Control Rods
Devices, usually in the form of rods or bars, attached to the expansion joint assembly whose
primary function is to distribute the applied movement between the two bellows of a
universal expansion joint. Control rods are not designed to restrain bellows pressure thrust.
11 Limit Rods
primary function is to restrict the bellows movement range during normal operation. In the
event of a main anchor failure, limit rods are designed to prevent bellows over-extension or
over-compression while restraining the full pressure loading.
12 Tie Rods
primary function is to continuously restrain the full bellows pressure thrust during normal
operation while permitting only lateral deflection. Angular rotation can be accommodated
016.doc
only if two tie rods are used and located 90° from the direction of rotation. The tie rod
orientation is important and should be shown on vendor drawing and isometric. The tie
orientation should be such that it should allow the thermal movement.
13 Pantographic Linkages
A scissors like device. A special form of control rod attached to the expansion joint
assembly whose primarily function is to positively distribute the movement equally between
the two bellows of the universal joint throughout its full range of movement. Pantographic
linkages, like control rods, are NOT designed to restrain pressure thrust.
14 Shipping Devices
Shipping devices is provided to maintain the face to face dimension of an expansion joint
during shipment and installation. This usually consists of overall bars or angles welded to
the flanges or welded ends of expansion joint. This device is not removed till all expansion
joints, anchors and guides in the system have been installed and must be removed only prior
to start up.
15 Material of Construction
Bellows can be formed from most ductile materials that can be welded by the automatic
T.I.G. welding process and result in a homogenous weld structure.
Thorough consideration shall be given to the selection of the bellow material. Due to the fact
that a given media will vary from system to system, and that most media specifications
cannot accurately reflect what actually will occur during system operation, the vendor and or
metallurgist shall be consulted for the material selection.
Material Type ASTM* Material Specification
304 S/S A-240
304L S/S** A-240
316 S/S A-240
316 L S/S A-240
321 S/S A-240
Monel 400** B-127
Inconel 600 B-168
Inconel 625 B-443
Incoloy 800/800H** B-409
Incoloy 825** B-424
Hastelloy C-276** B-575
** ASME "SA" or "SB" materials are inventoried in limited gauges.
016.doc
10.2 Expansion Joint Movements
The various dimensional changes which an expansion joint is required to absorb such as those
resulting from thermal changes in a Piping System are as follows:
1 Axial Movements
Is a motion occurring parallel to the centreline of the expansion joint and can be either
tension (Cold) or compression (Hot). Generally the tension in the metallic expansion joint
shall be avoided by pre compressing it in installation condition.
2 Lateral Movements
Is a motion which occurs perpendicular or at right angles to the centreline of the expansion
joint. Lateral deflection can occur along one or more axis simultaneously.
3 Angular Rotational Movements
This is the bending of expansion joint along its centreline.
4 Torsional Movements
016.doc
In addition to axial, lateral and angular movements an expansion joint may be subjected to
torsional motion or twisting. Torsion imposes severe stresses on expansion joints & shall be
avoided at any cost.
10.3 Generation of forces & moments by metallic expansion joints in piping network
Expansion joint is used to absorb effective thermal movements offered by a piping network
operating at elevated temperature. Hence the endeavour is to define the right pipe support type at
proper location to achieve the optimum purpose of usage of expansion joint. In the bargain of
absorbing the movements, expansion Joint would offer forces & moments to piping network with
need to be diffused by proper selection and design of supports and structures.
1 Spring Force
Spring force is a force required to deflect an expansion joint in axial, lateral or angular
motion. Spring force is a function of resistance offered by metallic expansion bellow and is
defined in the following manner.
Spring Force (F) = Spring Rate (K) x Deflection (∆)
Spring rate is a constant defined in Kg/mm of deflection based on material and dimensional
details of bellow. The reaction force due to deflection of bellow need to be killed at anchor
points located on either side of bellow.
016.doc
e.g.. A spring force of an expansion joint installed in 500 NB (20") size duct with an axial
spring rate of 15 kg/mm for an axial compression of 50 mm would need a spring force of 15
kg/mm x 50 mm = 750 kg. This would mean an equal and opposite reaction force need to be
killed at anchor points.
2 Pressure Thrust Force
Pressure thrust force is often misunderstood. It is a condition created by the installation of a

flexible unit, such as an expansion joint, into a rigid piping system which is under pressure.
Pressure thrust is the force created by the pressure acting on a bellow. This Force is the
system pressure times the effective area. When the piping without expansion joint is
pressurized, the system will not move because the pipe is counteracting the force in tension.
When an unrestrained expansion joint is introduced in the network, the force tends to pull
the ends away from the expansion joint causing damage to itself and the pipe. The pressure
thrust must be contained with either main anchors or restrained expansion joint design to
carry the pressure thrust loads.
016.doc
In cases of internal or positive pressure, the convolutions are pushed apart, causing the
bellows to extend or increase in length while the opposite is observed in cases of external or
negative pressure. The force required to maintain the bellows at its proper length is equal to
this pressure thrust and can be significantly higher than all other system forces combined.
3 Determining Pressure Thrust Force
Pressure thrust is the force created by Pressure P

The magnitude of pressure thrust force (Fs) in kg is determined by the following equation;
Fs = P*A
Where : (P) is the design pressure (kg/cm2)

and : (A) is the effective area of the expansion joint (cm2)
The following example will illustrate the effect of pressure thrust. Suppose that an expansion
joint is to be installed in a 20 in. diameter pipe system which operates at 10 kg/cm2g
016.doc
pressure. From the manufacturer of the expansion joint the effective area is found to be 2827
cm2
A = π/4*(Dm) 2
The pressure thrust force (Fs) is found to be:
Fs = P*A = (15 x 2827) = 42405 kg
Note that when determining pressure thrust forces, the pressure value used in Fs = P*A
should equal to max. Anticipated pressure that the system is likely to experience. For this
reason any pressure test must be considered. Be careful not to specify unrealistic safety
factors which could lead to over-design of the anchors at additional cost.
Refer Attachment B for the Thrust force behaviour of nozzle.
11 Various Type of Metallic Expansion Joints
1 Axial
2 Universal
3 Tied
4 Swing
5 Hinged
6 Gimbal
7 Pressure Balanced
11.1 Definition & Application
1 Axial (Single and Double Expansion Joints)
Axial expansion joint is meant to absorb mainly axial movements of piping network within
the defined anchor point locations. However, lateral movement mainly due to sustained load
of piping network absorbed by expansion joint.
Single Expansion Joint
016.doc
Application of Single Expansion Joint
Double Expansion Joint
Application Double Expansion Joint
2 Universal
Universal expansion joint as its name defines can absorb axial, lateral as well as limited
amount of angular movement. This is achieved by containing two bellows jointed by a
common connector for the purpose of absorbing any combination of the above basic
movement.
Universal Expansion joint
016.doc
3 Single Tied and Universal Tied
Tied expansion joint is meant to absorb only lateral movement of piping network. However,
this type of expansion joint with tie rod device helps in eliminating pressure thrust
developed due to internal pressure in piping system. Tied bellow would not allow any axial
movement or angular rotational movement because of its rigid configuration due to tie rods
provided along length of bellow. However, axial growth of bellow proportional to its length
is absorbed within the expansion joint. The tie rod, tie rod plates, tie rod nuts and welds are
designed to take full test pressure thrust.
Single Tied Expansion Joint
Application of Single Tied Expansion Joint
Tied Universal Expansion Joint
016.doc
Application of Tied Universal Expansion Joint
Also Single tied and Universal tied expansion joint can be used with Limit rods.
Single Tied Expansion Joint with Limit rods
4 Hinged
Hinged expansion joint contains one bellow and is designed to permit angular
rotation in one plane only by use of a pair of pins running through plates attached to the
expansion joint ends. Hinged expansion joints should be used in sets of 2 or 3 to perform the
required duty condition.
016.doc
Hinged Expansion Joint
Application of Hinged Expansion Joint
5 Gimbal
Gimbal expansion joint is designed to permit: angular rotation in any plane by the use of two
pairs of hinges affixed to a common floating gimbal ring,
Gimbal Expansion Joint
Application of Gimbal Expansion Joint
016.doc
6 Pressure Balanced
Pressure balanced expansion joint is designed to absorb axial movement and /or lateral
deflection while restraining the bellows pressure thrust force by means of the devices
interconnecting the flow bellows with an opposed bellow also subjected to line pressure.
This type of expansion joint (elbow type) is installed at a place where change of direction
occurs in a run of pipe.
a. Elbow type Pressure Balanced Expansion Joint:
This type of expansion joint is really a combination of several types. Its purpose is to
retain and balance the pressure thrust so that main anchoring of the pipe or adjacent
equipment is not required, and forces and movements on attachment flanges of
delicate equipment, such as turbines, are kept to acceptably low.
Reference to the diagram above shows that during the movement cycle, internal
pressure acting on bellow element (A), which is in the flow line, is balanced by the
same pressure in the balancing bellow element (B). The force exerted by the internal
pressure against the line elbow is balanced by an equal and opposite force transmitted
to the line through the tie rods (D) from the blank end (C) of the balancing section.
This type of expansion joints usually seen at a turbine casing or other piece of rotating
equipment where minimum forces and moments are required. It is also used in
installation where the application of a main anchor would not be practical the only
loads seen by the turbine are the sum of the axial force required to compress or extend
the line bellows and balancing bellows in the expansion joint.
Elbow type Pressure Balanced Expansion Joint
016.doc
Application of Elbow type Pressure Balanced Expansion Joint
b. In-Line Pressure Balanced Expansion Joint:
When axial deflections exist, and anchoring is impractical for structural or economic
reasons, such as high in the air or short straight pipe runs between two large vessels,
the in-line pressure balanced expansion joint is a powerful solution to a difficult
design problem.
An in line pressure balanced assembly is designed to absorb small amount of axial and
lateral movement while counteracting the pressure thrust in a system. This is achieved
with a series of rods similar to the pressure balanced elbow assembly and a balancing
bellows with twice the effective area as the line bellows. The elimination of the elbow
is what makes this expansion joint unique.
In-Line Pressure Balanced Expansion Joint
Application of In-Line Pressure Balanced Expansion Joint
016.doc
c. Selection of Expansion Joints:
Max
Type of Elimination
Sr. Axial Lateral Angular Acceptable
Expansion of Pressure Remark
No. Movement Movement Rotation Movement
Joint Thrust
mm
1 Axial × × × 75 to 100 -
2 Universal × 75 to 100 -
in Axial &
50 to 75 in
Lateral
3 Universal × × 50 to 75 in -
Tied Lateral
4 Hinged × × - Angular
Rotation
in single
Plane
Only
5 Gimbal × × - Angular
Rotation
in any
Plane
6 Pressure × 75 to 100
Balanced in Axial &
50 to 75 in
Lateral
Torsional movement imposes severe stresses on expansion joints & hence shall be
avoided. But if it occurs, shall be referred to the manufacturer.
11.2 Importance of selection of Pipe Support & proper supporting of Piping Network for
optimum usage of Expansion Joints
No piping network can behave during operation in a manner conceived during design stage by
Piping Engineer unless it is properly supported. It is often experienced while carrying out stress
analysis that minimal support in a piping network within defined anchor points quickly qualifies
the system as safe. However no system is qualified as properly supported unless it takes into
account, safe support span and proper selection rest, guide, limit stops and anchor supports.
The major movement of pipe takes place in six different directions and can be defined in
conventional terminology as +x, -x, +y, -y, +z,-z and usually represented in next point.
11.3 Type of Pipe Supports
Following type of pipe supports are generally encountered by a Piping Engineer while designing a
Piping Network Support System.
• Rest Support
• Guide Support
• Restraints Support
• Anchor Support
016.doc
11.3.1 Rest Support
This type of support is used to transfer the static load of pipe, content, insulation and piping
components to control the sagging phenomenon i.e. deflection of piping network within allowable
limits. Rest support allows movements of pipe in all directions except vertically downward
movements. Rest support means pipe resting directly on supporting structure on a saddle plate or
pipe shoe.
11.3.2 Guide Support
This type of support is used to restrict lateral movement of pipe. This is used in combination with
rest support. This type of support also can be used to restrict vertically upward movement of pipe.
11.3.3 Restraints Support
This type of support is used to restrict movement of pipes in specific direction based on job need.
This type is used in combination with rest and guide support.
11.3.4 Anchor Support
This type of support is usually used for segmenting the piping network to restrict the movements
of pipe of reasonable amount within the defined piping network. This type of support do not allow
movement in any direction i.e. it ceases all axial, lateral and torsional movements offered by
Piping Network. It can be achieved by welding the support component to pipe and supporting
structures or by using a combination of rest, guide and restraint support.
11.3.5 Causes of Bellow Failure
Bellow failures can occur for many reasons. The following list, which shows some typical causes
but is by no means all-inclusive, is presented with the intent that, as knowledge of the causes of
failure becomes more widespread, action can be taken to prevent or minimize these occurrences:
• Shipping and handling damage. Examples: Denting or gouging of bellows from being
struck by hard objects (tools, chain falls, forklifts, adjacent structures, etc.); improper
stacking for shipping or storage; insufficient protection from weather or other adverse
environmental conditions.
• Improper installation and insufficient protection during and after installation.
Examples: Joints with internal liners installed in the reverse direction with respect to flow;
installing an expansion joint in a location other than as prescribed by the installation
drawings; premature removal of shipping devices; springing of bellows to make up for
piping misalignment; insufficient protection from mechanical damage due to work in the
surrounding area; insufficient protection of bellows during nearby welding operations and
failure to remove shipping devices before placing system in operation.
• Improper anchoring, guiding and supporting of the system.
• Anchor failure in service.
• Bellows corrosion, both internal and external.
• System over-pressure (in-service or hydrotest).
• Bellows vibration (mechanical or flow induced resulting in high cycle fatigue).
• Excessive bellows deflection (axial, lateral, angular deflections greater than design
values).
• Torsion.
• Bellows erosion.
016.doc
• Packing of particulate matter in the bellows convolutions which inhibits proper

movement of the bellows.
016.doc
Appendix A: Case Study
In this case study a typical Reactor system have been considered. This case study covers description
(requirement & type of bellows) regarding few important bellows.
Process description:
1. Atmospheric air through blower is injected into the air pre heater. Through air pre heater it travels to
the reactor made up of refractory at temperature of 850 deg.C through 30” duct (node nos. 10 to 200).
This is the highest temperature in the system.
2. In reactor, incomplete combustion takes place at 850 deg C which generates the smoke which is a
mixture of product and waste gas. The smoke passes from reactor to air pre heater where it exchanges
its heat with incoming air.
3. The smoke comes out of air pre-heater from top at around 650 deg. C and enters into the oil pre heater
where it exchanges its heat with the oil and comes out at about 300 deg C & travel further to quench
tower.
Behavior of the System in View of Stress Analysis:
Fixed point / Anchor: The base of the Air pre-heater is the main anchor for this system. Air pre-heater is a
tall, heavy equipment fixed to the ground and hence acts as a anchor point. Reactor is floating equipment
since it is supported on rollers & floats away from the air pre-heater.
016.doc
A very important point in this system is the difference in the material of construction for reactor and the
hot air duct between air pre-heater and reactor which determines the relative movement and hence the
necessity of bellows. The length of the reactor and connected duct is around 26m. The skin temperature of
the reactor is 250 deg C and its expansion would be approximately (at node 10) 75 mm where as the duct
has temperature of 850 deg. C and SS material; and would move by 420 mm.
To absorb big axial movement of the duct, the duct is anchored at every main grid at 6250m with a axial
bellow which absorbs around 90 mm (0.017*6.250*850=90.3125) of movement. Hence bellows B,C,D &
E are axial bellows with limit stops (node nos. 50,90,130 & 170) on either side to take thrust force. In this
case pressure is 0.85 kg/sq. cm & hence the thrust force is (3.14/4*79.5*79.5*.85) = 4200 kg .
Also because of material difference, start up and shut down conditions become critical. Reactor being of
refractory lining will become hot slowly whereas the duct will become hot quickly. Hence it is assumed as
a conservative approach that when duct is hot reactor is cool and vice-versa. To take care of this
differential movement of approximately 50 mm a tied universal bellow is used at node 20-30 (Bellow A).
This bellow is a tied bellow since a spring has been provided at node 40 to take the weight of the duct.
The bellow F is a tied universal bellow since it has to take the axial movement at node no 210. A fixed
support is provided between node 230 & 240.
016.doc
The bellow G is also a Tied universal bellow which takes care of the vertical growth of leg 210 to 240
against node 250-260.
Summary:
Bellow A: Tied Universal Bellow to take differential expansion between reactor and duct during start up &
shut down condition and also in normal operating condition
Bellow B,C,D & E: Axial un-tied bellows to absorb the axial movement of the 30” SS duct.
Bellow F: Tied Universal to take care lateral movement.
Bellow G: Untied Universal bellow to take care axial and lateral movement.
016.doc
Appendix B: Example from EJMA

To Calculate the Thrust force acting on nozzle due to Un-tied axial expansion joint-
Forces Acting in the System:

Spring force of Bellow
Fa= Bellow Spring Rate * Total expansion (L3+Lb+L2)
Pressure Thrust Due to Bellow.
Fs= Effective Bellow Area * Design Pressure
Axial Force in Pipe
Fp= internal Pipe area * Design Pressure
Force Acting on Nozzle B = Fa+ Fs–Fp

Force Acting on Anchor A = Fa + Fs
Force Acting on Anchor C = -Fa - Fs
016.doc
Appendix C: Rubber Bellow Catalog
016.doc
Appendix D: References
EJMA: Standard of Expansion Joint Manufacturers Association, INC.

Expansion Joint Systems, Inc. catalog
KE Burgmann catalog
016.doc

Guide to Selecting and Using Expansion Joints

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Guide to Selecting and Using Expansion Joints

Uploaded by

Copyright:

Available Formats

Guideline for Expansion Joints Mott MacDonald Consultants (India) Pvt.Ltd.

Guideline for Expansion Joints

Mott MacDonald Consultants (India) Pvt.Ltd.

List of Contents Page

2 Definition of Expansion Joints 1

3 Why Expansion Joint is used in Piping System? 1

4 Hazards of usage of Expansion Joints 1

5 Where Expansion Joints shall not be used? 1

6 Where Expansion Joints are recommended? 1

7 Different Types of Expansion Joints 2

8 Characteristics of each type of Expansion Joint 2

9 End Connection Details of Expansion Joints 4

10 Metallic Expansion Joint as per EJMA 5

11 Various Type of Metallic Expansion Joints 12

Appendix A: Case Study 20

Appendix B: Example from EJMA 22

Appendix C: Rubber Bellow Catalog 23

P:\Andheri\Management\Ashtikar\Piping Guidelines\PIPDG016\PIP-DG- iii

2 Definition of Expansion Joints

3 Why Expansion Joint is used in Piping System?

4 Hazards of usage of Expansion Joints

5 Where Expansion Joints shall not be used?

6 Where Expansion Joints are recommended?

• At suction nozzle of large cooling water pumps.

7 Different Types of Expansion Joints

8 Characteristics of each type of Expansion Joint

8.2 Fabric Expansion Joint

(i) Maximum pressure withstanding capability of such expansion joint is up to 50 KPa.

8.3 Metallic Expansion Joints

9 End Connection Details of Expansion Joints

10 Metallic Expansion Joint as per EJMA

7 Hollow Reinforcing Rings

8 Solid Root Rings

Material Type ASTM* Material Specification

304 S/S A-240

304L S/S** A-240

316 S/S A-240

316 L S/S A-240

321 S/S A-240

Monel 400** B-127

Inconel 600 B-168

Inconel 625 B-443

Incoloy 800/800H** B-409

Incoloy 825** B-424

Hastelloy C-276** B-575

** ASME "SA" or "SB" materials are inventoried in limited gauges.

10.2 Expansion Joint Movements

3 Angular Rotational Movements

This is the bending of expansion joint along its centreline.

Spring Force (F) = Spring Rate (K) x Deflection (∆)

2 Pressure Thrust Force

Pressure thrust force is often misunderstood. It is a condition created by the installation of a

3 Determining Pressure Thrust Force

Pressure thrust is the force created by Pressure P

Where : (P) is the design pressure (kg/cm2)

The pressure thrust force (Fs) is found to be:

Fs = P*A = (15 x 2827) = 42405 kg

Refer Attachment B for the Thrust force behaviour of nozzle.

11 Various Type of Metallic Expansion Joints

11.1 Definition & Application

1 Axial (Single and Double Expansion Joints)

Single Expansion Joint