Gas Turbine Power Plant

Expansion Joints
Gas Turbine Power Plant
Expansion
Gas Joints
Turbine &
Combined Cycle Plants
 Introduction

With a worldwide reputation for excellence, DEKOMTE de Temple manufactures fabric and stainless
steel expansion joints for all applications within a gas turbine power station, and offers varying
technical standards to suit the technical requirements, maintenance cycles, and budgets for each joint.

Gas turbine power stations subject the exhaust duct
and HRSG casing to extreme stress and fatigue, with the
expansion joint being the focus point of the systemic
issues. Both fabric and metal expansion joints are used
in many positions around the plant.
Base Load Operational Plants
Base load stations can obtain acceptable performance
from a basic design, due to the reduced stresses and
fatigue caused by fewer start-ups and shutdowns.
Good construction techniques and fabrication quality
are essential to bring simpler solutions to the required
reliability. Stations originally designed for base load are
now being asked to run cyclically.
Cycling Operational Plants
Conversely, cycling plants are subject to increased
maintenance when using basic duct and joint
constructions that were not designed for the increased
stresses and fatigue. DEKOMTE’s designs and
constructions offer technically based guarantees and
a lifespan of up to 25 years, depending on the site‘s
operating conditions.
The biggest challenges occur in high-cycling plants.
Steel frame designs should minimize the temperature
gradient across frame to minimize stress and fatigue.
Design of the flow plate is made in such a way that
the axial, lateral and possible angular movements are
considered to make sure that no points are fixed and
stressed during the movements.
DEKOMTE has proven designs for cycling operational
plants with installations in a vast number of power
stations around the world, as OEM equipment and as
retrofitted systems. DEKOMTE offers improvements in
the construction of the fabric joint and insulating bolster
to allow use of the latest materials and production
processes. The tailored joints are built on custom molds
giving higher joint flexibility and greater plant availability.
The clamping area and the bolts are designed in
such a way that there is no overheating, allowing the
application of constant pressure during operation.

CONTENTS

4 GT Exhaust / HRSG Inlet 6 GT Exhaust / HRSG Inlet 8 HRSG Outlet

(Hot Casing) (Cold Casing)

2
 DEKOMTE is accredited to RAL GZ 719, the world-class a GT Inlet
quality standard for fabric expansion joints, ensuring
that a detailed and thorough technical approach is b GT Outlet (hot casing)
maintained in all products offered, and the highest
quality is ensured in the delivered solutions. c HRSG Inlet (cold casing)

d HRSG Outlet

e Penetration Seals

d
c a

10 Penetration Seals 12 Pumpable Insulation and 14 Inspection, Monitoring, and

Casing Repairs Installation

3
 GT Exhaust / HRSG Inlet
(Hot Casing)

Gas turbine power stations subject the exhaust duct and HRSG casing to extreme stress and fatigue,
with the expansion joint being the focus point and relief. Many problems with the complete design
become evident in this area.

Base load stations can obtain acceptable performance
from a basic design, due to the reduced stresses and
fatigue caused by fewer start-ups and shutdowns.
Conversely, cycling plants are subject to increased
maintenance when using basic duct and joint
constructions that were not designed for the increased
stresses and fatigue.
The use of a competent third-party design authority
(such as DEKOMTE), to verify and compare each of the
solutions offered can establish a consistent basis for
the comparison of possible design solutions.
The design is broken into key elements to establish
independent technical criteria for each one.
The expansion joint also represents a system that
requires a complete analysis of the total scope using the
latest technology. In DEKOMTE’s experience, the only
reliable way to carry out a technical analysis is using
FEA (Finite Element Analysis) and CFD (Computational
Fluid Dynamics) programs, taking extreme care to
ensure the correct boundary conditions and calculation
parameters are used in these processes.

4
Key elements of the design are:

1 Steel Frame Design 4 Fabric

This is the most critical aspect of hot casing solutions.
The temperature gradient created on the frame during
transient operating conditions of the gas turbine
creates high fatigue stresses that may result in
cracking and gas leakage with cycling.
Formed fabrics that prevent creasing, crumpling and
folding through all movement are important for cycling
and longer life. Durable multi-layer compositions with
high temperature membranes and outer protection
protect the gas-tight seal from stress and damage.

2 Flow Plate 5 Bolting / Clamping Detail

Smooth cross section changes in the duct are important A gas-tight seal is achieved with proper design of the
to reduce turbulence and insulation degradation. bolting and clamping to meet the required site pressure.

3 Internal Bolster 6 Duct Connection

Fully encapsulated and formed insulating bolsters Both welded and bolted flange systems are available
(or pillows) protect the joints from the inside, and with consideration given to thermal fatigue, distortion
segmented sections can reduce compression and and remaining gas-tight.
damage caused by the movements.
7 Adjacent Insulation and Cladding
The expansion joint system is further protected from
excess external radiated temperatures by tightly
integrating adjacent insulation and cladding insulation.

5 5 3
4

3 5 5
3 3
7 1 1 7 7

6 6 7 1 1

2 2
6 2 6

Other details to consider when looking at the joint design are the duct condition, stiffeners, supports, and moving points,
ensuring that they work as a system with the correct movements.

5
 GT Exhaust / HRSG Inlet
(Cold Casing)

Expansion joints that are installed within a section of duct with internal lining, known as cold casing
duct arrangements, experience lower stresses than hot casing arrangements. Protecting the expansion
joint frame and bolster from the highest gas temperatures will increase the joint‘s life and reliability.

DEKOMTE recommends a review of the connection
and internal lining of the joints to ensure that no heat
path becomes a weak element of the design.
The design is broken into key elements to establish
independent technical criteria for each one. The
expansion joint also represents a system that requires
a complete analysis of the total scope using the latest
technology. In DEKOMTE’s experience, the only
reliable way to carry out a technical analysis is using
FEA (Finite Element Analysis) and CFD (Computational
Fluid Dynamics) programs, taking extreme care to
ensure the correct boundary conditions and calculation
parameters are used in these processes.

596oF
572oF

392oF

212oF

63oF

6
Key elements of the design are:

1 Steel Frame Design 4 Fabric

As a cold casing system, the steel frame design is not
subjected to the thermal stresses, as long as the
frame can remain cold.
2 Flow Plate
Formed fabrics that prevent creasing, crumpling and
folding through all movement are important for cycling
and longer life. Durable multi-layer compositions with
high temperature membranes and outer protection
protect the gas-tight seal from stress and damage.

Smooth cross section changes in the duct are important

to reduce turbulence and insulation degradation. 5 Bolting / Clamping Detail
The liner plate should cover over the complete A gas-tight seal is achieved with proper design of the
expansion joint space, allowing flexibility by floating/ bolting and clamping to meet the required site pressure.
sliding sections. A liner that is seamless over the
adjacent flanged connections protects the casing and 6 Duct Connection
interface to the expansion joint frame. Both welded and bolted flange systems are available
with consideration given to thermal fatigue, distortion
3 Internal Bolster and remaining gas-tight.
Fully encapsulated and formed insulating bolsters
(or pillows) protect the joints from the inside, and
segmented sections can reduce compression and
damage caused by the movements.

4
4
3 5 5

3
5 1 1
5
6 6
6 1 1
6 3

6 6 6
2 6 2
2
2

Other details to consider when looking at the joint design are the duct condition, stiffeners, supports, and moving points,
ensuring that they work as a system with the correct movements.

7
 HRSG Outlet

The HRSG outlet is a cool condition operating expansion joint, where the temperature conditions are
typically a maximum temperature of 302oF, which are favorable to a simple material and thin layered
expansion joint.

The movements are also not significant due to the
low temperature, and the main function is isolating
the structure of the duct, HRSG, and stack to allow
civil structural tolerances, vibration elimination, and
flexibility from dynamic weather loading.
DEKOMTE recommends the retrofit addition of water
barriers, drains, and flow plate systems. These give
the security of a cleaner, longer functioning expansion
joint by eliminating the build-up of water, deposits, and
debris from the inner joint space.

DEKOMTE recommends the use of a ¼” reinforced Careful consideration of the material selection will help
rubber expansion joint or a multi-layer PTFE expansion a joint at the stack connection reach an expected life
joint with rubber sealing area as the best solutions, as of 20 years. Short-term cost savings can result in high
these address the main issues: maintenance costs on an expansion joint where the cost
• Weather tightness of access is prohibitive.
• Water sealing
• Environmental degradation

The effect of these aspects include heavy corrosion

on the roof section caused by weather ingress into the
duct through the joint flanges, and also on the bottom,
caused by water leakage out through the flange from
inside the unit.

8
Key elements of the design are:

1 Steel Frame Design

The use of the correct material, coating, and drain
design reduces corrosion and extends the life.

2 Flow Plate
A protective flow plate and water barrier prevents
condensation, water and debris from pooling in the
expansion joint space.

3 Fabric
Materials that are stable for the environmental and
plant conditions will maximize the maintenance life
cycle. Fabric compositions that include water sealing
materials along with gas-tightness will extend the life
of the joint.

2
2

Other details to consider when looking at the joint design are the duct condition, stiffeners, supports, and moving points,
ensuring that they work as a system with the correct movements.

9
 Penetration Seals
Penetration seals are the most challenging expansion joints in a combined cycle power plant. The
high levels of movement of these small joints in this environment demand the best technical solutions
and highest quality of products to survive.
Leaking packing glands and mechanical seals have a
detrimental impact on casings and adjacent equipment –
not only do they require more regular maintenance, but
they can necessitate additional maintenance and repairs
to the surrounding area, that in the longer term make
them an expensive and unreliable solution.
DEKOMTE solutions are gas-tight and ensure no loss of
flue gas or heat to the environment.
DEKOMTE offers both metallic bellows and fabric
expansion joints for this application, and the choice
is normally established by the HRSG OEM. Metallic
bellows offer the lowest initial cost and are therefore
favored for the first installation. In high movement
areas and for retrofit, fabric joints offer the best
solutions and flexibility in the most compact design.
Retrofitting metallic bellows is uncommon due to the
necessity to either:
• Deliver the bellows in split halves resulting in:
- welding the bellow on site, which is notoriously
difficult and leaves areas prone to corrosion
and failure
10
- limiting construction to a single layer bellow,
which is stiffer than multi-layer solutions
• Deliver the completed bellows resulting in:
- A bellow more flexible than a split halve bellow
- Cutting the steam nozzle to slide over the
completed bellow
- Complete NDT on the nozzle
- Coded welding to re-attach the nozzle
- Complete the pre-weld and post-weld heat
treatment
In almost every case, the bellow failed due to
movement-induced issues, therefore installing the same
or less flexible solution is not going to deliver reliability.
DEKOMTE has developed the most reliable fabric
solutions for penetration seals, both as an OEM
installation with cost optimization being a key function
of design, through to retrofit where longevity, durability
and reliability are the keys to the design.
Key elements of the design are:
1 Steel Frame Design
Casing collars can align the joints by resetting the pipe
concentricity to the casing position. Pipe collars can
manage temperatures in the seals and offer space for
integration of piping insulation to protect the seal
from the inside.
2 Internal Bolster
Fully encapsulated and formed insulating bolsters
(or pillows) protect the joints from the inside, and
segmented sections can reduce compression and
damage caused by the movements.
3 Fabric
Formed fabrics that prevent creasing, crumpling and
folding through all movement are important for cycling
and longer life. Durable multi-layer compositions with
high temperature membranes and outer protection
protect the gas-tight seal from stress and damage.
2
4
3
2
4
1
Other details to consider when looking at the joint design are the duct condition, stiffeners, supports, and moving points,
ensuring that they work as a system with the correct movements.
11
4 Bolting / Clamping Detail
A gas-tight seal is achieved with proper design of
the bolting and clamping to meet the required site
pressure. When possible to attach to the pipes, bolted
flanges can eliminate the maintenance required of a
circumferential clamp.
5 Casing Insulation and Nozzle Liner
The insulation around a nozzle in the casing is subject
to highly turbulent gas flow, which invariably pits and
pulls the insulation into the gas stream. DEKOMTE
can avoid this by installing encapsulated casing
bolsters and redesigned nozzle liner plate sections.
Ensuring casing temperature is maintained will ensure
the further reliability of the penetration seal.
6
Pipe Insulation
Tight integration of the insulation to the expansion
joint pipe collar prevents damage from excess external
radiated temperature.
 Pumpable Insulation
and Casing Repairs

In cold casing duct systems with liner plates securing the insulation in place, the condition of the
insulation is paramount to ensure that the casing stays in good condition. The cold casing must stay
cold and well-insulated.

If the liner plate system and attachments are in sound Pumpable Internal Insulation
mechanical condition, then repairing the insulation can
The pumpable soluble fiber insulation is a mix of short
be intrusive and expensive.
fibers dispersed in high temperature binders that, upon
drying, produces a strong insulation structure with low
DEKOMTE can repair missing insulation pockets and
thermal conductivity.
hot areas of casing by injecting liquid insulation from
the outside, while the unit is running.
Applications:

Causes of insulation loss: • GT Casings

• GT Exhaust Diffuser
• No liner
• Penetration Seals
• Liner plate damage
• HRSG Casings
• Gas flow under liner (by distortion / gap in liners)
• Compacting of insulation
• Degradation of insulation (by vibration / moisture)

Effects of insulation loss:

• Casing cracks leading to gas leakage
• Temperature-induced material fatigue
• All effects cause adjacent safety and environmental
concerns

12
Insulation Technical Details

Pumpable Material Typical Casing Insulation

• Low thermal conductivity (1100°F - 0.05 btu) • Low thermal conductivity (1100°F - 0.05 btu)

• Use limit 2300 °F • Use limit 2300 °F

• Melting point >2730 °F • Melting point >2730 °F

• Wet density 70 lb/cu.ft • Dry density 6 lb/cu.ft

• Dry density 17 lb/cu.ft • No adhesion

• Low shrinkage • Resistant to flue gas velocities up to 16 ft/s

• Good adhesion
• Resistant to flue gas velocities up to 65 ft/s

642oF 271oF 258oF 112oF

80 680 60 660 60 620 55 600

Casing Repairs
DEKOMTE also offers casing repairs, liner modifications,
and new attachment solutions. These are aimed at
maintaining casing temperatures for a longer life.

13
 Inspection, Monitoring,
and Installation

Engineering support in the form of annual inspections or lifetime assessments can form a critical part
of the maintenance planning of a power plant or industrial manufacturing process.

The integration of duct supports, stiffeners, and bracing It is our primary objective to guarantee plant availability,
sections into the expansion joint solution can result even under the harshest conditions over many years.
in a complete problem solving package, rather than
contractually interfaced scopes. DEKOMTE manages Following installation, the DEKOMTE Customer Service
the technical and commercial aspects of the various team is available at all times to answer your questions.
on-site disciplines and trades.
Design Studies and Technical Support
DEKOMTE also supports and advises its customers
on supply and installation appropriate to their Design comparison, investigation, and modelling can
requirements. The design of the expansion joint uses be achieved using DEKOMTE’s extensive database of
the latest materials and composition to optimize cost empirical knowledge.
and technical function.
DEKOMTE offers objective technical support at short
We provide a quality package comprising creativity, notice for critical problems.
design, practical experience and technical expertise to
be able to offer the optimum selection of components
and fully developed solutions.

14
Engineering Services
DEKOMTE pushes the boundaries of product
development with the latest computer and industry best
practice tools and procedures. The discerning use of
FEA (Finite Element Analysis) and CFD (Computational
Fluid Dynamics), together with 2D and 3D design,
allows a correlation of on-site empirical experience
and theoretical models. Formulation of specifications,
tenders and design critique are also offered as an
independent technical service.
Plant Survey
DEKOMTE has experienced site engineers and
designers who are able to review all expansion joints in
15
a plant and produce a technical report for maintenance
planning and plant improvement, establishing a baseline
of the site’s expansion joints and helping to build a plan
to reduce total costs.
Turnkey Installation
The use of skilled design engineers, technicians, and
service engineers, together with qualified on-site skilled
labor means DEKOMTE offers a complete turnkey
contracting solution for duct problems.
Please contact us for further information and to discuss
your specific requirements.
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DEKOMTE de Temple LLC

885 Franklin Gateway

Suite 335
Marietta, GA 30067
USA

Tel: +1 888 2553520

Fax: +1 888 4532066
E-mail: info@dekomte.us
www.dekomte.com