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2.5 Piping Thermal Expansion

and Flexibility
• Basics of pipe thermal expansion
• Stresses induced by thermal expansion
• Appropriate methods to absorb thermal
expansion - Expansion bends, loops, and
expansion joints
• Piping loads on load-sensitive equipment -
Requirements and best practices

Piping Flexibility Analysis

• Piping flexibility studies (thermal studies) are
commonly done on piping systems to ensure the
static stresses, static forces and static deflections due
to loads from pressure, temperature, and weight are
within safe limits. In systems that have significant
pressure pulsations, like those attached to a
reciprocating compressor, there are dynamic forces
that must also be considered.
• These additional dynamic forces cause vibration
(dynamic deflection) and vibratory (dynamic) stress,
and are typically investigated during a dynamic study.

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Piping Flexibility
• Piping systems must have sufficient flexibility to
prevent thermal expansion from causing failure of
piping or anchors from overstress or overstrain, leakage
at joints, or excessive thrusts and moments on
connected equipment.
• If substantial anchor or terminal movements are
anticipated, then these movements must be taken into
consideration in the piping system design.
• Bends, loops, and offsets are commonly used to
provide adequate flexibility. Expansion joints are used
by exception where space or pressure drop limitations
make bends, loops, or offsets impracticable.

Pipe Thermal Expansion

• All pipes will be installed at ambient temperature. Pipes
carrying hot fluids operate at higher temperatures and will
expand, especially in length, with an increase from ambient
to working temperatures.
• This will create stress upon certain areas within the piping
system, e.g. pipe joints, which could result in piping failure.
• The amount of the expansion is readily calculated using the
following Equation:
Expansion ΔL (mm) = L ΔT α
L = Length of pipe between anchors (m)
ΔT = Temperature difference between ambient & operating temps (°C)
α = Expansion coefficient (mm /m°C) x 10-3

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Pipe Thermal Expansion

• In the case of a pipe length which is restrained against
lengthening or shortening, a change in pipe
temperature results in the development of an axial
compressive or tensile stress.
• This stress is resisted by a compressive or tensile
force that acts on the pipe ends, or at any point in the
pipe at which it may be anchored.
• Should this reaction stress and resultant force be
sufficiently large it could lead to performance
problems in, or damage to a piping component, to
connected equipment, or to the supporting structure.

Thermal Coefficients for Metals (ASME B31.3) [μin/in-oF]

CS 5Cr-Mo Austenitic 12Cr, UNS Copper
Temp., C-Mo-Cr Through Stainless 17Cr, 25Cr-20Ni N04400 3-1/2Ni and
°F Through 9Cr-Mo Steels 27Cr Monel Copper
3Cr-Mo 18Cr-8Ni 67Ni-30Cu
−50 5.80 5.45 8.90 5.00 ... 7.15 5.88 9.04
−25 5.85 5.51 8.94 5.05 ... 7.22 5.94 9.11
0 5.90 5.56 8.98 5.10 ... 7.28 6.00 9.17
25 5.96 5.62 9.03 5.14 ... 7.35 6.08 9.23
50 6.01 5.67 9.07 5.19 ... 7.41 6.16 9.28
70 6.07 5.73 9.11 5.24 ... 7.48 6.25 9.32
100 6.13 5.79 9.16 5.29 ... 7.55 6.33 9.39
125 6.19 5.85 9.20 5.34 ... 7.62 6.36 9.43
150 6.25 5.92 9.25 5.40 ... 7.70 6.39 9.48
175 6.31 5.98 9.29 5.45 ... 7.77 6.42 9.52
200 6.38 6.04 9.34 5.50 8.79 7.84 6.45 9.56
225 6.43 6.08 9.37 5.54 8.81 7.89 6.50 9.60
250 6.49 6.12 9.41 5.58 8.83 7.93 6.55 9.64
275 6.54 6.15 9.44 5.62 8.85 7.98 6.60 9.68
300 6.60 6.19 9.47 5.66 8.87 8.02 6.65 9.71
325 6.65 6.23 9.50 5.70 8.89 8.07 6.69 9.74
350 6.71 6.27 9.53 5.74 8.90 8.11 6.73 9.78
375 6.76 6.30 9.56 5.77 8.91 8.16 6.77 9.81
400 6.82 6.34 9.59 5.81 8.92 8.20 6.80 9.84

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Thermal Coefficients for Metals (ASME B31.3) [μin/in-oF]

CS 5Cr-Mo Austenitic 12Cr, UNS Copper
Temp., C-Mo-Cr Through Stainless 17Cr, 25Cr-20Ni N04400 3-1/2Ni and
°F Through 9Cr-Mo Steels 27Cr Monel Copper
3Cr-Mo 18Cr-8Ni 67Ni-30Cu
425 6.87 6.38 9.62 5.85 8.92 8.25 6.83 9.86
450 6.92 6.42 9.65 5.89 8.92 8.30 6.86 9.89
475 6.97 6.46 9.67 5.92 8.92 8.35 6.89 9.92
500 7.02 6.50 9.70 5.96 8.93 8.40 6.93 9.94
525 7.07 6.54 9.73 6.00 8.93 8.45 6.97 9.97
550 7.12 6.58 9.76 6.05 8.93 8.49 7.01 9.99
575 7.17 6.62 9.79 6.09 8.93 8.54 7.04 10.1
600 7.23 6.66 9.82 6.13 8.94 8.58 7.08 10.04
625 7.28 6.70 9.85 6.17 8.94 8.63 7.12 ...
650 7.33 6.73 9.87 6.20 8.95 8.68 7.16 ...
675 7.38 6.77 9.90 6.23 8.95 8.73 7.19 ...
700 7.44 6.80 9.92 6.26 8.96 8.78 7.22 ...
725 7.49 6.84 9.95 6.29 8.96 8.83 7.25 ...
750 7.54 6.88 9.99 6.33 8.96 8.87 7.29 ...
800 7.65 6.96 10.05 6.39 8.97 8.96 7.34
825 7.70 7.00 10.08 6.42 8.97 9.01 7.37
850 7.75 7.03 10.11 6.46 8.98 9.06 7.40
875 7.79 7.07 10.13 6.49 8.99 9.11 7.43
900 7.84 7.10 10.16 6.52 9.00 9.16 7.45

Thermal Expansion of Piping (in/100 ft)

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Example: Pipe Thermal Expansion

• A 25 m length of carbon steel pipe is to be used to
transport fuel oil at 185°C. If the pipe is installed at
25°C, determine the expansion.
1- Using the expansion equation:
Expansion ΔL (mm) = L ΔT α
α in the range 0 - 200 oC = 14.9 x 10-3 mm / m °C for
carbon steel pipe (Table next slide)
Expansion = 25 (185 – 25) (14.9 x 10-3) = 59.6 mm
2- Using Chart, approximate expansion = 55 mm

Thermal Expansion Coefficients

Expansion coefficients (α) (mm/m °C x 10-3)

Material Temperature range (°C)

<0 0 - 100 0 - 200 0 - 300 0 - 400 0 - 500 0 - 600 0 -700
Carbon steel
12.8 13.9 14.9 15.8 16.6 17.3 17.9 -
0.1% - 0.2% C
Alloy steel
13.7 14.5 15.2 15.8 16.4 17.0 17.6 -
1% Cr 0.5% Mo

Stainless steel
9.4 20.0 20.9 21.2 21.8 22.3 22.7 23.0
18% Cr 8% Ni

Expansion (mm) = α L ∆T
L = Length of pipe between anchors (m)
∆T = Difference between ambient temperature and operating temperatures (°C)
α = Expansion coefficient (mm /m °C) x 10-3

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Thermal Expansion of Piping

(in/100 ft pipe)

Expansion Rate, in/100 ft pipe

Piping Material oF
Temp, 70 300 500 800 1000
Carbon Steel 0 1.82 3.62 6.7 8.9
Stainless Steel 0 2.61 5.01 8.8 11.5

Expansion in Various Steel Pipe Lengths

at Various Temperature Differences
Temperature difference °C

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Expansion in
Steel Pipes

Thermal Expansion of Stainless Steels

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Thermal Expansion Comparison

Pipe Thermal Expansion –

Thermal Loads
• Piping systems are subject to thermal expansion and
contraction which must be accounted for in the
design.
• The stresses which result from thermal expansion or
contraction are complex and depend on the system
configuration.
• The piping system must be configured with
appropriate flexibility to accommodate the thermal
movements and stresses.
• Although calculations can be done manually, these
are typically done by computer.

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Pipe Thermal Expansion –

Axial Stress
• The magnitude of the tensile or compressive axial stress
that can be generated in a pipe that is constrained both
against axial and lateral deformation may be computed
using the following equation:
S = E α ΔT
S = Tensile of compressive stress in axial direction, psi
E = Modulus of elasticity (effective modulus for plastics), psi
α = Coefficient of expansion/contraction, in/(in. oF)
ΔT = Temperature differential, oF

Pipe Thermal Expansion –

Axial Thrust
The thermal thrust in a pipe that is constrained against
axial movement may be calculated from the axial stress
by means of the following equation:

F=SA
F = Thrust (tensile or compressive), lbs
S = Stress (tensile of compressive), psi
A = Cross sectional area of pipe perpendicular to stress
direction, in2

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Example: Thermal Stresses

1. A 4 inch diameter (a = 3.17 in2), 25 ft long standard steel
steam pipe is installed at 60 oF. The pipe temperature increases
to 220 oF when in use.
Determine the thermal expansion of the pipe:
Δ L = (α)(Δ T)(L)
Δ L = (0.000 0065 in/F)(160F)(25 ft)(12 in/ft) = 0.312 in
2. Assume the pipe had been anchored "rigidly" at both ends.
Determine the stress in the pipe caused by this temperature
change
S = (E)(strain) = (E)(ΔL/L)
S = (29,000,000 psi)(0.312 in)/(300 in) = 30,160 psi.

3. Determine the force this stress would exert on anchors

F = (stress)(area)
F = (30,160 psi)(3.17in2) = 95,600 pounds of force

Piping System Flexibility - 1

Piping system movement caused by thermal expansion/contraction
can typically be compensated for by using expansion loops and
direction changes, along with the proper placement of piping
supports and anchors.

H/2

(Min H/4) H H
H/2

L L L

Loop Z-Bend Single Offset

The offset size (H) is a function of the pipe diameter (D) and the
length the pipe moves during a thermal cycle (ΔL)

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Simplified Flexibility Analysis

Guided Cantilever Approach
This method is based on the guided cantilever method (Kellogg).
L

δ Deflection

A guided cantilever is a cantilever beam restrained in such a way

that the free end will not rotate when it is deflected in a direction
perpendicular to the longitudinal axis of the beam.
The behavior of piping systems under thermal expansion
loads approximates that of a guided cantilever. The thermal
expansion forces the pipe leg to translate, while the pipe rotations
are restricted by piping continuity.

Simplified Flexibility Analysis

Guided Cantilever Approach
dx
B’
dy
B’
A B A B

L
Δ
C
C
dy C’
L
dx C

Free Expansion Constrained Expansion

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Simplified Flexibility Analysis

Guided Cantilever Approach
Deflection, Δ
X
Force, F

L = 6 ED/2S F = 12 E I Δ/ L3 Offset, L

For steel pipes,

X
E = 200 x 109 N/m2; S = 60 x 106 N/m2
L = 0.1D F = 24 I  / L3
L = Length of offset required, m
F = Force, Newton
E = Modulus of Elasticity, N/m2
I = Moment of Inertia, cm4
Δ = Deflection, mm
D = Pipe diameter, mm
S = Allowable Stress, N/m2

Example – Thermal Expansion

Pipe: NPS 6 carbon steel A106 Gr.B at 200 °C.
From Table, L1 thermal expansion = 22 mm
L2 thermal expansion = 33 mm
L2 = 15 m Δ2= 33 mm

Δ1= 22 mm

L1 = 10 m

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Piping System Flexibility - 2

The offset and loop size can be calculated using
equation:
H = 6.35 x (D x ΔL)1/2
H = 76.4 x (D x ΔL)1/2 (Metric)
H = Minimum expansion loop length (ft or mm)
D = Actual outside diameter of the pipe (in or mm)
ΔL = Change in length (in inches or mm) due to expansion or
contraction

Piping System Flexibility - 3

Example:
A 530-foot straight length of 2" C.S. pipe. The
pipe will be installed at 60°F, operated at 75°F,
and experience temperatures of 0°F in winter and
120°F in summer.
ΔL = 5.9 x 10-6 x (120-0) x 530 x 12 = 4.5 in
H = 6.35 x (2.375 x 4.50)1/2 = 20.8 ft.

Therefore, the minimum expansion length offset

or direction change is 20.8 feet.

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Single Offset Length for Steel Pipes

Calculate the expansion (∆) in the longer leg of a pipe with an offset between
the anchors. Read the offsets from the tables below which are shown in metres
under the nominal bore.
∆ PIPE SIZE
Expansion 15 20 25 32 40 50 65 80 100 125 150 200
1mm 0.39 0.45 0.50 0.57 0.64 0.71 0.81 0.90 1.00 1.12 1.23 1.42
3mm 0.67 0.78 0.87 0.98 1.10 1.23 1.40 1.55 1.74 1.94 2.12 2.45
5mm 0.87 1.00 1.12 1.27 1.42 1.58 1.81 2.00 2.24 2.50 2.74 3.17
10mm 1.23 1.42 1.58 1.79 2.00 2.24 2.55 2.83 3.16 3.54 3.87 4.47
15mm 1.50 1.73 1.94 2.19 2.45 2.74 3.12 3.47 3.87 4.33 4.75 5.48
20mm 1.73 2.00 2.24 2.53 2.83 3.16 3.61 4.00 4.47 5.00 5.48 6.33
30mm 2.12 2.45 2.74 3.10 3.47 3.87 4.42 4.90 5.48 6.12 6.71 7.75
40mm 2.45 2.83 3.16 3.58 4.00 4.47 5.10 5.66 6.33 7.07 7.75 8.95
60mm 3.00 3.47 3.87 4.38 4.90 5.48 6.25 6.93 7.75 8.66 9.49 10.96
80mm 3.47 4.00 4.47 5.06 5.66 6.33 7.21 8.00 8.95 10.00 10.96 12.65
100mm 3.87 4.47 5.00 5.66 6.33 7.07 8.06 8.95 10.00 11.18 12.25 14.14
No pipe alignment guides should be fitted and the pipes should be supported
by hangers or sliding supports.

Piping Flexibility: Z-Bend Sizing

Anchor-to-Anchor Expansion Length
Min Min
Feet Feet
X
Anchor Offset Anchor

X
Moment Guide

1. Calculate total expansion Anchor-to Anchor

2. Find Minimum Leg length (Min Feet) for this amount of
expansion from chart (next slide). This represents the
minimum length for offset and minimum length of expansion
type support required on EACH side of the Z-bend.

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Piping Flexibility: Z-Bend Sizing

Anchor-to-Anchor Expansion (inches)
NPS 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
Minimum Offset and Each Side of Z-Bend Required (Min. Feet)
2 6 7 9 10 11 12 12 13 14
3 7 9 10 12 13 14 15 16 17
4 8 10 11 13 14 16 17 18 19
6 9 11 13 15 17 19 20 22 23
8 9 12 14 17 19 20 22 24 25
10 10 13 16 18 20 23 25 27 28
12 11 14 17 20 22 24 26 28 30
14 11 14 17 20 22 25 27 29 32
16 11 14 17 20 22 25 27 30 33
18 11 14 17 20 25 26 28 31 34
20 12 15 18 20 25 27 29 32 35
24 13 15 18 21 26 28 30 33 36

Expansion Loops
• A basic approach to assess the need for additional
thermal stress analysis for piping systems includes
identifying operating conditions that will expose the
piping to the most severe thermal loading conditions.
• Once these conditions have been established, a
thermal analysis of the piping can be performed to
establish location, sizing, and arrangement of
expansion loops, or expansion joints (generally,
bellows or slip types).
• Expansion loops can be used in vertical or horizontal
planes.

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Expansion Loops
Designing to a stress range SA= 103 MPa (15,000 psi)
and assuming E = 1.92 × 105 MPa (27.9 × 106 psi), the
above equation reduces to:
L = 74.7(D)0.5 (Metric Units)
L = 6.225(D)0.5 (English Units)

This formula is based on guided-

X
cantilever-beam theory in which
both ends are fixed and limited Y
Guide
pipe rotation is assumed. The loop
is symmetrical with the middle 40 D 40 D
parallel leg (X) equal to ½ of each min min
of the tangential legs (Y).

Expansion Loop Capacity - Steel Pipe

The expansion loop is a common way to absorb the
temperature expansion in steel pipes. Expansion loops can be
fabricated from standard pipes and elbows.

Approximate Expansion Capacity - ΔL (mm)

Nominal Width of Expansion Loop - W - (m)
Pipe Size
(mm) 0.5 1.0 1.5 2.0 2.5

25 35 130
32 25 100 210 2W W
40 20 70 150
50 65 125 200
65 50 100 150 220
80 40 75 125 190
100 35 65 115 150

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1/4
Problem 1: Expansion Loops
Problem 1:
A 145-m-long (475-ft-long) steel, 200-mm (8-in.)
diameter liquid process pipe operates at 90°C (194°F)
and 1.55 MPa (225 psig). The expansion caused by
the process stream must be absorbed using U-bends
without damage to the pipe.
Solution 1:
Step 1. Establish the temperature differential (T).
Assume an installation temperature of 4.4°C (40°F).
Thus, the temperature differential would be
90°C – 4.4°C = 85.6°C (194°F – 40°F = 154°F).

2/4
Problem 1: Expansion Loops
Step 2. Determine the thermal expansion ().
 = L0(T)
where:
 = thermal expansion of pipe run, mm (in.)
 = coefficient of thermal expansion, 11.7 × 10–6 mm/(mm
°C), (6.5 × 10–6 in./[in. °F])
L0 = original length of pipe run, mm (in.)
T = temperature differential
 = 11.7 × 10–6 mm/(mm °C) × 145,000 mm ×
85.6°C
(6.5 × 10–6 in./(in. °F) × 5700 in × 154°F)
 = 145.2 mm (5.71 in.)

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3/4
Problem 1: Expansion Loops

Step 3. Determine dimensions of expansion loop.

The expansion loop is centered between anchored
supports as schematically shown in Figure below.

X
Y
Guide

40 D 40 D
min min

4/4
Problem 1: Expansion Loops

L = X + 2Y = 74.7(D)0.5 (Metric Units)

= 6.225(D) 0.5 (English Units)
and
Y = 2X
So
L = 5X = 74.7(145.2 mm × 220 mm)0.5
= 6.225 (5.71 in. × 8.625 in.)0.5
L = 5X = 13,351 mm (43.7 ft)
X (parallel leg) = 2670 mm (8.74 ft)
Y (perpendicular leg) = 2(2670 mm) = 5340 mm (17.5 ft)

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Flexibility by Using Expansion Joints

• If natural (inherent) flexibility is insufficient, or the
resultant forces are excessive, then expansion joints
are the next solution.
• There are several different types of expansion joints
and it must be decided which is the best for the pipe
system being designed.
• The positions and strengths of anchors and guides
must be considered. Different types of expansion
joint, when combined with the piping system
parameters, will impose different forces.

Types of Expansion Joints

• Definition - Any device used to absorb
dimensional changes such as those caused by
thermal expansion or contraction of a pipe-
line, duct or vessel.
• Types - There are basically three (3) types of
expansion joints:
– the pipe loop,
– the bellows-type joint.
– the slip-type joint, and

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Bellows Expansion Joints

• The joint consists of small, flexible corrugations
(convolutions). The number of corrugations is
proportional to the total displacement of the bellows.
• The overall flexibility of the corrugations enables the
bellows to absorb the dimensional changes in a
thermally cycling piping system, preventing
excessive stresses and “end-reactions”.
• A bellows can be designed to absorb axial deflection,
lateral deflections, angular rotation, or any
combination of the three.

EJMA Standards
Expansion Joint Manufacturers Association
The EJMA Standards are recognized
throughout the world as the authority
on the proper selection and
application of metallic bellows type
expansion joints for safe and reliable
piping and vessel installation.

The 10th Edition standards combine

the knowledge and experience of the
leading manufacturers of expansion
joints into an invaluable reference
document.

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Bellows Expansion Joints

Bellows Expansion Joints

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Types of Bellows Expansion Joints

Bellows Expansion Joints

Bellows Terminology
The bellows is the flexible element of the expansion joint. It must be
strong enough circumferentially to withstand the pressure and flexible
enough longitudinally to accept the deflections for which it was
designed, , and as repetitively as necessary with a minimum resistance

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Restrained Expansion Joints

Application of lateral, hinged and gimbal expansion joints
Restrained expansion joints are equipped
with restraints such as tie rods, hinges and
gimbals.
Tied expansion joints are used where the
equipment and structure of pipeline systems
cannot accept pressure thrust forces.
It is not allowed to install them as axial
bellows to absorb axial movement. In the
piping systems, such as “L”, “Z” and “U”
bends they accept lateral or angular
movement.
The total force acting at fix points is less for
pressure thrust and the main advantage of a
tied expansion joints is that they need very
light anchors and intermediate anchors.

Bellows Expansion Joints

• Tie Rods - Devices usually in the form of rods
or bars, attached to the expansion joint
assembly, whose primary function is to
continuously restrain the full bellows pressure
thrust during normal operation while
permitting only lateral deflection.
• Angular rotation can be accommodated only if
two tie rods are used and located 90 degrees
from the direction of rotation.

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Bellows Expansion Joints

• The design of pipe restraints must take into
account the forces resulting from the bellows
pressure thrust (both static- and sliding-
friction), any hydraulic thrusts, the bending of
pipe segments, and any effective wind-loads.
• The spring rate of the bellows also must be
considered.

Bellows Expansion Joints

• Although a bellows lowers the forces caused by
thermal displacement strains, it does not eliminate
them entirely.
• Because a bellows must be carefully engineered into
a piping system, it should be treated as a “last resort”
to lower the piping end reactions.
• Use the flexibility of the piping system as a first
resort.

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Expected Cycles Vs. Movement

Movement
125 100 95 85 75 50 25
(% of Design)
Expected Cycles
25 100 125 250 500 5,000 500,000
(% of Design)

Example: Consider an expansion joint that is designed to give

3000 cycles at 50 mm movement, but is only required to move
by 42.5 mm; i.e. 85% of its design capability. This is shown in
table as the % of design movement and equates to 250%
expected cycles. This would mean that the expansion joint will
in fact operate without failure for 2.5 times the number of
design cycles, i.e. 7500 cycles.

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Slip-Type Expansion Joint

Slip/Sleeve Type Expansion Joints is generally used in the pipe lines
to absorb high amount of axial movement.

Slip-Type Expansion Joint

• Slip type (Dresser® Style) pipe expansion joints are
used when the primary problem is a large axial
movement. Materials can be selected to accommodate
high temperatures and pressures.
• Design details include selection of packing and seals
compatible with process fluids, and appropriate
materials of construction including hard surfacing if
required for resistance to abrasive wear. Special
features such as "wipers" can be included to prevent
potential clogging of the space between the sleeves.

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Slip-Type Expansion Joint

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