MANDATORY APPENDIX 5
FLANGED AND FLUED OR FLANGED ONLY
EXPANSION JOINTS
04 5-1 GENERAL
5-1(a) Flanged and flued or flanged only expansion
joints used as an integral part of heat exchangers or other
pressure vessels shall be designed to provide flexibility
for thermal expansions and also function as pressure con-
taining elements. The rules in this Appendix are intended
to apply to typical single layer flanged and flued or flanged
only elements shown in Fig. 5-1. They are limited to
applications involving only axial deflections.
The suitability of the expansion joint for the specified
design, pressure, and temperature shall be determined by
methods described in this Appendix.
5-1(b) In all vessels with expansion joints, the hydro-
static end force caused by pressure and /or the joint spring
force shall be contained by adequate restraining elements
(i.e., tube bundle, tubesheets or shell, external bolting,
anchors, etc.). The average primary membrane stress [see
UG-23(c)] in these restraining elements shall not exceed
the maximum allowable stress at the design temperature
for the material given in the tables given in Subpart 1 of
Section II, Part D.
5-1(c) Joint flexible elements shall not be extended,
compressed, rotated, or laterally offset to accommodate
connecting parts which are not properly aligned, unless
such movements have been accounted for in the design
under the provisions of U-2(g).
5-1(d) The rules of this Appendix do not address cyclic
loading conditions. As such, this Appendix does not
require a cyclic life determination. The User is cautioned
that the design of some expansion joints (especially
flanged-only joints) may not be governed by cyclic load-
ing. If cyclic loading [see UG-22(e)] is specified for a
vessel containing the expansion joint, see U-2(g).
5-1(e) This Division does not contain rules to cover
all details of design and construction of expansion joints.
The criteria in this Appendix are therefore established to
cover most common forms of flanged and flued or flanged
only expansion joints, but it is not intended to limit con-
figuration or details to those illustrated or otherwise
described herein. For designs which differ from the basic
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concepts of this Appendix (e.g., multilayer, asymmetric
geometries or loadings, etc.), the design requirements of
U-2(g) apply.
5-2 MATERIALS
Materials for pressure retaining components shall con-
form to the requirements of UG-4. For carbon and low
alloy steels, minimum thickness exclusive of corrosion
allowance shall be 0.125 in. (3 mm) for all pressure
containing parts. The minimum thickness for high alloy
steel shall conform to requirements of UG-16.
5-3 DESIGN 04
The design of expansion joints shall conform to the
requirements of Part UG and those of (a) through (f)
below.
5-3(a) The design of expansion joint flexible elements
shall satisfy, in both the corroded and noncorroded condi-
tion, the following combinations of maximum stress com-
ponents and corresponding stress limits [see (b) below].
5-3(a)(1) Pressure Loadings Only. The maximum
stress at any location within the joint shall be limited to
1.5S [where S is the maximum allowable stress value
(see UG-23) for the joint material], except as provided
below. The references to maximum stress do not include
any effect of stress concentrations.
(a) For tubular heat exchangers, considering tube
side pressure, the stresses may be evaluated only in accor-
dance with provisions of (a)(2) below if the restraining
elements are not dependent on the stiffness of the expan-
sion joint in order to satisfy the stress requirements of
5-1(b).
(b) For tubular heat exchangers, considering shell
side pressure, when the restraining elements are not
dependent on the stiffness of the expansion joint in order
to satisfy the stress requirements of 5-1(b):
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 5-3
rb
Corner
Rb
(a) Flanged Only
Ra , Rb  inside radius of expansion joint straight flange)
t  uncorroded thickness of expansion joint straight flange
FIG. 5-1 TYPICAL FLANGED AND FLUED OR FLANGED ONLY FLEXIBLE ELEMENTS
(1) the maximum membrane plus bending
stress in the annular plates or straight flanges (see Fig.
5-1) shall be limited to 1.5S;
(2) the maximum membrane stress in the cor-
ners and torus (radius portion of the flange or flue, see
Fig. 5-1) shall be limited to 1.5S;
(3)(a) the maximum membrane plus bending
stress in the corners and torus shall be limited to 1.5S
except as provided in (3)(b) below;
(3)(b) the maximum membrane plus bending
stress in the corners and torus shall be limited to SPS [see
UG-23(e)], provided it is demonstrated that rotational
stiffness at the corners and torus is not needed to maintain
the maximum stress in the annular plates or straight
flanges equal to or less than 1.5S.
5-3(a)(2) Pressure Plus Axial Deflection (Pressure
or Thermally Induced) Loadings. Considering the most
severe combination of pressure(s) and axial deflection,
the maximum stress (not including any effects of stress
concentration) at any location in the joint shall be limited
to SPS [see UG-23(e)].
5-3(b) The calculation of the individual stress compo-
nents in (a) above and their combination shall be per-
formed by any method of stress analysis which can be
shown to be applicable to expansion joints.
5-3(c) The knuckle radius ra or rb of any formed ele-
ment shall not be less than three times the element thick-
ness t as shown in Fig. 5-1.
5-3(d) The spring rate of the expansion joint assembly
may be determined either by calculation or by testing.
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MANDATORY APPENDIX 5 5-4
Straight flange (typ.)
Outer torus (typ.)
Annular plate (typ.) rb
Inner torus (typ.) t
ra
Rb
Ra
(b) Flanged and Flued
GENERAL NOTE: ra , rb  3t.
5-3(e) Thinning of any flexible element as a result of
forming operations shall be considered in the design and
specifications of material thickness.
5-3(f) Extended straight flanges between the inner and
outer torus of flexible elements are permissible. Extended
straight flanges with lengths in excess of 0.5 冪Rt shall
satisfy all the requirements of UG-27 where
t p uncorroded thickness of expansion joint straight
flange
R p inside radius of expansion joint straight flange
at the point of consideration
p Ra or Rb
5-4 FABRICATION
The following requirements shall be met in the fabrica-
tion of expansion joint flexible elements.
5-4(a) All welded joints shall comply with require-
ments of UW-26 through UW-36.
5-4(b) All longitudinal and circumferential weld
seams shall be full penetration welds, Type (1) of Table
UW-12.
5-4(c) Longitudinal welds shall be ground flush and
smooth on both the inside and outside surfaces prior to
being formed into expansion elements.
5-4(d) Other than the shell attachment welds and
flange welds, no circumferential welds are permitted in
the fabrication of the flexible elements, i.e., inner torus,
annular plate, and outer torus, unless the welds are ground
flush and fully radiographed.
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 5-4
Min.  0.2 (Rbt ) /2
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FIG. 5-2 TYPICAL NOZZLE ATTACHMENT DETAILS SHOWING MINIMUM LENGTH OF STRAIGHT FLANGE
5-4(e) Flexible elements shall be attached by full pene-
tration circumferential welds.
5-4(f) Nozzles, backing strips, clips, or other attach-
ments shall not be located in highly stressed areas of the
expansion joint, i.e., inner torus, annular plate, and outer
torus. Nozzles or other attachments located in the outer
straight flange shall satisfy the axial spacing requirements
of Fig. 5-2.
5-4(g) Alignment tolerances of the completed expan-
sion joint attached to the shell shall meet the tolerances
specified by UW-33.
5-5
5-5(a) All expansion joint flexible elements shall be
visually examined and found to be free of unacceptable
imperfections, such as notches, crevices, weld spatter,
etc., which may serve as points of local stress concentra-
tion. Suspect surface areas shall be further examined by
liquid penetrant or magnetic particle examination.
5-5(b) Longitudinal welds shall be fully radiographed
in accordance with UW-51. All full penetration butt type
welds shall be examined 100% on both sides by the liquid
penetrant or magnetic particle methods after forming.
5-5(c) The circumferential attachment welds between
the expansion joint and shell shall be examined 100%
on both sides by liquid penetrant or magnetic particle
examination.
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2004 SECTION VIII — DIVISION 1 5-6
1
1
Min.  0.2 (Rbt ) /2
t t
Rb Rb
(a) Nonreinforced Nozzle (b) Reinforced Nozzle
Rb  inside radius of expansion joint straight flange
t  uncorroded thickness of expansion joint straight flange
5-5(d) The completed expansion joint shall be sub-
jected to a pressure test in accordance with UG-99. The
pressure testing of an expansion joint may be performed
as a part of the final vessel hydrostatic pressure test pro-
vided the joint is accessible for inspection during pressure
testing.
5-5(e) Expansion joint restraining elements [see Fig.
5-1 sketch (b)] shall also be pressure tested in accordance
with UG-99 as a part of the initial expansion joint pressure
test or as a part of the final vessel hydrostatic pressure
test after installation of the joint.
5-5(f) In addition to inspecting the expansion joint for
leaks during the pressure test, flanged and flued or flanged
INSPECTION AND TESTS only expansion joints shall be inspected before, during,
and after the pressure test for visible permanent distortion.
5-6 MARKING AND REPORTS 04
The expansion joint Manufacturer, whether the vessel
Manufacturer or a parts Manufacturer, shall have a valid
ASME Code U Certificate of Authorization and shall
complete the appropriate Data Report in accordance with
UG-120.
5-6(a) The Manufacturer responsible for the expan-
sion joint design shall include the following additional
data and statements on the appropriate Data Report:
5-6(a)(1) uncorroded and corroded spring rate
5-6(a)(2) axial movement (+ and −) and associated
loading condition, if applicable
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 5-6 MANDATORY APPENDIX 5 5-6

5-6(a)(3) that the expansion joint has been con- 5-6(c) Markings shall not be stamped on the flexible
structed to the rules of this Appendix elements of the expansion joint.
5-6(b) A parts Manufacturer shall identify the vessel
for which the expansion joint is intended on the Partial
Data Report.

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