Expansion Joints In-depth Webinar

U.S. Bellows, Inc. Worldwide Leader in Metallic and Fabric Expansion Joints ▫ Fast Turnaround ▫ Repair ▫ Replace ▫ Refurbish ▫ Quick Delivery ▫

Introduction to U.S. Bellows
Pioneer in expansion joints, in business since the 1960’s
Joined the PT&P Family in 1995
5x the resources: PT&P, SWECO, Pipe Shields and Fronek Anchor Darling
Better location next to the Houston Ship Channel (one of the largest ports in the U.S. and in the world)
U.S. Bellows got a further shot in the arm with the acquisition of RM Engineered Products
Manufacturing Facility
More than 450,000 sq/ft of covered shop space
35 acre property
Continuing to expand

Certification / Membership
EJMA Member
Approx. 10 years now!
Representation on:
Technical Committee (Roy Felkner, Rakesh Agrawal)
Management committee (Durga Agrawal, Rakesh Agrawal)
EJMA Technical Committee Meeting (Barcelona, November 2009)

Certification / Membership
ASME U-Stamp, R-Stamp and NS Certified
Minority Business Enterprise
Houston Minority Business Council
ISO 9001:2008
ASME Section IX
AWS D1.1
MIL-STD-248
Manufacturing Qualifications QA / QC Approval
UOP
GE / Stewart and Stevenson

Quality Control / Assurance
Get all materials together and perform MTR’s (Material Test Report) - Check the following:
Material Thickness
Material Grade, etc.
If required, perform a PMI (Positive Material Identification) test
Weld the bellows can and perform a dye-penetrant test on the long seam
If required, x-ray test the bellows and/or pipe spool and pieces
If the tests are good, next punch the bellows and perform a dye penetrant test
Weld the punched bellows to the spool and/or flanges - (referred to as the attachment weld) and perform a dye penetrant test on the attachment welds
If required, perform a pneumatic test, vacuum test, and/or a hydro-test
Final Dimension Inspection - Check over the entire assembly:
overall length
diameters
cosmetics
accessories
tags, etc.
Bellows QC Process SASOL Quality Assurance Plan
100% x-ray
100% dye pen
Hydro-test
Pneumatic Test
Positive Material Identification (PMI)
Specific SASOL paint procedures

Experienced Manufacturer
In-house Training
Welding School
JQ & QC Training Courses
Expansion Joint Application Classes
Expansion Joint Fabrication Classes
Continuous Improvement Courses
Since the 1960’s

U.S. Bellows Team
Combined experience of 600+ years
35 Manufacturing (500+ years)
6 Engineering (100+ years)
3 Field Service (75+ years)
2 Shifts – Day and Night
John Demusz Manager of U.S. Bellows Manuel Perez U.S. Bellows Production Manager Dennis Satorre U.S. Bellows Scheduler/Planner

The U.S. Bellows Team Scott Runge Engineer Aydin Eyup Engineer Chaitanya Deekonda Engineer Vilson Joseph Engineer

The U.S. Bellows Team Linda Cai CAD Operator Ronald Rogers CAD Operator Hank Lippold Quality Control Manager David Forman Quality Control: Expansion Joints

The U.S. Bellows Team

Manufacturing Capabilities
2” to 138” in Diameter
.010” to .500” Wall Thickness
Stock Bellows
Stock Material
Stock Machines

Sub ARC Welding
Up to 96” Long Seam
Up to 10’ Round Seam
20 High Frequency TIG Welding Machines
Electronic Eye Burning Table
Capacity for 3 Acetylene Torches
3 Plasma Cut Machines
SS from ¼” to 1-½”
Shear (10’ Wide)
Up to ⅛”
Drill Press
Vertical Saw
Pipe Expander
75 ton capacity
Manufacturing Capabilities Equipment
Long Seam Welding Machine
2” to 6” dia. x 24” max. long can
Plate Roll Machines
2” dia. x 24” max. long can, < 18 ga. thick
3” to 6” dia. x 36” max. long can, < ⅛” ga. thick
6” to 120” dia. x 65” max. long can, < ⅛” ga.
10” to 12’ dia. x 75” max. long can, < ⅝ ga.
Punch Machines
2” to 2-1/2” dia.
3” to 5” dia.
6” to 30” dia.
24” to 120” dia.
3 Reroll Machines (2” to 120” dia.)
2 Horizontal Lathe (up to 30” O.D.)
Vertical Turret Lathe (up to 77” O.D.)
Mill Machine (36” x 24” table)

Bellows Materials Based on operating temperature + media + pressure requirements + desired life cycle
300 Series Stainless Steel (any type of general service: H=high temperature, L=low carbon content)
304, 604L, 304H, 316, 316L, 316H and 321
High Nickel Materials
Monel 400 (sea water, high corrosive) and Inconel 600 (seawater/marine)
Inconel 625 LCF (low cycle fatigue): oil refineries & chemical plants in high temperature service due to high strength at high temperatures
Hastelloy C-276 (highly corrosive service – destruction of toxic gasses, sulphuric acid plants)
Incoloy 800 / 800H and 825 (high temperature applications)

Materials:
Single layer PTFE: temperatures up to 600°F
3-layer Belt and Insulation Pillow: temperatures up to 2,000°F
Inside Layer: 100% fiberglass, coated with an aluminum compound on both sides
Middle Layer: ½” thick KO wool
Outside Layer: PTFE fiberglass reinforced
Capacity: 40’ Length and 20’ Wide
Fabric Expansion Joints Duct Expansion Joint – Low Temperature Duct Expansion Joint – High Temperature (up to 1200°F) 10’ square fabric expansion joint w/ high temp. and corrosion resistant composite belt

GE Standard:
Liner and flange used to be 2 pieces
We combined the liner and flange into one piece
As result, there is less welding for us and a smoother flow in the duct work for them
Fabric Expansion Joints

24/7 Quick Turn Service
Emergency?
On-call team… available 24/7
Online emergency form with a guaranteed response time within 30 minutes
Stock bellows for quick assembly
Same Day Turn-around 2-Day Emergency Repair 3-Day Refurbishment

Expansion Joint Emergency Quick turnaround on a refurbishment of a 54 " pressure balanced elbow turbine crossover expansion joint for a power generation plant.

Quality & Product Testing
Magnet Particle
Ultrasonic
Radiography
PMI Test
Pneumatic
Dye Penetrant Hydrostatic Helium Leak Fatigue Burst

Engineering & Design Finite Element Analysis (FEA) CAESAR CFD Analysis / Pipe Stress

Redesigned with turning vanes to that redirect the flow steam, creating a smother flow, eliminating vibration impact on the bellows
CFD Analysis to determine the design of the turning vanes
321 SS bellows and liner and air and soap tested
Expansion Joint – CFD Analysis 60" Pressure Balanced Expansion Joint with Turning Vanes Drawing on Next Slide 

Expansion Joint – CFD Analysis Drawing: 60" Pressure Balanced Expansion Joint with Turning Vanes

Expansion Joint – Ansys FEA 36" and 18" Dual Hinged Expansion Joints Portion of 36 " Bellows Assembly Portion of 18 " Bellows Assembly FEA on the connection of the tie rods to the bellows. The tie rods are connected to a plate-gusset assembly, which is welded to the bellows. Stresses in the Plate-Gusset Assembly Stresses in the Tie Rod Plate

Expansion Joint – CAESAR Universal Pressure Balanced Expansion Joint Drawing on Next Slide 

Expansion Joint – CAESAR Drawing: Universal Pressure Balanced Expansion Joint

Expansion Joint – Refractory-lined
Clean Fuels Project
Inconel 625 LCF bellows
ASTM A-516 GR 70 Carbon Steel shell
Insulating and abrasion resistant refractory
Pressure tested with air at 15 PSIG
63" In-line Pressure Balanced Expansion Joint Drawing on Next Slide 

Expansion Joint – Refractory-lined Drawing: 63" In-line Pressure Balanced Expansion Joint

Cut-out Section Refractory-lined Expansion Joint Model

Expansion Joint Universal Hinged Expansion Joint
92” diameter
304 SS bellows
Designed for 100 PSIG at 300°F
Water Treatment Facility Drawing on Next Slide 

Expansion Joint Drawing: Universal Hinged Expansion Joint

Expansion Joint Tied Universal Expansion Joint with 45 Degree Mitered Elbow Installation in a Flue Gas System Drawing on Next Slide 

Expansion Joint Drawing: Tied Universal Expansion Joint with 45 Degree Mitered Elbow

Duct Work Prior to Painting the Duct Work Acid Plant

Duct Work 72" Diameter Drawing on Next Slide 

Duct Work - Drawing

Duct Work Drawing on Next Slide 

Duct Work – Drawing

Case Study Problems with Bellows Attachment Welds

Case Study Field Installation Problem

Technical Information Featured Projects Pictures and Project Details Webinar Registration Details on Upcoming Webinars Quick Access to U.S. Bellows Online Quote System Emergency Service Online Catalogs Downloadable Software E-NEWS Webinars (Twice a Month!) Technical Presentations On-line, at no cost Team of Experts On stand-by to answer questions

Thank You!

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Expansion Joints In-depth Webinar

by Piping Technology & Products, Inc. on Mar 16, 2011

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Expansion Joints In-depth Webinar — Presentation Transcript