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 6” to 120” dia. x 60” max. long can 6” to 120” dia. x 80” 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)
Manufacturing Capabilities 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)
Manufacturing Capabilities 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
Manufacturing Capabilities 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 &quot;  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&quot; Pressure Balanced Expansion Joint with Turning Vanes Drawing on Next Slide  
Expansion Joint – CFD Analysis Drawing: 60&quot; Pressure Balanced Expansion Joint with Turning Vanes
Expansion Joint – Ansys FEA  36&quot; and 18&quot;   Dual Hinged Expansion Joints Portion of 36 &quot;  Bellows Assembly Portion of 18 &quot;  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 – 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&quot; In-line Pressure Balanced Expansion Joint Drawing on Next Slide  
Expansion Joint – Refractory-lined Drawing: 63&quot; 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&quot; Diameter Drawing on Next Slide  
Duct Work - Drawing
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!

Expansion Joints In-depth Webinar

  • 1.
    U.S. Bellows, Inc.Worldwide Leader in Metallic and Fabric Expansion Joints ▫ Fast Turnaround ▫ Repair ▫ Replace ▫ Refurbish ▫ Quick Delivery ▫
  • 2.
    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
  • 3.
    Certification / MembershipEJMA 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)
  • 4.
    Certification / MembershipASME 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
  • 5.
    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
  • 6.
    Experienced Manufacturer In-houseTraining Welding School JQ & QC Training Courses Expansion Joint Application Classes Expansion Joint Fabrication Classes Continuous Improvement Courses Since the 1960’s
  • 7.
    U.S. Bellows TeamCombined 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
  • 8.
    The U.S. BellowsTeam Scott Runge Engineer Aydin Eyup Engineer Chaitanya Deekonda Engineer Vilson Joseph Engineer
  • 9.
    The U.S. BellowsTeam Linda Cai CAD Operator Ronald Rogers CAD Operator Hank Lippold Quality Control Manager David Forman Quality Control: Expansion Joints
  • 10.
  • 11.
    Manufacturing Capabilities 2”to 138” in Diameter .010” to .500” Wall Thickness Stock Bellows Stock Material Stock Machines
  • 12.
    Sub ARC WeldingUp 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 6” to 120” dia. x 60” max. long can 6” to 120” dia. x 80” 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)
  • 13.
    Manufacturing Capabilities BellowsMaterials 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)
  • 14.
    Manufacturing Capabilities 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
  • 15.
    Manufacturing Capabilities GEStandard: 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
  • 16.
    24/7 Quick TurnService 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
  • 17.
    Expansion Joint EmergencyQuick turnaround on a refurbishment of a 54 &quot; pressure balanced elbow turbine crossover expansion joint for a power generation plant.
  • 18.
    Quality & ProductTesting Magnet Particle Ultrasonic Radiography PMI Test Pneumatic Dye Penetrant Hydrostatic Helium Leak Fatigue Burst
  • 19.
    Engineering & DesignFinite Element Analysis (FEA) CAESAR CFD Analysis / Pipe Stress
  • 20.
    Redesigned with turningvanes 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&quot; Pressure Balanced Expansion Joint with Turning Vanes Drawing on Next Slide 
  • 21.
    Expansion Joint –CFD Analysis Drawing: 60&quot; Pressure Balanced Expansion Joint with Turning Vanes
  • 22.
    Expansion Joint –Ansys FEA 36&quot; and 18&quot; Dual Hinged Expansion Joints Portion of 36 &quot; Bellows Assembly Portion of 18 &quot; 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
  • 23.
    Expansion Joint –CAESAR Universal Pressure Balanced Expansion Joint Drawing on Next Slide 
  • 24.
    Expansion Joint –CAESAR Drawing: Universal Pressure Balanced Expansion Joint
  • 25.
    Expansion Joint –CAESAR Drawing: Universal Pressure Balanced Expansion Joint
  • 26.
    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&quot; In-line Pressure Balanced Expansion Joint Drawing on Next Slide 
  • 27.
    Expansion Joint –Refractory-lined Drawing: 63&quot; In-line Pressure Balanced Expansion Joint
  • 28.
    Cut-out Section Refractory-linedExpansion Joint Model
  • 29.
    Expansion Joint UniversalHinged Expansion Joint 92” diameter 304 SS bellows Designed for 100 PSIG at 300°F Water Treatment Facility Drawing on Next Slide 
  • 30.
    Expansion Joint Drawing:Universal Hinged Expansion Joint
  • 31.
    Expansion Joint TiedUniversal Expansion Joint with 45 Degree Mitered Elbow Installation in a Flue Gas System Drawing on Next Slide 
  • 32.
    Expansion Joint Drawing:Tied Universal Expansion Joint with 45 Degree Mitered Elbow
  • 33.
    Duct Work Priorto Painting the Duct Work Acid Plant
  • 34.
    Duct Work 72&quot;Diameter Drawing on Next Slide 
  • 35.
    Duct Work -Drawing
  • 36.
    Duct Work -Drawing
  • 37.
    Duct Work Drawingon Next Slide 
  • 38.
  • 39.
    Case Study Problemswith Bellows Attachment Welds
  • 40.
    Case Study FieldInstallation Problem
  • 41.
    Technical Information FeaturedProjects 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
  • 42.

Editor's Notes

  • #18 Steam Service of 97 PSIG at 634F 27’ long, 27,000 lb. Refurbished in less than 4 weeks 321 SS bellows CS root rings Dye penetrant
  • #21 job #109219
  • #22 Drawing for job #109219
  • #23 Element used was Ansys solid 187 element, a 10 node tetrahedral element 36” Bellows Assembly Plate Dimensions: 46” x 46” x 2” Tie Rod Diameter: 1” Gusset Thickness: ¾” Load per Tie Rod: 19,297 lb. Steel: A-240 tp304H Bellows Operating Temp: 1076°F Allowable Stress: 10 ksi 18” Bellows Assembly Plate Dimensions: 24-¾” x 24-¾” x 1” Tie Rod Diameter: 1” Gusset Thickness: ⅜” Load per Tie Rod: 5,443 lb. Steel: A-240 tp304H Bellows Operating Temp: 1076°F Allowable Stress: 10 ksi
  • #24 Kansas City Power &amp; Light (KCP&amp;L) Job #93183 Diameter? Material? Carbon Steel? Specs: Design conditions? -Design Temp: -Design Load:
  • #25 Drawing for job #93183
  • #27 Engineers India Limited (EIL) Job #98679
  • #30 Alberici Job #110901 Diameter: 92” 304 SS Bellows and the rest is Carbon Steel Design Temp: 100 PSIG at 300 F Tested to 150 PSIG
  • #32 Job # 94513 Diameter: 60” Length: 215” A-516 GR 70 carbon steel pipe Inconel 625 LCF bellows 100 % x-rayed and hydro-tested to 15 PSIG Specs: Design conditions? -Design Temp: -Design Load:
  • #34 Rhodia Acid Plant (Feb. 2008) Diameter? How much feet of duct work did we supply? Material? Carbon Steel? Specs: Design conditions? -Design Temp:
  • #35 Rhodia Duct Work Job #93646 Diameter? Material? Carbon Steel? Specs: Design conditions? -Design Temp: -Design Load:
  • #38 Rhodia Duct Work Job #97767 Diameter? Material? Carbon Steel? Specs: Design conditions? -Design Temp: -Design Load: