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f Corract selection and installation of
J
l expansion joints will add years to their
f service life
. Dick Pengelly, Vokes Ltd., Guildford, England
I
! T,\.ELVE PERCENT IS the generally accepted figure of
, capil:t! expenditure for piping systems in the hydrocarbon
l processing industry. Expansion joints are used extensively
! to provide flexibility for vibration and thennal expansion.
, Proper selection and installation of expansion joints will
l add years to their service life.
; Historically, problems due to thermal expansion were
! solved by the use of loops. Earl: systems developed into
! more sophisticated standard design loop systems. Further
l developments led to the use of bellows expansion joints
j incc,[)Orating multi-ply designs.
! construction is the best technical compromise
1
between the requirements of pressure containment (thick
wa][ shallow convolution) and high flexibility (thin wall
deep convolution). The force required to deflect a con-
volution increases with the cube of the thickness. A num-
ber of individual thinner walls provides the strength
required for pressure containment without sacrificing
flexibility.
Although bellows are used in "sealed" types of appli-
catic;1s, such as valves, this article concentrates on thermal
expansion absorbers (pipe line and vessel applications)
and flexible connectors (exhaust systems).
Flexible connectors applied in the past to both flexible
hose and expansion joints. In this article we include
rnanifolds, interconnecting and uptake bellows (Fig. 2)
and gas turbine exhaust units. Cnits within this range
are generally designed for low pressure, medium/high
lernperatme applications, e.g. 1 at 450 C, al-
thou:!: the 300 series stainless steel convolution material
sene:::J.lly used in this application can operate successfully
'.lp to a maximum temperature oi 650 C.
The multi-ply design is widely used in flexible con-
nectors providing the following features:
...._The stability of multi-ply construction absorbs low
arnplitude high frequency vibr:J.tion, associated with these
flvnRocARBON PRocEssiNG :\farch 1978
applications, and eliminates "vibration in sympathy"
which leads to fatigue failure in single-ply thick wall units.
..... Lateral movement across the axis of the unit can be
better absorbed. This is particularly important in appli-
cations on exhaust engine manifolds where misalignment
on assembly, particularly at the engine refurbishing stage,
is a common occurrence.
..,.. The multi-ply design provides low flexure stress within
the convolution resulting in extended life.
Piping/vessel applications. Stock units range from
simple single axial bellows 32mm-300mm N.B. for heating
and ventilating, to 4.5m dia. units for steel works furnace
gas mams.
Basic types of expansion joints range from simple
single units to complex restrained units suitable for com-
bined movements. Pressure vessels and heat exchangers
generally use simple unrestrained single units to absorb
differential expansion/contraction between shells. As an
example, one such unit uses an expansion joint 1,800mm
in diameter with design conditions of 37 at
335 C. In this example the shell at the expansion joint
is approximately 35mm thick. The complete expansion
joint assembly with end fittings is pressure tested at
50 at the expansion joint manufacturers' works.
This test will be repeated on the final assembled vessel,
including expansion joints.
This assembly, although the simplest type of expansion
joint, requires maximum attention to all details during
manufacture, assembly, testing and installation as the
complete vessel is basically built around the convolution
section. Failure or malfunction of the expansion joint
would most likely result m a major strip down of the
complete vesseL
End fittings ha\e to be designed to suit customer
mating equipment whether the unit is supplied in flanged
or pipe-ended form. Final assembly of the unit between
the end fittings is generally left to the expansion joint
supplier who will fit standard design convolutions within
the overall frame work wherever possible. Standard con-
volutions are theoretically designed by computer and
tested on destruction fatigue rigs to ensure safety. De-
signs are compared with established standards within the
141
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SELECT EXPANSION JOINTS PROPERLY
industry, e.g. Esso, Kellogg, EJMA etc., as customers gen-
erally refer to these standards.
Theoretical fatigue life requirements, requested by
customers, are considered against theoreticaljpractical re-
sults to give standard unit movement. A simple calcula-
tion then gives the permissible movement for the re-
quired life cycles. In this way cyclic life variations of
any magnitude can be designed. Basically designs show-
ing life cycles in excess of 1,000,000 are termed infinite
life.
Selection. Expansion joint suppliers prefer to discuss
applications at a very early stage of system design, prior
to the finalization of full piping runs, vessel siting, p1inth
positions, anchor positions, etc. Early planning can result
in greater use of standard units offering advantageous
price and delivery. Early planning also insures that custom
designed units, such as the pressure balanced type shown
in Fig. 1, are delivered when needed.
The specified cyclic life of an expansion joint must not
be an assumption. Investigations of plant operation and
design life can usually provide reasonably accurate figures.
Theoretical life cycle requirements and safety factors for
all expansion joints should be listed by the piping/stress
engineers. In this way the supplier can recommend the
use of standard design convolutions where possible.
Examples are readily available where an "estimated"
life requirement has been increased at each stage of plant
design resulting in an unpractical and costly specification.
Discussion with experts can reduce this possibility. Two
standards, hinged or gimbal units, can replace an unwieldy
Twin-Tied unit with a saving in transport cost. For large
diameter exhaust ducting two standard single units can
often replace a very long Twin.
Assuming that the basic information has been assessed,
(diameter, pressure, temperature, media cyclic life, etc.)
the selection of convolution material and type can begin.
First consideration should be given to the general type of
unit to be used (i.e. restrained or unrestrained) . This
consideration is determined by a number of factors but
the main one is working pressure.
Fig. 1-Axial pressure balanced units designed to fit into a
tight system where space is restricted.
142
Historically, externally reinforced comolutions were
used in medium/high pressure applications, but the use
of this specific type of convolution is now restricted due
to the added complication of relying on rings positioned
in the base of the convolution to resist the pressure within
the system.
Examples of unit types catagorized by pressu;-(' are
shown in Fig. 2, Table 1. .\s a rule expansion
operating at pressures below 2 are of the twin
unrestrained type to accept combined axial and latera}
movement. The Twin-Tied type units of two or three tie
bars can be used for working pressures up to 10 Kg/cm2.
Hinged and gimbal type units are used above this pres-
sure. It is important to note that the Twin-Tied/Two-Tie
bar unit has the added feature of allowing slight angula-
tion (approximately 3) of the end flange in additirll1 to
combined lateral movement. This can be part:n; Ltrly
important in systems having elbows other than 90Cl or
where the system angles slightly (i.e. the base of a tank).
Consideration of siting anchors is of importance as this
will determine thermal movement and divides the system
into a number of simpler pipe runs. Normally major
items of equipment such as pumps, compressors, heat
exchangers, turbines etc. will be main anchors. It is
essential that the movement, and therefore the !nJ.uing,
is not "pushed" tm,ards these as they are the major
connections to be protected within the system. Vnre-
strained units tend to be cheaper than restrained ones.
Restrained units do have the ad\antage of reducing the
number of anchors and guides so the overall system may
be Jess expensive even though the individual expansion
joints are higher priced.
In taking the basic steps described, systems will gen-
erally fall into a fairly small range. Involving e:-::J:msion
joint manufacturers at all stages of selection is bcne:lcial
to a project.
Materials. The. 300 of Austenitic stainless steels
have long forming convolution sections.
Individual manufacturers choose the 321, 316 or 304
types of material. This range, however, is prone to pitting
and oorrosion when
used in chio;iae or 'sulfur laden environments there
fore it is essential to consider not only the medi: p:1'sing
through the expansion joint, but also the atrn,,sphcrr
around the system.
Fortunately other materials are available for use in
these conditions, each with varying temperature limita
tions. lncoloy 825 is suitable for this environment up to
a temperature of 4SOO C, and Incoloy 800 'is suitable for
temperatures around 800 C depending on working pres
sure and movement.
It is possible, in certain applications, to reduce pitting
corrosion by keeping the convolution temperature above
t in a
dewpoint. Steam tracers can be used to mama .
minimum continuous temperature. The additional cost !S
often offset by less use of expensive corrosion resistant
materials.
March 1978
srr:G
HYDROCARBON PROCES
Fi
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) im;
Installation techniques. All units arnvmg at a site
should be fitted with external convolution protection
shrouds and temporary sizing bars, whether supplied
free length or cold set. End fittings should also be covered
to prevent entry of dirt.
Unloading of equipment should be done with care to
ensure that slings are not positioned around the convolu-
tions or the protection shrouds. It is advisable to design
permanent lifting lugs, holes on flanges or restraint
carriers for units weighing in excess of 60 Kg. This
will reduce bad slinging and mishandling by slinging
from tie bars. Ample labelling should be placed on all
units detailing lifting positions, temporary sizing bars,
design drawing number, serial number and the manu-
facturers name, address and telephone number.
It is essential that full up-dated drawings of the ex-
pansion joints are held on site for easy reference. The
manufacturer should be advised of any changes in site
operating conditions that could effect expansion joints.
All units should be installed with the convolutions pro-
tected and the temporary sizing bars in place.
Not more than one unrestrained unit should be posi-
tioned between two anchor points. This rule virtually
applies without exception and ensures that the system
does not become unstable due to pressure thrust on elbows

Comments
tLe
I
Type of Normal Application (All units manufactured from series 300 stainless steels will
1m expansion pressure normally operate from- 160 to + 650 C and units
joint range manufactured from lnco/oy 825 from -160 to+ 450 C.)
!0!1

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14
1l
Axial
Twin
Two tier
bar
twin tied
Three tie
bar
twin tied
Hinged
Gimbal
Pressure
balanced
A Full vacuum to Straight pipe runs, exhaust
40 kg/em' depend- systems. Axial movement only.
B
c
D
E
F
G
H
ing on joint diameter
Full vacuum to
2 kg/em'
Full vacuum to
10 kg/em'
Full vacuum to
10 kg/em'
Full vacuum to
40 kg/em'
Full vacuum to
40 kg/em'
Full vacuum to
10 kg/em'
Low pressure systems using a
combination of axial and lateral
movement. Exhaust lines, low
pressure heating lines.
Tank settlement and bulge and
pipe growth. Lateral movement
with angulation of end flanges
to absorb combined
movements.
Similar to two tie bar unit but
suitable for lateral movement
only. Tank settlement and
bulge and pipe growth.
Normally used in pairs or
threes on higher pressure
systems where guiding has to
be minimal.
Used in pairs or threes on high
pressure systems. Suitable for
angular movement on any
plane.
Fitted generally on pipe elbows
to balance both pressure thrust
and spring rate. Particularly
useful in conjunction with
delicate equipment such as
turbines.
HYDROCARBON PROCESSING
March 1978
This is the simplist type of expansion joint but other than with
exhaust low pressure (max. 2 kg/em') applications to use it
correctly it must have the pipe anchored and guided either side
of the unit. Anchors must be substantial enough to withstand
the axial spring rate and pressure end thrust. For example
a 150 mm NB bellows compressed to full movement at 21 kg
produces an anchor load of approx. 6 tonnes.
Twin bellows can absorb lateral movement with a limited amount
of axial movement. This type of unit transfers the pressure
thrust into the pipework system and suitable guides are
essential. Where large twin units are used, some additional
support of the center tube may be necessary.
This is the cheapest form of restrained unit. Lateral movement
with angulation of end flanges to absorb combined movements.
Pressure thrust contained within the tie bars with vacuum
loadings controlled by the limit tubes on tie bars. Anchors are
therefore generally reduced or eliminated.
These units absorb lateral movement on two planes but with no
angulation of end flanges.
Suitable for angular movement in one plane only. These are
very robust units with hinges in double shear.
Particularly advantageous where combined large movements
are present as spacing of units can reduce angulation and
therefore increase life. Both gimbal and hinged units have
limit stops fitted, thereby eliminating the need for intermediate
anchors.
This type of unit has main advantages in tight pipework systems
where combined movements are present and terminal loads
have to be kept low.
143
!
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SELECT EXPANSION JOINTS PROPERLY
etc; and that convolutions with lower spring rate are not
subjected to more than design movement.
Anchors should be designed with a safety factor to
accept total loading due to the following:
1. The force required to compress or extend the convolu-
tion the calculated amount (i.e. spring rate times
movement)
2. System working pressure times expansion joint effec-
tive cross section area (i.e. pressure thrust)
3. Frictional resistance due to the total system guides
4. Centrifugal thrust due to the flow of media when the
anchor is situated at a pipe elbow.
Generally items 1 and 2 are by far the largest. In
addition to the above, anchors might have to be designed
to accept additional stresses such as shock loads, wind
loads, pipe/vessel weights and system pressure tests.
Accurate guiding of the systems (Fig. 3) is essential
especially where unrestrained units are used. Expansion
joint manufacturers can recommend a variety of simple
and planar guides. Each manufacturer will have specific
recommendations regarding position of these guides, but
as a general rule, guides should allow sufficient clearance
between pipe and fixtures to ensure positive guiding with-
out excessive frictional loads.
Position of pipe guides close to the expansion joint
is most critical. The first guide should be located a
maximum of four pipe diameters from the expansion
joint and the second a maximum of 14 pipe diameters
from the first. Intermediate guides should be positioned
within the maximum distances recommended by the
expansion joint manufacturer. Expansion joints should
be positioned at least four pipe diameters from valves,
dampers, reducers etc. and not be used to correct pipe
misalignment unless specifically designed to do so.
Next is the installation of the expansion joint with the
following precautions:
Protect convolutions from weld spatter by use of heat
resistant materials or anti-splatter grease
Fig. 3-Well guided unrestrained single expansion joint show-
ing the first guides close to the expansion joint.
144
Fig. 4-Multi-Tie Bar tw:n unit fitted into a petrochemica' flare
gas system.
Check that the flow arrm, marked on the unit coin.
cides with the direction of the main pipe line flow
Check that the insulation is chloride free and it does
not come in contact with comolutions. This is pre\entecl
by the fitting of external protection shrouds
Check that the system is correctly filled and \cntccl
in order to remove all air from the line before
site pressure tests
Check that the convolution does not come in contact
with paint on the pipe end as this can cause corrosion. Zir11
embrittlernent of stainless steel operating at ele\ated tcnr
peratures is a known hazard.
After installation, the unit should be chrckcd
thoroughly for damage, particularly in the conmlution
area. If checks are satisfactory, the temporary in,tall.rtion
bars can be removed.
Cause of failures. The maJonty of site failures ocrur
within the first few months of installation. A few of tl11
causes are:
Corrosion due to use of incorrect convolution material.
resulting in cracking
Incorrect installation, either due to inadequat': :L:rdwrs
guides or the unit being due to pi;in;.: crro;.,
with torsional twist. This will drastically reduce tile eye::
life of any expansion joint
Site damage to the comolution, another reason f,:
the fitting of production shrouds
d
. l
Vibration in the system which has not been pre
1
cte-c:
Once these problems ha\'e been overcome, a multi-?:;
bellows expansion joint normally gives long
free life.
The object of economic plant design should
be to design equipment for full plant life whether
11
.
three or thirty years. Expansion joints are no
and will give satisfactory life in the majority o.f
cations if the basic rules, mentioned in this arocle, .ll
11
obeyed.
March 1978
HYDROCARBON PRoct:ssJ!(':
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