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10/17/2013

U.S. Bellows, Inc.


presents:

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U.S. Bellows, Inc.

Presenter

John T. Demusz
Manager US Bellows, Inc.

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10/17/2013

U.S. Bellows, Inc.

Certifications

Manufacturing Facility

EJMA Member

ASME U-Stamp

ASME R-Stamp

ASME NS Certified

ISO 9001:2008 Certified

Minority Business Enterprise


(MBE) by City of Houston

Houston Minority Business


Council (HMBC)

Houston, Texas USA

450,000 Square Feet of Covered


Shop Space on a 35 Acre
Property

Located Near the Port of Houston

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EJMA Members

CodeCalc program snapshot


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10/17/2013

U.S. Bellows, Inc.

Expansion Joint

Metallic

Fabric

Rubber

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U.S. Bellows, Inc.

Fossil Fuel
Power Plant

Chemical &
Petrochemical

Stationary Engine
Exhaust

Pulp & Paper

Power

Heat
Exchangers

Municipal Water
Districts

Aerospace Turbo
Engine Exhaust

District
Energy

FCC Units

Waste Water
Treatment

Truck Exhaust

Gas Turbines

U.S. Navy

Solid Waste
Incineration

Heavy Metal

Steam
Distribution

Kilns

Environmental
Applications

Marine Piping &


Exhaust

Geothermal
Power Plants

Furnace Sealing
Bags

Liquefied Natural
Gas (LNG) Service

Refinery

Research &
Development

HVAC Building
Heating & Cooling
Systems

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10/17/2013

U.S. Bellows, Inc.

O Introduction
O Pipe & Duct Movement
O Metallic vs. Fabric
O Expansion Joints
O Metal
O Fabric

O Expansion Joint Failures


O Maintenance
O Conclusion

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Chemical Plant

Power Plant

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U.S. Bellows, Inc.

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U.S. Bellows, Inc.

O A flexible

assembly, that
includes a metallic,
fabric or rubber
flexible component,
that will be installed
into a pipe, tube or
duct.

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10/17/2013

U.S. Bellows, Inc.

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U.S. Bellows, Inc.

Complexity

Movement

Simple

Semi
Complex

None

Moves up &
down a little bit

Really
Complex

Moves in all
directions,
vibrates, & large
movements

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U.S. Bellows, Inc.

OUTSIDE
DIAMETER

INSIDE DIAMETER

WALL THICKNESS

LIVE-LENGTH OF
BELLOWS

PITCH

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U.S. Bellows, Inc.

Axial Movement

Lateral Movement

Angular Movement

Torsional Movement

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10/17/2013

U.S. Bellows, Inc.

Gimbal Expansion Joint

Tied Single Expansion Joint

Expansion Joint Movement

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U.S. Bellows, Inc.

Universal Expansion Joint


Tied Universal Expansion Joint

Hinged Universal Expansion Joint

Single Expansion Joint

Slotted Hinged Expansion Joint

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10/17/2013

U.S. Bellows, Inc.

O Pipe diameter
O Type of media
O Flow media rate
O Type & amount of movement

O End fittings & extra components


O Design Pressure
O Design Temperature
O Service conditions

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U.S. Bellows, Inc.

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10/17/2013

U.S. Bellows, Inc.

Metallic
Expansion Joints

Fabric Expansion
Joints

Design Time

1-2 days

1-2 days

Project Time

8 weeks

8 weeks

Fabrication
Complexity

Complicated

Moderately
complicated

Engineer Time
Alotted

Takes more time

Takes less time

Other

Customer
Approval,

Customer
Approval

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U.S. Bellows, Inc.

Depending on the style or design of a bellows, wall


thicknesses may range from:
.010 TO .500 wall with varying
number of plies in the various alloys

STAINLESS STEEL T-321, T-316, L & H, T-304, L &H


MONEL 400
INCONEL 625
INCONEL 625 LCF
INCOLOY 800
INCOLOY 825
HASTELLOY C-276
TITANIUM

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10/17/2013

U.S. Bellows, Inc.

The original
piece of steel

Creation of the
convolutions/bell
ows

The reroll
process of the
bellows

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10/17/2013

U.S. Bellows, Inc.

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U.S. Bellows, Inc.

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10/17/2013

U.S. Bellows, Inc.

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U.S. Bellows, Inc.

O THE LOAD IN POUNDS REQUIRED TO COMPRESS A

BELLOWS ONE INCH (lb/in).

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10/17/2013

U.S. Bellows, Inc.

Burst Test

Dye Penetration Testing

Hydrostatic Testing
Magnetic Particle
Ultrasonic
Cycle Test
Burst Test
Helium Leak Detection
Liquid Penetrant
Inspection
Radiography Test
Positive Material
Identification (PMI) Test
Pneumatic Testing
Spring Rate Testing
Fatigue Testing

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U.S. Bellows, Inc.

Stresses
Temperature Change
Repetitive Mechanical
Movements
Vibrations
Cycle Test on a 12" diameter A240-321SS Bellows with 8 convolutions.
The bellows has met the EMJA cycle life calculation of 1,000 cycles and
failed in the root of the convolutions at 1,285 cycles.

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10/17/2013

U.S. Bellows, Inc.

Limit Rods

It is sometimes desirable to limit the axial expansion or compression


of the expansion joint. Limit rods, shown above, provide freedom of
movement over a range determined by the location of nut stops along
the rods. In the event of a main anchor failure, limit rods are designed
to prevent bellows over-extension while restraining the full pressure
thrust of the system.

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24" In-line Pressure Balanced Expansion Joints designed for 175


PSIG and 610F for a petrochemical plant in Venezuela

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10/17/2013

U.S. Bellows, Inc.

Pressure Balanced Elbow


Expansion Joints designed for 150
PSIG and 450F for a 42" steam line

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U.S. Bellows, Inc.

36" Pressure Balanced Elbow Expansion Joints

54" Pressure
Balanced Elbow
Turbine Crossover
Expansion Joint
(Refurbished)

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10/17/2013

U.S. Bellows, Inc.

Universal Expansion Joint


Single Expansion Joints

Tied Universal Expansion Joint


Tied Universal Expansion Joint
with Stainless Steel Flanges

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U.S. Bellows, Inc.

55" O.D. Double Gimbal Universal Expansion Joint for an FCC Unit.
The expansion joint is equipped with floating rings and Inco 625 LCF bellows.

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10/17/2013

U.S. Bellows, Inc.

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U.S. Bellows, Inc.

44" Universal Refractory


Lined Expansion Joint
designed for 30 PSIG and
1400F

70" Tied Universal


Expansion Joint designed
for 51 PSIG and 1460F

36" Double Hinged


Expansion Joint
designed for 50 PSIG
and 1000F

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10/17/2013

U.S. Bellows, Inc.

Protective Covers & Internal Liners

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U.S. Bellows, Inc.

* Ability to absorb large mounts of axial travel

* Pressure is applied externally to the bellows

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10/17/2013

U.S. Bellows, Inc.

Thick Wall Metallic Expansion


Joint

108" Diameter Thick Wall Expansion


Joint (with 2 convolutions)

Rectangular Expansion Joint

71" x 143" Round Corner Regular


Expansion Joint for an oil refinery in India

78" I.D. x 100" O.D. Thick Wall Expansion


Joint

Rectangular Metallic
Expansion Joint
240" x 80" and 157" x 65"

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U.S. Bellows, Inc.

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10/17/2013

U.S. Bellows, Inc.

Metallic

Fabric

Cryogenic high temps.

High temperatures

Flexible element - bellows

Flexible element - fabric belt

High pressure services

Low pressure services

Maintenance free

Minimal maintenance

Timely repair & preset

Easy repair & preset

Limited movement

More movement

Limited size restraints

No size restraints

Non-combustible

Combustible

No torsional movement

Torsional movement

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Standard Fabric Expansion Joint

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10/17/2013

U.S. Bellows, Inc.

Fabric
Belt

Metal
Frame
Fabric EJ on
attached to duct
work

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U.S. Bellows, Inc.

Reinforced Silicone
Fabric
Temperature

PTFE Coated Glass


Cloth

Aluminized Glass
Cloth

Chemical
Resistance

Applications

Medium

High

Hot and Cold Water, Low


Pressure Steam, Neutral
Solutions

Resistant to deterioration by
weathering and engine oil
remains, UV / ozone / fungus
resistant

Low

High

Gaskets or Seals,
Recirculation Air, Air Intake

PTFE Impregnated Fiberglass,


PTFE Coated Glass Cloth

High tear / crease resistant,


Smooth / low friction / nonstick surface / high tensile
strength

Low

Medium

Exhaust Ventilation, Fume


Protection, Gaskets or Seals

Silica Fabric Cloth

High abrasion resistance,


Won't rot or mildew

Low

Low

Boiler Exhaust

Low

Low

Furnaces,
Kilns

Materials

Advantages

Low
Ambient - 250F

Butyl Rubber, Neoprene, Viton

High tensile strength,


Ozone and weathering
resistance

Medium
250 - 500F

Fiberglass, Reinforced Silicone

High
500 - 700F

High
700 - 1000F
High
1000 - 1800F
*3-layer

Silica Oxide Glass


Cloth

Silica/PTFE Fabric with Kaowool,


Excellent resistance to
Aluminized Glass Cloth with
chemicals, High temperature
Kaowool & PTFE
stability

Pressure

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10/17/2013

U.S. Bellows, Inc.

FD Fan to Air Preheater


Air Preheater to Boiler
Air Preheater to Pulverizer
Air Preheater to Inlet from
Boiler
Air Preheater to
Precipitator or Bag house
Precipitator or Bag house
to ID Fan
ID Fan to Scrubber
Scrubber to Stack

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High Temperature 3-Layer Expansion Joint

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10/17/2013

U.S. Bellows, Inc.

High-Temp 23 " I.D. Fabric Expansion Joint

Stitching the Fabric Belt on the 1st Layer

128" x 229" Rectangular Fabric Expansion Joint


(Includes a Three Layer Belt)

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Emergency Response

Same-Day Emergency Service on an 8" Single Expansion Joint

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10/17/2013

U.S. Bellows, Inc.

Engineering and Design


O Piping, pipe support and

structural design

O 3D modeling technology
O Pipe Stress Analysis
O ANSYS

O Finite Element Analysis


O

Special stress/thermal problems

Pro/E for 3-D Part Design

ANSYS for Mesh Generation


+ Analysis + Results Analysis

O Field Testing

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U.S. Bellows, Inc.

Please forward any additional questions or inquiries to us at


sales@usbellows.com, call us at 877-660-1795 or visit our
website at www.usbellows.com

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