Академический Документы
Профессиональный Документы
Культура Документы
LONESTAR
WARM GREETINGS
LONESTAR INDUSTRIES
LONESTAR
Presentation
By
R.V. RAMACHANDRAN
TOPICS
Let us consider the stress due to the movement and thermal expansion.
The stress on the wall of the piping is related to the force or movement
exerted on it by external restraints.
When either the values of the stresses or the values of the external forces
or moments exceed the maximum allowable values, the flexibility of the
pipe must be increased artificially.
This can be done either by altering the layout of the pipe or by inserting
high flexibility section into it.
Bellows
Movement
Axial Movement
Movement
Lateral Deflection
z The relative displacement two end of the Expansion Joint,
perpendicular to its axis due to thermal expansion / contraction of
the pipe
BASICS
Movement
Angular Rotation
z The Rotational displacement of the longitudinal axis from its initial
straight line position into a circular arc.
BASICS
Movement
Torsional Rotation
z The twisting of one end of the Expansion Joint with respect to
the other end about its axis.
BASICS
Pressure Thrust
z Since a pipe under internal pressure or vacuum will have its wall
subjected to circumferential and longitudinal loading, introducing a
discontinuous member such as a Bellows will transfer the
longitudinal-pressure forces to the main anchors.
z Pressure thrust is the product of internal pressure times the Bellows
effective area.
BASICS
z The effective area / pressure thrust area of a Bellows is based on the mean diameter of the
Bellows convolutions.
z If adequate main anchors cannot be provided to absorb the pressure thrust or if connected
equipment cannot accept the pressure thrust loading then the joint must be equipped with tie
bars. However a tie rod equipped Bellows cannot absorb the axial movement.
z If no main anchors are present, the bellows cannot absorb the pressure loading without ripping
open; in the case of vacuum loading, the joint would collapse.
BASICS
Spring Rate
Stability
Column in-stability
Inplane in-stability
Bellows - Categories
Un-reinforced Bellows
Bellows - Categories
Reinforced
z TIED SINGLE
z TIED UNIVERSAL
z HINGED
z GIMBAL
z This is achieved by tie rod restraints which connects the Line Bellows
and an Opposite Balancing Bellows subjected to the line pressure
z 2 – Ply Construction
Control Rods
Limit Rods
Pantograph Linkages
z A scissors-like device
z Primary function is to positively distribute the movement equally
between the two Bellows of the Universal Expansion Joint
throughout its full range of movement.
z Pantograph linkages are not designed to restrain pressure thrust.
EXPANSION JOINT – ACCESSORIES
Internal Sleeve
z A cylindrical body welded inside the Expansion Joint, one end free
to allow the Bellows to move
EXPANSION JOINT - ACCESSORIES
to prevent the erosion of Bellows by flow medium containing solid particles, catalyst etc
to facilitate packing to prevent the entry of undesired elements in the flow medium
to facilitate insulation to bring down high the flow medium temperature to the required level
EXPANSION JOINT – ACCESSORIES
Purge Connection
z Whenever required they are installed
at the sealed end of each inner
sleeve of an Expansion Joint
z A liquid or gas can be injected thru
purge connection between the
Bellows and internal sleeve to keep
the area clear of erosive and
corrosive media and / or solids that
could pack the convolutions.
z Purging may be continuous or
intermittent or at start up or shut
down as required
EXPANSION JOINT – ACCESSORIES
External Shroud
z A cylindrical member to cover the Bellows
outside, removable type, made of two or three
halves
z One end fixed and other end free to allow
Bellows to move
z Facilitate for external insulation of Bellows
z Prevent the damage of Bellows
– from falling objects,
– during handling and transport
– from weld arc strike / spatter during welding
at adjoining areas
EXPANSION JOINT – ACCESSORIES
Shipping Brackets
z Brackets or Rods fixed at both sides of
a Bellows
z Generally painted in yellow colour
z Helps to maintain the Overall Length of
the Expansion Joint during
transportation, handling and installation
z They should be removed after
completion of installation of Expansion
Joint, Pipe Supports, & Guides and
prior to Pressure testing of the line
SPECIFYING A METAL EXPANSION JOINT / BELLOWS
z Movement
SPECIFYING A METAL EXPANSION JOINT / BELLOWS
Material compatibility
z Specify the Bellows material compatible for
flow medium
z Considerations to be given for,
– the possibility of Chloride ion stress Failed Bellows under
corrosion in Austenitic Stainless steel, Chloride Atmosphere
– the possibility of Caustic induced stress
corrosion in Nickel alloys
– the possibility of leaching of corrodents
from insulating materials
SPECIFYING A METAL EXPANSION JOINT / BELLOWS
Flow medium
Indicate details of flow medium such as,
Velocity,
a thicker sleeve is required if
the flow velocity is higher to
prevent the turbulence and
resonance vibration
Density,
certain flow material will settle and pack in
between the convolutions resulting in pre-
mature failure
SPECIFYING A METAL EXPANSION JOINT / BELLOWS
Composition,
Direction,
Pressure
z The system design and test pressures should be specified without
adding arbitrary safety factors.
z Excess Bellows thickness required to withstand the unrealistic
higher pressures will produce adverse effect on Bellows fatigue life
and result in Bellows design of higher stiffness.
Temperature
z Maximum, minimum and installation temperatures should be
specified accurately.
z Pre-positioning / pre-stressing of the Expansion Joint during
installation shall be required in case of significant variation in the
ambient temperature.
SPECIFYING A METAL EXPANSION JOINT / BELLOWS
Movement
Insulation
Vibration
Thick Cover
Limit Rods
z Limit rods, specifying limit rods will prevent the
Bellows from stretching out and getting
damaged in the event of failure of main
anchors.
SPECIFYING A METAL EXPANSION JOINT / BELLOWS
Lifting Lugs
Specify the Lifting lug (s) when the weight of Expansion joint exceeds
250 kgs. If more than one lug is furnished then each lug shall be
designed to carry the assembly weight.
Other details
STORAGE:
z Area
Preservation
Preservation
Do not remove the shipping brackets, they
should remain in place.
Keep the Expansion joints on horizontal flat
surface resting on weld end pipe or flange
Do not place the Bellows element directly
touching the ground
Do not keep the Expansion Joints on bare
earth.
INSTALLATION
Metal Expansion Joint / Bellows
Considerations
Inward Inspection:
Do not use wire brush, steel wool and any other abrasive tools on
Bellows. Scratches and abrasion will reduce cycle life and cause
premature failure.
INSTALLATION
Metal Expansion Joint / Bellows
Verify the opening / space into which the Expansion Joint will be
installed / slided that it does not exceed the installation tolerance
designated in the specification.
Check inside the Expansion Joint for desiccant bags or any other
material and remove the same.
Lift the Expansion Joint using the lifting lugs and position into
piping.
INSTALLATION
Metal Expansion Joint / Bellows
Cover the Bellows with chloride free fire retardant cloth in case of
Expansion Joints with Weld Ends. This will help to prevent the arc
strike, weld spatter etc., which will damage the Bellows.
Orient the Flanges of Expansion Joint so that the bolt holes are
aligned with pipeline flanges in the case of Expansion Joints with
flange ends.
Do not force / rotate the Expansion Joint to match the bolt holes of
the mating flange. This will cause torsion on the Bellows and will
severely reduce the Bellows capability and may cause premature
failure.
LINE TESTING
LINE TESTING
Some water may remain in the Bellows convolutions after the test. If this is
detrimental to the Bellows or system operation, work out the ways to
remove such water.
Do not subject the Expansion Joint to test pressure higher than the
specified.
If the system has been designed for a gas, and to be tested with water,
Check whether any provision has been made to support the dead weight.
Provide additional support due to the weight of water, if not there.
INSTALLATION
Metal Expansion Joint / Bellows
Vibration
Metal Bellows Expansion Joint is not a Vibration
Isolator.
In applications where the possibility of
vibrations – originating from rotary machines
such as Pumps, blowers etc., Metal Expansion
Joint shall be used with proper evaluation.
Metal Bellows can be used in applications
where the Vibration is of low amplitude and high
frequency.
TYPICAL CAUSES OF EXPANSION JOINT FAILURE
Vibration
Vibration
Fatigue Failure
Evaluate the total system thoroughly to specify the life of the
Expansion Joint in terms of cycles, while preparing the
specifications.
This is based on different modes of plant operation.
If the Plant operates at different modes with varying operating
conditions, the cyclic requirements based on each operating
conditions should be specified.
If the specified data is based only on Normal Operating Conditions
then any Bellows designer will consider only these data for design.
In actual system operation the Bellows Expansion Joints imposed
with different modes of varying operating conditions will
prematurely fail.
TYPICAL CAUSES OF EXPANSION JOINT FAILURE
Excess Pressure
Do not operate the system at a pressure higher
than the specified design pressure.
The excessive pressure will cause higher
membrane stress resulting in reduced Bellows life.
The pressure higher than the specified pressure
will lead to Bellows Instability.
The Bellows will lose its profile /shape. The results
are reduced pressure capability, reduced
movement compensating capability and sudden
failure.
TYPICAL CAUSES OF EXPANSION JOINT FAILURE
Excess Movement
Ensure that the Bellows Expansion Joints are not imposed with higher
thermal movements than the specified value.
The higher magnitude of movement than the specified design movement
during operation will cause higher bending stresses in the Bellows
resulting in pre-mature failure.
Evaluate thoroughly for realistic thermal movement of piping and
movement of connected equipments etc.
Adding arbitrary safety factors will also result in highly flexible joint
compromising the stability or result in un-economical design.
TYPICAL CAUSES OF EXPANSION JOINT FAILURE
Improper Storage
During installation, placing the Expansion Joint with its sleeve against the
flow direction will result damage of Bellows.
The back flow will lead to buckling of sleeve and cause Bellows failure.
Arc strikes and weld spatter on Bellows from adjoining weld will damage
the Bellows.
During installation and till completion of installation cover the Bellows with
chloride free fire retardant cloth.
TYPICAL CAUSES OF EXPANSION JOINT FAILURE
Torsion
Torsional movement / rotation of Bellows is one of the important
causes of Bellows failure.
Bellows should not be subjected to torsion as the same
produce severe stress on Bellows resulting twisting and failure.
The piping system should be adequately designed to avoid the
imposition of torsion on Bellows.
The Expansion Joints will also be designed with special
hardware to restrain the Expansion Joint from absorbing the
torsion.
TYPICAL CAUSES OF EXPANSION JOINT FAILURE
Erosion
The flow medium containing the abrasive particles such as
Catalyst, Ores, Slurry etc., should clearly be defined in the
specification.
The abrasive nature of flow medium will erode the Flow Liner and
Bellows which results in failure.
A higher thickness sleeve in hardened material will be a solution in
applications where the flow medium has abrasive particles.
In some cases, a special abrasion resistant lining of inside
Expansion Joint will be considered to come out this problem.
TYPICAL CAUSES OF EXPANSION JOINT FAILURE
Corrosion
External corrosion
External corrosion
Internal corrosion
The flow medium of higher pH
will lead to inter granular
corrosion and cracking and lower
pH will result in Trans-granular
corrosion and cracking.
Hydrogen stress cracking is
another cause in aged material.
In hydrogen services, the
hydrogen is getting diffused at
areas where the hardness is
greater than 360 BHN and
results in cracking.
TYPICAL CAUSES OF EXPANSION JOINT FAILURE
Internal Corrosion
Corrosion of thin walled Bellows due
to condensation of SO2 Gas to
H2SO4 and accumulating in the
annular space between the Bellows
and Liner,
Condensation will occur because of
temperature drop due to
Sudden plant breakdown
Power failure
Exposure of Bellows outside
to cold conditions