10/17/2013
U.S. Bellows, Inc. presents:
Attention Attendees: to listen to the audio portion, check that your speakers or headset are on and turned up OR dial the number and use the access code listed in your confirmation email. Attention P.E.’s: this Webinar is worth 1 PDH credit for TX P.E.’s (send request to
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U.S. Bellows, Inc.
Presenter…
John T. Demusz Manager US Bellows, Inc.
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10/17/2013
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Certifications
Manufacturing Facility
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EJMA Member
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ASME U-Stamp
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ASME R-Stamp
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ASME NS Certified
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ISO 9001:2008 Certified
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Minority Business Enterprise (MBE) by City of Houston
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Houston Minority Business Council (HMBC)
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Houston, Texas USA
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450,000 Square Feet of Covered Shop Space on a 35 Acre Property
•
Located Near the Port of Houston
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U.S. Bellows, Inc.
EJMA Members
CodeCalc program snapshot www.usbellows.com
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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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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.
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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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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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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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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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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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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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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U.S. Bellows, Inc.
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U.S. Bellows, Inc.
O
O
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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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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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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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U.S. Bellows, Inc.
24" In-line Pressure Balanced Expansion Joints designed for 175 PSIG and 610F for a petrochemical plant in Venezuela
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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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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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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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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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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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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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U.S. Bellows, Inc.
Standard Fabric Expansion Joint
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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 - 250°F
Butyl Rubber, Neoprene, Viton
High tensile strength, Ozone and weathering resistance
Medium 250 - 500°F
Fiberglass, Reinforced Silicone
High 500 - 700°F
High 700 - 1000°F High 1000 - 1800°F *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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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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U.S. Bellows, Inc.
High Temperature 3-Layer Expansion Joint
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U.S. Bellows, Inc.
High-Temp 23 ¼" 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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U.S. Bellows, Inc.
– Emergency Response
Same-Day Emergency Service on an 8" Single Expansion Joint
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10/17/2013
U.S. Bellows, Inc.
O
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
O
Pro/E for 3-D Part Design
O
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
[email protected], call us at 877-660-1795 or visit our website at www.usbellows.com
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