 LONESTAR INDUSTRIES

LONESTAR

WARM GREETINGS
  LONESTAR INDUSTRIES
LONESTAR

METAL EXPANSION JOINTS /

BELLOWS

Presentation
By
R.V. RAMACHANDRAN
TOPICS

z BASICS - BELLOWS EXPANSION JOINTS

z TYPES, SELECTION & APPLICATION

z SPECIFYING BELLOWS EXPANSION JOINTS

z TYPICAL CAUSES OF FAILURE

z STORAGE & PRESERVATION

z GOOD PRACTICES IN INSTALLATION

BASICS

BELLOWS TYPE EXPANSION JOINT

z Any device containing one or more Bellows (a flexible,

corrugated member) with End Connections
BASICS

Why an Expansion Joint?

Any pipe connecting two points is subjected to numerous types of
actions, which result in stresses on its wall.
These stresses are due to,
Internal or External pressure at working temperature,
Frequent changes in temperature or pressure,
Movement imposed on pipe section by external restraints such as
equipment rigidly connected to it,
Vibration of Equipment or Structure to which the pipe is
connected,
Thermal expansion,
BASICS

Why an Expansion Joint?

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.

This is precisely the function of Expansion Joints.

BASICS

Bellows

z A flexible element, having one or more corrugations /

convolutions and end tangents with Lb/Db ≤ 3.
z The straight un-convoluted portions at the end of the Bellows is
termed as tangent.
BASICS

Movement

Axial Movement

z The dimensional shortening of an Expansion Joint due to

thermal expansion of pipe and / or dimensional increment due
to pipe contraction along its axis.
BASICS

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

Pressure Thrust – contd…

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

z The force required to deflect a Bellows axially,

z The spring rate is a function of the dimensions of the Bellows

and the material from which it is made,
BASICS

Stability

z Excess internal pressure may cause a multi-convoluted

Bellows to become unstable and squirm.
z Squirm is detrimental to Bellows performance, it can
greatly reduce both life and pressure capacity.
z The two types are
- Column squirm and
- In-plane squirm.
BASICS

Column in-stability

z Column squirm is a gross lateral

shift of the centre section of the
Bellows. It results in curvature of
the Bellows centre line.
BASICS

Inplane in-stability

z In-plane squirm is a shift or

rotation of the plane of one or
more convolutions such that the
plane of these convolutions is no
longer perpendicular to the axis of
the Bellows.
BASICS

Bellows - Categories

Un-reinforced Bellows

z A bare Bellows without a

Reinforcing member in
between its convolutions
is termed as Un-reinforced
Bellows.
BASICS

Bellows - Categories
Reinforced

z A Bellows fitted with a member in between its

convolutions to reinforce the root of the
convolution against internal pressure is
termed as Reinforced Bellows.

z Reinforcing rings are used if the

circumferential stresses become excessive as
a result of high operating pressures.

z The reinforcing rings absorb circumferential

Stresses so that the wall of the Bellows can
remain relatively thin and flexible overall.
EXPANSION JOINT - CATEGORIES

z Untied Expansion Joints

z Tied Expansion Joints

EXPANSION JOINT - CATEGORIES

Untied Expansion Joints

z The Expansion Joints free to travel along its axis
z Pressure Thrust Load will act on anchors
z Anchors to be designed for both pressure thrust load and spring
forces
EXPANSION JOINT - CATEGORIES

Tied Expansion Joints

z The Expansion Joints are restrained to travel along its axis
(exception – pressure balanced types)
z Pressure Thrust Load is contained within the Expansion Joint
z Pressure thrust load need not to be considered for anchor
design
UNTIED EXPANSION JOINTS - TYPES

Single Expansion Joint

z Simplest form of an Expansion Joint
z Compensate Axial, Lateral and Angular movements –
individually or combined of small magnitude
UNTIED EXPANSION JOINTS

Untied Single Expansion Joints - Illustration

UNTIED EXPANSION JOINTS - TYPES

Universal Expansion Joint

z A pair of Bellows connected with a Centre Spool
z Compensate large amount of Axial, Lateral and Angular
movements – individually or combined
UNTIED EXPANSION JOINTS

Untied Universal Expansion Joint - Illustration

TIED EXPANSION JOINTS - TYPES

z TIED SINGLE

z TIED UNIVERSAL

z HINGED

z GIMBAL

z PRESSURE BALANCED – ELBOW

z INLINE PRESSURE BALANCED

TIED EXPANSION JOINTS - TYPES

Tied Single Expansion Joint

z A Single Expansion Joint installed with Tie Rods
z Compensate only Lateral Movement of smaller magnitude
 TIED EXPANSION JOINTS – TYPES

Tied Single - Contd…

TIED EXPANSION JOINTS - TYPES

Tied Universal Expansion Joints

z Universal Expansion Joint (a pair of
Bellows with Centre Spool) with overall
tie rods
z Shall be used in a 90 Degree piping
offset – both single plane and two plane
z Due to the presence of Overall tie rods,
no external axial movement
TIED EXPANSION JOINTS – TYPES

Tied Universal – contd…

TIED EXPANSION JOINTS - TYPES

Hinged Expansion Joint

z Hinged Expansion Joints are
intended to compensate the
angular rotation in one plane.
z The arrangement consists of pair
of hinges connected by a hinge
pin.
 TIED EXPANSION JOINTS – TYPES

Hinged Expansion Joints – contd…

z The hinges are designed to

restrain the pressure thrust
loads and other external loads
such as dead weight and wind.
z Hinged Expansion Joints are
used, to absorb angular
movement when the movement
occurs in only one plane.
 TIED EXPANSION JOINTS – TYPES

Hinged Expansion Joints - Illustration

z 2 Hinged Expansion Joints can

be used in “Z” Offset pipe
section to compensate huge
lateral movement

z The expansion of offset pipe is

absorbed by the natural
flexibility of the horizontal pipe
section

z It is a good practice to keep the

distance L1 as maximum and
L2 as minimum
 TIED EXPANSION JOINTS – TYPES

Hinged Expansion Joints - Illustration

z 3 Hinge System shall be

considered to compensate
both sections of pipe
expansion
z The distance L1 & L2
shall be kept to a
maximum and L3 to
minimum
TIED EXPANSION JOINTS – TYPES

Gimbal Expansion Joint

z Gimbal Expansion Joints
are used to absorb
angular movement when
it occurs in all planes.
TIED EXPANSION JOINTS – TYPES

Gimbal Expansion Joints –

contd…

The construction of a Gimbal Joint

incorporates a pair of hinges
connected to a common floating
Gimbal Ring.
TIED EXPANSION JOINTS – TYPES

Gimbal Expansion Joints –

contd…
z The Hinges & Gimbal Ring are
designed to restrain the pressure thrust
loads and other external loads such as
dead weight and wind.

z A Single Gimbal Expansion Joint is

intended to compensate angular
rotation in all directions.
TIED EXPANSION JOINTS - TYPES

Gimbal Expansion Joints –

Illustration
z In a multi-planer piping
system, at multi-plane “Z”
bend, 2 Gimbal Expansion
Joints shall be used
z The thermal expansion in the
offset leg is absorbed by
flexibility in the horizontal
pipe runs
TIED EXPANSION JOINTS – TYPES

Gimbal Expansion Joints - Illustration

z In a multi-planer piping system, at

multi-plane “Z” bend, 2 Gimbal
Expansion Joints shall be used

z An additional Hinged Expansion

Joint shall be employed in the
horizontal pipe segment, when it is
insufficiently flexible to absorb the
expansion of the offset leg.
TIED EXPANSION JOINTS – TYPES

Pressure Balanced Expansion Joint – Elbow

z Is capable of compensating axial and / or lateral movement and
at the same time to contain the pressure thrust load within the
Expansion Joint Assembly
TIED EXPANSION JOINTS – TYPES

Pressure Balanced Expansion Joint – Elbow

TIED EXPANSION JOINTS - TYPES

Pressure Balanced Expansion Joint – Elbow – contd…

z This is achieved by tie rod restraints which connects the Line Bellows
and an Opposite Balancing Bellows subjected to the line pressure

z This type of Expansion Joint can be used only at a change in direction

of pipeline.
TIED EXPANSION JOINTS - TYPES

Pressure Balanced Expansion Joint – Elbow – Illustration

TIED EXPANSION JOINTS – TYPES

Inline Pressure Balanced Expansion Joint

TIED EXPANSION JOINTS - TYPES

Inline Pressure Balanced Expansion Joint – contd…

z In this assembly the Line Bellows is

tied with the Balancing Bellows
having twice the Effective area.
z Due to tie arrangement, when the
line Bellows is getting compressed
to compensate the Pipe Expansion,
the balancing Bellows will extend
the equal amount, thus the volume
across the Expansion Joint is
maintained, hence no pressure
thrust load
 TIED EXPANSION JOINTS - TYPES

Inline Pressure Balanced Expansion Joint – Contd…

z Inline Pressure Balanced

Expansion Joints are used in
straight pipe between two
anchors to compensate the
axial pipe growth, at the
same time not to transfer the
pressure thrust load to
anchors.
z They can accommodate
small amount of lateral
movement also.
EXPANSION JOINTS – SPECIAL TYPES

EXTERNALLY PRESSURIZED EXPANSION JOINTS

z There are certain applications the Expansion Joint is intended to
compensate huge amount of axial movement.
EXPANSION JOINTS – SPECIAL TYPES

Externally Pressurized Expansion Joint – contd…

z An internally pressurized Expansion Joints with
more number of convolutions to compensate
the required axial movement is totally unstable
even under small pressure.
z Externally Pressurized Expansion Joints in
which the flow medium pressure is guided
external to the Bellows, is a ideal solution to
compensate huge axial movement.
z Since the Bellows inside is subjected to only
atmospheric pressure, there is no instability or
squirm.
EXPANSION JOINTS – SPECIAL TYPES

REDUNDANT PLY DESIGN

z 2 – Ply Construction

z Each ply designed to withstand the Design / Operating conditions

 EXPANSION JOINTS – SPECIAL TYPES

Redundant Ply Design – Contd…

z If one ply fails, the other ply will take its place until a
scheduled replacement
EXPANSION JOINT – ACCESSORIES

Control Rods

z For individual Bellows in an

Universal Expansion Joint

z To limit the movement per

Bellows

z Not designed to withstand the

Bellows Pressure Thrust Load
in the event of Anchor failure
EXPANSION JOINT – ACCESSORIES

Limit Rods

z Installed in Untied Expansion

Joints to restrict the Bellows
movement range during normal
operation.

z In the event of a main anchor

failure, they are designed to
prevent the Bellows over-
stretching or over-compression
while restraining the full pressure
thrust load.
EXPANSION JOINT – ACCESSORIES

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

Internal Sleeve – contd…

They prevent the direct contact of flow medium with Bellows

They are used

to hold friction losses to a minimum

to ensure smooth flow

to prevent flow induced vibration resulting from turbulence of flow

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

Consider the following prior to

preparing a Technical Specification

for a Bellows type Metal Expansion Joint

SPECIFYING A METAL EXPANSION JOINT / BELLOWS

z Piping System Layout

z Vibration
z Material compatibility
z Special features
z Flow Medium

z Pressure z Lifting Lugs

z Temperature z Others which may affect the

performance of an
z Insulation Expansion Joint

z Movement
SPECIFYING A METAL EXPANSION JOINT / BELLOWS

Review of Piping System Layout,

z to determine the location of Expansion Joints
z to check the availability of supporting structures for anchoring /
guiding of the piping
z for the magnitude and direction of thermal movements to be
compensated while selecting the location and type of Expansion
Joint
z to incorporate special hardware to prevent the torsional rotation of
Bellows
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

Flow medium – contd…

Composition,

to check the compatibility of material

used in the EJ assembly

Direction,

Single or bidirectional, bidirectional flow

requires a telescopic type of sleeve and /
or higher thickness sleeve to prevent
buckling due to back flow and to prevent
the damage of the Bellows.
SPECIFYING A METAL EXPANSION JOINT / BELLOWS

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

z The system designer shall specify the movements of connecting

equipments / anchors and mis-alignment (if any) in addition to the thermal
movement of the piping.

z Similar to pressure, the movements being specified should be realistic.

Adding excessive safety factor requires the Bellows of higher number of
convolutions compromising the Bellows stability.

Insulation

z If required to be performed at site, the details shall be provided to consider

the weight of the same in the design.
SPECIFYING A METAL EXPANSION JOINT / BELLOWS

Vibration

z Specify the amplitude and frequency of vibration to be imposed on Bellows

such as those caused by machineries such as pumps, blowers etc.

z A resonant condition in the Bellows will result in cracking and failure.

SPECIFYING A METAL EXPANSION JOINT / BELLOWS

Additional Requirements / Special features

Thick Cover

z In cases of hazardous flow medium / very high

pressures, it is desired to specify higher
thickness external cover to prevent the radial
escape of flow medium and to prevent the
harm to working personnel.

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

Additional Requirements / Special

features

2 – Ply testable Bellows

– A 2 – ply testable Bellows, with

each ply designed to withstand the
specified conditions. The annular
space between the plys can be
monitored for leakage and can be
planned to replace the joint in the
next scheduled maintenance.
SPECIFYING A METAL EXPANSION JOINT / BELLOWS

Additional Requirements / Special features

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

Other details which may affect the performance of the Expansion

joint such as environmental details (saline, atmosphere
contaminated with SO2 etc.) shall also be included.
 STORAGE & PRESERVATION
Metal Expansion Joint / Bellows

STORAGE:

z Area

Free of moisture, dampen-chemicals, dirt and work traffic

Not exposed to weld spatter or molten metal or falling heavy

objects

Cleared of any sharp objects or protrusion

 STORAGE & PRESERVATION
Metal Expansion Joint / Bellows

Preservation

Cover with water proof / resistant sheets

Do not remove desiccant / protective coating in the packing;

keep them through out the period of storage

Do not stack Expansion Joints one above another

 STORAGE & PRESERVATION
Metal Expansion Joint / Bellows

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

Consider the Bellows Expansion Joint as a

highly engineered product and not a general
commodity item.

Utmost care shall be given at all stages of

Installation of an Expansion Joint
 INSTALLATION
Metal Expansion Joint / Bellows

Inward Inspection:

Check for possible damages during transit when an Expansion

Joint is received at site.

Check for broken hardware, loose shipping bars, dents and

scratches.

Check the container for Gaskets, Fasteners, Removable Liners

and any other components which form a part of Expansion Joint
assembly
 INSTALLATION
Metal Expansion Joint / Bellows

LIFTING & HANDLING

Lift only with designated lifting lugs.

Do not use chains or any other handling

devices directly on Bellows element or Bellows
Cover.

Do not use Shipping bars (painted in yellow) to

lift the Expansion Joint. They are not designed
to lift the Expansion Joint.
 INSTALLATION
Metal Expansion Joint / Bellows

LIFTING & HANDLING

Never lift an unrestrained Bellows /

Expansion Joint. Doing so will result in
damage and the unit will fail in service.

For Expansion Joints not provided with

lifting lugs (less than 500 kgs.) the best
lifting method should be evaluated at the
time of installation.

Do not remove the shipping bars (painted

in yellow) till the completion of installation
including all pipe restraints.
 INSTALLATION
Metal Expansion Joint / Bellows

CARE DURING INSTALLATION

Ensure adequate care to prevent

Dents & Score Marks on thin
Bellows.

Safe guard the Bellows from arc

strike and weld spatter.

Keep the Bellows free from

corrosion. Certain chemicals, dirt
and metal filings will damage the
Bellows material.
 INSTALLATION
Metal Expansion Joint / Bellows

CARE DURING INSTALLATION

Do not use cleaning chemicals such as soap, detergents and

solvents containing chlorides, caustics or sulphides. They can
lead to stress corrosion and will be known only after sometime
after put into the operation.

Use only chloride free insulation material if insulation of Expansion

Joints is required.

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

CARE DURING INSTALLATION

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 the area; they should be free of any sharp objects or

protrusions. If not removable, they should be notified so that they
can be avoided.

Check for the edges of the connecting pipes. They should be

clean, smooth and parallel to each other.
 INSTALLATION
Metal Expansion Joint / Bellows

CARE DURING INSTALLATION

Check the ends of the Expansion Joints for any protective

covering and remove them.

Check inside the Expansion Joint for desiccant bags or any other
material and remove the same.

Do not remove the shipping bars until the installation is complete.

Lift the Expansion Joint using the lifting lugs and position into
piping.
 INSTALLATION
Metal Expansion Joint / Bellows

CARE DURING INSTALLATION

Orient the Expansion Joint with flow arrow pointing in direction

of flow when there is a presence of Sleeve / Flow Liner.
 INSTALLATION
Metal Expansion Joint / Bellows

CARE DURING INSTALLATION

Do not use the Bellows to correct for misalignment of piping

unless it has been considered in the design.

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.

Use proper electrode to weld the Expansion Joint to the adjacent

piping.
 INSTALLATION
Metal Expansion Joint / Bellows

CARE DURING INSTALLATION

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.

It is good practice to leave one pipeline flange loose until the

Expansion Joint is installed.
 INSTALLATION
Metal Expansion Joint / Bellows

CARE DURING INSTALLATION

Install gaskets and bolt to the required torque recommended by
the flange manufacturer.
Do not entertain the movement of the Expansion Joint
(Compression, Extension, Offset and Rotation) due to piping
misalignment which has not been anticipated and considered in
the design.
The most common installation error is forcing the Bellows to fit
an excessive, beyond- construction-tolerance gap in the piping.
Any misalignments of greater magnitude will result in premature
failure of Bellows.
 INSTALLATION
Metal Expansion Joint / Bellows

CARE DURING INSTALLATION

Ensure that construction personnel make the piping fit the

Expansion Joint and not vice versa.

Installation of Anchors, guides and pipe supports shall be in strict

accordance with the piping system drawings.

Any field variances from planned installation may affect proper

functioning of the Expansion Joint and must be brought to the
attention of competent design authority for resolution.
 INSTALLATION
Metal Expansion Joint / Bellows

Checking prior to pressure testing

A careful inspection of the entire piping systems shall be made with

particular emphasis on the following: -

Are anchors, guides and supports installed in accordance with the

system drawings?

Is the proper Expansion Joint in the proper location?

Is the Expansion Joint’s flow direction and pre-positioning correct?

Have all of the Expansion Joint shipping devices been removed?

 INSTALLATION
Metal Expansion Joint / Bellows

Checking prior to pressure testing

Are all guides, pipe supports and the Expansion Joints free to
permit pipe movement?
Has any Expansion Joint been damaged during handling and
installation?
Is any Expansion Joint misaligned? Measuring the Joint overall
length, inspection of the convolution geometry and checking
clearances at critical points on the Expansion Joint and at other
points in the system can determine this.
Are the Bellows and other movable portion of the Expansion Joint
free of foreign material?
 INSTALLATION
Metal Expansion Joint / Bellows

LINE TESTING

Inspect the entire system to ensure proper installation of anchors,

guides and pipe supports in strict accordance with piping system
drawings.

Remove shipping bars (painted in yellow) prior to pressure testing

once the pipe line anchors, guides and pipe supports are in place.

Pressurise and test the line with Expansion Joint.

 INSTALLATION
Metal Expansion Joint / Bellows

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.

Use water for pressure test free of chloride.

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

Checking during pressure testing

Extreme care must be exercised while inspecting any pressurized

system or component.
A visual inspection of the system shall include checking for
the following: -
Check the evidence of leakage or loss of pressure.
Check for Distortion or Yielding of anchors, Expansion Joint
hardware, the Bellows and other piping components.
 INSTALLATION
Metal Expansion Joint / Bellows

Checking during pressure testing

Check for any unanticipated movement of the piping due to
pressure.
Check for Evidence of instability (Squirm) in the Bellows.
Check for the evidence of binding of the Guides, Expansion
Joints and other movable parts of the system.
Check for any evidence of abnormality or damage, the same shall
be reviewed and evaluated by competent design authority.
 INSTALLATION
Metal Expansion Joint / Bellows

Checking after system commissioning

Perform a visual inspection and ensure that the thermal

expansion is being absorbed by the Expansion Joints in the
manner for which they are designed.

Check the Bellows Expansion Joints for evidence of any

unanticipated vibration.
TYPICAL CAUSES OF EXPANSION JOINT FAILURE

z Vibration z In-sufficient protection of

Bellows during installation
z Fatigue
z Excess Pressure z Anchor failure in service

z Excess Movement z Torsional rotation of

z Improper shipping & Bellows
handling
z Erosion
z Improper storage
z Packing of flow medium
z Wrong sleeve direction
z Pre-mature removal of z Corrosion
shipping brackets
TYPICAL CAUSES OF EXPANSION JOINT FAILURE

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

The higher flow velocity results in turbulence

and flow induced vibration; a properly
designed internal sleeve to be used.

Metal Bellows will fail imposed with vibration

of higher amplitude and low frequency such
as originating from Reciprocating Machines.

It is important to furnish the Vibration Data

such as amplitude and frequency of the
system to the Bellows designer.
 TYPICAL CAUSES OF EXPANSION JOINT FAILURE

Vibration

It should be ensured that frequency of system vibration do not

coincide with Bellows Natural frequency.

The Bellows will be designed to have its Natural Frequency 2/3

times less than the system frequency or greater than 2 times the
system frequency.
 TYPICAL CAUSES OF EXPANSION JOINT FAILURE

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 Shipping & Handling

Dents, gouging, scratches, score marks produced

on thin Bellows as a result of improper shipping and
handling of Metal Expansion Joints will reduce the
life of the Bellows. Though the failure will not happen
immediately, the life span of Bellows will get reduced
to great extent and failure will be sudden.
 TYPICAL CAUSES OF EXPANSION JOINT FAILURE

Improper Storage

There were several cases of shorter Bellows

life where they were not stored / preserved
properly.

The condensation and settlement of dissolved

gases in the atmosphere (saline, SO2 etc.,) will
produce adverse effect on Bellows material
resulting in corrosion and erosion.

Storing of Expansion Joints in high traffic areas

result in hitting of thin Bellows with hard objects
/ sharp edges damaging the Bellows.
 TYPICAL CAUSES OF EXPANSION JOINT FAILURE

Wrong Sleeve direction

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.

Premature removal of shipping brackets

Do not remove until the completion of installation of anchors, supports

and pipe guides.

The premature removal of shipping brackets lead to imposing of

unwanted huge loads on Bellows resulting in deformation and failure.
 TYPICAL CAUSES OF EXPANSION JOINT FAILURE

Insufficient protection of Bellows during installation

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

Anchor failure in service

Improper / inadequate design of anchors will
result in distortion, bending and failure.
Improper installation of anchors, deviating
from the Piping System Drawings will also
result in failure of anchors.
It is preferred to specify the Limit rods which
are designed to withstand the Bellows
pressure thrust load. In the event if the main
anchor fails, the Expansion Joint remains in
its position without stretching out.
 TYPICAL CAUSES OF EXPANSION JOINT FAILURE

Anchor failure in service

Any Expansion Joint will function only between two anchors. The anchors
are meant for withstanding the Bellows Pressure Thrust Load and Spring
forces where Unrestrained / Untied Expansion Joints are employed. In
cases where Restrained / Tied Expansion Joints are employed the
anchors should bear the Bellows spring forces.
The failure of anchors will result in stretching out of Bellows and results in
failure.
 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

Packing of flow medium

A flow medium containing dust particles combined with moisture
will lead to packing in between the convolutions and the annular
space between the Bellows and Liner.
The packing will result in improper functioning of Expansion Joint
and lead to failure.
Insulating the annular space effectively and / or Purging with air /
nitrogen in the annular space periodically will prevent the packing /
settlement of medium.
 TYPICAL CAUSES OF EXPANSION JOINT FAILURE

Corrosion

Corrosion is the main cause of Bellows failure in several

applications having adverse environment and / or adverse flow
medium.

External corrosion

In the form of pitting and general metal loss.

TYPICAL CAUSES OF EXPANSION JOINT FAILURE

External corrosion

The saline nature of plant

atmosphere and / or gases /
pollutants in the atmosphere in
combination with moisture lead to
accumulation on Bellows material
resulting corrosion.

Presence of chloride will result in

stress corrosion cracking on
austenitic stainless steel.
TYPICAL CAUSES OF EXPANSION JOINT FAILURE

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