LONESTAR INDUSTRIES Chennai, India

IGPGroup
Design,Engineering,Manufacturing&Testingof BellowstypeExpansionJoints

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

Bellows type Metal Expansion Joints
Metal Bellows Expansion Joints are used in several applications / end uses. They can be designed for various combinations of operating conditions, Pressure as high as 200 kg/cm2 (g) Temperature as high as 1450o C Metal Bellows can be manufactured from any formable material, the most popular material in modern day uses are, Austenitic Stainless Steels (304, 304L, 304H, 316, 316L, 316H, 316Ti, 321), Duplex & Super Duplex Stainless Steels, Super Austenitic Stainless Steels (AL 6XN, 254 SMO, 904L), High Nickel Alloys (230, C276, 400, 600, 601, 625, 800, 800H, 825), Titanium & Titanium alloys, The End connection Pipes shall be in the above grades in addition to Carbon Steel , Low Alloy Steel and combination of any of , these,

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

INPUT FOR DESIGN By Customer: Type of Expansion Joint Size, Nominal Pipe Size / OD of Connecting Pipe x Thickness Type of End Connection Flanged / Welded End (Flange Dimensions in case of Flanged End) Temperature Maximum Operating / Design Pressure Maximum Operating / Design Movements Axial, Lateral & Angular (individually or combination of any of these) Material of Construction Bellows / Connecting Pipe, compatible for process medium Flow Medium Liquid / Gas / Solid / Semisolid / Composition Flow Velocity Overall Length / Maximum Space Available External Loads Wind / Seismic / Dead Weight Installation Position Horizontal / Vertical / Inclined Insulation Details Code Compliance By Manufacturer: Bellows Design: Bellows ID Convolution Depth (Height) Convolution Pitch Thickness of Bellows Convolutions Number of Plies of Bellows Convolutions Type of Bellows Unreinforced (Single / Universal) & Reinforced (Single / Universal) Centre Distance between the Bellows (in case of Universal)

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

Pitch

Depth
By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

Codes & Standards, Pre-dominantly Followed, EJMA (Expansion Joint Manufacturers Association) ASME Sec VIII Div. 1 Appendix 26 (for Bellows Expansion Joints for Shell & Tube Heat Exchangers) ASME B31.3 (Process Piping Code) ASME B31.1 (Power Piping Code)

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

Acceptable Design: Pressure Stresses within the specified limit, Reference: Codes / Standards Bellows Tangent Circumferential Membrane Stress S1 due to pressure Cwb * Allowable Stress of Bellows Material at specified temperature Cwb, Bellows longitudinal weld joint efficiency, 1 if 100% radio graphed, 0.8 if not, Collar Circumferential Membrane Stress S1 due to pressure Cwc * Allowable Stress of Bellows Material at specified temperature Cwc, Collar longitudinal weld joint efficiency, 1 if 100% radio graphed, 0.8 if not, Bellows Circumferential Membrane Stress S2 due to pressure Cwb * Allowable Stress of Bellows Material at specified temperature Cwb, Bellows longitudinal weld joint efficiency, 1 if 100% radio graphed, 0.8 if not, Bellows Meridional Membrane Stress S3 due to pressure / Bellows Meridional Bending Stress S4 due to pressure, S3 + S4 Cm* Allowable Stress of Bellows Material at specified temperature Cm 3, for Bellows in as formed condition Cm 1.5, for Bellows subjected to annealing, after forming Limiting Design Pressure: Bellows LIMITING DESIGN PRESSURE (LDP) based on Column Instability and / or Inplane Instability, should be equal or higher than the specified Pressure, if the Operating / Design Temperature is above 200o C should be 1.5 times higher than the specified Pressure, if the Operating / Design Temperature is less than 200o C

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

Spring Rate: The spring rate (Stiffness) of the Bellows shall be within the specified limit by the Customer Permissible Life: The permissible Life of Bellows shall be equal or above the specified Design Life by the Customer Expansion Joint under External Pressure / Vacuum: Cylindrical End Connection & Centre Spool (Universal Bellows) - Evaluated as per ASME Sec VIII Div. 1 Bellows - If the moment of inertia of Bellows is higher than the moment of inertia of the pipe (that the Bellows replaces), then the Bellows is considered to be equivalent to the pipe for the elastic buckling analysis

I 1-1

I 1-1

I 2-2

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

Design of other Hardware: Limit Rods / Tie Rods: - Evaluated for Tensile Load and for Compressive Load Hinge Pins: - Evaluated for Shear / Bending Load

Hinge Plates: - Evaluated for longitudinally applied Tensile & Compressive loads - Shear & Bearing forces at hinge pin hole - Bending load resulting from Wind & Torsion Support Brackets / Support Rings: - Evaluated for Bending Load under both Positive Pressure and Vacuum Lugs / Lug Pads / Stiffeners: - Evaluated for Shear Load Load for Design of Hardware: Bellows full Pressure Thrust Spring Forces Additional Load Unsupported weight of connecting pipe, Weight of contained fluid under operating / testing conditions (specified by the customer) Other Loads Wind & Seismic (specified by the customer) Torsion about the longitudinal axis of the Expansion Joint

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

Heat treatment of Bellows: Pre-dominantly, the Bellows after forming is not subjected to any form heat treatment, since the post forming heat treatment of Bellows is in no way beneficial in enhancing the life of Bellows, the enhanced strength property of the material due to cold working has been included in evaluating stress due to pressure, Bellows Meridional Membrane Stress S3 due to pressure / Bellows Meridional Bending Stress S4 due to pressure, S3 + S4 Cm* Allowable Stress of Bellows Material at specified temperature Cm 3, for Bellows in as formed condition Cm 1.5, for Bellows subjected to annealing, after forming Heat treatment of Bellows after forming can be considered in case if the Expansion Joint is meant for sour service, where the evaluation of Bellows Pressure Stresses is different UNLESS SPECIFIED, THE HEAT TREATMENT OF BELLOWS AFTER FORMING SHALL BE AS PER EITHER ASME CODE OR MATERIAL MANUFACTURERS RECOMMENDATIONS

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

Internal Sleeve: Internal Sleeves are required in cases, the higher flow velocities could induce resonant vibration, internal sleeves must be provided, in case if the flow velocity exceeds 8 m/sec in case of liquid flow medium and 20 m/sec in case of gaseous flow medium it is necessary to minimize the friction losses and to ensure smooth flow, the flow medium is abrasive in nature leading to erosion of thin gauged Bellows, the flow medium of higher temperature, to facilitate an annular gap, this annular gap is insulated adequately to reduce the temperature at outer Bellows skin, To minimize the flow induced vibration, the thickness of sleeve should be adequate, the thickness of sleeve corresponds to Sleeve Length, Flow Velocity and Flow Medium Temperature. The thickness increase factors shall be used on minimum sleeve thickness when, the length of sleeve exceeds 18 (457 mm) the flow velocity exceeds 31 m/sec the flow medium temperature exceeds 149o C SNo 1 2 3 4 5 6
By R.V. RAMACHANDRAN

Size(NB) 2 3 4 10 12 24 26 48 50 72 Above72

MinimumSleeveThickness(mm) 0.6 0.9 1.22 1.5 1.9 2.3

LONESTAR INDUSTRIES Chennai, India

Vibration:

Bellows type Expansion Joints can be used for applications involving vibration provided if the vibration of HIGH FREQUENCY & LOW AMPLITUDE They are not suitable if the vibration of LOW FREQUENCY & HIGH AMPLITUDE, e.g., Reciprocating Machines, Bellows type Expansion Joints are not meant to remove vibrations especially resulting from Pressure Pulses, The system designer should consider, Pulsation Dampeners so that the vibration loads are not detrimental to the function of the Bellows, When the vibration is present and frequency is known, the metal Bellows can be designed in such a way that its NATURAL FREQUENCY shall be LESS THAN 2/3 of system frequency or GREATER THAN 2 TIMES the system frequency,

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

COLD SPRINGING Defined as the Lateral or Angular Offset of the ends of the Expansion Joint, when installed, Cold Springing is considered to reduce the force required to deflect the Expansion Joint, the preferred amount of cold springing is 50%, In applications, where the Expansion Joint has to compensate huge lateral deflection, the angular rotation induced on the individual Bellows in the assembly is also huge leading to instability, By cold springing the Expansion Joint by 50%, at installation, the displacement of the convolution is reduced by 50%, thus the Expansion Joint will be more stable and with enhanced fatigue life.

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

EXPANSION JOINTS FOR FCCU COLD SHELL CONSTRUCTION Bellows Construction 2 Ply testable Annular Area Packed with Ceramic Pillow Metal Seal to prevent the entry of catalyst in the annular area External Insulation to prevent the temperature drop below dew point Control Rods to limit individual Bellows Movements Slotted Hinges to support dead weight of center section Pantograph linkages to uniformly distribute the movements among the Bellows Centre Gimbal to allow two plane lateral deflection Heat Resistant & Abrasion Resistant Lining

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

EXPANSION JOINTS FOR FCCU HOT SHELL CONSTRUCTION Bellows Construction 2 Ply testable Annular Area Packed with Ceramic Pillow Metal Seal to prevent the entry of catalyst in the annular area Control Rods to limit individual Bellows Movements Slotted Hinges to support dead weight of center section Pantograph linkages to uniformly distribute the movements among the Bellows Centre Gimbal to allow two plane lateral deflection Abrasion Resistant Lining

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

Expansion Joints for CCR Platforming Reactors & Pacol Reactors Incorporated in the internal piping of the Reactor, Compliance to ASME B31.3, Piping Code Typical Design Temperature of 549o C Typical Design Pressure of 1.05 kg/cm2 (g), Differential, Bellows shall be of Single Ply, made out of Alloy 800 (ASTM B409 / ASME SA 409 UNS N08800) End Connection Flanges in SS 321 / SS 347 / A 182 Gr. F 11 Removable type Internal Sleeve, with internal polished surface

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

Expansion Joints for Shell & Tube Heat Exchanger Incorporated both on shell side & tube side, When installed on shell side, should withstand the shell side pressure (internal) & full vacuum When installed on tube side, should withstand both shell side pressure (external) & tube side pressure (internal) Compliance to ASME Sec VIII Div. 1 Appendix 26, The Expansion Joint should be designed individually for different operating conditions with cumulative fatigue verification, Weld Ends shall be fully machined to meet the close tolerance on the clearance between shell inside dia and Baffle Full bore Sleeve, to ensure smooth flow is considered,

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

Expansion Joints for High Temperature Process Piping Preferably Single Ply Bellows, Stainless Steel Material with H grade, i.e., minimum carbon content of 0.04%, Floating Ring type Tie Bar Supports with Shear Pads / Split Shear Rings to allow the radial growth of the pipe,

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

MANUFACTURING FLOW CHART BELLOWS TYPE EXPANSION JOINTS
RAW MATERIAL Ordering, Receipt at Stores, Inward Inspection, Identification & Correlation, Check Testing (wherever required)

COMPONENT - BELLOWS Preparation of Sheet Layout & Cutting Rolling of Sheet into cylinder Longseam Welding of Cylinder NDE (as required) Forming of Bellows convolutions NDE (as required) Trimming of Edges

COMPONENT-CONNECTING PIPES Preparation of Layout & Cutting Rolling into shell and longseam welding NDE (as required) Machining (wherever required) Edge Preparation (wherever required)

COMPONENTFLANGES Flanges Bought Out

COMPONENT-HARDWARE Supports, Brackets, Lugs etc., Fabricated as per drawings

ASSEMBLY Fitment of Bellows element with Connecting Pipes & Welding Fitment & Welding of Other Components NDT (as required)

CLEANING Bellows element / SS Parts With Solvent / Pickling& Passivation Exposed CS Parts Blast / Power tool cleaning

PAINTING Bellows element / SS Parts Nil Exposed CS Parts Shop Primer / As required by Customer

MARKING Affixing of Name Plate, Marking of Flow Direction

Preparation for Shipment Fixing of Shipping Brackets, Packing, Marking on Packing

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

Convolution Forming: Mandrel Forming Roll Forming / Roll Sizing Hydro Forming Elastomer Forming Welding Process: Bellows long seam Welding GTAW in Semi Automatic Fixture Bellows Edge Fusing Resistance Seam Welding / GTAW Bellows to Pipe attachment Welding Similar & Dissimilar Welding GTAW Other Carbon Steel to Carbon Steel Welding MIG / MMAW / SAW

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

Non Destructive Examination: Bellows Long Seam Prior to forming: 100% X Ray / 100% LPE After forming: 100% LPE Pipe Long Seam: 100% RT / 100% LPE / 100% MPI Bellows to Pipe attachment weld: 100% LPE Any other Butt Welds: 100% RT / 100% LPE Any other Fillet / Load bearing Welds: 100% LPE Leak Test: Pneumatic / Helium Leak Test (Optional) / Vacuum Pressure Test: Hydrostatic @ ambient temperature @ specified pressure Parts) Others: 100% Positive Material Identification (on Alloy Steel, Stainless Steel & High Nickel Alloy Raw Material (Check Testing, if required) Chemical Composition Mechanical: Tensile, Yield & % Elongation Intergranular Corrosion Check

By R.V. RAMACHANDRAN

LONESTAR INDUSTRIES Chennai, India

Destructive Examination: Squirm, Meridional Yield, Rupture & Fatigue Life Cycle Squirm: The deformation of the convolution(s), beyond 15% UNDER PRESSURE. The Pressure at which the Bellows deforms beyond 15% is termed as Squirm Pressure; Meridional Yield: The permanent deformation of the convolution(s), beyond 15% EVEN AFTER RELIEVING THE PRESSURE. The Pressure at which the permanent deformation occurs is termed as Yield Pressure; Rupture: Gross deformation, Ballooning followed by rupture, the pressure at which the Bellows ruptures is termed as Rupture Pressure; Fatigue Life Cycle: The number of cycles corresponding the movement that a Bellows undergo;

By R.V. RAMACHANDRAN