TRAINING MANUAL PIPING BELLOWS EXPANSION JOINT

Uhde India Limited

DOC No. : 29040-PI-UFR-0035 Rev. Page : R0 : 1

CONTENTS

Page 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 Cover Sheet Introduction Application Bellow Pressure Thrust Bellow Types System Design Considerations Internal Sleeve Requirement Bellow Pre-Compression 1 2 2 25 5 14 14 16 16 17 17 - 18

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TRAINING MANUAL PIPING BELLOWS EXPANSION JOINT

Uhde India Limited

DOC No. : 29040-PI-UFR-0035 Rev. Page : R0 : 2

1.0

INTRODUCTION: In a piping system a Bellow is like a sealed spring. Sealed because it is required to contain the fluid pressure which is flowing through it and spring because it is required to respond to the movement of the connected piping without offering appreciable stiffness to the piping system. A Bellow element employed in a piping system is an assembly of generally more than one convolute in series. The convolutes are designed strong enough to withstand the internal pressure of the system, at the same time the typical contour of the convolute assembly allows it to flex under thermal movement of the connected piping. As a result of this extreme flexibility the Bellow as such is highly incapable of absorbing any longitudinal loads by its own, thereby requiring external attachments to transfer these longitudinal loads to its connected piping for maintaining the overall stability of the piping system under question.

2.0

APPLICATION:

The Bellows are generally employed in a piping system in one of the following situations: When the space constraints do not permit providing adequate flexibility by conventional methods (e. g. expansion loops etc.) for maintaining the system stresses within acceptable limits. When conventional solutions (e.g. expansion loops etc.) create unacceptable process conditions (e.g. excessive pressure drop). When it is not practical to limit the piping induced loads on the terminal nozzles of the connected equipment within admissible limits by conventional methods. When the equipment such as Compressors, Turbines, Pumps etc. necessitate isolating the mechanical vibrations from being transmitted to the connected piping.

3.0

BELLOW PRESSURE THRUST:

The end anchors in a piping system employing a Bellow requires special considerations owing the large imbalance axial force generated due to internal system pressure acting on the bellow convolutes. At the same time the inherent weakness of the Bellow to transfer the longitudinal force across its ends.

It is therefore imperative that a proper assessment of the imbalance Pressure Thrust of the Bellow and its effects on the piping end terminals be evaluated prior to using the Bellow on a piping system of large diameter and sizable internal pressure.

To understand the above phenomena let us consider a straight length of pipe of internal diameter D capped at its both ends and subject to an internal pressure P (refer Exhibit 35.1, Fig 1A below). The longitudinal Pressure Force acting at each capped end is: Pf = PD / 4
2

TRAINING MANUAL PIPING BELLOWS EXPANSION JOINT

Uhde India Limited

DOC No. : 29040-PI-UFR-0035 Rev. Page : R0 : 3

The above longitudinal force is carried in tension in the Pipe wall and the system remains stable with the opposite and equal force acting at the capped end balancing each other. Now let us introduce a Bellow in the middle of the above pipe section (refer Exhibit 35.1, Fig 1B). Since the above Bellow does not have any appreciable longitudinal stiffness it will tend to straighten out as shown in Exhibit 35.1, Fig 1C resulting into rapture of the convolutes. It is therefore necessary to provide end anchors (refer Exhibit 35.1, Fig 1D below) to counter the pressure force acting at the ends and thereby stopping the bellow convolute from flattening. The magnitude of above force will be combined longitudinal force acting at the Bellow inside diameter and the imbalance pressure thrust acting on the side-wall, of the convolute.

Exhibit-35.1

In order to derive the imbalance pressure thrust for a Bellow let us cut a strip of unit width from the convolute of a Bellow subject to internal pressure p. The above can be

approximately represented by a free body diagram of a fixed ended beam with uniform load W = ph where h is the height of the convolute (refer Figure-1, Exhibit 35.2 below).

TRAINING MANUAL PIPING BELLOWS EXPANSION JOINT

Uhde India Limited

DOC No. : 29040-PI-UFR-0035 Rev. Page : R0 : 4

One half of the above uniform load W is carried in tension at the crest of the convolute and the other half is carried in compression at the inside diameter of the convolute resulting into the Reaction at the ends of above beam

Rid = Rod = ph / 2

Figure-1 (Exhibit 35.2)

The tensile force Rod at the crest of the convolute is balanced due to equal and opposite side walls of the convolute and hence the only force contributing to the imbalance pressure thrust is the compressive force Rid which needs to be absorbed by the end anchors.

The total effective area of the full ring of the convolute taking part in generating the above imbalance pressure thrust is therefore Sw = {(D + 2h/ 2)
2

-D }/4
2

Hence the total effective pressure thrust area

= Area of the pipe I. D. + Sw = D / 4 + {(D + 2h/ 2)

2 2

-D }/4
2

= {(D + 2h/ 2) / 4
2

TRAINING MANUAL PIPING BELLOWS EXPANSION JOINT

Uhde India Limited

DOC No. : 29040-PI-UFR-0035 Rev. Page : R0 : 5

= Dm / 4
2

(where Dm is the Mean diameter of the Bellow)

Hence the Total Pressure Thrust to be absorbed by the End Anchors = p Dm / 4

2

4.0

BELLOW TYPES:

Simple Expansion Joint. Universal Expansion Joint. Pressure Balanced Expansion Joint. Hinged Expansion Joint. Gimbal Expansion Joint.

Following paragraphs illustrate the typical situations for employing the above type of Bellows depending upon the application and configuration of the piping profile.

SIMPLE EXPANSION JOINT: 1.0 Expansion Joint for absorbing axial displacement. 1.1 Single Element Bellow installed in a straight line A typical arrangement of the above application is shown in the accompanying sketch (Figure1, Exhibit 35.3) below. The Bellow is locked between the end anchors (Main Anchors) and is normally located close to one of the above Main Anchors. The other end of the Bellow is accompanied by First Alignment Guide G1 (as close as possible to the below) followed by Second Alignment Guide G2 at a distance of 14 D (as per EJMA recommendation). The Second Alignment Guide G2 is, followed by the Intermediate Guides (located as per the normal support span) if required as per the length of the line.

Figure-1 (Exhibit 35.3)

1.2 Single Element Bellow installed in a straight line with an offset. A typical arrangement of the above application is shown in the accompanying sketch (Figure2, Exhibit 35.3) below. The application of this type is normally not recommended and will perform satisfactory only within certain limits. The axial pressure thrust of the Bellow is transmitted to the Main Anchor through the offset, resulting into bending moment in the piping. The remaining arrangement of the Main Anchors, First and Second Alignment Guides and rest of the Intermediate Guides remains same as that of the Bellow installed in a straight line.

TRAINING MANUAL PIPING BELLOWS EXPANSION JOINT

Uhde India Limited

DOC No. : 29040-PI-UFR-0035 Rev. Page : R0 : 6

Figure-2 (Exhibit 35.3) 1.3 Double Element Bellow employing an intermediate anchor in the middle when installed in a straight line A typical arrangement of the above application is shown in the accompanying sketch (Figure1, Exhibit 35.4) below. The arrangement is generally employed in the situations where the linear expansion of the line is of a very large magnitude. The Bellow assembly consists of 2 elements separated by an Intermediate Anchor. Thereby absorbing the linear expansion of the 2 sections of the pipeline individually. It may be noted that the above Intermediate Anchor need not be designed for the bellow axial force, which cancels out between the 2 Bellow Elements. The remaining arrangement of the Main Anchors, First and Second Alignment Guides and rest of the Intermediate Guides remains same as that of the Bellow installed in a straight line.

Figure-1 (Exhibit 35.4)

1.4 Double Element Bellow employing a main anchor in the middle, installed in a straight line at the interface of changed line size (i.e. reducer)

A typical arrangement of the above application is shown in the accompanying sketch (Figure2, Exhibit 35.4) below. The arrangement is similar to that of Double Element Bellow on a straight pipeline except that the middle anchor between the 2 Bellow Elements is required to be designed as Main Anchor for the differential axial thrust of the 2 Bellows employed on each side of the Reducer.

Figure-2 (Exhibit 35.4)

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Uhde India Limited

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1.5 Three Element Bellow employing a main anchor in the middle, installed at the junction of the branch connection A typical arrangement of the above application is shown in the accompanying sketch (Figure1, Exhibit 35.5) below. The middle anchor between the 3 Bellow Elements in this case is required to be designed as Main Anchor for the axial thrust imposed by the Bellow of the branch pipe.

Figure-1 (Exhibit 35.5)

2.0 Expansion Joint for absorbing lateral movement, angular rotation and combined movement 2.1 Single Element Bellow employing a directional anchor, installed in the longer leg of L shaped piping profile A typical arrangement of the above application is shown in the accompanying sketch (Figure1, Exhibit 35.6) below. The Bellow is located at 1 end of the longer leg and thereby absorbing the linear expansion of the longer leg as axial displacement. The Main Anchor near the Bellow is a Directional Anchor, which prevents the pipe end from moving axially, at the same time allowing the expansion of the shorter leg, which is absorbed by the Bellow as a lateral deflection. The Anchor on the shorter leg is required to be designed, only as Intermediate Anchor. The remaining arrangement of the First and Second Alignment Guides and rest of the Intermediate Guides remains similar to that of the Bellow installed in a straight line to prevent the straight pipe of the longer leg from rotating/ buckling.

Figure-1 (Exhibit-35.6)

TRAINING MANUAL PIPING BELLOWS EXPANSION JOINT

Uhde India Limited

DOC No. : 29040-PI-UFR-0035 Rev. Page : R0 : 8

2.2 Single Element Bellow employing a directional anchor, installed in the shorter leg of L shaped piping profile

A typical arrangement of the above application is shown in the accompanying sketch (Figure2, Exhibit 35.6) below. The Bellow is located in the shorter leg and thereby absorbing the linear expansion of the longer leg as lateral displacement. The Main Anchor near the Bellow is a Directional Anchor, which prevents the pipe end from moving axially, at the same time allowing the expansion of the long leg, which is absorbed by the Bellow as a lateral deflection. The Anchor on the longer leg is required to be designed, only as Intermediate Anchor. Only 1 Guide is required on the longer leg for alignment purpose.

Figure-2 (Exhibit 35.6)

2.3 Single Element Bellow employing a tie rod in place of a directional anchor, installed on the shorter leg of L shaped profile

A typical arrangement of the above application is shown in the accompanying sketch (Figure1, Exhibit 35.7) below. This is a modified arrangement wherein, by employing a tied Bellow (in the shorter leg) the need of the Directional Anchor is eliminated. Owing to tie rods the bellow can only absorb lateral deflection (other than its own axial growth) and hence the axial growth of shorter leg must be accommodated by the flexibility in the longer leg.

Figure-1 (Exhibit 35.7)

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Uhde India Limited

DOC No. : 29040-PI-UFR-0035 Rev. Page : R0 : 9

UNIVERSAL EXPANSION JOINT:

1.0 Bellow with tie rod installed in a Z shaped piping profile in a single plane A typical arrangement of the above application is shown in the accompanying sketch below (refer Figure-1, Exhibit 35.8). Typically the assembly employs 2 Bellow elements tied across. The above bellow is purely lateral, and hence the axial expansion of the leg (excluding the expansion of the Bellow itself) housing the Bellow is, required to be accommodated by the Flexibility of the adjoining legs. To prevent the longer legs from rotating necessary Directional Guides are provided as shown. The End Anchors are required to be designed as Intermediate Anchors only.

Figure-1 (Exhibit 35.8)

2.0 Bellow with tie rod installed in a Z shaped piping profile in two plane A typical arrangement of the above application is shown in the accompanying sketch (refer Figure-2, Exhibit 35.8) below. The arrangement is completely similar to that of the earlier situation except that the Bellow is subject to lateral deflection in a resultant plane derived from the magnitude of the 2 linear expansion components of the longer legs.

Figure-2 (Exhibit 35.8)

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Uhde India Limited

DOC No. : 29040-PI-UFR-0035 Rev. Page : R0 : 10

3.0 Bellow with pantographic linkage

A typical arrangement of the above application is shown in the accompanying sketch (Figure2, Exhibit 35.9) below. Owing to the limited space between the 2 directly connected equipment nozzles the Bellow is required to absorb axial as well as lateral deflection. In such case the equipment nozzles must be designed to take the axial force due to Bellow imbalance area. The Pantographic linkage is provided to distribute the expansion between the 2 Bellows and control their movements.

Figure 1 (Exhibit 35.9)

PRESSURE BALANCED EXPANSION JOINT As it is evident from the forgoing discussion the axial thrust imposed by the imbalance area of the Bellow under internal pressure is a main concern in designing the Piping System employing such Bellows. The conventional method of designing such systems is by employing Main Anchors to absorb the above axial force. It is however not always practical (due to space/ access constraints) to achieve these conventional solutions. The excessive magnitude of the axial force could also become prohibitive in some instances. The Pressure Balance Bellow design, which basically is a combination of a Flow Bellow and a Balancing Bellow, comes handy in addressing many of such situations. The working principle of the above Bellow relies on the fact that since both Flow and Balancing Bellow have identical cross sectional area, they will produce equal, but opposite in direction, forces under the same internal pressure. If the ends of these Bellows are locked to each other by a suitably designed tie-rod, the above equal and opposite forces will cancel out to transmit no axial force on the end terminals of the connected piping. At the same time the above tie rod will not interfere with the Flow Bellow in absorbing axial/ lateral deflections.
O

1.0 Single Element Bellow installed at the 90

turning of a piping profile

The sketches below show a typical arrangement of 3 such applications (refer Figure-1, Figure-2 and Figure-3 of Exhibit 35.10). In all the 3 cases the Bellow is capable of absorbing primarily axial movement along with a small amount of lateral movement. Since the axial thrust due to internal pressure is cancelled out between the two Bellows the system requires only Intermediate Anchors wherever applicable.

TRAINING MANUAL PIPING BELLOWS EXPANSION JOINT

Uhde India Limited

DOC No. : 29040-PI-UFR-0035 Rev. Page : R0 : 11

Figure-1

Figure-2

Figure-3 Exhibit 35.10

TRAINING MANUAL PIPING BELLOWS EXPANSION JOINT

Uhde India Limited

DOC No. : 29040-PI-UFR-0035 Rev. Page : R0 : 12

2.0 In-line Pressure Balanced Bellow

A typical arrangement of the above application is shown in the accompanying sketch (Figire-1, Exhibit 35.11) below. The above arrangement is typically employed in the situations where the bellow is required to be, installed on a long line without the possibility of installing the Main Anchors. The common balancing Bellow effectively nullifies the imbalance axial force of the 2 flow Bellows, at the same it allows the required deflection to be absorbed within the assembly. The piping end anchors are, therefore required to be designed as intermediate anchors only.

Figure 1 (Exhibit 35.11)

3.0 Double Element Bellow installed at the 90 large lateral movements

turning of a piping profile for absorbing

A typical arrangement of the above application is shown in the accompanying sketch below. Where large amount of lateral deflections, are involved a Pressure Balanced Universal Joint (with tie rod) may best suit to the situation. By a proper design of the tie rods to rotate around its attachment points it is possible to absorb the lateral deflection by the combination of 2 flow bellows where as the balancing bellow is subject to only axial deflection.

Figure 2 (Exhibit 35.11)

HINGED EXPANSION JOINT Hinged expansion joints are usually used in sets of 2 or 3 elements to absorb lateral deflection in one or more directions in a single plane. Each element of the assembly is subject to pure angular rotation by its hinge pin. Each pair of bellow element connected by a segment of pipe will act in unison to absorb lateral deflection in much the same way as universal joint in a single plane. The hinges are designed strong enough to take the axial pressure thrust and also to transmit the piping deflections in a plane perpendicular to the plane of hinge rotation. The magnitude of the lateral deflection that could be absorbed by a hinged bellow is directly proportional to the length of spool piece connecting the bellow elements.

TRAINING MANUAL PIPING BELLOWS EXPANSION JOINT

Uhde India Limited

DOC No. : 29040-PI-UFR-0035 Rev. Page : R0 : 13

1.0 Two Element Bellow A typical arrangement of the above application is shown in the accompanying sketch (Figure1, Exhibit 35.12) below. Since the axial pressure thrust is absorbed by the hinges the piping end anchors need to be designed as intermediate anchors only. The position of the pipe guides on the axial pipes should provide adequate flexibility to absorb the expansion of the offset leg housing the bellow.

Figure-1 (Exhibit 35.12)

2.0 Three Element Bellow

A typical arrangement of the above application is shown in the accompanying sketch (Figure1, Exhibit 35.13) below. The above arrangement is typically employed in the situations where the flexibility in Z shaped profile (in a single plane) is not sufficient to absorb the thermal expansion of the offset leg.

Figure-1 (Exhibit 35.14)

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Uhde India Limited

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GIMBAL EXPANSION JOINT A typical arrangement of the above application is shown in the accompanying sketch (Figure1, Exhibit 35.15) below. Just as hinged expansion joints offer a great capacity to absorb lateral expansion in a single plane, the Gimbal Expansion Joints offer the same feature in a multiple plane system. Generally the ability of Gimble Joint to absorb the lateral movement in any plane is best utilized by employing 2 of such bellows connected together by a pipe spool. The structure of the Gimble ic adequately designed to absorb the axial pressure thrust and hence the piping end Anchors need to be designed as Intermediate Anchors only. Similar to hinged joint the growth of the offset leg accomodating the bellows must be absorbed by the adjoining piping legs.

Figure-1 (exhibit 35.15)

5.0

SYSTEM DESIGN CONSIDERATIONS:

Following design considerations shall apply to the Piping System employing a Bellow. The design of the piping system employing a Bellow shall take into account the recommendations made by EJMA Standard. The specification for the Bellow shall as a minimum provide technical information as per Specification Sheet given as Appendix-A of EJMA. The same is enclosed as attachment to this chapter. The type of the Bellow shall be selected depending on the Magnitude of the thermal movement of the connected piping The configuration of the piping profile in relation to the location of the Bellow. In general, caution shall be exercised in employing a Bellow in a piping system operating under cyclic loading condition (e. g. due to temperature cycle). If no solution is available as an alternative to Bellow then the number of temperature cycles anticipated during the design life of the system shall clearly be indicated in the Bellow Specification for the Vendor to confirm the Fatigue Life Expectancy.

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Under normal circumstances stress relieving or annealing shall not be specified for the Bellow since the life of a Bellow greatly relies on its improved fatigue strength due work hardening of Austenitic Stainless Steel during the forming operation of the convolutes. The supporting of the piping system employing a Bellow shall be such that the movement of the connected piping at the Bellow ends is positively predictable. As a golden rule the supporting system in relation to the location of the Bellow and the configuration of the piping profile shall be similar to any one of the numerous examples given in Section 4 of this chapter based on EJMA recommendations. The support shall be adequately designed for the highest pressure either during operation or hydro test condition. The Bellow shall not be subjected to Torsional Rotation. The Bellow material shall be compatible with the flowing medium. Specific consideration shall be given to the following. Series 300 Stainless Steel against Chloride Stress Corrosion. Nickel Alloys against Caustic induced Stress Corrosion. Nickel Alloys against presence of Sulphur. Compatibility of Bellow material against pipeline cleaning chemicals if they are dozed in the piping system on regular intervals. Leaching of the Bellow material from the insulation material.

Requirement of Internal Sleeves shall be specified in an application involving fluid velocities which, can induce resonant vibrations. The evaluation of acceptable flow velocity limits (based on EJMA, Section C-3) is covered in Section (Internal Sleeve Requirement) of this chapter. The sleeves are normally installed in the direction of flow. However in case back flow is anticipated during operation the same shall then be highlighted clearly in the Specification to allow the Bellow manufacturer to provide extra heavy sleeve and thereby preventing a possible damage of the Bellow resulting from the buckling of the sleeve. The Design Pressure of the Bellow shall be based on the actual maximum working pressure of the pipeline under question. No ad-hoc cushion shall be allowed in specifying the Design Pressure. The Hydraulic Test Pressure of the Bellow shall be 1.5 times the design pressure (1.1 times in case of pneumatic test pressure) with due allowance for temperature correction factor. However the Test Pressure calculated in the above manner must not produce membrane stresses in excess of Yield Strength at room temperature. The Maximum, Minimum and Installation temperature shall be specified accurately and a suitable pre-compression of the Bellow shall be considered and specified accordingly if ambient temperatures may vary significantly during pipeline construction. The above aspect is addressed in Section (Bellow Pre-Compression) of this chapter in detail based on EJMA recommendation (Section B-2.1.2 and B-2.1.3) The Insulation Guard Sleeve shall be specified in case of insulated Bellows. The displacements to be absorbed by the Bellow shall be based on the expected piping growth including the terminal movements. In addition to the above the specified displacements shall also account for the following eventualities:

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Uhde India Limited

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The actual metal temperature of the piping may not necessarily attain the design temperature used for calculation of the expected thermal growth of the piping. The installed location of the Piping Supports (e.g. guides/ anchors etc.) in the field may not necessarily be exactly in accordance with the design. The temperature range attained during actual operation cycle may not necessarily be exactly same as anticipated in the design. The Bellows when handling process fluids which can solidify or scale to pack the convolutions shall be provided with necessary means to avoid the same. Use of internal sleeve, purge connections (for gas/ vapour mediums) and drip hole (for trapped liquid) are some of the ways to achieve the same. Depending on the severity of the process/ design condition the Bellow may be specified with extra safety features as below: Extra heavy external cover which would impede the effect of the jet/ splash of escaping fluid in case of a Bellow failure. Limit Rods employed from the consideration of dynamic loading can be designed for restraining the pressure thrust in case of a an anchor failure. A two-ply or concentric double shell Bellow with both the plys capable of withstanding the full line pressure. It is normally a good practice to provide a sketch of the piping system with details of all supports and other design data as part of the Bellow Specification for establishing a clear understanding with the Bellow Manufacturer. The supports on a piping system employing a Bellow shall have clear space around the supports to allow access for their inspection during hydro test and during plant operation.

6.0 INTERNAL SLEEVE REQUIREMENT:

Internal sleeves are recommended when it is necessary to reduce the system pressure drop to minimum. Internal sleeves are recommended when flow velocities exceed the following values. Air, steam and other gases: Up to 6 diameter Over 6 diameter 4 ft/ Sec./ inch of diameter. 25 ft/ Sec.

Water and other Liquids: Up to 6 diameter Over 6 diameter 2 ft/ Sec/ inch of diameter 10 ft/ Sec.

Note: When turbulent flow is generated within 10 pipe diameter of the Expansion Joint by use of valve, tee, elbow or cyclonic devices the actual flow velocities should be multiplied by 4 before applying the above criteria.

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An internal sleeve shall be provided when flow velocities exceed 75 % of the value of the resonant velocity calculated based on the following equation = (0.81 * ksr / W) / C where = inside convolution width (inch) W = Weight of Bellow including reinforcement (lbs.) and including weight of liquid contained between convolutions if applicable. Ksr = Overall Bellow Spring Rate (lbs./ inch) - data supplied by Bellow manufacturer C = Correlation factor as per Fig C16 of EJMA (for U shaped convolutions C = 0.22)

The Bellows when used in a fluid service carrying Crystals (e.g. slurry service) shall be provided with internal sleeve to avoid any possibility of erosion.

7.0 BELLOW PRE - COMPRESSION:

On certain occasions when the piping system employing a bellow is required to function in a wide band of operating temperature (i.e. to swing on both sides of the installation temperature) the bellow will require to be designed to absorb both axial compression as well as expansion. It is however possible in such situations, to specify a bellow with axial compression only by suitably pre-compressing the bellow, as illustrated in the following example. Example: Given a 150 Feet of Carbon Steel straight pipe operating between 25 O (installation temperature to be considered as 70 F. Expansion Rate at 375 F O Expansion Rate at 25 F Total change in length of pipe
O O

F and 375

= 2.48 in./ Foot = -0.32 in/ Foot = 150 * (2.48+0.32)/ 100 = 4.2 inches

The above change in length is made of 2 components Contraction of pipe from its installed condition when operating at 25 expansion of the bellow by an amount of 0.48 inches (i.e. 0.32*150/100) Expansion of Pipe from its installed condition when operating at 375 compression of the bellow by an amount of 3.72 inches (i.e. 2.48*150/100)
O

F to cause

to cause

Assuming that we select a bellow with Rated Movement of 5 inches. The required pre-compression of the bellow = = 5 * 0.48 / 4.2 0.57

In general terms the above pre-compression can be expressed by following expression:

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Pre-compression = (Rated Movement) * (Exp. Coeff. At T inst - Exp. Coeff. at T min) Exp Coeff. at T max Exp. Coeff. at T min