U.S. Bellows Fabric Expansion Joints

This presentation will briefly touch on the basics of fabric expansion joints; however, is mainly focused on the various designs, material details, and applications. Learn how fabric expansion joints are engineered and fabricated for various applications and the many factors that influence those designs. View the abundance of materials used, including Fluoroplastic and Fluoroelastomer, and their respective capabilities. Take a journey through a Fossil Fired Power Plant and see exactly where fabric expansion joints are required.

1. U.S. Bellows, Inc.
Worldwide Leader in Metallic and Fabric Expansion Joints
▫ Fast Turnaround ▫ Repair ▫ Replace ▫ Refurbish ▫ Quick Delivery ▫

2. www.usbellows.com
Certifications & Manufacturing Facility
U.S. Bellows, Inc. – Expansion Joints
Piping Technology & Products, Inc
3701 Holmes Rd.
Houston, TX 77051
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3. www.usbellows.com
U.S. Bellows Team
•Combined experience of 600+ years
–35 Manufacturing (500+ years)
–8 Engineering (100+ years)
–3 Field Service (75+ years)
•2 Shifts – Day and Night
Scott Runge
Bellows Engineer
Hasan Alsabea
Bellows Engineer
Jose Silva Rivas
Bellows Engineer
Jie Shi
Bellows Engineer
Mustakin Khan
Bellows Engineer
John Demusz
Manager of U.S. Bellows
Manuel Perez
Production Manager
Dennis Satorre
Scheduler/Planner
Aydin Eyup
Assistant Manager
Serzhena Forsman
Bellows Engineer
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4. •Pioneer in expansion joints, in business since the 1960’s
•Joined the PT&P Family in 1995
–5x the resources: PT&P, SWECO, Pipe Shields and Fronek
Anchor Darling
–Better location next to the Houston Ship Channel (one of
the largest ports in the U.S. and in the world)
–U.S. Bellows got a further shot in the arm with the
acquisition of RM Engineered Products
•Acquired the expansion joint assets of Lortz Manufacturing in
2011
Manufacturing Facility
•More than 450,000 sq/ft of
covered shop space
•40 acre property
•Continuing to expand
Introduction to U.S. Bellows
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5. •EJMA Member
–Approx. 15 years now!
–Representation on:
•Technical Committee
•Management committee
EJMA Technical Committee Meeting (Vienna, October 2016)
Certification / Membership
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6. •ASME U-Stamp, R-Stamp and NS Certified
•Minority Business Enterprise
•Houston Minority Business Council
•ISO 9001:2015
•ASME Section IX
•AWS D1.1
•MIL-STD-248
Manufacturing Qualifications QA / QC Approval
•UOP
•GE / Stewart and
Stevenson
Certification / Membership
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7. This presentation will cover the following topics
•Fabric Expansion Joint Basics
•Applications
•Fabric Belt Materials
•Installation Instructions
Presentation Overview
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8. •Fabric expansion joints compensate
for duct misalignment and duct
thermal growth
•Fabric expansion joints can absorb
larger movements than metal
expansion joints using a smaller
“span”
•A fabric expansion joint has two
main components—the fabric gas
seal material and the metal frames
•Fabric expansion joints are found
where there is a need to convey hot
media in low pressure applications
such as “in flowing air” and “out
flowing gas” in large combustion
processes.
What is a Fabric Expansion Joint?
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9. Fabric Belt Material Introduction
The fabric belt deforms to allow thermally induced
movements. The belt must be able to withstand
the thermal, pressure and chemical conditions.
Resist
“Flutter”
High
Temperatures
Heavy
Particulates
Wet Corrosive
Chemicals
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10. TYPE OF PLANTS
–Fossil Fired Power
Plants
–Pulp and Paper
Plants
–Cement Plants
–Refineries
–Chemical Plants
Where are Fabric Joints Found?
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11. •Fossil Fired Power Plant
–Boiler
–Economizer
–Air Heater
–FD Fan
–Precipitator
–ID Fan
–Scrubber
–Stack
A fossil fired power plant is used to illustrate a
range of conditions that can be found in many
industrial applications.
Fabric Expansion Joint Applications
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12. Economizer to
Air Heater
Expansion Joint
Economizer
Air Heater
Application Example
Economizer to
Air Heater
Expansion Joint
Economizer to Air Heater Example
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13. Application Example
High Temperature Dirty Flue Gas
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14. HOW TO FILL OUT THE DATA SHEET
–Contact Information
Fabric EJ Data Sheet
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15. A: FABRIC BELT
B: ACCUMULATION BARRIER
C: FRAME
D: RADIUS CORNER
E: LINER
F: FASTENER
G: BACKUP BAR
Data Sheet Input = Design Output
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16. •Part Terminology
–Belt Attachment Frame
–Gasket and/or
Insulation Tape
–Insulation Pillow
–Accumulation Barrier
–Fabric Belt
–Back-up-Bars
–Fasteners
Fabric Expansion Joint Basics
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17. Bolt In vs. Weld In Designs
• Framed EJs that weld in are less expensive to manufacture than framed bolt in
designs.
• Weld in designs reduce potential problems in field fit up.
• Weld in designs, when factory integrated into purchased ducting, save the
customer money.
• U-shaped designs are an alternative to framed EJs but should be used in
limited applications
Expansion joints can either bolt or weld directly to the duct
or duct flanges. Comparisons include the following.
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18. Metal Attachment Frames – No Baffles
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19. Metal Attachment Frames – With Baffles
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20. Metal Attachment Frames – With Baffles, Pillows, & Seals
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21. Fabric Expansion Joint Basics
Factors influencing expansion joint design
•Belt material
• Frame material
• Frame design
• Liner
• Insulation Pillow
• Accumulation Barrier
• Face to face
• Standoff
• Drain
• Gasket
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22. Factors influencing expansion joint design
–Temperature
–Wet Corrosive Media
–Movements
–Abrasive Media / Particulate Accumulation
–Pressure / “Flutter”
Fabric Expansion Joint Basics
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23. Particulate Deflector
Expansion Joint Components
Additional components are available to augment certain
fabric expansion joint styles in specific applications.
Insulation Pillow
Accumulation
Barrier Bolt In Liner
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24. Fabric Belt Materials
Fabric belt material selection is a critical factor
in the successful design of each fabric expansion
joint. A number of materials are widely accepted
for use in fabric expansion joint applications.
These materials fall into two general families—
Fluoroplastics (PTFE)— Also known
commercially as Teflon®. The chemical resistance
of this material is unequaled.
Fluorelastomers— A general name for the group
of synthetic “rubber” materials that are characterized
by their elastic property. These materials are
also known by their commercial names as Viton®,
Hypalon®, EPDM, and Chlorobutyl.
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25. Fabric Belt Variables
Fabric belt material variables include:
– Fiberglass Tensile Strength
– Chemical barrier thickness
– Addition of a bonded insulation
mat of varying thickness
– Cross film technology
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26. Materials Comparison Chart
Temperature Materials Advantages Pressure Chemical
Resistance
Applications
Low
Ambient - 250°F
Butyl Rubber,
Neoprene, Viton
High Tensile
Strength, Ozone and
weathering
resistance
Medium High Hot and Cold
Water, Low
Pressure Steam,
Neutral Solutions
Medium
250 - 500°F
Fiberglass,
Reinforced
Silicone
Resistant to
deterioration by
weathering and
engine oil remains
Low High Gaskets or Seals,
Recirculation Air,
Air Intake
High
500 - 700°F
PTFE
Impregnated
Fiberglass, PTFE
Coated Glass
Cloth
High tear / crease
resistant; Smooth,
low friction, non-stick
surface, high tensile
strength
Low Medium Exhaust
Ventilation, Fume
Protection,
Gaskets or Seals
High
700 - 1000°F
Silica Fabric
Cloth
High abrasion
resistance, Won’t rot
or mildew
Low Low Boiler Exhaust
High
1000 - 1800°F
*3-layer
Silica/PTFE
Fabric with
Kaowool
Excellent resistance
to chemicals, High
Temp. Stability
Low Low Furnaces, Kilns
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27. Fabric Belt Materials Fluoroplastics – PTFE
PTFE Coated Glass Cloth
Features
• Excellent Chemical Resistance
Physical Properties
• Upper Temperature: 600°F
• Tensile Strength: 1200 lb./in.
• Thickness: .047″
• Weight: 60 oz/yd
2
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28. Fabric Types
Reinforced Silicone Fabric
Features
• Excellent Gasketing Material
• Extremes High & Low Temperature Resistant
• UV / Ozone Resistant
• Non-Toxic, Chemically Inert
Physical Properties
• Temperature Range: 70 +/-10
• Tensile Strength, PSI: 1300
• Pain Weave Thread Count: 20 x 18
• Fiberglass Diaphragm Burst Strength (psi): 750
• Compression Set: 35 Max
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29. Fabric Types
Aluminized Glass Cloth
Features
• Resists most acids & alkalis
• 20% Liquid Aluminum Compound
• K Factor of .25 (ANSI /ASTM C 3335)
Physical Properties
• Tensile Strength: 400 lb./in.
• Thickness: .045″
• Weight: 38.5 oz/yd
2
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30. Fabric Types
Silica Oxide Glass Cloth
Features
• Non-Flammable
• Maintains High Tensile Strength at
Elevated Temperatures.
• Remains Flexible at High Temperatures
• High Product Value
Physical Properties
• Weave Style: Satin
• Nominal Weight: 26 oz/yd
2
• Width: 38, 60 in.
• Thickness: .030 in.
• Roll Length: 50 yards
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31. Fabric Types
PFA Fluoropolymer Film
Features
• Outstanding flex life and stress crack resistance
• Performance from -254°C to 260°C
• Outstanding anti-stick release properties
• Excellent electrical properties
• Excellent weather ability
Physical Properties
• Thickness: .0005″ to .010″
• Widths up to 64″
• Insoluble
• Clear or Translucent
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32. Fabric Types
Insulation
Physical Properties
• Density: 4, 6, 8 pf
• Thickness: fi-2 (12.5-50) in.
• Melting Point: 3200°F
• Max cont. use limit: 2000°F
• Max temp. rating: 2300°F
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33. Fabric Expansion Joint Adhesives
Loctite 404
• Transparent / Colorless
• Low Viscosity
VersaChem Red Silicone 650
• High Temperature up to 650°F
• Red Pasta
Adhesives
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34. Fabric Types
Braided Material
• Available in 304, 321, & 316L Stainless Steel
• Temp. from cryogenic to 1500°F
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35. Fabric Belt Materials - Elastomers
Elastomer belt materials are built up
into a multi-layered sheet reinforced
with fiberglass or Aramid fabric.
The finished product:
• 1/8″ to 1/4″ thick
• Used as a flat belt or as an integrally
flanged U-shaped cross section that
bolts directly to duct or equipment
flanges.
• Inherent characteristics of flexibility,
abrasion resistance, and flutter
resistance = long service life when
applied properly.
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36. Single Ply vs. Two Ply Elastomers – Rubber / Viton
Reinforcement
Reinforcement
Elastomer
Elastomer
Typical 1/8″ thick
belt with single ply
reinforcement
Typical 1/4″ thick
belt with two ply
reinforcement
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37. Manufacturing Capabilities
•Materials:
–Single layer PTFE: temperatures
up to 600°F
–3-layer Belt and Insulation Pillow:
temperatures up to 2,000°F
•Inside Layer: 100% fiberglass, coated with
an aluminum compound on both sides
•Middle Layer: ½” thick KO wool
•Outside Layer: PTFE fiberglass reinforced
•Capacity: 40’ Length and 20’ Wide
Fabric Expansion Joints
Duct Expansion Joint – Low Temperature Duct Expansion Joint – High Temperature (up to 1200°F)
10’ square fabric expansion joint w/ high temp.
and corrosion resistant composite belt
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38. Fabric Expansion Joints
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Viton Boots

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Fabric Expansion Joints
Viton Boots

40. Fabric Expansion Joints
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Viton Boots

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Fabric Expansion Joints
Viton Boots

42. Fabric Expansion Joints
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Viton Boots

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Fabric Expansion Joints
Viton Boots

44. A Variety of Fabric Expansion Joints
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45. A Variety of Fabric Expansion Joints
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46. Fabric EJ Installation
•Pre-Installation Check
–Confirm dimension data per U.S. Bellows
drawing
–Confirm duct/duct flanges are in good
condition
–Confirm duct/duct flanges are lined up
correctly
–Prior to installing the frames, the opening to
which the unit will be installed must be
inspected to make sure it meets design
requirements
–Make available necessary tools such as a drill,
come along, rope and pry bar
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47. Fabric EJ Installation
•Use the U.S. Bellows drawing as
a guide for dimensional info
•Clean duct/flange surfaces and
prepare for welding or bolting
•Using proper lift equipment,
attach straps to the expansion
joint (do not attach to the
shipping bars)
•If the unit has a liner, make
certain the flow arrow of the
liner is in the proper system flow
direction
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48. Fabric EJ Installation
•If ducting is in place & cannot
be moved for the installation
–Lift expansion joint into place
using sufficient straps
–Fit up and tack weld one flange
of the expansion joint into
place.
–During any welding, protect
the fabric belt material from
potential weld splatter
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49. US Bellows Experience
•General Electric
•Exxon Mobile Houston
•Tulsa Heaters
•KBR
•Augering Technology
•Bechtel
•ALBEMARLE Corp.
•Rhodia
•Jacobs
•Exelon
•Andritz
•Dupont
•Valero
•Indian Oil Corp.
•TransAlta
•Evapco
•KCPL
•American Arcyl
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50. Neoprene/Rubber
Features
•Sizes: 1.5” to 144” Diameter
•1 to 4 Arches as Required
•Choice of Cover and Liner Materials
•Reinforcement – Wire or Solid Rings
•Built to your Specifications
Operational Features
•Minimum 3 to 1 safety factor, rated
to burst pressure
•High Temp. Resistant fabric for up
to 400°F
•Pressure cured components, for
structurally sound long life service
•Optional exterior coat for Hypalon
paint for additional protection
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51. Neoprene/Rubber
Neoprene Expansion Joints for a Gas Turbine Application
EPDM Expansion Joints Designed
for a Generator Fan
Neoprene Expansion Joints for Air Intake
at a Packaged Power Facility
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52. High Temp. Furnace Bags
•Bag consists of multiple layers of flexible, flame
and heat resistant, impervious fabric
•Designed to operate from start up to high
temperature design conditions and expand and
contract with the varying furnace temperatures
•Our bags are nickel reinforced with a special
coating that reduces airborne fibers and increases
tensile strength
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53. High Temp. Furnace Bags
•Stainless steel
clamps or band
straps connect one
end of the pipe that
goes through the
penetration opening
and the other to
another sleeve in
the floor.
•A tapered steel coil
is installed around
the conduit inside
the bag to prevent
the fabric from
collapsing inward
during vacuum
conditions.
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54. High Temp. Furnace Bags
•Look for rips or tears in the
fabric and openings at the
seal
•Observe any damage or
corrosion of the clamping
elements
•Seal can function through
maintenance “shut-down”
cycles
•Easy to replace after several
years of operation
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55. U.S. Bellows provides custom designed expansion joints in duct work and
fabricated duct work assemblies. The assemblies may include fabricated elbows,
tees, and straight sections of duct work, in carbon steel or stainless steel, and in
diameters of 42" or larger. The duct sections can include fabric or metallic
expansion joints and can be rectangular or round.
72" Dia. Duct Work with Mitered Elbows Designed for
Absorbing Tower Piping in an Acid Plant
Duct Work Assembly
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56. Fabric Expansion Joint & Duct Work Assembly
78" Fabric Expansion Joint
and Duct Work Assembly
with a 90° Elbow
• Designed for 5 PSIG @ 750°F
• 2.5" Lateral Deflection (cold preset)
• 2" Axial Compression
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57. Fabric Expansion Joint & Duct Work Assembly
60" Ductwork with
Fabric Expansion Joint
for a Sulfuric Acid Plant
Completed within 6 weeks
for a plant shutdown
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58. Manufacturing Capabilities
Fabric Expansion Joints
•New Customer Standard:
–Liner and flange used to be 2 pieces
–We combined the liner and flange into one piece
–As result, there is less welding for us and a
smoother flow in the duct work for them
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59. 24/7 Quick Turn Service
•Emergency?
–On-call team… available 24/7
–Online emergency form with a guaranteed
response time within 30 minutes
–Stock bellows for quick assembly
Same Day Turn-aroundSame Day Turn-around 2-Day Emergency Repair2-Day Emergency Repair3-Day Refurbishment3-Day Refurbishment
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60. Technical Information
Featured Projects
Pictures and Project Details
Webinar Registration
Details on Upcoming Webinars
Quick Access to Site
Online Quote System
Emergency Service
Online Catalogs
Downloadable Software
E-NEWS
Webinars (Twice a Month!)
Technical Bulletins / Articles
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61. •U.S. Bellows is a diverse manufacturer of a wide
variety of high-quality, competitively priced
expansion joints.
•U.S. Bellows has focused experience in supplying
expansion joints around the world.
•U.S. Bellows is here for all your engineering
needs…
Conclusion
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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