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U.S. Bellows, Inc.Worldwide Leader in Metallic and Fabric Expansion Joints
▫ Fast Turnaround ▫ Repair ▫ Replace ▫ Refurbish ▫ Quick Delivery ▫
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Certifications & Manufacturing Facility
U.S. Bellows, Inc. – Expansion JointsPiping Technology & Products, Inc
3701 Holmes Rd.Houston, TX 77051
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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 John DemuszManager of U.S. Bellows
Manuel PerezProduction Manager
Dennis SatorreScheduler/Planner
Scott RungeBellows Engineer
Aydin EyupBellows Engineer
Blake GrundyBellows Engineer
Linda CaiCAD Operator
Jose Silva RivasBellows Engineer
Jie ShiBellows Engineer
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• 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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• EJMA Member– Approx. 10 years now!– Representation on:
• Technical Committee (Roy Felkner, Rakesh Agrawal)
• Management committee (Durga Agrawal, Rakesh Agrawal)
EJMA Technical Committee Meeting (Barcelona, November 2009)
Certification / Membership
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• ASME U-Stamp, R-Stamp and NS Certified• Minority Business Enterprise• Houston Minority Business Council• ISO 9001:2008
• 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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This presentation will cover the following topics
• Fabric Expansion Joint Basics• Applications• Fabric Belt Materials • Installation Instructions
Presentation Overview
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• 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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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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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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• 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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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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Application Example
High Temperature Dirty Flue Gas
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HOW TO FILL OUT THE DATA SHEET
– Contact Information
Fabric EJ Data Sheet
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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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• 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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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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Metal Attachment Frames – No Baffles
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Metal Attachment Frames – With Baffles
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Metal Attachment Frames – With Baffles, Pillows, & Seals
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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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Factors influencing expansion joint design
– Temperature– Wet Corrosive Media– Movements– Abrasive Media / Particulate Accumulation– Pressure / “Flutter”
Fabric Expansion Joint Basics
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Particulate Deflector
Expansion Joint Components
Additional components are available to augment certain fabric expansion joint styles in specific applications.
Insulation PillowAccumulationBarrier Bolt In Liner
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Fabric Belt Materials
Fabric belt material selection is a critical factorin the successful design of each fabric expansionjoint. A number of materials are widely acceptedfor use in fabric expansion joint applications.These materials fall into two general families—
Fluoroplastics (PTFE)— Also knowncommercially as Teflon®. The chemical resistanceof this material is unequaled.
Fluorelastomers— A general name for the groupof synthetic “rubber” materials that are characterizedby their elastic property. These materials arealso known by their commercial names as Viton®,Hypalon®, EPDM, and Chlorobutyl.
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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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Materials Comparison Chart
Temperature Materials Advantages Pressure Chemical Resistance
Applications
LowAmbient - 250°F
Butyl Rubber, Neoprene, Viton
High Tensile Strength, Ozone and weathering resistance
Medium High Hot and Cold Water, Low Pressure Steam, Neutral Solutions
Medium250 - 500°F
Fiberglass, Reinforced Silicone
Resistant to deterioration by weathering and engine oil remains
Low High Gaskets or Seals, Recirculation Air, Air Intake
High500 - 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
High700 - 1000°F
Silica Fabric Cloth
High abrasion resistance, Won’t rot or mildew
Low Low Boiler Exhaust
High1000 - 1800°F
*3-layer
Silica/PTFE Fabric with Kaowool
Excellent resistance to chemicals, High Temp. Stability
Low Low Furnaces, Kilns
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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/yd2
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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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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/yd2
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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/yd2
• Width: 38, 60 in.• Thickness: .030 in.• Roll Length: 50 yards
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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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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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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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Fabric Types
Braided Material
• Available in 304, 321, & 316L Stainless Steel• Temp. from cryogenic to 1500°F
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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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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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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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A Variety of Fabric Expansion Joints
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A Variety of Fabric Expansion Joints
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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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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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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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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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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
Neoprene/Rubber
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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
High Temp. Furnace Bags
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• 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
High Temp. Furnace Bags
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• 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.
High Temp. Furnace Bags
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• 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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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 forAbsorbing Tower Piping in an Acid Plant
Duct Work Assembly
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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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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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Manufacturing CapabilitiesFabric 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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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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Technical Information
Featured ProjectsPictures and Project Details
Webinar Registration Details on Upcoming Webinars
Quick Access to Site Online Quote System Emergency Service
Online Catalogs Downloadable Software
E-NEWSWebinars (Twice a Month!)
Technical Bulletins / Articles
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• 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
