YY LS os %, Ry NS AMERICAN BOA INC Expansion Joints Design StandardsContents 3 Multiply Expansion Joints 3 Designing Expansion Joints 4 Effects of Temperature 6 Effects of Pressure 10 Gycle Lite 42 Concurrent and Equivalent Pipe Movements 15 Pre-Set Movement 16 _ Installation Guidelines 18 How to Specify and Order Expansion Joints 20 085 psi Expansion Joint Data 24 150 psi Expansion Joint Data 28 300 psi Expansion Joint Data 30 600 psi Expansion Joint Data Figures 4 Reduced Travel at Elevated Temperatures 5 Thermal Expansion of Pipe 7 Pressure Thrust Diagram 8 Pressure Thrust Graph 9 Reduced Pressure at Elevated Temperature 1) Gye Lite Graph 42 Rhombus Diagram 15 Pre-Set Travel Diagram 32 Plate Flange Conversions © 1986 American Boa Inc.Expansion joints are engineered components which require careful attention when designing a piping system. This catalog provides the technical information required by a system designer. The in- formation is believed to be accurate and is offered to assist in selecting the proper expansion joint for your application. By con- tinuing to select BOA products, you can be assured of receiving reliable, high quality and safe products.MULTI-PLY EXPANSION JOINTS BOA pioneered the development of the multi-ply bellows design which has proven to be excep- tionally effective in absorbing thermal expansion in piping systems. BOA multi-ply bellows are manufactured from a laminated tube consisting of thin gauge stainless steel plies. This tubular body is formed into corrugations by means of a manufacturing process which assures exacting dimensions of the bellows geometry. BOA multi-ply bellows withstand high line pressures with the combined strength of several layers, yet retain the flexibility and movement capacity associated with each individual layer. Plies between inner and outer layers are spiral-wound and act as a labyrinth seal. The labyrinth seal- ing effect protects against a sudden rupture making the BOA expansion joint the safest design available, in addition to being the most flexible. CONSIDERATIONS IN DESIGNING EXPANSION JOINTS The bellows is the basic element of an expansion joint and the following characteristics are given special attention during the bellows design process. Flexibility—Thin gauge material is used in the manufacture of multi-ply bellows increasing flex- ibility and reducing deflection forces. Stress Analysis—Mechanical stresses are evaluated with relation to temperature and pressure and maintained within acceptable limits. Cycle Life—The contour of the thin gauge multi-ply convolution is designed to minimize pressure and deflection induced stresses. Full load thermal cycles are evaluated with relation to total travel. Maximum Travet—Maximum axial, lateral, and angular movements are optimized considering the lowest possible spring rates and the shortest overall length. Fail-safe Design—Bellows are designed for safety in care of system failures or the occurrence of excessive operating conditions. These characteristics are considered for every application involving expansion joints and have led to the design features discussed in this and other BOA bulletins.THE EFFECTS OF TEMPERATURE Changes in pipe length are caused by temperature variation. These changes become signifi- cant at high temperatures or for long pipe runs. Calculation for maximum movements between the highest and lowest temperatures experienced by the pipe is necessary for proper expand- sion joint selection. Note that the coefficient of thermal expansion is not linear, but increases with temperature. Temperature also affects the mechanical characteristic of material. Certain metals and their alloys resist high temperatures better because their tensile and yield strengths decrease more slowly. Heat resistant materials should be selected for systems subject to higher temperatures. ‘Temperature must be considered in relation to the maximum expected pressure when select- ing material for expansion joints. At high temperatures allowable mechanical stresses are reduced. An expansion joint designed for a given pressure range should not be used at its maximum pressure if the temperature exceeds the design temperature. See the pressure reduction graph on page 9 for guidance on operation at high temperatures. When applications exceed 1000’ F the allowable pressure should be verified by the factory. Special alloys available today make it possible to use expansion joints at temperatures up to 1800" F. Accurate information on maximum temperatures must be known to select the most appropriate material for the expansion joint. Expansion joints listed in this catalog are designed for 600° F. They may be used at higher temperatures, but the movement range given in the data tables must be reduced to maintain stress levels within acceptable limits. To maintain life expectancy at increased temperature, the allowable movement should be determined by using the Travel Reduction Graph that follows: Reduced Travel at Elevated Temperature aa 100. %. | 6. ao1ss _| 4 2, cof '5000 Cycles 600 700 © 800 9001000, Temperature *F Example: 24" FS 7150 expansion joint treated for 2.8" axial movement is to be used in a system operating at 150 psig at 900" F. To maintain a life expectancy of 5000 cycles at 900" F the movement must be reduced to 97% of rated movement. Rated movement 2.8" x .97 equals 2.71" allowable at 900° F.THERMAL EXPANSION OF PIPE x see = ? rs eee nes 2 33 i S 3 3 & 3 = 2 2 8 Boe = BiB = 8 2 & = Boe SERESER 25252 S8RG98 secece savzca ee: ne Notes: Expansion in inches per 100 feet. “This data for information ony and tis not to be Implied that materials ar suitable fr al tomperatures shown,THE EFFECTS OF PRESSURE Unlike temperature, pressure does not directly affect pipe growth. However, pressure is taken into account in calculating the wall thickness of both pipes and expansion joints, as well as for determining the location of pipe anchors and guides. At higher pressures, the walls of the bellows must be thicker, which in turn increase the bellows spring rate and reduce its capacity to absorb pipe growth. To decrease spring rate and increase allowable movements, a longer expansion joint with more convolutions is the solution commonly used. However, BOA multi- ply expansion joints offer another possibility. The wall thickness can be increased by using a greater number of thinner plies. This decreases spring rate and increases movement range While maintaining the same overall length and squirm pressure. Thrust Force ‘One of the most misunderstood factors in the application of expansion joints is the thrust forces experienced by pipe anchors. Expansion joints are fiexible elements placed in a piping system to allow movement as the temperature of the pipe changes. If a pipe is anchored at one end and grows longer because of a temperature increase, this growth will be resisted by the friction of pipe supports and by the spring force of the expansion joint. Spring Force —_ Friction Force Pipe Guides Expansion Joint Spring and friction forces can be significant, but often the pipe contains a fluid under pressure. This fluid pressure can cause an additional thrust force which may be much greater than all the other forces combined. If a pipe is closed at both ends and filled with a fluid under pressure, the pressure of the fluid acting on the walls at the end of the pipe causes forces that try to push the ends of the pipe apart.The ends of the pipe do not move because the force created by the pressure acting at each pipe end opposes the force at the other end through axial tensile stresses created in the pipe walls. As long as the material in the pipe wall is strong enough the pipe ends will not move apart. When an expansion joint is placed in the pipe, this situation changes. An expansion joint is designed to allow movement, not resist it. With a flexible element in the system the pipe ends will move apart with a force equal to the fluid pressure acting on the area at the end of the pipe. This can be a very powerful force if the pressure is high. The following diagram shows in more detail how to calculate “Pressure Thrust” and illustrates what a significant factor it can be. The pressure forces shown schematically by the arrows at the end of the diagram do not act directly on the expansion joint. They act on a valve, elbow or other component in the system. The total pressure thrust acting on an anchor is calculated as the product of the bellows effec- tive area and the pressure of the medium as shown below. This takes into account the pressure forces acting directly on the expansion joint, as well as forces acting on other system components transmitted through the pipe walls. PRESSURE THRUST Pressure Thrust Axp Effective Area A Bellows Mean Diam Internal Pressure F 7Pressure thrust acts upon the piping system and its anchors axially. Since the mean diameter depends on the corrugation height of the expansion joint, it can be seen that in order to obtain reduced thrust forces, the corrugation of the expansion joint must be made as shallow as possible. Adecrease in corrugation height leads to lower thrust forces, a decrease in the cost of anchors, and an increase in system safety. American BOA's design for multi-ply expansion joints permits the use of low corrugation heights even at higher pressures. This is possible because of the flexibility inherent with thinner plies of material. BOA expansion joints minimize spring rates while simultaneously providing lower thrust forces. It is possible to manufacture expansion joints that work reliably up to 1500 psi with the capacity to absorb significant axial movement. Pressure Thrust Graph Diameter Pressure Thrust x 10,000 Lbs. Example: a) 4" Diameter expansion joint operating at 85 psi yields a pressure thrust of 1955 Ibs. b) 20° Diameter expansion joint operating at 300 psi yields a pressure thrust of 111,000 Ibs.‘Temperature plays a major role in determining the design pressure of expansion joints. The @ _ult-ply betiows used in BOA expansion joints are made of stainless steel or other heat resis tant materials. Pressure/temperature relationships for pipes, flanges and fittings are not applicable. Expansion joints in this catalog are designed for the listed pressures at temperatures up to 600" F. For applications at higher temperatures pressure must be reduced to maintain stresses within acceptable limits, The allowable operating pressure at temperatures above 600" F should be determined by using the Pressure Reduction Graph that follows. If the reduced allowable pressure at the maximum temperature falls below the required operating pressure, an expan- sion joint with a higher design pressure should be selected. Reduced Operating Pressure at Elevated Temperatures A TTT : ‘5000 Cycles 3218S ai 10 { peer oe | @ ‘ f Reddotonn ss » * I a " CEE ry a aa 7 200 300 400 00 600 700 800 900 1000 Temperature °F Example: 16" FS 7085 expansion joint rated for 85 psi operating pressure is to be used in e@ a system that will operate at 1000" F. To maintain a life expectancy of 5000 cycles at 1000’ F the pressure must be reduced to 78% of rated pressure. Rated pressure 85 psi x .78 equals 66 psi allowable pressure at 1000" F.CYCLE LIFE The geometry of the BOA multi-ply convolution is designed to minimize stresses caused by pressure and deflection. The low stress level experienced by the bellows during operation substantially improves life expectancy. The life expectancy of an expansion joint is defined as the number of “Full Load Cycles” it can achieve during its lifetime. A full load cycle is the movement from an initial position through the complete range of compression to extension or deflection and return to the initial position of the expansion joint, Typically, the maximum movement an expansion joint experiences occurs only during the cold start-up of a system. This may happen only once or twice a year. Many systems shut down periodically but never cool down completely, and perhaps only 50% of the design movement occurs. The system may also have daily temperature cycles that produce movements equal to 10% of the maximum travel. In a case like this, all three movement conditions must be evaluated in selecting the most reliable expansion joint. The movement ranges listed in the data tables of this catalog are based on 5000 full load cycles at maximum pressure ratings and design temperatures of 600" F. If the actual movement requirements are less than the values listed in the tables, the cycle life will be greater. By using the Cycle Life Graph that follows it is possible to determine the increased cycle life for reduced non-concurrent movements. Bellows During Cycle Life Testing.Percent of Rated Movement 100. 90. 80: 70: 60: 50: Cycle Life Diagram 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 8 90 95 100 Example: #1 Axial - Requirement #2 Lateral - Requirement x 1000 Cycles 20" FS 9085 rated for 6.3" axial travel is to be used in an application requiring 4.5'axial travel. 4.5" is 72% of the total rated travel. 72% can be read on the graph as yielding a life of 20,000 cycles. 14" FS 9300 rated for .98" lateral travel is to be used in an application requir- ing a lateral travel of 0.625". 0.625" lateral corresponds to 64% of total rated lateral travel. 64% can be read on the graph as yielding a life of 31,000 cycles. "1CONCURRENT AND EQUIVALENT PIPE MOVEMENTS. Axial expansion joints are designed to accommodate pipe expansion in the axial direction of a straight pipe section. They can also absorb small lateral deflections or slight angular rota- tions concurrent with a reduced axial movement, depending on the length and diameter of the bellows. These movements are not the primary function of axial expansion joints, and if the application requires more lateral or angular movement than given in the data tabie, another type of expansion joint may be required. Determining Allowable Concurrent Movements Allowable concurrent movements can be determined either graphically or analytically. The graphical method is discussed first. By drawing a rhombus diagram, any combination of concurrent axial and lateral movements can be evaluated. The total movement range given in the data tables are the maximum values for non-concurrent movements. These values are plotted on the axes of the rhombus diagram as illustrated in the example below: Example Analysis indicates a requirement for an expansion joint that will accommodate plus and minus 0.25" lateral movement and plus and minus 1" axial movement in a 40" diameter 150 psig piping system. After reviewing the data tables in this catalog, a 40" 9150 bellows is selected. 40" 9150 Bellows - Rated Travel: 7.9" axial or .72" lateral. Step 1: Plot the total allowable non-concurrent ax- ial and lateral movements on the X and Y axes respectively. Connect these points to form a rhombus diagram Step 2: Draw horizontal lines across the Y axis at the required lateral movement. (Required movement plus and minus 0.25" lateral). Step 3: Draw two vertical lines connecting the horizontal lines making a box within the rhombus diagram. Step 4: Read the axial movement indicated by the vertical lines as they intersect the X axis. Lines show an allowable axial movement of plus and minus 1.22" indicating the re- quirement of plus and minus 1" axial is acceptable. The procedure can be reversed by first plotting the required axial movement and then drawing horizontal lines to determine the allowable lateral movement. The rhombus diagram is an excellent tool for determining allowable movements when combined axial and lateral travel is required. If the non-concurrent movements from the data tables are used, the rhombus diagram in this case will be valid for a design life of 5000 cycles. 12The allowable axial movement for a given lateral, or the allowable lateral movement for a given axial, may also be found analytically. The following formulas may be used to determine the allowable movements without plotting the rhombus diagram. it g - AB) ‘A = Total Rated Axial (nonconcurrent) aes B = Total Rated Lateral (nonconcurrent) e 4 = Allowable axial movement for ¢ amount of lateral (concurrent) c= BA) d lowable lateral movement for d amount of axial (concurrent) A oa Using the same expansion joint example from the rhombus diagram, calculate the allowable lateral movement for an application requiring two inches total axial movement 40" _9150'Bellows A=79 c¢ = 0.72(7.9-2) 79 c = 0.537" allowable lateral movement. Combining Cycle Life for Different Operating Conditions Piping systems frequently operate under different conditions at different times. An expansion joint can experience different movements and different numbers of cycles for each different condition, depending on system operation. Making sure the correct expansion joint has been selected is slightly more involved under these circumstances, but still relatively straightforward, as illustrated in the following example. In this example the amount of cycle life used for each operating conditions calculated and then combined to determine the life expectancy of the expansion joint in the proposed operating environment. Example ‘An expansion joint is to be installed in a piping system. The expansion joint is expected to pro- Vide servi for 10 years while operating under the following mavement conditions at 80 psi and 600° F: Condition | - Installation and Plant Start-up Required movements: 4" Axial - Plant expects to be shut down cold twice a year. Total cycles required: 2 x 10 years = 20 cycles Condition Il - Emergencies and Short-term Plant Shut-down Required movements: 3" Axial, 0.12" Lateral - Plant expects these short-term outages four times a month Total cycles required: 4 x 12 months x 10 years = 480 cycles Condition Ill - Plant's Daily Operating Events Required movements: 2" Axial, 0.062" Lateral, 5° Angular - Plant will cycle twice per day. Total cycles required: 2 x 365 days x 10 years ~ 7300 cycles The first step is to select an expansion joint from this catalog that will accommodate the condi- tion with the greatest movement. Next, determine the percent cycle life used for each condi- tion, as previously illustrated. The combined usage percent for each operating condition should be less than or equal to 100 percent. 13Selected Expansion Joint: 20" 8085 Series—Rated Movements: 4.2" Axial, 0.43" Laterial, 23° Angular @ Condition 1 Ail Lateral Angular Condition I Axial Lateral Angular Condition Ill Axial Lateral Angular Total Usage 83% * Adjusted Cycle Lite for percent travel used is determined by using the Cycle Life Diagram. The total usage of 83% for all conditions when plotted on the Cycle Life Diagram yields an expected total lite @ of 10500 cycles. Cycle Life Diagram Percent of Rated Movement 100. 90: 80: 70: 20: 10: Poe HS HEHEHE HEHEHE HED w x 1000 Cycles 14PRE-SET MOVEMENT BOA multi-ply expansion joints have large movement capacity, but care must be taken to in- sure that the rated movement is not exceeded. When an expansion joint is in the cold position it should not exceed its maximum length. Therefore, a correct pre-set length for installation is very important. Expansion joints must be pre-set or positioned such that the installation length corresponds with the pipe temperature during installation. An expansion joint does not usually have to be pre-set to the maximum length except during installation at very low temperatures. In other cases, the pre-set movement must be positioned such that the expansion joint can extend further at lower temperatures without exceeding its maximum length. If pipe expansion has been calculated exactly, there is no danger of exceeding the maximum movement. The pre-set travel listed in the data tables are valid for 5000 full load cycles. The main point to consider when pre-setting travel is not to exceed the maximum limits of movement capacity. If only a small percentage of movement is required, then pre-set travel is not important. lation Length 15INSTALLATION GUIDELINES During installation of expansion joints there are several points which require special attention They are of utmost importance for expansion joints to function properly. Anchors Intermediate anchors are designed to withstand differences in spring forces and friction forces. In the case of different pipe diameters, the anchor must be designed to withstand the difference in pressure thrust of the two pipe sections. Anchors at the ends of pipe sections are usually called main anchors and must be designed to withstand the full pressure thrust of the bellows in addition to other forces. * Apipe section in which an expansion joint is installed must be firmly fixed with anchors at both ends. * Expansion joints should be installed adjacent to an anchor; otherwise, a pipe guide must be installed on each side of the expansion joint. * Pressure thrust is the result of the bellows effective area multiplied by the medium pressure. If pressure changes, pressure thrust changes. * Forces transmitted to the pipe anchors are the sum of the spring rate, friction forces of the pipe guides, and pressure thrust of the bellows. (Provisions for pressure thrust are not required if the expansion joint has tie rods.) When pipe movement requires the use of several axial expansion joints intermediate anchors are necessary. Only one expansion joint can be installed between two anchors. If two or more expansion joints are installed in series, intermediate anchors are required to equally distribute thermal growth to each expansion joint. Pipe Alignment Guides * An expansion joint should not support the weight of the pipe. * Pipe sections must be properly guided in an axial direction by guides adjacent to the expansion joint. In installations with axial expansion joints the pipe growth, or expansion, should push the expansion joint axially. To assure this, the pipe must be guided directly before the expansion joint. Pipe hangers are not sufficient; the pipe must be embraced or clamped. Clearance in pipe guides should only be sufficient to allow the pipe to glide easily. The distance between the expansion joint and the first pipe guide should not exceed four pipe diameters. The distance between the first and second pipe guides should not exceed 14 pipe diameters, and the distance between any remaining guides should be based on equations from the standards of the Expan- sion Joint Manufacturers Association. This information can also be found in BOA Bulletin No. EB-222. 16Pipe Guides 4 Pipe Dia. 14 Pipe Dia Special Notes Torsion ‘An expansion joint should never be subjected to torsion. This factor must be considered when welding the companion flange on the pipe end. Covers Expansion joints require careful handling and must be protected from any impact, weld spat- ter, etc. before insulating an expansion joint, care must be taken that foreign material is not trapped in the corrugations. It is suitable to install a metal cover over the flanges and then wrap the insulation around it. Tie Rods Tie rods are devices with the primary function of continuously restraining the full bellows pressure thrust during operation. Limit Rods Limit rods are devices with the primary function of restricting the bellows movement range. Limit rods are designed to prevent bellows over-extension or over-compression while restrain- ing the full pressure thrust in the event of a main anchor failure. Control Rods Control rods are devices attached to the expansion joint with the primary function of distributing movement between the two bellows of a universal expansion joint. Control rods are not designed to restrain bellows pressure thrust. qiHOW TO SPECIFY AND ORDER EXPANSION JOINTS BY MODEL NUMBER BOA Expansion Joints can be specified and ordered by model number. To determine model number refer to the data tables and fill in the information below. Step 1 Step 2 gx xc8aaor Step 3 - FSP FL FLP FLL FLLP cs Step 4 Step 5 - 18 Determine the nominal diameter of expansion joint required Determine type of expansion joint to be used Single (Single axial expansion joints have no designation except for type of ends) Hinged Double Gimbal Pressure Balanced Elbow Inline Pressure Balanced Universal External Pressure Select type of end fittings to be used on expansion joint (any combination of end fittings may be selected). Fixed Forged Flanges Fixed Plate Flanges Floating Forged Flange One End Floating Plate Flange One End Floating Forged Flanges Both Ends Floating Plate Flanges Both Ends Welding Ends Customer Special Select the required bellows series number from the data tables based on pressure class and other technical considerations. Make certain the pressures, temperatures, movements and cycle life data are consistent with the application. If any parameters are exceeded the other data must be rated according to the methods discussed in this catalog. Series numbers range from 1000 to 9900. Examples from this catalog are: 6085, 7150, 8300, 9600... Series numbers with “S" as a suffix indicate a special design Series numbers with “E” as a suffix indicate exhaust applications. Specify overall length in inches to two decimal places, if required. Overall lengths listed in data tables are standard; increasing these lengths can easily be ac- complished by adding or increasing the spacer pipe. If a shorter length than is listed in the tables is desired, please consult factory.Step 6 Step 7 - Step 8 - Specify all optional features that are required as part of the expansion joint. Such features often include: Anchor Base Liner or Inner Sleeve Shroud or Outer Cover Tie Rods Limit Rods Control Rods An important step in determining the expansion joint model number is correctly specifying the bellows material. Use care in specifying bellows material; if uncer- tain about material, consult with a metallurgist. 3048S 304LSS M4 316LSS M3 316SS M5 321SS American BOA Standard M6 — Monel 400 M7 Inconel 600 Mii 3108S M8 Incoloy 825 Mg__Nickel 200 M15 Inconel 625 Special Materials Bellows made from Hastelloy, tantalum, or titanium are occasionally required. These are coded as MO, followed by the specific material desired. The factory must be consulted before specifying bellows of these materials. Combined Materials BOA multi-ply expansion joints can be manufactured with combined materials to economically provide corrosion resistance. Inner and/or outer plies can be constructed of an exotic corrosion resistant material, while remaining plies are constructed of a 300 grade stainless steel. These combinations offer excellent resistance in a cost effective manner. Such material combinations include: M16 Inner ply Monel 400 M29 Outer ply Nickel 200 M37 Inner & Outer ply Inconel 600 (Consult Factory for your specific requirements) All end fittings, whether weld ends, plate, or forged flanges, are of steel material. If stainless steel end fittings and optional features are required, the grade of stainless and fitting type must be specified in writing with the Model Number. 19